Continuous belt for manufacturing tire base

Abstract

A method of manufacturing a continuous strip of tire base layers, the method comprising: providing a sheet of material having a first transverse edge portion and a second transverse edge portion, where the first transverse edge portion is separated from the second transverse edge portion by a central portion; placing a first reinforcing element on the sheet at a location where the first lateral edge portion intersects the central portion, and placing a second reinforcing element on the sheet at a location where the central portion intersects the second lateral edge portion; folding the first lateral edge portion over the first reinforcing element; folding the second lateral edge portion over the second reinforcing element; and securing the first lateral edge portion and the second lateral edge portion to the central portion.

Description

Technical Field

[0001] The present invention relates to a method and an apparatus for manufacturing a continuous strip of a tire base layer and the resulting continuous strip of a tire base layer. The present invention can also be extended to a method and an apparatus for manufacturing a tire by using a continuous strip of a tire base layer. Background Art

[0002] Tires (which may be, for example, tires for vehicles that are any device for transporting people or goods) are typically manufactured using a batch process that requires manual labor during intermediate steps of the process as well as during multiple steps of the process itself. For example, in an initial step, the bead wire is typically formed into a ring for use in the tire, the bead wire is placed by hand on a ring of tire base material on a drum, and the bead wire is then secured within the tire base. A preformed rubber strip for forming the tread may then be placed on the tire base on the drum. The combined ring of tread and tire base is moved to an expansion mold where a curve is added to the flat surface of the ring. The partially formed tire may then be placed by hand into a separate curing mold so that the tire can be further shaped and the tread pattern formed during the curing process.

[0003] Such batch processing is inefficient in terms of time and cost. It would therefore be beneficial to achieve a more efficient tire manufacturing process. Summary of the invention

[0004] From a first aspect, the present invention provides a method for manufacturing a continuous belt of a tire base layer, the method comprising: providing a material sheet having a first lateral edge portion and a second lateral edge portion, wherein the first lateral edge portion is separated from the second lateral edge portion by a center portion; placing a first reinforcing element at a position on the sheet where the first lateral edge portion intersects the center portion, and placing a second reinforcing element at a position on the sheet where the center portion intersects the second lateral edge portion; folding the first lateral edge portion over the first reinforcing element; folding the second lateral edge portion over the second reinforcing element; and fixing the first lateral edge portion and the second lateral edge portion to the center portion.

[0005] The tire base layer is a layer provided below the tread of the tire and provides a framework for the tire. In a pneumatic tire where there is an inner tube or inner liner, the base layer covers the inner tube or the inner liner to provide protection and constrain the inner tube or the inner liner, thereby supporting resistance to internal pressure. The tire base layer may include a fiber composite material. The fibers of the fiber composite material may be referred to as the carcass of the tire.

[0006] A reinforcing element is any feature that provides a reinforcing effect to the tire base. The reinforcing element therefore helps to impart rigidity to the tire base, thereby helping the tire base to maintain its shape and ability to withstand internal pressure. The material sheet of the tire base can be a flexible material to provide toughness to the base and assist the tire in grasping the surface when in use. The material sheet can be a fabric sheet, an elastomer sheet, or a composite sheet. The fabric sheet can include a mesh, that is, the sheet can have an open structure resulting from the fiber separation of the mesh fabric sheet. The reinforcing element can be in the form of a bead wire. A bead wire is a section of material similar to a cable or a rod because it extends significantly in one dimension. When the bead wire is laid on the material sheet, the bead wire extends in one direction without forming a ring. Bead wire is not necessarily limited to a metal wire.

[0007] The method enables the formation of a base layer including reinforcing elements in a continuous manner. The base layer including reinforcing elements can be formed as a flat piece that does not necessarily have a length commensurate with the circumference of the tire. Instead, using the above method, a long section of base layer can be produced that is several times the circumference of the tire and can be cut to appropriate size as required. Providing a continuous strip of tire base layer allows the base layer to be incorporated into a continuous process for forming a tire.

[0008] The sheet may include a longitudinal length, the first transverse edge portion intersecting the central portion along a line parallel to the longitudinal length of the sheet, and the central portion intersecting the second transverse edge portion along a line parallel to the longitudinal length of the sheet.

[0009] Thus, the width of the material portion folded over the reinforcing element remains constant along the longitudinal length of the base layer.The longitudinal length of each of the reinforcing elements is thus provided parallel to the longitudinal length of the base layer.

[0010] When a bead wire is used as the reinforcing element, the bead wire will extend in and parallel to the longitudinal length of the base layer. The reinforcing element will maintain the same distance from the edge of the base layer along the entire length of the base layer. Therefore, when used in a tire, when the two ends of the base layer are joined, each of the reinforcing elements will closely intersect with the other end of the reinforcing element.

[0011] The material sheet may include any suitable material for the base layer of the tire. For example, plastic or metal. The sheet of any such material may be provided in the form of a mesh including surface through-holes or in the form of a continuous / plate (i.e., a continuous material) that does not include surface through-holes.

[0012] After folding the first lateral edge portion over the first reinforcing element and after folding the second lateral edge portion over the second reinforcing element, the first lateral edge portion and the second lateral edge portion may overlap, and the method may include: fixing the first lateral edge portion to the second lateral edge portion.

[0013] If the width of the material folded over the reinforcing portion is large enough, the overlapping area of ​​the first lateral edge portion and the second lateral edge portion can be joined. The base layer can thus be constructed to have increased strength, specifically increased tensile strength in the lateral direction. Additionally, the overlapping portion will form an additional material layer through the thickness of the base layer, thereby improving the base layer properties, such as strength, toughness, damage resistance and puncture resistance.

[0014] The reinforcing element may be a bead wire comprising metal, a thermoplastic polymer or a thermosetting polymer.

[0015] The bead wire may comprise Kevlar or other suitable aramid materials. The bead wire may comprise steel, aluminum or other suitable metals or metal alloys.

[0016] The first reinforcement element and / or the second reinforcement element may be secured to the sheet of material.

[0017] The first reinforcing element and / or the second reinforcing element are therefore engaged to the sheet of material so that they cannot be easily moved from their fixed position. In the case where the sheet of material includes a component (such as a suitable elastomer) that can act as a heat-activated adhesive component, the material can be heated so that the tire bead is fixed in place. The first reinforcing element and / or the second reinforcing element can be fixed to the sheet of material by sewing the reinforcing element to the sheet of material. Optionally, the line for sewing the reinforcing element to the sheet of material is a nylon line, a UHMW polyethylene line or an aramid line. In the case where the sheet of material includes a fabric and / or a mesh fabric, it may be particularly advantageous to sew the first reinforcing element and / or the second reinforcing element to the sheet of material.

[0018] By securing the reinforcement element to the sheet of material, the reinforcement element may be more effectively held in place.

[0019] When the first transverse end and / or the second transverse end are folded over the first reinforcing element and / or the second reinforcing element before fastening the reinforcing element to the sheet of material, the dimensional accuracy of the folding procedure is increased.

[0020] The sheet of material may include fibers and optionally one or more of an elastomer and a binder.

[0021] The fiber may comprise any suitable material, such as one or more of nylon, cotton, polyester, aramid and semi-synthetic fibers (such as rayon yarn). The fiber may be provided in a mesh structure to form a fabric sheet having an open structure (i.e., a structure comprising holes penetrating the surface).

[0022] In the case where the sheet includes fibers and one or more of an elastomer and an adhesive, the sheet of material will therefore include a fiber composite material. The adhesive may be an epoxy resin. The fibers used for the fiber composite material in the tire base layer may be referred to as a carcass. The fibers may include one or more of nylon, cotton, polyester fibers, and aramid fibers. The elastomer may include rubber, a thermoplastic elastomer, or a thermosetting elastomer. The elastomer may be in the form of a coating on the fiber. For example, the sheet of material may include nylon fibers and a rubber coating, or may include nylon fibers and a thermoplastic elastomer.

[0023] The fiber composite material provides high strength and high toughness, and in particular the fiber has high tensile strength.

[0024] In some language usage, the tire base layer including the fiber composite material may be referred to as the carcass of the tire, in which case the method of the present invention may be extended to manufacture a continuous strip of carcass for a tire. The sheet of material may include fibers arranged in a woven or knitted pattern, and wherein the longitudinal length of the fibers in the woven pattern is offset from the longitudinal direction of the sheet of material.

[0025] The woven pattern or the knitted pattern include fibers extending in different directions and arranged so that the fibers overlap each other and / or are woven up and down each other. The woven pattern and / or the knitted pattern may include a first unidirectional fiber group and one or more second fiber groups for fixing the first fiber group relative to each other. The material sheet may be formed via biaxial braiding or triaxial braiding. The material sheet may include a warp and weft density of 5T (total number of fibers per square inch) or higher. The material sheet may include a warp and weft density of 50T or higher.

[0026] The weaving pattern or the knitting pattern may produce a mesh (open) structure including surface through-holes or a continuous structure including no surface through-holes. Oxford cloth is an example of a continuous structure including no through-holes formed by weaving.

[0027] The fiber composite tire base material sheet can start as an initial sheet of two widths of similar magnitude, and at least some of the fibers can extend parallel to the width of the sheet. To produce a length of base material sheet in which the longitudinal length of the fibers is offset from the longitudinal direction of the sheet, the base material sheet is cut from the initial sheet at a desired angle relative to the width of the initial sheet. By utilizing fibers that are offset from the length of the base layer and therefore from the circumferential length of the tire in which the base layer is formed, the high tensile strength of the fibers can provide strength in multiple directions of the tire.

[0028] The woven material or the knitted material may be coated with an elastomer. Specifically, Oxford cloth may be coated with thermoplastic polyurethane and used as the material sheet for the tire base layer.

[0029] The longitudinal length of the fibers may be offset from the longitudinal direction of the sheet of material by 30 degrees or more.

[0030] Optionally, the fibers can be staggered 45 degrees to the longitudinal direction of the sheet of material. Staggering the fibers a higher degree allows for a more even distribution of strength across the direction of the tire.

[0031] The securing may include welding the overlapping materials together using welding or may include a sewing operation.

[0032] The welding operation can increase the strength of the joint between the overlapping parts. The welding operation can include one or more of heated tool welding, hot gas welding, ultrasonic welding, spin welding, infrared welding, high frequency welding, vibration welding, induction welding, microwave welding, resistance welding, extrusion welding and laser welding.

[0033] The welding operation may include applying heat and pressure, wherein the temperature of the material is optionally raised to above 140 degrees Celsius. This softens the material and provides adhesion when cooled. The heat may be applied by an external heat source, and / or the heat may be generated by mechanical movement, and / or the heat may be generated electromagnetically.

[0034] The stitching operation may comprise securing the overlapping materials to each other with thread. The stitching operation is particularly advantageous when the material sheet comprises a fabric and / or a mesh fabric.

[0035] The securing may include adding a bonding material to at least a portion of the overlapping portions of the sheets of material.

[0036] Optionally, the bonding material may be an adhesive such as a self-curing adhesive, a reactive adhesive, a pressure-sensitive adhesive, a thermosetting adhesive, etc. The bonding material may be a resin or an epoxy resin. The sheet of material may include an elastomeric coating, and during the heat treatment, the elastomeric coating may serve as a bonding material. The elastomeric coating may include rubber or a thermoplastic elastomer.

[0037] The fixing process can be improved via surface modification before joining, such as by plasma pretreatment or corona pretreatment applied to at least a portion of the overlapping portion of the material sheet. Such pretreatment, for example, cleans the surface and / or activates the surface to improve joining. Such surface modification can be combined with joining of fabric sheets to fabric sheets, composite sheets to composite sheets, elastomer sheets to elastomer sheets, and in the case where the joining material is added to at least a portion of the overlapping portion, the sheet material can be any one of a fabric, a composite material or an elastomer. In the case where the material sheet is composed of a fabric and / or a mesh fabric, plasma treatment or corona treatment is particularly advantageous.

[0038] The method includes providing a puncture protection layer on at least a portion of the central portion of the sheet of material.

[0039] The positioning of the puncture protection material on the central portion ensures that when the base layer is used in a tire, the puncture protection layer will be correctly positioned to protect the tire. The puncture protection material may extend along the length of the sheet of material and its central portion. The puncture protection layer may be provided on at least a central area of ​​the central portion so that when the base layer is used to form a tire, the puncture protection layer will be positioned below the tread, and therefore below where the tire contacts the road for optimal protection.

[0040] The puncture protection layer may be provided on at least a portion of the first lateral edge portion and / or the second lateral edge portion of the sheet of material. Thus, once the first lateral portion and the second lateral portion are folded over, the puncture protection layer will be properly positioned for use in the tire, thereby providing reinforcement to the ground contacting portion of the tire and to the sidewall of the tire which is also at risk of puncture.

[0041] The puncture protection layer may include one or more of an elastomer, a plastic, a composite material, a fiber sheet, a fiber reinforced elastomer, and a metal.

[0042] The material of the puncture protection layer is tough and can resist penetration or damage by an object. The puncture protection layer may include rubber or other suitable elastomers.

[0043] Once the first and second transverse edge portions are each folded onto the central portion, the puncture protection layer may be provided on one or both sides of the material sheet relative to the side surrounded by the first and second transverse edge portions.

[0044] The puncture protection layer may be in place on the sheet of material when the first and second lateral edge portions are folded, alternatively the puncture protection layer may be overmoulded onto the sheet of material after the first and second lateral edge portions are secured to the central portion.

[0045] The method may include winding the continuous strip of tire base layer onto the mandrel.

[0046] The continuous strip of base layer can be wound onto the reel, in particular in order to store the base layer before it is cut into the desired length for use in a tire.

[0047] From another aspect, the present invention provides a method for manufacturing a continuous belt of a tire base layer, the method comprising: providing a tubular material having a longitudinal length; inserting a first reinforcing element and a second reinforcing element into the tubular material so that the longitudinal length of each reinforcing element is parallel to the longitudinal length of the tubular material; and adhering the first reinforcing element and the second reinforcing element to opposite first and second longitudinal sides of the tubular material.

[0048] The tubular material has a hollow cross-section extending along its length. The tubular material may have a circular hollow cross-section; however, the tubular material may be flexible so that the cross-sectional shape may be changed. A reinforcing element is any feature that provides a reinforcing effect to the tire base layer. The reinforcing element therefore helps to impart rigidity to the tire base layer, thereby helping the tire base layer to maintain its shape and withstand internal pressure. The material sheet of the tire base layer may be a flexible material to provide toughness to the base layer and assist the tire in gripping the surface when in use. The reinforcing element may be in the form of a bead wire. A bead wire is a length of material similar to a cable or a rod because it extends significantly in one dimension. When the bead wire is laid on the material sheet, the bead wire extends in one direction without forming a ring. Bead wires are not necessarily limited to metal wires.

[0049] The reinforcement elements are adhered relative to each other such that the length of material between the two reinforcement elements is the same above and below the reinforcement elements when viewed in a cross section perpendicular to the length of the tubular material.

[0050] The method enables the formation of a base layer including reinforcing elements in a continuous manner. The base layer including reinforcing elements can be formed as a flat piece that does not necessarily have a length commensurate with the circumference of the tire. Instead, using the above method, a long section of base layer can be produced that is several times the circumference of the tire and can be cut to appropriate size as required. Providing a continuous strip of tire base layer allows the base layer to be incorporated into a continuous process for forming a tire.

[0051] Providing the tubular material may include providing a sheet of material having a first edge portion and a second edge portion opposite the first edge portion; and securing the first edge portion to the second edge portion to form the tube.

[0052] The first and second reinforcement elements may be introduced into the tubular material when the first edge portion and the second edge portion are secured together.

[0053] The reinforcement element may thus be fed into position as the tubular material is being formed.

[0054] Securing the first edge portion of the sheet of material to the second edge portion may include sewing the first edge portion to the second edge portion.

[0055] Securing the first edge portion of the tubular material to the second edge portion may include welding the overlapping materials together using a welding operation or sewing the overlapping materials together.

[0056] The welding operation may include one or more of heated tool welding, hot gas welding, ultrasonic welding, spin welding, infrared welding, high frequency welding, vibration welding, induction welding, microwave welding, resistance welding, extrusion welding, and laser welding. The welding operation may include applying heat and pressure to the overlapping materials. The heat may be applied by an external heat source, and / or the heat may be generated by mechanical movement, and / or the heat may be generated using electromagnetics.

[0057] The securing the first edge portion of the tubular material to the second edge portion may include adding a joining material to the sheet of material.

[0058] Optionally, the bonding material may be an adhesive such as a self-curing adhesive, a reactive adhesive, a pressure sensitive adhesive, a thermosetting adhesive, etc. The bonding material may be a resin or an epoxy resin. The tubular material may include an elastomeric coating, and during the heat treatment, the elastomeric coating may act as a bonding material.

[0059] The tubular material between and above the first reinforcement element and the second reinforcement element may be joined to the tubular material between and below the first reinforcement element and the second reinforcement element.

[0060] Thus, a length of flat base layer is formed including the bead wire embedded in the base layer.

[0061] The joining of the associated portions of tubular material may include welding the overlapping tubular material together using a welding operation.

[0062] The welding operation may include one or more of heated tool welding, hot gas welding, ultrasonic welding, spin welding, infrared welding, high frequency welding, vibration welding, induction welding, microwave welding, resistance welding, extrusion welding, and laser welding. The welding operation may include applying heat and pressure to the overlapping tubular materials. The heat may be applied by an external heat source, and / or the heat may be generated by mechanical movement, and / or the heat may be generated using electromagnetics.

[0063] The tubular material may include fibers and one or more of an elastomer and an epoxy resin. Therefore, the tubular material may include a fiber composite material. The fiber of the fiber composite material used in the tire base layer may be referred to as a carcass. The fiber may include any suitable material, such as nylon, cotton, polyester fiber, and aramid. The elastomer may be a thermoplastic elastomer, a thermosetting elastomer, or rubber. The elastomer may be in the form of a coating on the fiber. For example, the material sheet may include nylon fibers and a rubber coating, or the material sheet may include nylon fibers and a thermoplastic elastomer.

[0064] The fiber composite material provides high strength and high toughness, and in particular the fiber has high tensile strength.

[0065] The tubular material may include fibers arranged in a weave pattern, and wherein the weave pattern is staggered with the longitudinal length of the tubular material.

[0066] The braid pattern and / or the knit pattern may include a first unidirectional fiber group and one or more second fiber groups for fixing the first fiber group relative to each other. The material sheet may be formed via biaxial braiding or triaxial braiding. The material sheet may include a warp and weft density of 5T (total number of fibers per square inch) or higher. The material sheet may include a warp and weft density of 50T or higher.

[0067] The fiber composite base material sheet can start as an initial sheet of two widths of similar magnitude, and at least some of the fibers can extend parallel to the width of the sheet. To produce a length of base material sheet in which the longitudinal length of the fibers is offset from the longitudinal direction of the sheet, the base material sheet is cut from the initial sheet at a desired angle relative to the width of the initial sheet before the first side portion and the second side portion are secured to each other to form the tubular material.

[0068] By utilizing fibers that are staggered with the length of the base layer, and therefore with the circumferential length of the tire in which the base layer is formed, the high tensile strength of the fibers can provide strength in multiple directions of the tire.

[0069] The longitudinal length of the sheet of material may be offset by at least 30 degrees from the longitudinal direction of the tubular material. Optionally, the fibers may be offset by 45 degrees from the longitudinal direction of the sheet of material.

[0070] Optionally, the fibers may be staggered 45 degrees to the longitudinal direction of the sheet of material. Staggering the fibers a greater degree allows for a more even distribution of strength across the direction of the tire.

[0071] The method may include providing a puncture protection layer on at least a portion of the overlapping portions of the tubular material.

[0072] The puncture protection material is positioned on the overlapping portion of the tubular material to ensure that when the base layer is used in a tire, the puncture protection layer will be correctly positioned to protect the tire. The puncture protection material extends along the length of the tubular material and its overlapping portion.

[0073] The puncture protection layer may be provided over at least a central region of the overlapping portion so that when a tyre is formed using the base layer, the puncture protection layer will be positioned below the tread and hence below where the tyre contacts the road for optimum protection.

[0074] The puncture protection layer may include one or more of an elastomer, a plastic, a composite material, a fiber sheet, and a fiber-reinforced elastomer.

[0075] The material of the puncture protection layer is tough and can resist penetration or damage by an object. The puncture protection layer may include rubber or other suitable elastomers.

[0076] The puncture protection layer may be provided on the radially outer side of the tubular material when viewed in a cross section perpendicular to the longitudinal length of the tubular material, and / or the puncture protection layer may be provided on the radially inner side of the tubular material when viewed in a cross section perpendicular to the longitudinal length of the tubular material.

[0077] The puncture protection layer may be inserted into the tubular material when the first edge portion and the second edge portion are secured together. Alternatively, the puncture protection layer may be overmolded onto the tubular material after the first and second reinforcing elements are adhered to the opposing first and second longitudinal sides of the tubular material. The puncture protection layer and / or the reinforcing element may be fed into position simultaneously as the tubular material is formed.

[0078] The method of any of the aspects described above may comprise: providing a continuous strip of tyre base layer according to the method of any of the preceding claims; and cutting the tyre base layer strip into lengths suitable for use in a single tyre.

[0079] The belt can be cut to a size that is commensurate with the circumference of a single tire. The belt can be cut to a size that is a fraction of the circumference of a single tire.

[0080] The method may include applying heat to the tire base layer and stretching the tire base layer over the surface of the wheel so that the tire base layer adopts a curvature.

[0081] The heat causes the tire base layer to become ductile so that the tire plastically deforms when stretched over the wheel. The tire base layer is cooled so that the curvature adopted by the tire base layer when stretched over the wheel is maintained by the tire base layer.

[0082] Stretching the tire base layer over the wheel may be performed in a continuous process such that a continuous strip of the tire base layer is fed over the wheel and removed from the wheel without cutting the tire base layer.

[0083] Shaping the tire base layer may reduce the complexity and / or increase the efficiency of another process for forming a tire using the tire base layer.

[0084] The tire base layer can be stretched over the surface of the wheel to adopt a hyperbolic tire shape. The hyperbolic tire shape includes: a curvature with a radius of curvature r in a transverse cross section and a curvature with a radius of curvature R in a cross section perpendicular to the longitudinal cross section of the cylindrical tire. The tire base layer will then have a shape corresponding to the shape of the tire.

[0085] The method may include: inserting a section of the continuous belt of the tire base layer into the cavity of the tire base layer mold; applying heat and pressure to the section of the tire base layer in the tire base layer mold so that the section of the continuous belt of the tire base layer adopts the shape of the cavity of the tire base layer mold, wherein the shape of the cavity of the tire base layer mold includes at least one segment of a cylindrical tire having at least one curvature, wherein the arc of the segment extends along the longitudinal length of the cavity.

[0086] The tire base layer is thus modified to include a shape corresponding to the shape of the tire.

[0087] Although the molding process will be performed over discrete segments of tire base, the tire base can be fed into and out of the tire base mold in a continuous manner so that after molding, the tire base at the rear end of the tire base mold is pulled to the front end of the tire base mold and the molding process is repeated to mold subsequent tire bases along the length of the tire base strip.

[0088] Alternatively, the tire base strip may be cut to a desired length prior to entering the tire base mold.

[0089] The shape of the cavity of the tire base mold can correspond to a segment of a circle. The segment can be a segment of 45 degrees or less, a segment of 45 degrees or more, a segment of 90 degrees or more, a segment of 180 degrees or more (i.e., a semicircle), or a segment of 270 degrees or more.

[0090] The segments of a cylindrical tyre may comprise hyperbolas, such that the tyre has a radius r in a transverse cross section and a radius of curvature R in a cross section perpendicular to the longitudinal direction of the cylindrical tyre.

[0091] The base layer will have a shape corresponding to the shape of the tire.

[0092] The shape of the cavity of the tire base mold may include multiple segments of a cylindrical tire. The arc of each of the multiple segments may extend along the longitudinal length of the cavity, and the midpoints of at least a pair of adjacent segments may extend in the same transverse direction relative to the longitudinal length of the cavity, thereby forming a convex pattern.

[0093] Additionally or alternatively, the arc of each of the plurality of segments may extend along the longitudinal length of the cavity, and the midpoints of at least a pair of adjacent segments may extend in opposite transverse directions relative to the longitudinal length of the cavity, thereby forming a sinusoidal wave-like pattern. The mold thus reduces the size and complexity of the mold by flattening the mold relative to a curve having a radius R in a cross section perpendicular to the longitudinal direction of the cylindrical tire.

[0094] By dividing the entire circumference of the tire into several segments and arranging these segments along a section of the tire base mold, a simplified linear arrangement of the molding equipment and process can be provided compared to molding the entire tire circumference at one time. This may contribute to an efficient continuous process for molding the tire base.

[0095] The tire base mold can be a substantially flat mold including a shell, the shell including at least one longitudinal inner cavity extending between at least two opposite main walls and two opposite edge walls, wherein: each of the main walls has at least one protrusion and at least one recess; each protrusion and each recess extends and is inclined in the transverse direction and the longitudinal direction of the cavity; the protrusions and the recesses are arranged alternately along the length of the tire base mold; and the protrusions of one main wall are opposite to the recesses of another main wall.

[0096] The mold thus reduces the size and complexity of the mold by flattening the substantially flat mold relative to a curve having a radius r in transverse cross section and a curve having a radius R in cross section perpendicular to the longitudinal direction of the cylindrical tire.

[0097] Viewed from another aspect the invention provides a continuous strip of tyre base layer manufactured according to the method of any preceding claim.

[0098] By continuous strip is meant that the length of the tire base layer is not provided as discrete lengths for individual tires, but rather the base layer including the reinforcing elements is provided in a form that can be used in a continuous process or in a form that can be cut into desired lengths.

[0099] Viewed from another aspect, the present invention provides a method of manufacturing a tire base and tread elements, the method comprising: providing a continuous strip of tire base according to the method described above; inserting a section of the tire base into a tread mold; injecting an elastomeric material into the tread mold; allowing the elastomeric material to solidify so that the elastomeric material and the tire base adopt the shape of the tread mold; and removing the engaged tire base and the elastomeric material from the tread mold.

[0100] When the engaged tire base and elastomeric material are removed from the tread mold, the tire base and the tread elements can be formed in the form of a continuous band of tire base and tread elements by entraining additional tire base of the continuous band of base into the tread mold. When the tire base is entrained and repositioned in the tread mold, a continuous tread can be formed on the continuous band of tire base by aligning the ends of the previously formed tread with the associated ends of the mold. Alternatively, the tread can be formed discontinuously along the continuous band of tire base so that gaps exist between adjacent segments of tread.

[0101] The solidification of the elastic material may cause the elastic material to engage with the tire base. Alternatively, additional bonding materials may be used between the elastic material and the tire base. The hardening and / or cooling of the elastic material enables the shape of the mold to be maintained in the elastic material and the tire base.

[0102] Prior to the overmolding of the elastomeric material, the surface of the base layer to be joined to the tread may be subjected to a pretreatment. The pretreatment may be a plasma treatment or a corona treatment. The pretreatment may modify the surface so that an improvement in the strength and reliability of the joint may be achieved. The pretreatment may, for example, clean the surface and / or activate the surface to improve the joint.

[0103] The shape of the cavity of the tread mold may include at least one segment of a cylindrical tire having at least one radius of curvature.

[0104] The shape of the cavity of the tread mold may correspond to a segment of a circle. The segment may be a segment of 45 degrees or less, a segment of 45 degrees or more, a segment of 90 degrees or more, a segment of 180 degrees or more (i.e., a semicircle), or a segment of 270 degrees or more.

[0105] The continuous strip of tire base layer may have a pre-shape as described above, and the radius of curvature adopted by the tire base layer may be greater than the radius of curvature of the cavity of the tread mold.

[0106] Thus, when a tire base mold and a tread mold are used, the radius of curvature of the at least one segment of the tire base mold is greater than the radius of curvature of the at least one segment of the tread mold. That is, the lateral extent and longitudinal extent of the at least one segment in the tire base mold are greater than the lateral extent and longitudinal extent of the at least one segment in the tread mold. Thus, at least one segment of the tire base preform has a larger size than the size of the at least one segment of the tread mold into which it is inserted.

[0107] Since the thermal expansion of the material of the tire base layer differs from the thermal expansion of the tread material, the curvatures of the base layer and the tread will align after the tread is deposited onto the base layer and subsequently cooled. Thus, the difference in thermal expansion of the different materials can be taken into account.

[0108] According to the method described above, the tire base continuous strip may have a substantially flat shape, wherein the sizes of the depressions and projections of the tire base mold are larger than the sizes of the depressions and projections of the tread mold.

[0109] Thus, when a substantially flat tire base mold and a substantially flat tread mold are used, the size difference between the molds results in the tire base being formed being larger than the equivalent size of the tread being formed. Due to the difference in thermal expansion of the material of the tire base and the thermal expansion of the tread material, the curvature of the base and tread will align after the tread is deposited onto the base and subsequently cooled. Thus, the difference in thermal expansion of the different materials can be accounted for.

[0110] From another aspect, the present invention provides a method of manufacturing a tire; the method comprises: providing at least one section of tire base and tread element according to the method described above, and joining the ends of the at least one section of tire base and tread element to form a complete ring.

[0111] A complete round tire can be formed from a single section of tire base and tread elements so that one longitudinal end is joined to the other longitudinal end, or alternatively a plurality of tire bases and tread elements can be joined at respective longitudinal ends to form a ring. In this manner, tires of various sizes can be made from a continuous strip of tire base and tread elements or from discrete tire base and tread elements.

[0112] From another aspect, the present invention provides an apparatus for manufacturing a continuous belt of tire base layer, the apparatus comprising: a tire base material reel for storing material sheets; one or more reinforcing element reels for storing reinforcing elements; an assembling unit for receiving material from the tire base material reel and a first reinforcing element and a second reinforcing element from the one or more reinforcing element reels, and for assembling the continuous tire base layer, wherein the assembling unit comprises a folding device for folding a first edge portion of the material sheet over the first reinforcing element and folding the second edge portion over the second reinforcing element.

[0113] The folding apparatus may include securing means for securing the first edge portion and the second edge portion to a central portion of the sheet of material.

[0114] The fixing unit may include a welding device. The welding device may be adapted to perform one or more of heated tool welding, hot gas welding, ultrasonic welding, spin welding, infrared welding, high frequency welding, vibration welding, induction welding, microwave welding, resistance welding, extrusion welding, and laser welding. The heat may be applied by an external heat source, and / or the heat may be generated by mechanical movement, and / or the heat may be generated using electromagnetics.

[0115] The fixing unit comprises a heat gun for applying hot air to the material sheet. Optionally, the heat gun is configured to raise the temperature of the carcass material to above 140 degrees Celsius.

[0116] The apparatus may comprise a reel for storing puncture protection material and means for supplying the puncture protection material to the assembly unit.

[0117] The folding device may include a stitching machine for stitching the first and second reinforcement elements into their respective positions on the sheet of material. BRIEF DESCRIPTION OF THE DRAWINGS

[0118] Certain embodiments of the invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:

[0119] Figure 1Sheets of tire base material and reinforcing elements are shown, which may exceed the dimensions indicated in the figures in length.

[0120] Figure 2a A tire base layer including reinforcing elements is shown.

[0121] Figure 2b A tire base layer including reinforcing elements is shown.

[0122] Figure 3a An apparatus for forming a tire base layer including reinforcing elements is shown.

[0123] Figure 3b An apparatus for providing an assembly for forming a tire base layer including reinforcing elements is shown.

[0124] Figure 3c A reel on which a continuous strip of tire base layer including reinforcing elements is wound is shown.

[0125] Figure 4 Sheets of tire base material and reinforcing elements are shown, which may exceed the dimensions indicated in the figures in length.

[0126] Figure 5 A tire base layer including reinforcing elements is shown.

[0127] Figure 6a A cross section through the longitudinal length of a continuous strip of tire base layer including reinforcing elements is shown.

[0128] Figure 6b A cross section through the longitudinal length of a continuous strip of tire base layer including reinforcing elements is shown.

[0129] Figure 7a A cross section through the longitudinal length of a continuous strip of tire base layer including reinforcing elements and a puncture protection layer is shown.

[0130] Figure 7b A cross section through the longitudinal length of a continuous strip of tire base layer including reinforcing elements and a puncture protection layer is shown.

[0131] Figure 7c A cross section through the longitudinal length of a continuous strip of tire base layer including reinforcing elements and a puncture protection layer is shown.

[0132] Figure 8 An apparatus for providing a puncture protection layer for forming a continuous strip of a tyre base layer comprising reinforcing elements and a puncture protection layer is shown.

[0133] Fig. 9 Tubular materials and reinforcing elements are shown for forming a tire base layer and may extend in length beyond the dimensions indicated in the figures.

[0134] Fig.10 A tire base layer comprising a reinforcing element comprising a tubular material is shown, the tire base layer comprising the reinforcing element may exceed in length the dimensions indicated in the figure.

[0135] Fig.11 A cross section through the longitudinal length of a continuous strip of tire base layer including reinforcing elements is shown.

[0136] Fig.12a A cross section through the longitudinal length of a continuous strip of tire base layer including reinforcing elements and a puncture protection layer is shown.

[0137] Figure 12b shows a cross section through the longitudinal length of a continuous strip of tyre base layer comprising reinforcing elements and a puncture protection layer.

[0138] Fig.12c A cross section through the longitudinal length of a continuous strip of tire base layer including reinforcing elements and a puncture protection layer is shown.

[0139] Fig.13 A segmented tire base layer including reinforcing elements shaped into a hyperbolic tire shape is shown.

[0140] Fig.14 An apparatus for shaping a tire base layer and reinforcing elements is shown.

[0141] Fig.15 A segmented mold for molding the tire base layer and reinforcing elements is shown.

[0142] Fig.16 Shows the use of Fig.15 The segmented mold forms the tire base and the reinforcing element segments.

[0143] Fig.17 A segmented mold for molding the tire base layer and reinforcing elements is shown.

[0144] Fig.18 A cross section through a longitudinally extending centerline of a substantially flat mold for molding a tire base layer including reinforcing elements is shown.

[0145] Fig.19 The lower half of a substantially flat mold for shaping a tire base layer including reinforcing elements is shown.

[0146] Fig. 20 A profile view of a substantially flat shape is shown.

[0147] Fig.21 A tire base layer including reinforcing elements is shown comprising a substantially flat shape.

[0148] Fig. 22 A tire base layer including reinforcing elements and an overmolded tread is shown.

[0149] Fig.23 An apparatus for manufacturing a continuous strip of tire base layer comprising reinforcing elements and an overmolded tread is shown.

[0150] Fig.24 A cross section through a longitudinally extending centerline of a substantially flat mold for overmolding a tread to a tire base layer including reinforcing elements is shown.

[0151] Fig.25 A tire base layer including reinforcing elements is shown, the tire base layer including an overmolded tread and including a substantially flat shape.

[0152] Fig.26 A segmented mold for overmolding a tread to a tire base layer including reinforcing elements is shown.

[0153] Fig. 27 A tire base layer including reinforcing elements is shown, the tire base layer including an overmolded tread including a hyperbolic tire shape, and using Fig.26 The mold is formed.

[0154] Fig.28 A segmented mold for overmolding a tread to a tire base layer including reinforcing elements is shown.

[0155] Fig.29 A tire base layer including reinforcing elements is shown, the tire base layer including an overmolded tread including a hyperbolic tire shape, and using Fig.28 The mold is formed.

[0156] Fig.30 A substantially flat tread mold and a preformed tire base layer including reinforcing elements are shown.

[0157] Fig.31 Two sections of a tire base layer including reinforcing elements are shown.

[0158] Fig.32 Two sections of a tire base layer are shown including reinforcing elements each including a hyperbolic shape.

[0159] Fig.33 A complete ring of tire base layer is shown formed by joining the ends of a single strip of tire base layer including reinforcing elements.

[0160] Fig.34 A complete ring of tire base layer is shown comprising a plurality of strips of tire base layer joined to the reinforcing elements.

[0161] Fig.35 The contact area between two sections of tire base layer is shown.

[0162] Fig.36 The contact area between two sections of tire base layer is shown.

[0163] Fig.37 The ends of two sections of tire base layer are shown.

[0164] Fig.38 Shows Fig.37 The contact area between two lengths of tire base layer is shown along with an indication of a piece of overmolding material to be added to the partially overlapping ends.

[0165] Figures 39a to 39d A plan view showing the configuration of the ends of the segments of tire base layer.

[0166] Figures 40a to 40c A transverse view of two sections of a tire base layer joined using an insert is shown.

[0167] Fig.41a A transverse view of two sections of a tire base layer joined using an insert is shown, shown in expanded form.

[0168] Fig.41b and Fig.41c Shown is a plan view of two sections of tire base layer joined using an insert.

[0169] Fig.42a A transverse view of two sections of flat tire base layer joined and including cushioning material is shown.

[0170] Figure 42b Two sections of a tire base layer comprising a hyperbolic shape, joined and including cushioning material are shown.

[0171] Fig.42c Shows Figure 42b Expanded view of .

[0172] Fig.43 Two lengths of tire base layer (comprising fibers) and cushion material (comprising fibers) are shown to be joined.

[0173] Fig.44a Two sections of a tire base layer are shown, including reinforcing elements and tread to be joined.

[0174] Figure 44b Two sections of a tire base layer are shown, including reinforcing elements and tread to be joined.

[0175] Fig.45 An apparatus for joining a first length of a tire base layer including reinforcing elements to a second length of a tire base layer is shown. DETAILED DESCRIPTION

[0176] like Figure 1 As shown, a pair of bead wires 12 are positioned on the base material sheet 10 and are each aligned with the longitudinal length of the sheet 10. The sheet 10 thus comprises a first lateral edge portion 14, a central portion 16 and a second lateral edge portion 18 defined by the bead wires 12.

[0177] Figure 2a It is shown that a sheet of tire base material is formed into a tire base layer including a reinforcing element by folding a first lateral edge portion 14 over a first bead wire 12a and folding a second lateral edge portion 18 over a second bead wire 12b. The first lateral edge portion 14 overlaps with the second lateral edge portion 18 to form an overlapping region 22. The first lateral edge portion 14 and the second lateral edge portion 18 may be fixed to the central portion 16. In the overlapping region 22, the first lateral edge portion 14 and the second lateral edge portion 18 may also be fixed to each other. Since a pair of bead wires 12 are positioned parallel to each other, the first longitudinal side 24 and the second longitudinal side 28 of the tire base layer including the reinforcing element 20 are also parallel to each other. The first lateral edge portion 14 and the second lateral edge portion 18 do not need to overlap to form the overlapping region 22; Figure 2b An example in which the first lateral edge portion 14 and the second lateral edge portion 18 are fixed only to the central portion is illustrated.

[0178] Figure 3a The process of folding the base material sheet 10 by the folding device 30 is shown. Figure 1 2 are provided in the relevant reference numerals in Figure 3a . The base material sheet 20 is fed into the folding device 30 from the first end 32 and moves along the folding device 30 in the direction A. The first folding device 31 comprises a first folding guide 34. The first folding guide 34 causes the first lateral edge portion 14 to be bent or folded around the first bead wire 12a and guides the first lateral edge portion 14 into a position adjacent to or in contact with the center portion 16. Further along the folding device 30, in the direction A, a second folding device 33 is provided. The second folding device 33 comprises a second folding guide 38, which causes the second lateral edge portion 18 to be bent or folded around the second bead wire 12b and guides the second lateral edge portion 18 into a position adjacent to or in contact with the center portion 16 and / or a position adjacent to or in contact with the first lateral edge portion 14 in the overlap region 22.

[0179] When the base material sheet 20 is fed through the folding device 30, a tire base layer including the reinforcing element 20 can be continuously produced. In this way, a continuous strip of tire base layer can be formed. This means that a tire base layer including reinforcing elements 20 sufficient for use can be formed into multiple tires without manual intervention. The tire base layer including the reinforcing element 20 leaving the second folding device 33 can be wound onto a reel for storage.

[0180] The first folding device 31 further comprises a fixing member, not shown, to fix the first transverse edge portion 14 to the central portion 16. Likewise, the second folding device 33 comprises a fixing member, not shown, to fix the second transverse edge portion 18 to the central portion 16 and / or the first transverse edge portion 14. For example, the fixing member of the first folding device 31 and / or the second folding device 33 may comprise a heat gun.

[0181] Figure 3b A base material reel 35, a first bead wire reel 36a and a second bead wire reel 36b are shown. The base material sheet 10 is fed directly from the base material reel 35 to an assembly unit comprising a folding device 30. Likewise, the first bead wire 12a and the second bead wire 12b are fed directly from the first bead wire reel 36a and the second bead wire reel 36b, respectively, to the folding device 30. Fixing means, not shown, may be used to fix the bead wires 12a, 12b in position on the base material sheet before the folding operation begins.

[0182] Figure 3c An assembled tire base layer is shown, which includes reinforcing elements 20, 61 wound onto a reel 38 for storage. The tire base layer including the reinforcing element 20 can be wound onto the reel 38 directly from the folding device 30, or wound onto the reel 38 after additional manufacturing steps (such as applying overmolding described below). The tire base layer including the reinforcing element 61 formed using tubular material (as described below) can also be wound onto the reel 38 directly after assembly or after additional manufacturing steps.

[0183] The continuous strip of tire base layer including reinforcing elements 20 can be pulled from the reel and cut into lengths that require further processing for use in a tire. The continuous strip of tire base layer including reinforcing elements 20 can be pulled directly from the reel into another device to process the continuous strip of tire base layer including reinforcing elements 20 for use in a tire. In this way, processing can remain continuous.

[0184] Instead, the continuous strip of tire base layer including reinforcing elements 20 can be fed directly from the folding device 30 to another device for processing the continuous strip of tire base layer including reinforcing elements 20 for use in tires. Similarly, in this way, processing can be maintained continuously.

[0185] Figure 4 A sheet of material 10 is shown that includes a fiber structure. The fibers of the fiber structure may be formed of nylon, cotton, polyester, or aramid. The fiber structure includes a unidirectional fiber group 40 (diagonal hatching indicates the presence and direction of a first fiber group), wherein each fiber in the fiber group 40 extends in a direction generally parallel to the other fibers in the fiber group 40. The unidirectional fiber group 40 is supported by a support fiber group, not shown, that is woven through the unidirectional fiber group 40 to secure the fibers relative to each other.

[0186] The sheet of material 10 is cut so that the direction of the unidirectional fiber groups 40 is offset by an angle α from the longitudinal direction of the sheet.

[0187] Figure 5 A tire base layer is shown which includes a reinforcing element 20 when the first lateral edge portion 14 is folded over the first bead wire 12a and the second lateral edge portion 16 is folded over the second bead wire 12b. As illustrated by the hatching, the direction of the unidirectional fiber group 40 in the center portion 16 will be different from the direction of the unidirectional fiber group in the first lateral edge portion and the second lateral edge portion. In other words, the base material provided between a pair of bead wires 12 in the tire base layer including the reinforcing element 20 will include fibers with different directions.

[0188] Figure 6a A cross section taken perpendicular to the longitudinal length of the tire base layer is shown, including the reinforcing element 20. The first lateral edge portion 14 is folded around the first bead wire 12a and fixed to the central portion 16. The second lateral edge portion is folded around the second bead wire 12b and fixed to the central portion 16 and to the first lateral portion 14 in the overlap region 22.

[0189] Figure 6b Shown with Figure 6a A similar cross section is shown in which the first lateral end 14 and the second lateral end 18 do not form an overlapping region 22 .

[0190] Figures 7a to 7c Similarly shown is a cross section of the tire base layer including the reinforcing elements 20 taken perpendicularly to its longitudinal extent. Figures 7a to 7c Each of the figures shows a puncture protection layer 50. In each case, the puncture protection layer 50 is provided at a middle portion 52 of the tire base layer including the reinforcing element 20. When the tire base layer is used in a tire, the middle portion 52 of the tire base layer including the reinforcing element 20 will coincide with the tread of the tire, and the first side portion 54 and the second side portion 58 of the tire base layer including the reinforcing element 20 will coincide with the sidewall of the tire. The middle portion 52 will be located adjacent to the ground contact area of ​​the tire. The puncture protection layer 50 is therefore located to at least coincide with the tread of the tire to provide the most useful protection.

[0191] Figure 7a The puncture protection layer 50 provided on the outer surface of the first lateral portion 14 and / or the second lateral portion 18 is illustrated.

[0192] Figure 7b A puncture protection layer 50 provided between the central portion 16 and the first lateral portion 14 and / or the second lateral portion 18 is illustrated.

[0193] Figure 7c A puncture protection layer 50 provided on the outer surface of the central portion 16 is illustrated.

[0194] The first transverse end 14 and the second transverse end 18 do not form a Figure 6b As shown in the example of the overlapping area 22, the puncture protection layer 50 can be Figures 7a to 7c are provided in the corresponding positions shown.

[0195] Figure 8 The folding device 30 is shown being provided to the puncture protection layer 50. In this example, the puncture protection layer may be bonded between overlapping portions of the sheet of base material, or secured to the sheet 10 using the steps described herein.

[0196] Fig. 9 A tubular material 60 for manufacturing a continuous strip of a tire base layer is shown. The tubular material 60 extends in a longitudinal direction, and during the manufacture of the continuous strip of the tire base layer, a first reinforcing element 12a and a second reinforcing element 12b are inserted into the tubular material 60 to extend in the same longitudinal direction. The first reinforcing element 12a and the second reinforcing element 12b thus extend parallel to the longitudinal length of the tubular material 60. Tubular means that the material provides a cylinder including a hollow center, and thus the reinforcing elements 12a, 12b are inserted into the hollow center. The tubular configuration of the tubular material can be formed while the reinforcing element is inserted into the center of the tubular material (such as by fixing the first longitudinally extending edge portion to the second longitudinally extending edge portion or by braiding the material) so that a tire base layer including the reinforcing element 61 can be continuously produced.

[0197] Fig.10 The tubular material is shown in a flattened state. To maintain the flattened shape, the tubular material on the first side 62 (e.g., above) of the first and second reinforcing elements 12a, 12b is fixed to the tubular material on the second side 64 (e.g., below) of the first and second reinforcing elements. The first side 62 and the second side 64 are located on opposite sides of the reinforcing elements 12a, 12b.

[0198] Fig.11A cross section taken perpendicular to the longitudinal length of a tire base layer is shown including reinforcing elements 61. The tubular material on a first side 62 (e.g., above) of the first and second reinforcing elements 12a, 12b is secured to the tubular material on a second side 64 (e.g., below) of the first and second reinforcing elements.

[0199] Fig.12a Analogously to FIG. 12 b , a cross section of a tire base layer including reinforcing elements 61 is shown, taken perpendicularly to its longitudinal extent. Fig.12a Each of the figures in Figure 12a and Figure 12b shows a puncture protection layer 50. In each case, the puncture protection layer 50 is provided at the middle portion 66 of the tubular tire base layer including the reinforcing element 61. When the tire base layer is used in a tire, the middle portion 66 of the tire base layer including the reinforcing element 61 will coincide with the tread of the tire, and the first side portion 67 and the second side portion 68 of the tire base layer including the reinforcing element 61 will coincide with the sidewall of the tire. The middle portion 66 will be located adjacent to the ground contact area of ​​the tire. The puncture protection layer 50 is therefore located to at least coincide with the tread of the tire to provide the most useful protection.

[0200] Fig.12a The puncture protection layer 50 is illustrated as being disposed on the radially outer side of the tubular material 60 when viewed from a cross section perpendicular to the longitudinal length of the tubular material. The puncture protection layer 50 may be continuously secured to the tire base layer tape. In a later step, the tread may be applied so that the puncture protection layer is located between the tread and the tire base layer, or the tread may be applied so that the tire base layer is located between the puncture protection layer 50 and the tread.

[0201] 12b illustrates a puncture protection layer 50 disposed on the radially inner side of the tubular material when viewed in a cross section perpendicular to the longitudinal length of the tubular material. The puncture protection layer may be inserted into the hollow portion of the tubular material when forming the tubular configuration (such as by securing the first longitudinally extending edge portion to the second longitudinally extending edge portion or by braiding the material) so that a tire base layer including the reinforcing element 20 and the puncture protection layer can be continuously produced.

[0202] The tire base layer including the reinforcing element 61 can be continuously produced. In this way, a tire base layer continuous band can be formed. This means that the tire base layer including the reinforcing element 61 enough to use can form multiple tires without manual intervention. The tire base layer including the reinforcing element 61 can be wound onto a reel for storage. The tire base layer continuous band including the reinforcing element 61 can be pulled out from the reel and cut into the length that needs further processing for use in the tire. The tire base layer continuous band including the reinforcing element 61 can be directly pulled into another device from the reel to process the tire base layer continuous band including the reinforcing element 61 used in the tire. In this way, processing can remain continuous.

[0203] In some examples, the tire base layer continuous strip is further processed to change the shape of the tire base layer including reinforcing elements 20, 61. The shape is modified to more closely match the shape of the tire base layer when used in a tire.

[0204] The modified shape will therefore have at least some curved features, reflecting Fig.13 Hyperbolic tire shape shown. The hyperbolic tire shape includes a curvature with a radius of curvature r in a transverse cross section and a curvature with a radius of curvature R in a cross section perpendicular to the longitudinal cross section of a cylindrical tire. The hyperbolic tire shape can also be described as a toroidal segment with an omega "Ω" cross section.

[0205] The tire base layer having a hyperbolic shape will include a first sidewall 74 including a first side portion of the tire base layer 54, 67 and a second sidewall 78 including a second side portion of the tire base layer 58, 68. The sidewalls 74, 78 extend generally radially and circumferentially around a radius of curvature R. The middle portion of the base layer 52, 66 will form an intermediate wall 72 extending generally circumferentially and axially around the radius of curvature R.

[0206] The size of the curvature of the tire base layer need not match the size of the curvature of the tire and / or the curvature that the base layer will adopt in the final tire. The curvature provided to the tire base layer including the reinforcing elements 20, 61 can be less than the final curvature in order to introduce a degree of shaping before assembling the tire, or the curvature provided to the tire base layer including the reinforcing elements can be greater than the final curvature in order to compensate for shrinkage that may occur during further processing of assembling the tire.

[0207] The wheel 80 can be used to shape a tire base layer including reinforcing elements 20, 61. The tire base layer including reinforcing elements 20, 61 is stretched over the surface of the wheel 80 and heat is applied so that the tire base layer including reinforcing elements 20, 61 adopts a certain curvature. Fig.14 As shown, the surface of the wheel 80 has a curvature radius r in a transverse cross section and a curvature radius R in a cross section perpendicular to the transverse cross section, because the tire base layer including the reinforcing elements 20, 61 stretched over the wheel adopts a hyperbolic tire shape. By inverting a portion of the tire base layer including the reinforcing elements 20, 61 to produce depressions and protrusions (such as Fig.21 The final formed tire base layer including the reinforcing elements 20, 61 can be manipulated into a substantially flat shape for further use.

[0208] A tire base layer including reinforcing elements 20, 61 may be formed into a hyperbolic tire shape using a segmented mold 90 that includes a cavity 92 that includes at least a portion of the hyperbolic tire shape. Fig.15 Such a segmented mold 90 is shown. The tire base including the reinforcing elements 20, 61 can be provided as a continuous strip of the tire base and drawn into the cavity 92, the upper and lower portions 94, 96 of the segmented mold closed to compress the tire base including the reinforcing elements 20, 61 within the cavity 92 and apply heat and pressure.

[0209] The tire base layer obtained by molding using the segmented mold 90 is Fig.16 The cavity 92 and the formed tire base layer have a curvature r in the transverse cross section and a radius R in the cross section perpendicular to the transverse cross section.

[0210] Fig.17 An alternative segmented mold 90 is shown in which a cavity 92 includes multiple segments. The shaped tire base layer including the reinforcing elements formed by the mold can be further manipulated (eg, bent or stretched) to eliminate joints between segments and form a continuous curvature.

[0211] Fig.18 A cross section (cut through the center of the mold) of a substantially flat tire base mold 100 is shown for preforming a tire base including reinforcing elements 20, 61. The cavity 101 created between the top sheet piece 102 and the bottom sheet piece 103 comprises depressions and protrusions extending in the transverse direction of the cavity 101 and in the longitudinal direction of the cavity 101.

[0212] Fig.19 A substantially flat bottom sheet piece 103 of a tire base mold 100 is shown having a plurality of depressions and protrusions.

[0213] Fig. 20 Contour diagrams of depressions and protrusions along a substantially flat tire base mold 100 are shown. Protrusions and depressions in the longitudinal direction of the cavity of the substantially flat tire base mold are shown along line LL; 104 indicates a peak and 105 indicates a valley. Depressions in the transverse direction are shown along line t1-t1; a high point 106 drops to a valley 105 and then rises to another high point 106. Protrusions in the transverse direction are shown along line t2-t2; a low point 107 rises to a peak 104 and then drops back to a low point 107.

[0214] Once the tire base layer including the reinforcing elements is removed from the substantially flat tire base layer mold 100, the depressions are reversed, i.e., inverted, so that the tire base layer including the reinforcing elements follows a single curvature in the longitudinal direction of the tire base layer including the reinforcing elements. Once the depressions are inverted, the curvatures provided by the depressions and protrusions are added together to form a segment of a circle. Likewise, the depressions and protrusions in the transverse direction now adopt complementary curvatures to form the sidewalls of the segment of the circle and form an "Ω"-shaped cross section.

[0215] In other words, the curvature adopted by the tire base layer including the reinforcing elements 20, 61 in the transverse direction assists in forming the sidewalls of the base layer within the tire, thereby assisting in forming the "Ω" cross section. The curvature adopted by the tire base layer including the reinforcing elements 20, 61 in the longitudinal direction of the base layer assists in forming the tire annular ring.

[0216] Fig.21 A tire base layer is shown comprising reinforcing elements 20, 61 which are preformed into a substantially flat shape comprising depressions and protrusions in the longitudinal and transverse directions.

[0217] In some examples, the substantially flat shape of the tire base layer including the reinforcing elements is stored in the described form and can be used later in a further process to form a tire. In some examples, the substantially flat shape of the tire base layer including the reinforcing elements is used directly in a further process to form a tire, and the inversion of the concavities and convexities occurs after a subsequent processing step.

[0218] Fig. 22 A cross section of a tire including a base layer is shown, the base layer being formed by a base layer including the reinforcing elements 20, 61 described above. The tire includes a tread 126 applied to an intermediate wall 72 of the base layer. In some examples, the tread may extend along the sidewalls 74 and 78 of the tire base layer. The tire tread is added to the tire base layer including the reinforcing elements 20, 61 using an injection molding device. The injection molding device includes a tread mold into which the tire base layer including the reinforcing elements 20, 61 is placed. The tire base layer including the reinforcing elements 20, 61 is located in the tread mold for overmolding. The elastomer is injection molded on the tire base layer including the reinforcing elements 20, 61 so that the tread is overmolded onto the tire base layer including the reinforcing elements 20, 61. In an example where the tire base layer is formed by a fabric or mesh fabric sheet, the injection molding material will penetrate the tire base layer and thus extend from one side of the tire base layer to the opposite side of the tire base layer.

[0219] Whether provided as a continuous strip of tire base (on a spool or otherwise) or provided as cut-to-size sections of the tire base including reinforcing elements, and / or whether provided flat or preformed as discussed above, the tire base including reinforcing elements can be further processed to add a tire tread using overmolding, an example of which is provided below.

[0220] exist Fig.23 , an injection molding apparatus 110 is shown receiving a tire base layer directly from a folding apparatus 30, the tire base layer including reinforcing elements 20, 61 in the form of a continuous strip of the tire base layer. The cavity of the tread mold 120 may have the same configuration as described above with respect to the tire base layer mold and with reference to Figures 18 to 20 The substantially flat shape described. Fig.24 , a substantially flat tread mold is shown below. A lower half 120a of the substantially flat tread mold 120 is provided on a fixed portion of the injection molding apparatus 110, and an upper half 120b of the substantially flat tread mold 120 is provided on a portion of the injection molding apparatus that can move relative to the fixed portion. When the two halves of the tread mold 120 are separated, a continuous strip of tire base layer is supplied from the folding apparatus 30 and aligned with the lower half of the tread mold 120a. The upper half 120b of the tread mold is moved so as to close the mold 120 and inject thermoplastic into the cavity of the mold. Once the injected thermoplastic solidifies and takes the shape of the cavity of the tread mold, the upper half 120b of the tread mold is moved away from the lower half 120a, and the continuous strip of tire base layer and the overmolded tread are pulled out of the tread mold. While the tire base layer continuous strip and the overmolded tread are moving, another tire base layer including the reinforcing elements included in the continuous strip is pulled from the folding device 30 into the injection molding device 110 .

[0221] A continuous strip of tire base layer may be fed from a reel into the injection molding apparatus 110 .

[0222] Fig.24 A section of a substantially flat tread mold 120 is shown, the section including a tread pattern 125 on a cavity wall 124 of a lower sheet 123 .

[0223] Fig.25A tire base layer having reinforcing elements 20, 61 and an overmolded tire tread 126 having a substantially flat shape are shown. The substantially flat shape of the combined tread 126 and the tire base layer including reinforcing elements 20, 61 are the result of the overmolding step, that is, a flat strip of the tire base layer may be inserted into a tread mold 120, and the application of an elastomer to form the tread 126 combined with the application of heat and pressure during the overmolding process may cause the tire base layer including reinforcing elements 20, 61 to adopt the shape of the depressions and protrusions of the substantially flat tread mold 120. In other examples, the tire base layer including reinforcing elements is pre-formed prior to entering the substantially flat tread mold 120, and the shape of the tire base layer and tread after overmolding may facilitate the tread molding process and pre-forming.

[0224] Fig.26 A segmented tread mold 130 is shown including a segmented cavity 132 formed into a hyperbolic tire shape. Fig. 27 A tire base layer is shown, the tire base layer including reinforcing elements 20, 61 and an overmolded tread 126 formed using a segmented tread mold 130, the overmolded tread including the hyperbolic tire shape described above with radii r and R. The combined overmolded tread 126 and the hyperbolic tire shape of the tire base layer 20, 61 may be the result of using an elastomer to form the tread 126 in conjunction with the application of heat and pressure during the overmolding process. A preformed tire base layer including reinforcing elements 20, 61 may be inserted into the segmented mold 130, the shaping of which may contribute to the final shape of the combined tread 126 and the tire base layer including reinforcing elements 20, 61.

[0225] Fig.28 A tread mold 140 is shown including a cavity 142 shaped into multiple segments of a hyperbolic tire shape. Fig.29 The resulting tire base layer is shown including reinforcing elements 20, 61 and overmolded tread 126. The joints between adjacent segments of the base layer and overmolded tread have been manipulated (eg, bent or stretched) compared to the shape of the cavity of tread mold 140 so as to form a continuous curvature. Fig.29 The shape shown can be further manipulated into a round tire shape if desired.

[0226] The tire base including the reinforcing elements 20, 61 may be preformed as described above, and the tread is then overmolded onto the preformed tire base. In some examples, the size of the tire base is larger than the size of the tread mold. Fig.30As shown, when the tire base layer including reinforcing elements 20, 61 is preformed into a substantially flat shape, the amplitude and wavelength of the depressions and protrusions are greater than the equivalent amplitude and wavelength of the substantially flat tread mold 120. That is, the height variation between the low point 107 and the peak 104, the high point 106 and the valley 105 of the tread mold 120, and the distance between the peak 104 and the valley 105 are all smaller than those of the preformed tire base layer. For clarity, Fig.30 The tread pattern 125 of the tread mold 120 has been omitted.

[0227] The relative differences in the amplitude and wavelength of the depressions and protrusions between the preformed tire base and the tread mold vary according to the thermal expansion characteristics of the tire base and the tread elastomer. In some cases, the amplitude and wavelength of the depressions and protrusions of substantially flat tread mold 120 are greater than the equivalent amplitude and wavelength of the preformed tire base. Alternatively, some dimensions may be larger in the substantially flat tread mold, while some dimensions are smaller compared to the preformed tire base.

[0228] Fig.31 A first segment of tire base layer 202 and a second segment of tire base layer 212 are shown. The first segment of tire base layer 202 includes a first end 204, a first main portion 206, and a first pair of reinforcing elements 208. The second segment of tire base layer 212 includes a second end 214, a second main portion 216, and a second pair of reinforcing elements 218. The first segment of tire base layer end 202 and the second segment of tire base layer end 212 are aligned and engaged as shown so that the reinforcing elements of the first pair of reinforcing elements 208 are aligned with the reinforcing elements of the second pair of reinforcing elements 218.

[0229] The first tire base section and the second tire base section may be flat, such as Fig.31 The first section of the tire base and the second section of the tire base may be preformed to include a curve. Fig.32 As shown, the first and second segments of the tire base layer can be preformed to have a hyperbolic shape, i.e., a curvature having a radius of curvature r in a transverse cross section and a curvature having a radius of curvature R in a cross section perpendicular to the longitudinal cross section of the cylindrical tire. The hyperbolic tire shape can also be described as a toroidal segment with an omega "Ω" cross section. The base layer will then have the first and second sidewalls 74, 78, and the intermediate wall 72 as described above.

[0230] The first segment of tire base layer 202 and the second segment of tire base layer 212 may be produced in a known manner.

[0231] The first section of tire base layer 202 and the second section of tire base layer 212 can be made by using any of the steps of the method for manufacturing a continuous strip of tire base layer described above. Before the joining operation, the continuous strip of tire base layer can be cut into the first section of tire base layer and the second section of tire base layer separated from each other and each having a predetermined length. Alternatively, before the joining operation, the continuous strip of tire base layer can be cut into individual pieces having a predetermined length, and then first.

[0232] The first tire base layer 202 and the second tire base layer 212 may be continuous. Fig.33 That is, the first end 204 and the second end 214 are arranged at the longitudinal ends of the same piece of the tire base. Therefore, only a single joint is required to form a complete ring of the tire base.

[0233] In other examples, multiple joints are required to form a complete base ring suitable for use in a tire. Fig.34 As shown, the first section of tire base layer 202 of one joint also provides the second section of tire base layer 212 for the other joint.

[0234] The contact area 220 is located between the first end 204 and the second end 214. Fig.35 and Fig.36 As shown. Fig.35 In the embodiment, the contact area 220 is formed by overlapping the first end 204 with the second end 214 to form a double-thickness tire base layer in the contact area 220. Fig.36 In the embodiment, the contact area 220 is formed by first segment base layer 203 ( Fig.31 The longitudinal surface of the second base layer 213 (shown) Fig.31 The longitudinal surfaces of the components are adjacent to each other.

[0235] A welding operation may then be performed in the contact area to secure the first segment of tire base layer 202 and the second segment of tire base layer 212 to each other. The first segment of tire base layer 202 and the second segment of tire base layer 212 may additionally or alternatively be secured by providing glue or an adhesive material between the first segment of tire base layer 202 and the second segment of tire base layer 212 in the contact area.

[0236] exist Fig.37 , an example is shown in which the first end portion 204 and the second end portion 214 include only a mesh fabric, while the first main portion 206 and the second main portion 216 include a mesh fabric and an elastomer. By at least partially overlapping the two end portions 204, 214, a contact area 220 ( Fig.3820). The joining of the two ends 204, 214 can then be achieved by overmolding the elastomer over the first end 204, the contact area 220, and the second end 214. Piece 222 represents an overmolded piece that will be added to the joined base layer once the overmolding process is performed. Piece 222 will therefore extend from the first main part 206 to the second main part 216 and join the first main part 206 to the second main part 216. By ensuring that the ends of the contact area 220 and the joints of the overmolded elastomer with the first main part 206 and the second main part 216 are staggered, a stronger joint can be made by avoiding the staggering of weak points at each joint. However, sufficient results are achieved by completely overlapping the first end 214 with the second end 204 to form the contact area 220. Since the mesh fabric has an open structure, the elastomer can penetrate the mesh fabric to produce a strong joint by improving the mechanical bonding between the first base layer and the second base layer and the chemical bonding between the elastomer and the fibers. Using this process, other base materials including fibers can also achieve similar advantages.

[0237] Specifically, when the contact area 220 is created by abutting the longitudinal end faces of the first section of the base layer 203 and the second section of the base layer 213, the end faces 203, 213 may have the following characteristics: Figures 39a to 39d The complementary shapes shown are such that the faces interlock when joined. Fig.39a In the embodiment, the end faces 203, 213 each have a straight line shape oriented perpendicular to the longitudinal length of the corresponding first and second segments of the tire base. Fig.39b In the embodiment, the end face has a plurality of lengths perpendicular to the length of the tire base layer, and the plurality of lengths form a stepped shape, which provides more contact surface area between the end faces. The longitudinal end face of the first segment of the tire base layer 203 has a stepped shape to also have a recess 205, and the longitudinal end face of the second segment of the tire base layer 213 has a stepped shape to also have a protrusion 215. The protrusion 215 fits into the recess 205. Fig.39c In the embodiment, the longitudinal end face of the second tire base layer 213 has an extended herringbone shape, and the longitudinal end face of the first tire base layer 203 has a cut herringbone shape. The herringbone shape is formed by a plurality of lengths that are not perpendicular to the longitudinal length of the tire base layer. Fig.39d In the embodiment, the longitudinal end surface of the second segment tire base layer 213 has a convex arc shape, and the longitudinal end surface of the first segment tire base layer 203 has a concave arc shape.

[0238] The insert 230 may be placed between the first segment of tire base layer 202 and the second segment of tire base layer 212 . Fig.40aThe insert 230 is shown located between the end surfaces 203, 213. The reinforcing elements 12 of the first and second tire base sections 203, 213 are aligned once joined. The insert is secured to each of the end surfaces 203, 213 to secure the first and second tire base sections 202, 212 to each other. Fig.40b An insert 230 is shown that includes an insert head 232 that protrudes above the first and second tire base segments 202, 212 and extends laterally and longitudinally above the first and second tire base segments 202, 212, while extending above the end portions 204, 214 and / or the main portions 206, 216.

[0239] exist Fig.40c , an example is shown in which a pair of reinforcing elements 12 extends through an insert 230 so that a connection can be established between a first pair of reinforcing elements and a second pair of reinforcing elements in a first section of tire base and a second section of tire base, respectively.

[0240] Fig.41a An expanded view of the joint is shown, ie, before contact is made and before joining is completed. Fig.41a The reinforcing elements 208 of the first section of the tire base layer 202 extending from the first end 204 are shown. The first pair of reinforcing elements 208 overlaps the second pair of reinforcing elements 218 in the longitudinal direction, so that once the joint is formed, the tips of the reinforcing element pair will abut each other. The tips can then be joined via welding, soldering, sewing or adhesive. For example, the stitching of the aramid reinforcing elements can be performed with aramid thread. Fig.41b This situation is shown in plan view. Fig.41c A similar example is shown where a first pair of reinforcement elements 208 and a second pair of reinforcement elements 218 extend from the first end 204 and the second end 214 , respectively, however the reinforcement elements overlap in the lateral direction.

[0241] Fig.42a A joint between a first segment of tire base layer 202 and a second segment of tire base layer 212 is shown, the joint including a cushioning material 240 joined to the first end 204 and the second end 214 .

[0242] Figure 42b An example is shown in which the first segment of tire base layer 202 and the second segment of tire base layer 212 are formed in a hyperbolic shape. Figure 42c Shows Figure 42b2 (i.e., without contact and engagement), which shows the location and extent of the gasket material 240 at the joint. The gasket material 240 extends from the radially outer surface (not shown) of the first side wall 74 relative to the radius of curvature r to the radially inner surface 73 of the first side wall 74 relative to the radius of curvature r, along the radially inner surface 72a of the intermediate wall 72 relative to the radius of curvature r, along the radially inner surface (not shown) of the second side wall 78 to the outer surface 77 of the second side wall 78.

[0243] The liner 240 can extend around the entire joint and can be considered a sleeve. The sleeve 240 can be tight enough and / or include an adhesive to secure the first section of the tire base layer 202 and the second section of the tire base layer 212 to each other. In some examples, the liner 240 includes fibers that provide additional strength.

[0244] Fig.43 An example is shown in which a liner 240, a first segment of tire base 202, and a second segment of tire base 212 include fibers. The fiber direction of each component is indicated in the direction of the cross-hatching in the figure. The fiber direction of the liner 240 is substantially aligned with the fiber direction of the first segment of tire base 202 and the second segment of tire base 212. In some examples, the liner 240 additionally or alternatively includes fibers extending in the longitudinal direction of the first segment of tire base 202 and the second segment of tire base 212. It should be understood that the liner and / or the first segment of tire base and the second segment of tire base may additionally include fibers extending in the longitudinal direction of the first segment of tire base 202 and the second segment of tire base 212. Fig.43 Fibers extending in a direction alternative to the direction indicated.

[0245] exist Fig.44a , the first segment of tire base layer 202 includes a first tread portion 252, and the second segment of tire base layer 212 includes a second tread portion 254. The first tread portion 252 is disposed over the first main portion 206 of the first segment of tire base layer 202 above the intermediate wall 72, but does not extend beyond the first end portion 204. The second tread portion 254 is disposed over the second main portion 216 and the second end portion 214. Once engaged according to any of the above discussions, the first end portion is disposed below (radially inwardly) the second end portion such that the first tread portion 252 is adjacent to the second tread portion 254.

[0246] exist Figure 44b , a first tread portion 252 extends over the first main portion 206 and the first end portion 204, and a second tread portion 254 extends over the second main portion 216 and the second end portion 214. A contact area 220 is provided by the longitudinal end faces of the first and second segments of the tire base and the tread portions so that the first and second segments of the tire base are fixed to each other and the first and second tread portions are fixed to each other.

[0247] In examples where an insert 230 is used, the insert may include an insert tread portion 234 , which may be provided on or in place of the insert head 232 .

[0248] Fig.45 A joining apparatus 260 is shown for joining the first length of tire base layer 202 with the second length of tire base layer 212. The joining apparatus includes a clamp 262 for holding the first and second lengths of tire base layer in place so that the ends 204, 214 can be properly joined. Fig.45 The illustrated bonding apparatus is configured to apply heat and pressure between the top clamping surface 264 and the bottom clamping surface 266 to form a bond.

Claims

1. A method for manufacturing a continuous belt of tire base layer, the method comprising: providing a sheet of material having a first lateral edge portion and a second lateral edge portion, wherein the first lateral edge portion is separated from the second lateral edge portion by a central portion; placing a first reinforcing element on the sheet where the first lateral edge portion intersects the central portion, and placing a second reinforcing element on the sheet where the central portion intersects the second lateral edge portion; folding the first transverse edge portion over the first reinforcing element; folding the second transverse edge portion over the second reinforcing element; as well as The first lateral edge portion and the second lateral edge portion are secured to the central portion.

2. The method of claim 1 , wherein the sheet includes a longitudinal length, the first lateral edge portion intersects the center portion along a line parallel to the longitudinal length of the sheet, and the center portion intersects the second lateral edge portion along a line parallel to the longitudinal length of the sheet.

3. The method according to claim 1 or 2, wherein after folding the first lateral edge portion over the first reinforcing element and after folding the second lateral edge portion over the second reinforcing element, the first lateral edge portion overlaps the second lateral edge portion, and the method comprises: The first lateral edge portion is secured to the second lateral edge portion.

4. The method according to claim 1, 2 or 3, wherein the reinforcing element is a bead wire comprising metal, a thermoplastic polymer or a thermosetting polymer.

5. Method according to any one of claims 1 to 4, wherein the first reinforcing element and / or the second reinforcing element are fixed to the sheet of material.

6. A method according to any one of the preceding claims, wherein the sheet of material comprises fibres and one or more of an elastomer and an epoxy resin.

7. A method according to any one of the preceding claims, wherein the sheet of material comprises fibers arranged in a woven or knitted pattern, and wherein the longitudinal length of the fibers in the woven pattern is offset from the longitudinal direction of the sheet of material.

8. The method of claim 7, wherein the longitudinal length of the fibers is offset from the longitudinal direction of the sheet of material by 30 degrees or more.

9. A method according to any one of the preceding claims, wherein said securing comprises welding overlapping materials together using a welding operation.

10. A method according to any preceding claim, wherein said securing comprises adding a joining material to overlapping portions of said sheets of material.

11. A method according to any preceding claim, wherein the method comprises providing a puncture protection layer on at least a part of the central portion of the sheet of material.

12. The method of claim 11, wherein the puncture protection layer comprises one or more of an elastomer, a plastic, a composite material, a fiber sheet, a fiber reinforced elastomer.

13. A method according to any one of the preceding claims, comprising winding the continuous strip of tyre base layer onto a reel.

14. A method of manufacturing a continuous strip of tire base layer, the method comprising: providing a tubular material having a longitudinal length; inserting a first reinforcing element and a second reinforcing element into the tubular material such that a longitudinal length of each reinforcing element is parallel to the longitudinal length of the tubular material; The first and second reinforcing elements are adhered to opposing first and second longitudinal sides of the tubular material.

15. The method of claim 14, wherein providing the tubular material comprises providing a sheet of material having a first longitudinally extending edge portion and a second longitudinally extending edge portion opposite the first edge portion; and The first longitudinally extending edge portion is secured to the second longitudinally extending edge portion to form a tube.

16. The method of claim 15, wherein the first and second reinforcing elements are introduced into the tubular material when the first and second edge portions are secured together.

17. A method according to claim 15 or 16, wherein securing the first edge portion of the sheet of material to the second edge portion comprises sewing the first edge portion to the second edge portion.

18. The method of claim 15 or 16, wherein securing the first edge portion of the tubular material to the second edge portion comprises welding the overlapping materials together using a welding operation or sewing the overlapping materials together.

19. The method of claim 15 or 16, wherein securing the first edge portion of the tubular material to the second edge portion comprises adding a joining material to the sheet of material.

20. The method of any one of claims 14 to 19, wherein tubular material between and above the first and second reinforcing elements is secured to tubular material between and below the first and second reinforcing elements.

21. The method of any one of claims 14 to 20, wherein the tubular material comprises fibers arranged in a weave pattern, and wherein the weave pattern is staggered with the longitudinal length of the tubular material.

22. A method according to claim 21, wherein the longitudinal length of the fibers is offset by at least 30 degrees from the longitudinal direction of the tubular material, optionally the fibers can be offset by 45 degrees from the longitudinal direction of the material sheet.

23. A method according to any one of claims 14 to 22, wherein the method comprises providing a puncture protection layer on or between at least a portion of the overlapping portions of the tubular material.

24. The method of claim 23, wherein the puncture protection layer comprises one or more of an elastomer, a plastic, a composite material, a fiber sheet, a fiber reinforced elastomer.

25. A method according to claim 23 or 24, wherein the puncture protection layer is provided on the radially outer side of the tubular material when viewed from a cross section perpendicular to the longitudinal length of the tubular material, and / or the puncture protection layer is provided on the radially inner side of the tubular material when viewed from a cross section perpendicular to the longitudinal length of the tubular material.

26. A method according to claim 23, 24 or 25 when dependent on claim 15, wherein the puncture protection layer is inserted into the tubular material when the first edge portion and the second edge portion are secured together.

27. A method for manufacturing a tire base layer, the method comprising: Providing a continuous strip of tire base layer according to the method of any one of the preceding claims; as well as The tire base strip is cut into lengths suitable for use in a single tire.

28. A method according to any one of the preceding claims, comprising: Heat is applied to the tire base layer and the tire base layer is stretched over the surface of the wheel, causing the tire base layer to adopt a curvature.

29. The method according to any one of claims 1 to 27, comprising: inserting a section of the continuous strip of tire base into the cavity of a tire base mold; applying heat and pressure to a section of the tire base within the tire base mold so that the section of the tire base continuous strip adopts the shape of the cavity of the tire base mold, wherein The shape of the cavity of the tire base mold includes at least one segment of a cylindrical tire having at least one curvature, wherein the arc of the segment extends along a longitudinal length of the cavity.

30. The method of claim 29, wherein the segments of a cylindrical tire comprise hyperbolas such that the tire has a radius r in a transverse cross section and a radius of curvature R in a cross section perpendicular to the longitudinal direction of the cylindrical tire.

31. The method of claim 29 or 30, wherein the tire base mold is a substantially flat mold comprising a shell including at least one longitudinal cavity extending between at least two opposing main walls and two opposing edge walls, wherein: Each of the main walls has at least one protrusion and at least one recess; Each protrusion and each depression extends and is inclined in the transverse direction and the longitudinal direction of the cavity; The protrusions and the depressions are arranged alternately along the length of the tire base mold; and The protrusion of one main wall is opposite to the depression of the other main wall.

32. A continuous strip of tyre base layer manufactured according to the method of any preceding claim.

33. A method of making a tire base layer and tread elements, the method comprising: Providing a continuous strip of tire base layer according to the method of any one of the preceding claims; inserting a section of the tire base layer into a tread mold; injecting an elastomeric material into the tread mold; solidifying the elastomeric material so that the elastomeric material and the tire base layer adopt the shape of the tread mold; as well as The engaged tire base layer and the elastomeric material are removed from the tread mold.

34. The method of claim 33, wherein the shape of the cavity of the tread mold comprises at least one segment of a cylindrical tire, the cylindrical tire comprising at least one radius of curvature.

35. A method according to claim 34, wherein the continuous strip of tyre base layer is provided according to any one of claims 28 to 31 and the radius of curvature adopted by the tyre base layer is greater than the radius of curvature of the cavity of the tread mould.

36. The method of claim 34, wherein the tire base continuous strip is provided according to claim 31, wherein the size of the depressions and projections of the tire base mold is greater than the size of the depressions and projections of the tread mold.

37. A method of manufacturing a tire; the method comprising: Providing at least one section of a tire base layer and a tread element according to the method of any one of claims 33 to 36; The at least one segment of the tire base layer and the ends of the tread element are joined to form a complete ring.

38. An apparatus for manufacturing a continuous strip of tire base layer, the apparatus comprising: A tire base material reel, the tire base material reel being used to store material sheets; one or more reinforcement element reels for storing reinforcement elements; as well as An assembly unit for receiving material from the tire base material reel and the first and second reinforcing elements from the one or more reinforcing element reels, and for assembling the continuous tire base, wherein the assembly unit includes a folding device for folding a first edge portion of the material sheet over the first reinforcing element and folding the second edge portion over the second reinforcing element.

39. An apparatus according to claim 38, comprising a fixing unit for fixing the first edge portion and the second edge portion to a central portion of the sheet of material.

40. Apparatus according to claim 38 or 39, comprising a reel for storing puncture protection material and means for supplying the puncture protection material to the assembly unit.

41. Apparatus according to claim 38, 39 or 40, wherein the folding apparatus comprises a stitching machine for stitching the first and second reinforcing elements into their respective positions on the sheet of material.

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