Splicing and matching forming machine

Abstract

A tire tread cutting apparatus for cutting a length of tire tread is disclosed herein. The tire tread cutting apparatus includes a track having a first track end and a second track end downstream of the first track end. The track includes a plurality of rollers positioned between the first track end and the second track end. The plurality of rollers are configured to facilitate the tire tread along the track. A tire hub is positioned downstream of and adjacent to the second track end. The tire hub is configured to receive a tire body. The tire body defines a tire body circumference along an outer surface of the tire body. A tread dispenser is positioned upstream of the track and is configured to dispense the tire tread. The tread dispenser includes a drive roller configured to drive the tire tread downstream toward the second track end.

Description

BACKGROUND

[0001] The present application relates generally to the field of pneumatic tires, and more particularly, but not by way of limitation, to the manufacture of retreaded tires.

[0002] The removal of the old tread from the carcass provides a generally smooth and treadless surface around the circumference of the carcass. The carcass can then be inspected for damage, which is skived and filled with repair gum. After the skiving process is complete, the buffed face can be sprayed with tire gum, thereby providing a tacky surface for the application of the bonding material and new tread. Next, a cushion gum layer is applied to the back face (i.e., the interior surface of the new tread layer), or alternatively, the cushion gum layer is applied directly to the tacky surface of the carcass. Typically, the cushion gum is a layer of uncured rubber material. The cushion gum and tread can be applied together around the circumference of the carcass to produce a retreaded tire assembly ready for vulcanization. Alternatively, a length of tire tread is wrapped around the carcass to which the cushion gum has been applied. The cushion gum forms a bond between the tread and the carcass during vulcanization.

[0003] After the assembly of the carcass, gum, cushion gum, and tread, the entire retreaded tire assembly is placed into a flexible rubber envelope. An airtight seal is created between the envelope and the tire beads. The entire envelope tire assembly is placed in a vulcanization chamber and subjected to pressure and elevated temperature for a specific period of time. The combination of pressure, temperature, and time bonds the cushion gum layer to both the carcass and the new tire tread.

[0004] The cold process retreading method described above is typically completed on a tire building machine. Conventional tire building machines include a main shaft on which the tire is mounted and a main shaft on which a tire cushion gum roll is mounted for dispensing. Typically, the cushion gum can be dispensed manually while the tire is rotating to adhere the cushion gum to the carcass. In certain applications, it can be advantageous to eliminate the spray gum entirely. This is especially true in geographic regions where the regulation of chemical use in spray gum products is becoming increasingly stringent. Additionally, the use of spray gum can increase the cost of producing retreaded tires due to product cost and equipment cost. Various solutions have been proposed that enable a gum-free process, such as extruding the heated cushion gum directly to the carcass. However, this process is expensive due to equipment cost and unnecessarily complex.

[0005] In conventional tire bench systems, after the cushion gum is applied, the circumference of the carcass with the cushion gum is measured, and the applicable tread length is typically measured on a separate bench. The tire tread is manually cut to length. Once the cushion gum has been applied and the tread is cut to length, the tread must be applied to the cushion gum and carcass. Due to the error in the cut length of the tire tread, it can be desirable to stretch the tire tread around the circumference of the carcass and cushion gum in order to produce a proper size splice. SUMMARY

[0006] In a first set of embodiments, a tire tread cutting apparatus for cutting a length of tire tread is described. The tire tread cutting apparatus includes a track having a first track end and a second track end downstream of the first track end. The track includes a plurality of rollers positioned between the first track end and the second track end. The plurality of rollers are configured to facilitate tire tread along the track. A tire hub is downstream of and adjacent to the second track end. The tire hub is configured to receive a tire body. The tire body defines a tire body circumference along an outer surface of the tire body. A tread dispenser is upstream of the track and is configured to dispense tire tread. The tread dispenser includes a drive roller configured to drive tire tread downstream toward the second track end. The tire tread has a first tread end and a roll end. The tire tread has a tire roll length defined by the first tread end and the roll end. The tire roll length is greater than a tire body circumference length. A cutting element is downstream of the tread dispenser and upstream of the track. The cutting element is to cut the tire tread to define a second tread end. The first tread end is adhered to the tire body and the second tread end defines a section of tire tread. The second tread end is determined based on a measurement of the tire body circumference. When the second tread end is cut, at least the first tread end is adhered to the outer surface of the tire body.

[0007] In a second set of embodiments, a method of cutting a length of tire tread for a retreaded tire having a tire body is described. The method includes measuring a circumference of the tire body positioned on a tire hub and a buffer gum. Dispensing tire tread from a tread dispenser along a track upstream of the tire hub. The tire tread has a first tread end and a tread length. The tread length is defined by a distance between the first tread end and a tire tread roll upstream of the tread dispenser. Transporting the first tread end along the track toward the tire body. Adhering the first tread end of the tire tread to an outer surface of the tire body and the buffer gum positioned on the tire hub. Determining a second tread end. The second tread end is determined based on a measurement of the tire body circumference. Cutting the tire tread at the second tread end to define a section of tire tread. The section of tire tread is defined by the first tread end adhered to the tire body and the second tread end.

[0008] In a third set of embodiments, a tire tread cutting apparatus for cutting a length of tire tread is described. The tire tread cutting apparatus includes a track having a first track end and a second track end downstream of the first track end. The track includes a plurality of rollers positioned between the first track end and the second track end. The plurality of rollers are configured to facilitate tire tread along the track. A tire hub is downstream of and adjacent to the second track end. The tire hub is configured to receive a tire body. The tire body includes a cushion layer to define a tire body circumference along an outer surface of the tire body. A tread dispenser is upstream of the track and is configured to dispense tire tread. The tread dispenser includes a drive roller configured to drive tire tread downstream toward the second track end. The tire tread has a leading end and a tread length. The tread length is defined by a distance between the leading end and a tire tread roll upstream of the tread dispenser. A cutting element is downstream of the tread dispenser and upstream of the track. The cutting element is to splice tire tread to define a trailing end. The leading end is adhered to the tire body and the trailing end defines a segment of tire tread. The trailing end is determined based on a measurement of the tire body circumference. At least the leading end is adhered to the outer surface of the tire body when the trailing end is cut. The length of the segment of tire tread is shorter than the tread length. BRIEF DESCRIPTION OF DRAWINGS

[0009] The foregoing and other features of the present disclosure will become more apparent from the following description and accompanying drawings. It should be understood that the drawings are only illustrative of several embodiments of the present disclosure and should not be considered as limiting its scope, which will be described with more specificity in connection with the following drawings.

[0010] Figure 1 is a side view of an integrated tire bench system according to an example embodiment.

[0011] Figure 2 is a perspective view of Figure 1 the integrated tire bench system without a set of rollers.

[0012] Figure 3 is a front view of Figure 1 the integrated tire bench system without a tread roll.

[0013] Figure 4 is a top view of Figure 1 the integrated tire bench system with an additional track according to an example embodiment.

[0014] Figure 5 is a side cross-sectional view of a wire guide of Figure 1 the integrated tire bench system according to an example embodiment.

[0015] Figure 6 is a cross-sectional view of a tire body in a press operation.

[0016] Figure 7 is a side view schematic of the kinematics of the tread application process.

[0017] The following detailed description is made with reference to the accompanying drawings. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description, drawings, and claims are not meant to be limiting. Other embodiments can be used, and other changes can be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and form part of this disclosure. DETAILED DESCRIPTION

[0018] Embodiments described herein generally relate to a tire bench that is a semi-automated retread tire building machine apparatus (e.g., a tire tread cutting apparatus) configured to assemble a retread tire. For aesthetic and structural strength purposes, it is generally desirable to match the tire tread design at each end of the tire tread length so that the two ends of the tire tread length match at the splice, the repeating pattern of the tire tread design is substantially continuous. To create this splice, it can be necessary to stretch the tire tread around the circumference of the tire casing and the buffer rubber, as the tire tread length can have been cut to an additional shortened length in order to match the tire tread design at both ends of the tire tread. The tire bench described herein is configured to allow an operator to apply tire tread to the tire casing prior to fully measuring and cutting the applied tire tread. Embodiments described herein provide improvements to current retread tire systems and methods by allowing an operator to influence the location of the final cut on the back end (e.g., second end) to ensure a match with the design of the front end (e.g., first end), while still achieving length matching and allowing the final cut to occur as the tire tread is applied to the tire casing. In some embodiments, the tire bench described herein includes a tread carriage (e.g., a tread track, a tread drive system, etc.) in which the placement of the tread rollers minimizes the likelihood of the tire tread jamming along the tire tread track.

[0019] Generally, the tire bench systems described herein are integrated tread benches that combine the processes of carcass measurement, tread measurement, tread cutting, and tread application into a single workbench machine while semi-automating the multiple steps required to produce a finished retread tire prior to vulcanization. The tire bench systems include integrated semi-automated methods and apparatus for cutting a tire tread to an appropriate length that allows for the application of a tire tread to a carcass with controlled stretch prior to cutting the ends of the applied tire tread. In some embodiments, the tire bench systems include an integrated buffer application process and apparatus that controls the stretch of the buffer during application to the carcass. In some embodiments, the integrated buffer application and tire tread cutting and application allow the applied buffer to produce a tire with a predetermined range of splice sizes such that periodic tire tread designs are substantially continuous in the retread tire.

[0020] Reference is made to Figures 1 to 4 , which shows a tire tread bench 100 that includes a rotatable tire hub 120 for mounting and measuring a carcass 200, a tread dispensing system 102, a presser system 104, and a pair of repeatability (e.g., redundant) control systems 122, 192 for operating the tread dispensing system and the presser system. In some embodiments, the tire hub 120 can be a variable size hub that incorporates an automatic inflation system and is configured to accommodate tires having different sizes (e.g., widths and radii). Generally, the tire tread bench 100 is configured to position the carcass 200 (shown as a dashed line in Figure 1 ) on the tire hub 120 allows an operator to apply a tread segment 184 to the carcass 200 with a buffer (or similar bonding layer) 180. The tire tread bench 100 allows an operator to apply a tire tread to a carcass prior to fully measuring and cutting the tire tread from a tread roll 160. In some embodiments, the tire tread bench 100 is configured to allow an operator to apply a buffer (or similar bonding layer) to a carcass 200 prior to applying a tire tread from a tread roll 160 to the carcass 200 without using another system or apparatus.

[0021] The tire hub 120 is configured to receive the tire body 200, facilitate inflation of the tire body 200, and align the tire body 200. In operation, an operator installs the tire body 200 to the tire hub 120. The tire hub 120 can move laterally along the rotational axis 142 to center the tire hub 120 relative to the longitudinal centerline of the tire tread bench 100. This movement is to center the tire body 200 with the track 152 in order to center the tread segment 184 on the tire body 200. The tire hub 120 can move longitudinally along the rotational axis 142 to center the tire hub 120 relative to the operator height. In some embodiments, the tire hub 120 can move longitudinally along the rotational axis 142 to center the tire hub 120 relative to the lateral centerline of the tire tread bench 100. The centerline of the tire tread bench 100 corresponds to the centerline of the tread roll 160 of the tread dispensing system 102. Once the tire body 200 is installed on the tire hub 120, the tire body 200 is inflated and centered. Centering the tire body 200 includes aligning the centerline of the tire body 200 with the centerline of the tread roll 160. In some embodiments, the tire hub 120 is automatically aligned with the tire tread bench 100 centerline by a system of clamps, guides, rollers, or other alignment devices. In some embodiments, the tire body 200 includes a cushion gum layer 180 that has already been applied, as shown. In some embodiments, the tire body 200 does not have a cushion gum 180 layer and the tire tread bench 100 is configured to apply a cushion gum layer to the tire body 200. Figure 6

[0022] ​Once the tire carcass 200 is positioned on the tire rim 120, the measuring system 150 is configured to determine measurements of the wheel circumference (and any cushioning rubber layer) of the tire carcass 200 on the tire rim 120 to apply and join the tread around the tire carcass 200. In some embodiments, the measuring system 150 includes at least one camera configured to monitor the surface of the tire carcass as the tire carcass 200 rotates about the axis of rotation 142 of the tire rim 120. In some embodiments, the camera or other vision (e.g., non-contact) device may be coupled to an encoding device that encodes changes in the tire carcass 200 to communicate with a central processing unit or control unit. In some embodiments, the measuring system 150 is a measuring wheel with a measuring arm 52 that can be pivoted by a pneumatic cylinder to engage surfaces (the tire carcass or the cushioning rubber applied to the tire carcass). In some embodiments, as the tire carcass 200 rotates on the axis of rotation 142, a measuring wheel rotates along the surface of the tire carcass, allowing an encoding device coupled to the measuring wheel to encode angular changes of the measuring wheel for communication with a central processing unit or processing unit. In some embodiments, the measuring system 150 is one or more lasers configured to identify positions along the circumference of the tire carcass 200 to determine the circumferential length of the tire carcass 200. In some embodiments, the measuring system 150 is coupled to a control unit that generates an appropriate measurement of the wheel circumference. In some embodiments, other measuring devices are incorporated into the design without departing from the spirit and scope of this disclosure. In some embodiments, the measuring system 150 is configured to allow an operator to begin the tread application process before the measuring system 150 determines the wheel circumference. In some embodiments, the operator can begin tread application from the tread roll 160 of the tread distribution system 102.

[0023] like Figures 1 to 4 As shown, the tread distribution system 102 of the tire tread platform 100 is generally configured to distribute tread from the tread roll 160 along a track 152 to the tire carcass 200 downstream and centered along the track 152. The tread distribution system 102 includes a tread carrier 110 for distributing tread onto the tire carcass 200 on a rotatable tire hub 120. The tread carrier 110 includes the track 152, the tread roll 160, a drive system 108, a set of rollers 154 along the track 152, and a cutting system 144. The tread carrier 110 is configured to facilitate the removal, application, and cutting of tread segments 184 having a front end 186 and a rear end 188. The tread roll 160, the tread rollers 162, and the drive rollers 164 define a tread distributor.

[0024] The upstream operator control panel 192 is configured to control the drive system 108, drive roller 164, cutting system 144, and / or other components of the tread distribution system 102 of the tread roller 162. Figure 1As shown, an upstream operator control panel 192 is proximate to the gantry end 138 downstream of the tread roll 160. The gantry end 138 is adjacent to the tread roll 160. The upstream operator control panel 192 includes a plurality of buttons and gauges 196 to partially control and monitor the operation of the tire tread gantry 100. The upstream operator control panel 192 is configured to be redundant and mirrored to the control of the system of the downstream operator control panel 122. In other words, an operator of the tire tread gantry 100 can control the drive system 108 of the tread rollers 162, the drive rollers 164, the cutting system 144, the presser rollers 130, and / or other components of the tread distribution system 102 from both the downstream operator control panel 122 and the upstream operator control panel 192. A monitor 194 is positioned above the upstream operator control panel 192 and is configured to provide visual feedback to the operator related to the operation and distribution of the tire tread from the tread roll 160. In some embodiments, the monitor 194 is configured to show an overlay of the cutting position of the knife 146 on the tread segment 184 to form the trailing edge 188. In some embodiments, the monitor 194 is connected to a camera positioned to provide visual feedback for the alignment of the tire hub 120. In some embodiments, the monitor 194 is coupled to the measurement system 150 to provide feedback and information related to generating the proper trailing end cutting position of the tread segment.

[0025] The track 152 has a first track end 128 and a second track end 140. In some embodiments, the track 152 is a curved track. The first track end 128 is proximate to the exit of the cutting system 144 and the second track end 140 is proximate to the tire hub 120. The tread roll 160 can be a two-piece tread roll. A set of rollers 154 (e.g., a plurality of rollers) are mounted along the track 152. In some embodiments, the set of rollers 154 are placed along the track 152 to minimize the occurrence of jamming caused by the two-piece tread roll. In some embodiments, the track 152 is configured to curve to provide a desired height of access for the operator at or near the knife 146. The knife 146 can be a deadhead bench cutting device. The track 152 is also appropriately curved to allow a desired height of access for the operator to the knife 146 while providing sufficient height at the opposite end to accommodate large size tires. Additionally, the track 152 is configured as a curve to provide for the application of the leading end 186 to the carcass 200 on the tire hub 120 before the trailing end 188 is cut by the cutting system 144. In other words, the track 152 is configured to deliver the tread segment 184 to the end of the track adjacent to the carcass 200 (e.g., the second track end 140) for assembly on that end without introducing any significant bending or stretching caused by a sudden change in the travel path of the tread segment 184. In other words, as the tread is driven off the tread roll 160, the leading end 186 of the tread segment 184 is on the carcass 200, downstream of the uncut trailing end 188, as Figure 4As shown. In some embodiments, the track 152 is angled such that the tread can be applied tangentially to the crown of the carcass 200. In other words, the approach angle of the tread is tangential to the surface of the crown of the carcass 200. In some embodiments, the carcass 200 is 52 inches or less.

[0026] like Figure 1 and Figure 4 As shown, a tread roll 160 is mounted to a tread roller 162, which is configured to drive a tread segment from the tread roll 160 along a track 152. In some embodiments, a tread roller crank 158 may be positioned below the tread roll 160 and configured to drive the tread segment from the tread roll 160 along the track 152. In some embodiments, an automatic drive system drives the tread segment from the tread roll 160 along the track 152. In some embodiments, the automatic drive system is operatively connected to a controller unit. In some embodiments, both the automatic drive system and the tread roller crank 158 may be used to drive the tread segment from the tread roll 160 along the track 152. A set of drive rollers 164 are downstream of the tread roll 160 (e.g., the second track end 140 is downstream of the bench end 138, and the bench end 138 is upstream of the second track end 140) and configured to pull the tread section 184 from the tread roll 160 and push the tread section 184 away from the rollers 164. In some embodiments, the drive rollers 164 include grooved roller surfaces configured to better facilitate movement of the tread section 184 downstream of the track 152. In some embodiments, it is possible to implement... Figure 5 The line guide 402 shown minimizes the occurrence of tread segment 184 or other material winding onto the surface of the grooved roller. In some embodiments, the line guide 402 prevents tearing or rolling from the tread roll 160 and can be configured to interact (e.g., enter) with the grooves on the roller. In some embodiments, the grooved roller 404 is also positioned on the “tensioning” portion of the track 152. In other words, the line guide 402, positioned at the center of the grooved roller 404, prevents the polyethylene protective backing on the tread from winding onto the tensioning roller.

[0027] As the tread segment 184 travels along the track 152, the encoder 178 proximate the second track end 140 measures the amount of tread that has passed the encoder 178. In some embodiments, the encoder communicates with a central processing unit or control unit configured to track the position of the leading end 186 relative to the tread roll 160 (e.g., uncut trailing end 188) as the encoder 178 determines how much tread has been transferred from the track 152 onto the carcass 200. The encoder 178 is used to identify the potential trailing end 188 of the tread segment 184 for splicing by the cutting system 144. In some embodiments, a fastening member can be coupled to the leading end 186 of the tread segment 184 to facilitate the downward movement of the leading end 186 along the track 152. In some embodiments, the fastening member includes an encoder in communication with the central processing unit or control unit configured to track the position of the leading end 186 relative to the tread roll 160 (e.g., uncut trailing end 188). In some embodiments, a substantially continuous monitoring system is implemented such that the upstream operator control panel 192 is configured to capture and provide to an operator the length of the tread segment 184 (e.g., tread segment length).

[0028] The cutting system 144 is positioned downstream of the tread roll 160 and is configured to cut a length of the tread segment 184 from the uncut tread from the tread roll 160. The cutting system 144 includes a knife 146 configured to cut the tread segment 184. In some embodiments, the cutting system 144 and the knife 146 are positioned at a desired height for an operator to access the knife 146 while providing sufficient height at the opposite end to accommodate large size tires. In operation, the leading end 186 of the tread segment 184 passes through the cutting system 144 and travels along the track 152 downstream toward the carcass 200 on the tire hub 120. In some embodiments, the cutting system 144 includes a tread length monitoring system configured to capture and determine the amount of tread (e.g., length, width, etc.) from the tread segment 184 that passes through the cutting system 144 toward the tire hub 120.

[0029] The press system 104 includes a downstream operator control panel 122, a first main shaft 170 having a bonding buffer roll 182 thereon, a second main shaft 172 having another similar bonding buffer roll thereon, and a press roller 130. Generally, the press system 104 is configured to apply new tread sections 184 from the tread dispensing system 102 along the carcass 200 on the rotatable tire hub 120. The press system 104 is also configured to apply buffer gum between a front end 186 and a rear end 188 of the tread sections 184 along the carcass 200 on the rotatable tire hub 120 to form a continuous tread along the carcass 200 (e.g., to retread a tire). In some embodiments, the press system 104 is configured to apply buffer gum along the carcass 200 on the rotatable tire hub 120. In some embodiments, the press roller 130 can also be configured as a press and applicator roller.

[0030] The downstream operator control panel 122 is configured to control the drive system 108 of the tread roller 162, the drive roller 164, the cutting system 144, the press roller 130, and / or other components of the tread dispensing system 102. The downstream operator control panel 122 is configured to be redundant and mirrored to the control of the system by the upstream operator control panel 192. In other words, an operator of the tire tread bench 100 can control the drive system 108 of the tread roller 162, the drive roller 164, the cutting system 144, the press roller 130, and / or other components of the tread dispensing system 102 from the upstream operator control panel 192. The operator can then move downstream toward the tire hub 120 and control the system from the previous state from the downstream operator control panel 122. As Figure 1 As shown, the downstream operator control panel 122 is downstream of the track 152. The downstream operator control panel 122 includes a plurality of buttons and gauges 126 to partially control and monitor the operation of the tire tread bench 100. A monitor 124 is positioned above the downstream operator control panel 122 and is configured to provide visual feedback to the operator regarding the operation and dispensing of the tire tread from the tread roll 160. In some embodiments, the monitor 124 is configured to show an overlay of the cutting position of the knife 146 on the tread section 184 to form the rear edge 188. In some embodiments, the monitor 124 is connected to a camera positioned to provide visual feedback for the alignment of the tire hub 120. In some embodiments, the monitor 194 is coupled to the measurement system 150 to provide feedback and information regarding generating an appropriate rear end cutting position of the tread section. In some embodiments, the monitor 124 is connected to a camera positioned to provide visual feedback for the alignment of the tire hub 120. In some embodiments, a foot-operated device 136 (e.g., a foot pedal) is configured to control one or more of the rotation of the first main shaft 170, the second main shaft 172, and / or the tire hub 120.

[0031] The presser roller 130 is configured to perform a press operation and application of the tread segment 184 to the carcass 200 positioned on the tire hub 120. In some embodiments, as the tread segment 184 is placed on the carcass 200 and the carcass 200 is rotated about the tire hub 120, the presser roller 130 can be moved along the presser track 132 to provide force onto the tread segment 184, such as in the direction indicated by arrow 508. In some embodiments, the presser roller 130 includes a set of rollers that can be moved relative to each other and can be moved adjacent to each other to form a single presser roller 130. In some embodiments, the presser roller 130 can also be moved in a direction substantially perpendicular to the surface of the carcass to apply a variable amount of force to the surface in contact with the presser roller 130. The presser roller 130 can be coupled to the power operated device 156 configured to provide power and facilitate movement of the presser roller 130. Figure 4

[0032] Turning now to Figure 6 , the tread segment 184 is shown applied to the carcass 200. The carcass 200 can be a carcass similar to the carcass 200 of Figure 1 . The carcass 200 includes a curved crown segment 502 and shoulders 504. The crown 502 is substantially the surface to which the tread segment 184 from the tread roll 160 is applied, as shown in Figure 6 . The presser roller 130 applies pressure to the tread segment 184 to stretch the tread segment 184 on the carcass 200 and allows for less tread segment 184 to be used and matching of the tread design on the front end 186 and the back end 188. In some embodiments, the presser roller 130 is configured to apply a cushion gum and a polyethylene protective layer to the carcass 200. In some embodiments, the polyethylene protective layer is configured to prevent adhesion to other cushion gum layers when rolled up and to prevent adhesion to the presser roller 130 during application. In some embodiments, the polyethylene protective layer is removed after the press operation is complete. In some embodiments, the tread segment 184 is applied to the carcass 200 by controlled stretching (velocity differential introduced by rotation of the tire hub 120). For example, due to the velocity differential between a point surface of the carcass 200 and a point on the tread surface, the tread can be compressed and stretched by the presser roller 130 and thus able to be applied to the carcass 200 on the tire hub 120.

[0033] Reference is now made to Figure 7 ​FIG. 6 shows a side view schematic of the kinematics of a tread segment application process, according to an example embodiment. The tread application from the tread roll 106 onto the tire body 200 over the tire hub 120 is shown. Due to the velocity difference between the point 620 on the surface of the tire body 200 and the point 622 on the surface of the tread segment 184 exiting the roller 154 along the second track end 140, the tread can be compressed and stretched by the presser roller 130 and thus be able to apply to the tire body 200 over the tire hub 120. As shown in Figure 7 the tread segment 184 exiting the roller 154 has an angular velocity ω2 612 and the tire hub 120 has an angular velocity ω1 610 such that the tire body 200 has an angular velocity ω1 610. To induce stretching of the tread segment 184 exiting the roller 154, the point 620 on the surface of the tire body 200 has a velocity V1 and the point 622 on the distributed tire tread has a velocity V2. A non-negative velocity difference Δν = V1 - V2 results because ω1 610 and ω2 612 are geared to provide different V2 and V1, where V1 is greater than V2. Thus, due to the velocity difference, as the tire body 200 rotates with the rotation of the tire hub 120, the tread segment 184 exiting the roller 154 is necessarily stretched and wrapped over the tire body 200. In some embodiments, it is desirable to provide a constant maximum velocity in a range of magnitudes during tire tread application. In some embodiments, because the maximum tangential velocity is constant in a range of magnitudes, a maximum tangential velocity of points (e.g., point 620) along the surface of the tire body 200 is achieved for a variety of tire bodies (e.g., widths and radii). In some embodiments, the tangential velocity (based on the dimensions of the tire body 200) of points (e.g., point 620) along the surface of the tire body 200 varies during tire tread application to provide a constant angular velocity in a range of magnitudes. In some embodiments, the application of the tread segment 184 onto the tire body 200 is substantially different than the application tire tread process shown in Figure 7 .

[0034] As the tread segment 184 is applied to the tire body 200, the presser roller 130 moves to engage the tread segment 184 and provide a force to the tread segment along the tire body 200. The tire body 200 rotates about the tire hub 120 while the presser roller 130 provides a force (e.g., in the direction indicated by arrow 508 in Figure 5 . In some embodiments, the presser roller 130 starts in the middle of the crown segment 502 and, during subsequent rotations, the presser roller 130 moves toward the shoulder 504 of the crown segment 502 in the direction indicated by arrow 510. This operation, often referred to as pressing, provides for the tread segment 184 to adhere to the surface of the cushion gum 180 on the tire body 200 (e.g., the crown segment 502 and the shoulder 504) while helping to remove any trapped air pockets between the cushion gum 180 and the tire body 200.

[0035] In embodiments where the tire tread bench 100 is configured to apply the cushion gum layer 180 to the bare carcass 200, the first spindle 170 and / or the second spindle 172 are coupled to one or more drive wheels configured to engage the surface of the carcass 200 and be driven by rotation of the tire wheel hub 120. In some embodiments, the drive wheels are connected to the first spindle 170 and / or the second spindle 172 through a system of gears and / or belts such that the first spindle 170 and / or the second spindle 172 rotate at a surface speed proportional to the surface speed at which the carcass 200 is rotated by the drive system of the rotating tire wheel hub 120. In some embodiments, the drive wheels are connected to the first spindle 170 and / or the second spindle 172 through a pneumatic system such that the first spindle 170 and / or the second spindle 172 rotate at a surface speed proportional to the surface speed at which the carcass 200 is rotated by the drive system of the rotating tire wheel hub 120. In some embodiments, the press roller 130 is configured to perform a press operation and application of the cushion gum to the carcass positioned on the tire wheel hub 120. In some embodiments, the tire tread bench 100 is configured to provide improved conformability of the cushion gum 180 to the contoured crown 502 of the carcass 200. The improved conformability provides uniform adhesion and contact of the cushion gum 180 to the crown 502, thereby causing the cushion gum edge to contact the carcass 200 substantially wrinkle-free, thereby further reducing the need to provide additional strips of cushion gum (e.g., cushion gum stripping) along the shoulder 504 of the crown 502. In some embodiments, the tire wheel hub 120 moves along a diagonal of the hub track to position the carcass adjacent to the joining cushion gum roll 182.

[0036] Returning to Figures 1 to 4 , the tread carriage 110 (and track 152) of the tire tread bench 100 is configured such that the leading end 186 of the tread segment 184 is applied to the carcass 200 prior to the knife 146 of the cutting system 144 determining and / or cutting the trailing end 188. In other words, the application of the leading end 186 and other portions of the tread segment 184 to the carcass 200 occurs prior to the full measurement and cutting of the tread segment 184. As the leading end 186 contacts the carcass 200, the tire wheel hub 120 rotates while the press roller 130 provides a variable controlled pressure to the tread segment 184 on the surface of the carcass 200. The pressure applied by the press roller 130 provides the leading end 186 and the tread segment 184 to adhere to the cushion gum layer 180 and extend the overall length of the tread due to the force applied by the press roller 130 and the associated Poisson effect.

[0037] The desired length of the tread segment 184 can be determined based on the measured circumference of the carcass 200 with the cushion gum 180 adhered thereto. The determined length and the length of the assigned tread segment 184 are monitored. Because the leading end 186 and the circumference of the carcass 200 and the location of the cushion gum 180 are known, the distance of the circumference that has not yet been covered by the tread segment 184 can be determined. By comparing the remaining distance of the circumference to be covered and the amount of tread that has not yet been applied, the presser roller 130 can be commanded to apply the appropriate force to provide the appropriate amount of stretch and ultimately to match the leading end 186 with the trailing end 188 that has not yet been cut. Once the trailing end 188 is cut, the tire tread bench 100 can monitor, determine, and adjust the force applied by the presser roller 130 to provide the appropriate amount of stretch and ultimately match the cut leading end 186. In some embodiments, the tire tread bench 100 can leave a gap with a gap length that falls within a predetermined range.

[0038] As the determined length is dispensed from the tread roll 160 and the tread segment 184 including the leading end 186 is applied to the carcass 200, the operator is able to identify the potential trailing end 188 of the tread segment 184. The operator can influence the location of the final cut of the trailing end 188 to ensure that the tread design (e.g., tread pattern, tread groove, etc.) matches the leading end 186 while still achieving the length match of the tread segment. In some embodiments, a stop element can be engaged when the desired length of the tread segment 184 is dispensed from the tread roll 160 by the tread roller 162 or is in contact with the drive roller 164. In some embodiments, the stop element can be an alarm on one or both of the monitors 124, 194 on the tire tread bench 100. In some embodiments, the stop element is a physical element that extends over the track 152. In some embodiments, the stop element is a command to the drive roller 164 to stop dispensing tread from the tread roll 160.

[0039] In some embodiments, the downstream operator control panel 122 is operably connected to the upstream operator control panel 192, enabling an operator to control the cutting system 144 and / or the drive system 108 from the downstream operator control panel 122. In some embodiments, the monitor 124 can be configured to replicate the display on the monitor 194. In some embodiments, an operator is able to be adjacent to the tire hub 120, monitor the tread segment 184 application on the tire carcass 200, and monitor the length and tire tread design of the tread segment 184 by the cutting system 144. When the potential trailing end 188 reaches the desired length and / or tire tread design, the operator is able to cause the knife 146 to cut the trailing end 188 of the tread segment 184 from the downstream operator control panel 122. The tire tread bench 100 is configured to allow the operator to make minor adjustments to the cutting location of the trailing end 188 of the tread segment 184 to match the periodic repeating tire tread design of the leading end 186 with the tire tread design at the trailing end 188 so that when the trailing end 188 is adhered to the tire carcass 200 and abuts the leading end 186, the pattern is substantially continuous.

[0040] Matching the design of the leading end 186 and the trailing end 188 at the splice area in the finished retreaded tire provides a continuously repeating tire tread design that is substantially not disrupted by the splice for structural strength and aesthetic appeal. For example, the tire tread design can have a first pattern end and a second pattern end such that the first pattern end is placed on the second pattern end to form a repeating substantially continuous pattern on the tire tread design. In some embodiments, the tire tread bench 100 includes an automated system that automatically identifies the appropriate leading end 186 location and engages the knife 146 to splice the tread based on the tire tread design and the desired length of the tread segment 184. In some embodiments, the cutting determination is controlled by and operably connected to a controller unit. Once the tread segment 184 is coupled to the tire carcass 200, the tire carcass 200 is removed from the tire hub 120 and vulcanized. In some embodiments, the finished tire carcass 200 (e.g., the tire carcass 200 with the cushion gum layer 180 and the tread segment 184) is placed in a pressurized flexible envelope for vulcanization.

[0041] It should be noted that the use of the term “example” herein when used in conjunction with various embodiments is intended to represent that such embodiments are possible examples, representations, and / or illustrations of possible embodiments (and such terms are not intended to imply that such embodiment is necessarily the best or only example). It should be noted that the use of the term “or” in the detailed description and / or in the claims is used to mean, for example, either or both. For example, the phrase “A or B” means “A or B or both.” For another example, the phrase “at least one of A and B” means “A or B or both.” For still another example, the phrase “at least one of A or B” means “at least one of A or at least one of B.”

[0042] As used herein, the term “downstream” is used to refer to a system, device, element, and / or component that occurs later in a production sequence or line as compared to other systems, devices, elements, and / or components. The term “upstream” is used to refer to a system, device, element, and / or component that occurs earlier in a production sequence or line as compared to other systems, devices, elements, and / or components.

[0043] As used herein, the terms "substantially" and like terms are intended to have their broad, ordinary meaning to persons of ordinary skill in the art to which the subject matter of the present disclosure pertains. It is understood by those of ordinary skill in the art to which this present disclosure is directed that these terms are intended to allow for a description of certain features without limiting the scope of those features to the precise numerical ranges provided. Thus, these terms should be construed as meaning that non-substantial or immaterial modifications or alterations of the described and claimed subject matter (e.g., within plus or minus five percent of a given angle or other value) are deemed to be within the scope of the present disclosure as described in the appended claims. In some embodiments, the term "substantially" refers to a tolerance of plus or minus ten percent. The term "about" when used in relation to a value refers to plus or minus five percent of the associated value.

[0044] The present application also sets forth directions in conjunction with the rotational axis of the tire. The terms "upwardly" and "upwardly" refer to the general direction toward the tread of the tire, while "downwardly" and "downwardly" refer to the general direction toward the rotational axis of the tire. Thus, when relative directional terms (e.g., "upper" and "lower") are used in conjunction with elements, the "upper" element is closer to the tread than the "lower" element. Further, when relative directional terms such as "above" or "below" are used in conjunction with elements, if a certain element is "above" another element, it means that the element is closer to the tread than the other element. Additionally, the term "radially inner" refers to an element that is closer to the rotational axis than a "radially outer" element. The terms "axially inwardly" and "axially inwardly" refer to the general direction toward the equatorial plane of the tire, while "axially outwardly" and "axially outwardly" refer to the general direction away from the equatorial plane of the tire and toward the sidewall of the tire.

[0045] The terms "coupled," "connected," and the like, as used herein, mean the joining of two members directly or indirectly to one another. Such joining can be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining can be achieved either

[0046] It is important to note that the construction and arrangement of the various example embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review the present disclosure will readily appreciate that many modifications (e.g., changes in sizes, dimensions, structures, shapes and proportions of the various elements, parameters, values, mounting arrangements, use of materials, colors, orientations, etc.) can be made to the embodiments described and illustrated without materially departing from the novel teachings and advantages of the subject matter described herein. Other substitutions, modifications, changes, and omissions can also be made in the design, operating conditions and arrangement of the various example embodiments without departing from the scope of the embodiments as described herein.

[0047] While this specification contains many specific implementation details, these should not be construed as limitations on the scope of any embodiments or of what can be claimed, but as descriptions of particular implementations of certain embodiments only. Certain features that are described in this specification in the context of separate implementations can also be implemented in combinations with each other. Conversely, various features that are described in the context of a single implementation can also be implemented on other implementations alone or in any suitable subcombination. Moreover, although features can be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination and the claimed combination can be directed to a subcombination or variation of a subcombination.

Claims

1. A tire tread cutting apparatus for cutting a length of tire tread, the tire tread cutting apparatus comprising: a track having a first track end and a second track end downstream of the first track end, the track including a plurality of rollers positioned between the first track end and the second track end, the plurality of rollers configured to facilitate the tire tread along the track; a tire hub positioned downstream of and adjacent to the second track end, the tire hub configured to receive a tire body, wherein the tire body defines a tire body circumference along an outer surface of the tire body; a tread dispenser positioned upstream of the track and configured to dispense tire tread, the tread dispenser including a drive roller configured to drive tire tread downstream toward the second track end, the tire tread having a first tread end and a roll end; a cutting element positioned downstream of the tread dispenser and upstream of the track, the cutting element configured for cutting the tire tread to define a second tread end, the first tread end and the second tread end defining a section of tire tread; a measuring device configured to measure the circumference of the tire body; and a control unit operably connected to the measuring device and the tread dispenser and configured to: cause the tread dispenser to dispense tire tread along the track to adhere the first tread end to the tire body; cause the tire hub to rotate the tire body to adhere the tire tread to the tire body; cause the measuring device to measure the circumference of the tire body while the tire body is rotating to adhere tire tread to the tire body; receive a measurement of the tire body circumference from the measuring device; determine a position of the second tread end based on the measurement; and cause the cutting element to cut the tire tread based on the determined position of the second tread end.

2. The tire tread cutting apparatus of claim 1, wherein the tire body includes a cushion gum layer, and wherein the measurement of the tire body circumference is the circumference of the tire body plus the cushion gum layer.

3. The tire tread cutting apparatus of claim 1, wherein at least one roller of the plurality of rollers includes a groove along a surface of the at least one roller, wherein the at least one roller is adjacent to the second track end.

4. The tire tread cutting apparatus of claim 1, further comprising a clamp element configured to clamp a portion of the tire tread adjacent to the first tread end prior to cutting the tire tread to define the second tread end, the clamp element driven to push the portion of the tire tread adjacent to the first tread end toward the second track end.

5. The tire tread cutting apparatus of claim 1, further comprising: ​ a press roller positioned above the tire hub, the press roller configured to apply a force to the first tread end on the outer surface of the tire body to adhere the first tread end to the outer surface of the tire body, wherein the press roller is configured to apply a force on the tire tread as the tire body rotates to adhere the tire tread to the outer surface of the tire body; and a buffer blanket downstream of the track, the buffer blanket configured to distribute buffer rubber along the tire body, wherein the press roller is configured to apply a force to the buffer rubber to adhere the buffer rubber to the tire body to define the tire body circumference.

6. A method of cutting a length of tire tread for a retreaded tire having a tire body positioned on a tire hub, the tire body having a layer of buffer rubber applied thereto, the method comprising: distributing tire tread from a tread dispenser along a track upstream of a tire hub, the tire tread having a first tread end and a tread length, the tread length defined by a distance between the first tread end and a tire tread roll upstream of the tread dispenser; conveying the first tread end along the track toward the tire body; adhering the first tread end of the tire tread to an outer surface of buffer rubber having the tire body positioned on a tire hub; rotating the tire body and the buffer rubber on the tire hub to adhere tire tread to the tire body; measuring a circumference of the buffer rubber applied to the tire body as the tire body and the buffer rubber rotate to adhere tire tread to the tire body; determining a second tread end based on the measurement of the circumference of the buffer rubber; cutting the tire tread at the determined second tread end to define a section of tire tread, wherein the section of tire tread is defined by the first tread end and the second tread end.

7. The method of claim 6, wherein the tire tread includes a repeating tread pattern, each tread pattern having a first pattern end and a second pattern end, such that adjoining the first pattern end and the second pattern end defines a continuous tread pattern, and wherein the first tread end has the first pattern end, and wherein determining the second tread end includes identifying a portion of the tire tread having the second pattern end.

8. The method of claim 6, further comprising displaying a location of the second tread end on a monitor.

9. The method of claim 6, wherein the track includes a plurality of rollers positioned between a first track end and a second track end downstream of the first track end, wherein at least one roller of the plurality of rollers includes a groove along a surface of the at least one roller, wherein the at least one roller is adjacent to the second track end.

10. The method of claim 6, wherein conveying the section of tire tread to the tire body along the track is caused by advancing the first tread end of the tire tread, the first tread end being conveyed to the tire body without subjecting the tire tread to any appreciable bending.

11. A tire tread cutting apparatus for cutting a length of tire tread, the tire tread cutting apparatus comprising: a track having a first track end and a second track end downstream of the first track end, the track including a plurality of rollers positioned between the first track end and the second track end, the plurality of rollers configured to facilitate the tire tread along the track; a tire hub positioned downstream of and adjacent to the second track end, the tire hub configured to receive a carcass, wherein the carcass includes a cushion layer to define a carcass circumference along an outer surface of the carcass; a tread dispenser positioned upstream of the track and configured to dispense tire tread, the tread dispenser including a drive roller configured to drive tire tread downstream toward the second track end, the tire tread having a leading end and a tread length defined by a distance between the leading end and a tire tread roll upstream of the tread dispenser; a cutting element positioned downstream of the tread dispenser and upstream of the track, the cutting element configured to splice the tire tread to define a trailing end, the leading end and the trailing end defining a segment of tire tread; a measuring device configured to measure the circumference of the carcass; and a control unit operably connected to the measuring device and the tread dispenser and configured to: cause the tread dispenser to dispense tire tread along the track to adhere the leading end to the carcass; cause the tire hub to rotate the carcass to adhere the tire tread to the carcass; cause the measuring device to measure the circumference of the carcass while the carcass is rotating to adhere tire tread to the carcass; receive a measurement of the carcass circumference from the measuring device; determine a location of the trailing end based on the measurement; and cause the cutting element to cut tire tread based on the determined location of the trailing end. ​

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