A tire with a multi-layered carcass and belt layer cross-woven structure and its manufacturing method.

Abstract

This invention relates to a tire with a multi-layered carcass and belt layer cross-woven structure and its manufacturing method, belonging to the field of tire technology. It includes a steel wire bead structure, a triangular rubber layer, and a multi-layered carcass and belt layer cross-woven structure. The multi-layered carcass and belt layer cross-woven structure includes multi-layered carcass weaving units and woven belt plies that are cross-bonded to the multi-layered carcass weaving units. Each multi-layered carcass weaving unit consists of a single-layered woven carcass ply and multiple double-layered woven carcass plies covering the surfaces of the single-layered and belt-layered woven plies. The single and double-layered carcass plies are continuous zigzag-woven tire ply tubes without end points. The belt layer woven structure is placed between every two layers of carcass woven plies. This invention effectively solves the problem of discontinuities in the carcass plies of traditional tires, enabling the carcass and belt plies to continuously and uniformly transmit the load, ensuring the continuity of tire skeleton tension, and improving tire stiffness and impact resistance.

Description

Technical Field

[0001] This invention relates to the field of tire technology, specifically to a tire with a multi-layered carcass and belt layer cross-woven structure and its manufacturing method. Background Technology

[0002] Tires are composed of a carcass material and rubber, making them a typical cord-rubber composite material. The cords act as reinforcement, primarily bearing the load of the entire structure, while the rubber, as the matrix, transmits the load. As the main load-bearing structure of the tire, the carcass material bears approximately 80% or more of the tensile stress experienced during tire inflation. The tire carcass material mainly consists of two parts: the tire carcass and the belt ply. The tire carcass primarily bears the radial tension, while the belt ply bears the circumferential tension. Therefore, the carcass material determines the tire's load-bearing capacity, rigidity, and other properties.

[0003] Chinese patent CN206733966U discloses a radial tire for low-section heavy-duty vehicles. This tire employs both a zigzag-wound cross-mesh structure belt layer and a continuously parallel spiral-wound belt layer, which significantly reduces the number of belt layer cord joints, effectively constrains circumferential deformation during use, optimizes the stress distribution of the belt layer, avoids discontinuities in the stiffness of the tire belt layer cords, and reduces the probability of damage to the tire shoulder area. However, the tire carcass still has a large number of reverse-wrap ends, resulting in interface adhesion defects in the reverse-wrap end area. This leads to holes and cracks appearing in this area early in use, greatly reducing the tire's service life. Furthermore, the discontinuity in the stiffness of the cords in this area severely restricts the tire's load-bearing capacity.

[0004] Therefore, how to provide a tire with a multi-layered carcass and belt layer cross-woven structure and its manufacturing method has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] To address at least one technical problem in the background art, this invention provides a tire with a multi-layered carcass and belt layer cross-woven structure and its manufacturing method. This eliminates the continuous cutting points generated during the traditional carcass ply manufacturing process, avoiding holes and cracks in the cutting point areas. Simultaneously, it significantly reduces the number of joints in the belt layer cords, preventing discontinuities in the stiffness of the tire belt layer cords and reducing the probability of damage to the tire shoulder area. This invention enables the entire tire's skeleton material to form a continuous winding structure, ensuring continuous and uniform transmission of radial and circumferential tension, which can significantly improve the tire's high-speed performance, impact resistance, load-bearing capacity, and service life.

[0006] To achieve the above objectives, the present invention provides a tire with a multi-layer carcass and belt layer cross-woven structure, including a steel wire ring structure, a triangular rubber layer and a multi-layer carcass and belt layer cross-woven structure, wherein the steel wire ring structure and the triangular rubber layer are both disposed inside the multi-layer carcass and belt layer cross-woven structure, and the triangular rubber layer covers the outside of the steel wire ring structure.

[0007] The multi-layer tire carcass and belt layer cross-woven structure includes multi-layer tire carcass weaving units and woven belt ply layers that are cross-bonded with the multi-layer tire carcass weaving units. The multi-layer tire carcass weaving units are divided into a single-layer tire carcass woven ply layer located at the center of the structure and multiple double-layer tire carcass woven ply layers covering the surfaces of the single-layer tire carcass woven ply layer and the belt layer woven ply layer. The single and double-layer tire carcass woven ply layers are tire carcass ply tubes formed by continuous zigzag weaving of cords or rubber-coated cords. The belt layer woven ply layer is placed between every two tire carcass woven ply layers and is formed by continuously winding cords or rubber-coated cords around the tire circumference at a certain angle.

[0008] Furthermore, it also includes a shoulder pad rubber layer, a sidewall rubber layer, and a bead protector layer. The inner side of the multi-layer carcass and belt layer cross-woven structure is provided with an airtight layer, and the outer side of the multi-layer carcass and belt layer cross-woven structure is provided with a multi-layer belt ply structure. The shoulder pad rubber layer, the sidewall rubber layer, and the bead protector layer are all bonded to the multi-layer carcass and belt layer cross-woven structure. The multi-layer belt ply structure is covered with a tread underlayer, a tread toplayer, and a crown belt layer.

[0009] Furthermore, the multi-layer carcass and belt layer cross-weave structure includes n+1 layers of carcass weaving units and n layers of woven belt ply layers that are cross-bonded with the n+1 layers of carcass weaving units, wherein n takes the value of 1 to 8; the first layer of carcass weaving unit is located at the center of the multi-layer carcass and belt layer cross-weave structure, the first layer of woven belt ply layer is bonded to the first layer of carcass weaving unit, the second layer of carcass weaving unit is bonded to the lower surface of the first layer of carcass weaving unit and the upper surface of the first layer of woven belt ply layer unit; and so on, each layer of carcass weaving unit is cross-bonded with the woven belt ply layer, wherein the first layer of carcass weaving unit is a single layer of carcass woven ply layer, and the second to n+1 layers of carcass weaving units are upper and lower layers of carcass woven ply layer, and finally, a multi-layer carcass and belt layer cross-weave structure is formed along the radial direction of the tire by cross-bonding n layers of belt ply layer and 2n+1 layers of carcass woven ply layer.

[0010] Furthermore, when n is 3, the multi-layer tire carcass and belt layer cross-woven structure is formed by cross-bonding 4 layers of tire carcass weaving units and 3 layers of woven belt cord fabric layers; wherein the tire carcass weaving units are the 1st tire carcass weaving unit, the 2nd tire carcass weaving unit, the 3rd tire carcass weaving unit and the 4th tire carcass weaving unit, and the woven belt cord fabric layer unit, the interlayer, the 2nd tire carcass weaving unit, the 3rd tire carcass weaving unit and the 4th tire carcass weaving unit are sequentially bonded to the upper and lower sides of the 1st tire carcass weaving unit.

[0011] A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure includes the following steps:

[0012] S1. A multi-layered tire carcass and belt layer cross-woven structure is formed by cross-bonding n+1 layers of tire carcass weaving units with n layers of woven belt plywood.

[0013] S2. On the upper surface of the prepared multi-layer carcass and belt layer cross-woven structure, weave another K layer of belt cord fabric, where K is 1 to 8.

[0014] S3. Prepare other structural layers required for tire manufacturing: Cut the airtight layer, shoulder pad rubber layer, sidewall rubber layer, steel rim covering layer, and bead protection layer to the appropriate lengths, and attach them to the multi-layer carcass and belt layer cross-woven structure and K-layer belt ply according to the tire's structural dimensions and positions, to obtain a semi-finished component of a rubber tire with a multi-layer carcass and belt layer cross-woven structure; then press the tread rubber layer onto the K-layer belt ply structure to obtain an uncured green tire with a multi-layer carcass and belt layer cross-woven structure;

[0015] S4. The prepared green tire is heated and pressurized using a vulcanizing machine. After vulcanization, a tire with a multi-layered carcass and belt layer cross-woven structure is obtained.

[0016] Furthermore, the manufacturing method of the multi-layer carcass and belt layer cross-woven structure includes:

[0017] S11, First layer of tire carcass braiding unit: Two steel wire rings are fixed parallel to each other at a certain interval, so that the triangular rubber layer is wrapped around the steel wire rings circumferentially. Select a cord with a rubber-coated surface, leave a certain length and fix it on one of the triangular rubber layers. Then, it is wound around the other lower triangular rubber layer with a certain tension and angle. This is done by continuously winding 360 degrees circumferentially. At the same time, the rubber-coated cord is rolled into a layer using a pressing roller. Finally, the rubber-coated cords are connected at the calculated connection points to make the first layer of braided tire carcass cord cylinder.

[0018] S12. Cover the upper and lower surfaces of the prepared first layer of woven fabric with a rubber layer and inflate it with air so that its outer contour expands to the shape of the woven fabric layer.

[0019] S13, First layer of braided belt cord: Prepare a cord, after coating the surface with adhesive, fix one end of it to the first layer of braided tire cord with adhesive coating. The fixing point is the position of the first end of the belt layer set in advance. Wrap it circumferentially along the outside of the first layer of tire cord braiding unit with adhesive coating with a certain tension and angle until the braiding width reaches the set width of the belt layer, forming the first layer of braided belt cord tube.

[0020] S14, Second tire carcass braiding unit: The upper surface of the first layer of braided cord ply is covered with a rubber layer. A rubber-coated cord is selected, with a reserved length, and one end is fixed to the center line of the tread of the first layer of braided cord ply covered with rubber. It is braided with a certain tension and angle on the upper surface of the first layer of braided cord ply covered with rubber and the lower surface of the first layer of tire carcass braiding unit covered with rubber. At the same time, they are pressed together. Finally, the rubber-coated cord is connected at the calculated connection point. This makes the second layer of tire carcass braiding unit, which can be divided into upper and lower layers along the radial direction of the tire.

[0021] The weaving methods of the braided belt ply and the braided carcass ply in steps S15, S13 and S14 involve sequentially cross-bonding n layers of braided belt ply and n+1 layers of carcass braiding units, ultimately forming a multi-layered carcass and belt layer cross-woven structure in the radial direction of the tire, consisting of 2n+1 layers of carcass braided ply and n layers of braided belt ply cross-bonding.

[0022] Furthermore, the winding angle of a single cord in each layer of the woven carcass ply is 0.1° to 3° or -0.1° to -3° with the axial direction of the tire, and the winding angle in the woven belt ply is 0.1° to 30° or -0.1° to -30° with the center plane of the tire tread.

[0023] Furthermore, the winding angles of the woven carcass ply layers should maintain a symmetrical relationship, including that the angles of the upper ply cords in each carcass layer are opposite to the angles of the lower ply cords; or the angles of the upper ply cords in each carcass layer are opposite to the angles of their adjacent upper ply cords, and the angles of the lower ply cords in each carcass layer are opposite to the angles of their adjacent lower ply cords.

[0024] Furthermore, in the multi-layered cross-bonded tire carcass braiding unit and the K-layer belt cord fabric layer, the number of braided belt cord fabric layer structures is even, and the winding angles of adjacent braided belt cord fabric layers are opposite.

[0025] Furthermore, the braided tire cord layer and the braided belt cord layer are formed by continuously and evenly winding a cord tape composed of a single adhesive cord or multiple adhesive cords to form a cord tube.

[0026] Furthermore, the cords of the braided body ply and the braided belt ply include steel wire, nylon, aramid, or a blend of nylon and aramid.

[0027] Furthermore, the steel wire loop structure in the single-layer braided carcass ply is formed by multiple steel wires winding and weaving. The core of the steel wire loop structure is a closed circular steel wire, and the outer layer of the core is wound and woven with multiple layers of steel wires or nylon, aramid, or nylon and aramid blended materials. The circumferential cross-sectional shape of the steel wire loop structure includes triangle, rectangle, circle, and regular hexagon.

[0028] Furthermore, after the cords in the tire body weaving unit are continuously woven with adhesive coating, the weaving end point will return to the starting position. The connection between the starting point and the end point is achieved by two methods: butt joint and lap joint.

[0029] Furthermore, the starting position of the continuous weaving of the cords after being coated with adhesive in the tire body weaving unit is determined by finite element analysis or tension calculation formula.

[0030] Furthermore, the stress distribution of the tire carcass braiding unit under inflation and load conditions was calculated using the finite element method, and the position with the minimum tension of the tire carcass cord was selected as the starting position for continuous braiding of the tire carcass braiding unit.

[0031] Furthermore, the thickness of the continuously woven rubber-coated cord in the tire body braiding unit and the braided belt ply is 0.5-2 times the cord diameter D.

[0032] Furthermore, the triangular adhesive layer is arranged circumferentially along the wire coil structure, including both radial and axial directions along the wire coil.

[0033] Furthermore, the tire body weaving unit and the weaving belt cord layer are formed by continuously and evenly winding a cord belt composed of a single rubber-coated cord or multiple rubber-coated cords to form a cord tube.

[0034] Furthermore, the cords in the cord belt composed of multiple rubber-coated cords are evenly distributed, and the distribution interval is determined by the tire structure design. The number of cords is 2-8.

[0035] Furthermore, the tire carcass braiding unit is directly bonded to the braided belt ply, or an adhesive layer is provided, the thickness H of which is greater than the diameter D of the tire carcass cord.

[0036] The beneficial effects of this invention are as follows:

[0037] 1. This invention not only improves the rigidity and impact resistance of the tire, but also suppresses the standing wave phenomenon generated when the tire rotates at high speed, increasing the service life of the tire when driving at high speed; it establishes a stable and continuous force transmission structure, strengthens the force transmission between the steel wire ring and the tire body, and between the tire body and the belt layer, and improves the rigidity of the overall tire structure.

[0038] 2. This invention eliminates the continuous cut points produced by the woven carcass ply processes of traditional carcass ply manufacturing, such as calendering, cutting, and splicing. This avoids the situation where the lack of coating at the cut points prevents effective adhesion to the rubber, thus preventing damage such as holes and cracks at the cut points during tire operation, and the pulling out of the carcass ply cords when the tire is subjected to impact loads. The continuous tension of the ply cords within the woven carcass ply and woven belt ply improves the tire's load-bearing capacity and service life. Attached Figure Description

[0039] Figure 1 This is a schematic diagram of the structure of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention;

[0040] Figure 2 This is a comparative schematic diagram of the traditional rubber tire structure and the tire structure of the present invention;

[0041] Figure 3 This is a schematic diagram of the winding of a single-layer woven carcass ply of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention.

[0042] Figure 4 This is a schematic diagram of the cord arrangement angle of a single-layer woven carcass ply of a tire with a multi-layer carcass and belt layer cross-woven structure according to the present invention.

[0043] Figure 5 This is a schematic diagram of the structure of a single-layer woven carcass ply of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention.

[0044] Figure 6 This is a schematic diagram of the winding of the double-layer woven carcass ply of a tire with a multi-layer carcass and belt layer cross-woven structure according to the present invention.

[0045] Figure 7 This is a schematic diagram of the cord arrangement angle of the double-layer braided carcass ply of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention.

[0046] Figure 8 This is a schematic diagram of the double-layer woven carcass ply of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention.

[0047] Figure 9 This is a schematic diagram of the single and double woven carcass ply layers of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention (green lines represent the cords of the single woven carcass ply layer, and red lines represent the cords of the double woven carcass ply layer).

[0048] Figure 10This is a schematic diagram of the double-layer woven carcass ply of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention.

[0049] Figure 11 This is a schematic diagram of the winding of the belt-woven ply layer of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention.

[0050] Figure 12 This is a schematic diagram of the arrangement of the triangular rubber layer on the bead of a tire with a multi-layered carcass and belt layer cross-woven structure according to the present invention.

[0051] Figure 13 A schematic diagram showing the combination of a single cord coated with adhesive and a cord strip composed of multiple cords coated with adhesive;

[0052] Figure 14 The stress distribution of the three types of tires in Example 1 is shown.

[0053] Figure 15 This shows the stress distribution of three different tire structures in Example 2.

[0054] Among them, 1-steel wire ring structure, 2-triangular rubber layer, 3-multi-layer carcass and belt layer cross-woven structure, 4-sidewall rubber layer, 5-shoulder pad rubber layer, 6-lower tread layer, 7-upper tread layer, 8-crown belt layer, 9-multi-layer belt ply structure, 10-airtight layer, 11-bead protection layer, 12-first layer of woven carcass ply, 13-second layer of woven carcass ply, 14-third layer of woven carcass ply, 15-fourth layer of woven carcass ply, 16-woven belt ply, 17-rubber sandwich. Detailed Implementation

[0055] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0056] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0057] In this application, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this application and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0058] Furthermore, in addition to indicating location or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0059] Furthermore, the terms "installation," "setup," "equipped with," "connection," "linking," and "socketing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this application based on the specific circumstances.

[0060] To improve the impact resistance and load-bearing capacity of existing tires, this invention proposes a tire with a multi-layered carcass and belt ply cross-woven structure. The carcass ply of this tire adopts continuous winding technology, eliminating the continuous cut points generated in the traditional carcass ply manufacturing process. At the same time, it couples with the continuous winding technology of the belt ply cords, cross-bonding the carcass and belt ply to form a multi-layered woven ply structure. This makes the entire tire skeleton material form a continuous winding structure, ensuring the continuous and uniform transmission of radial and circumferential tension, which can significantly improve the tire's high-speed performance, impact resistance, load-bearing capacity, and service life.

[0061] To achieve the above objectives, such as Figure 1 As shown, the present invention provides a tire with a multi-layer carcass and belt layer cross-woven structure, including a steel wire ring structure 1, a triangular rubber layer 2 and a multi-layer carcass and belt layer cross-woven structure 3. The steel wire ring structure 1 and the triangular rubber layer 2 are both disposed inside the multi-layer carcass and belt layer cross-woven structure 3, and the triangular rubber layer 2 covers the outside of the steel wire ring structure 1.

[0062] The multi-layer tire carcass and belt layer cross-woven structure includes multi-layer tire carcass weaving units and woven belt ply layers that are cross-bonded with the multi-layer tire carcass weaving units. The multi-layer tire carcass weaving units are divided into a single-layer tire carcass woven ply layer located at the center of the structure and multiple double-layer tire carcass woven ply layers covering the surfaces of the single-layer tire carcass woven ply layer and the belt layer woven ply layer. The single and double-layer tire carcass woven ply layers are tire carcass ply tubes formed by continuous zigzag weaving of cords or rubber-coated cords. The belt layer woven ply layer is placed between every two tire carcass woven ply layers and is formed by continuously winding cords or rubber-coated cords around the tire circumference at a certain angle.

[0063] The present invention also includes a shoulder pad rubber layer 5, a sidewall rubber layer 4, and a bead protector layer 11. An airtight layer 10 is provided on the inner side of the multi-layer carcass and belt layer cross-woven structure 3, and a multi-layer belt ply structure 9 is provided on the outer side of the multi-layer carcass and belt layer cross-woven structure 3. The shoulder pad rubber layer 5, the sidewall rubber layer 4, and the bead protector layer 11 are all attached to the multi-layer carcass and belt layer cross-woven structure 3. The multi-layer belt ply structure 9 is covered with a lower tread layer 6, an upper tread layer 7, and a crown belt layer 8.

[0064] To further optimize the technical solution, the multi-layer tire carcass and belt layer cross-weaving structure 3 includes n+1 layers of tire carcass weaving units and n layers of woven belt ply layers that are cross-bonded with the n+1 layers of tire carcass weaving units, where n is 1 to 8; the first layer of tire carcass weaving unit is located at the center of the multi-layer tire carcass and belt layer cross-weaving structure 3, and the first layer of woven belt ply layer is bonded to the first layer of tire carcass weaving unit, the second layer of tire carcass weaving unit is bonded to the lower surface of the first layer of tire carcass weaving unit and the upper surface of the first layer of woven belt ply layer unit; and so on, each layer of tire carcass weaving unit is cross-bonded with the woven belt ply layer, wherein the first layer of tire carcass weaving unit is a single layer of tire carcass woven ply layer, and the second to n+1 layers of tire carcass weaving units are upper and lower two layers of tire carcass woven ply layer, and finally, a multi-layer tire carcass and belt layer cross-weaving structure is formed along the radial direction of the tire by cross-bonding n layers of belt ply layer and 2n+1 layers of tire carcass woven ply layer.

[0065] To further optimize the technical solution, when n is 3, the multi-layer tire carcass and belt layer cross-woven structure 3 is formed by cross-bonding 4 layers of tire carcass weaving units and 3 layers of woven belt cord fabric 16; wherein the tire carcass weaving units are the first layer tire carcass weaving unit 12, the second layer tire carcass weaving unit 13, the third layer tire carcass weaving unit 14 and the fourth layer tire carcass weaving unit 15, and the upper and lower sides of the first layer tire carcass weaving unit 12 are sequentially bonded with the woven belt cord fabric unit 16, the interlayer 17, the second layer tire carcass weaving unit 13, the third layer tire carcass weaving unit 14 and the fourth layer tire carcass weaving unit 15. Figure 2 (a) is the structure of a traditional rubber tire. Figure 2 (b) is a tire with a multi-layer carcass and belt layer cross-woven structure, wherein the multi-layer carcass and belt layer cross-woven structure is composed of two layers of woven carcass ply and one layer of woven belt ply cross-bonded. Figure 2 (c) is a multi-layered carcass and belt layer cross-woven structure with 2 layers of woven belt fabric; Figure 2 (d) is a multi-layered carcass and belt layer cross-woven structure with 3 layers of woven belt fabric.

[0066] The present invention also provides a method for manufacturing a tire having a multi-layered carcass and belt layer cross-woven structure, comprising the following steps:

[0067] S1. A multi-layered tire carcass and belt layer cross-woven structure is formed by cross-bonding n+1 layers of tire carcass weaving units with n layers of woven belt plywood.

[0068] S2. On the upper surface of the prepared multi-layer carcass and belt layer cross-woven structure 3, K layers of belt cord fabric are woven again, and the value of K is 1 to 8.

[0069] S3. Prepare other structural layers required for tire manufacturing: Cut the airtight layer, shoulder pad rubber layer, sidewall rubber layer, steel rim covering layer, and bead protection layer to the appropriate lengths, and attach them to the multi-layer carcass and belt layer cross-woven structure and K-layer belt ply according to the tire's structural dimensions and positions, to obtain a semi-finished component of a rubber tire with a multi-layer carcass and belt layer cross-woven structure; then press the tread rubber layer onto the K-layer belt ply structure to obtain an uncured green tire with a multi-layer carcass and belt layer cross-woven structure;

[0070] S4. The prepared green tire is heated and pressurized using a vulcanizing machine. After vulcanization, a tire with a multi-layered carcass and belt layer cross-woven structure is obtained.

[0071] Further optimization of the technical solution includes the following manufacturing methods for a multi-layered carcass and belt layer cross-woven structure:

[0072] S11, First Layer of Carcass Braiding Unit: Two steel wire loops are fixed parallel to each other at a certain interval, so that the triangular rubber layer wraps around the steel wire loops circumferentially. A rubber-coated cord is selected, leaving a certain length, and fixed to one of the triangular rubber layers. Then, it is wound around the other lower triangular rubber layer with a certain tension and angle. This winding continues 360 degrees circumferentially. Simultaneously, a pressing roller is used to press the rubber-coated cord into a single layer. Finally, the rubber-coated cords are connected at the calculated connection points to form the first layer of braided carcass ply. Figure 3 As shown;

[0073] S12. Cover the upper and lower surfaces of the prepared first layer of woven fabric with a rubber layer and inflate it with air so that its outer contour expands to the shape of the woven fabric layer.

[0074] S13, First layer of braided belt cord: Prepare a cord, after coating the surface with adhesive, fix one end of it to the first layer of braided tire cord with adhesive coating. The fixing point is the position of the first end of the belt layer set in advance. Wrap it circumferentially along the outside of the first layer of tire cord braiding unit with adhesive coating with a certain tension and angle until the braiding width reaches the set width of the belt layer, forming the first layer of braided belt cord tube.

[0075] S14, Second tire carcass braiding unit: The upper surface of the first layer of braided cord ply is covered with a rubber layer. A rubber-coated cord is selected, with a reserved length, and one end is fixed to the center line of the tread of the first layer of braided cord ply covered with rubber. It is braided with a certain tension and angle on the upper surface of the first layer of braided cord ply covered with rubber and the lower surface of the first layer of tire carcass braiding unit covered with rubber. At the same time, they are pressed together. Finally, the rubber-coated cord is connected at the calculated connection point. This makes the second layer of tire carcass braiding unit, which can be divided into upper and lower layers along the radial direction of the tire.

[0076] The weaving methods of the braided belt ply and braided carcass ply in steps S15, S13, and S14 involve sequentially cross-bonding n layers of braided belt ply and n+1 layers of carcass braided units. Ultimately, in the radial direction of the tire, a multi-layered carcass and belt ply cross-woven structure is formed, consisting of 2n+1 layers of carcass braided ply and n layers of braided belt ply cross-bonding. Figure 9 Figure 10 and Figure 11 (a) Figure 11 As shown in (b).

[0077] To further optimize the technical solution, the winding angle of a single cord in the woven tire carcass ply forms an angle of 0.1° to 3° or -0.1° to -3° with the tire's axial direction. Figure 4 and Figure 5 (a) Figure 5As shown in (b). The angle of winding in the braided belt ply is 0.1° to 30° or -0.1° to -30° with the center plane of the tire tread, such as... Figure 7 and Figure 8 (a) Figure 8 As shown in (b).

[0078] To further optimize the technical solution, the winding angle of the woven tire carcass ply should maintain a symmetrical relationship, including that the angle of the upper ply cord of each tire carcass layer is opposite to the angle of the lower ply cord; or the angle of the upper ply cord of each tire carcass layer is opposite to that of its adjacent upper ply cord, and the angle of the lower ply cord of each tire carcass layer is opposite to that of its adjacent lower ply cord.

[0079] Further optimize the technical solution by ensuring that the number of woven belt fabric layers in the multi-layer cross-bonded woven fabric layer structure and the K-layer belt fabric layer is even, and that the winding angles of adjacent woven belt fabric layers are opposite.

[0080] To further optimize the technical solution, the tire body weaving unit and the weaving belt cord layer are formed by continuously and evenly winding a cord belt composed of a single rubber-coated cord or multiple rubber-coated cords to form a cord tube.

[0081] To further optimize the technical solution, the steel wire loop structure in the single-layer woven carcass ply is formed by multiple steel wires winding and weaving. The core of the steel wire loop structure is a closed circular steel wire, and the outer layer of the core is wound and woven with multiple layers of steel wires or nylon, aramid, or nylon and aramid blended materials. The circumferential cross-sectional shape of the steel wire loop structure includes triangle, rectangle, circle, and regular hexagon.

[0082] To further optimize the technical solution, after the cords in the tire body weaving unit are continuously woven with rubber coating, the weaving end point will return to the starting position. The connection between the starting point and the end point is achieved by two methods: butt joint and lap joint.

[0083] To further optimize the technical solution, the starting position of the continuous weaving of the cords after rubber coating in the tire body weaving unit is determined by finite element analysis or tension calculation formula.

[0084] To further optimize the technical solution, the stress distribution of the tire in the carcass weaving unit under inflation and load conditions was calculated using the finite element method, and the position with the minimum tension of the carcass cord was selected as the starting position for continuous weaving of the carcass weaving unit.

[0085] To further optimize the technical solution, the thickness of the continuously woven rubber-coated cord in the tire body braiding unit and the braided belt ply is 0.5-2 times the cord diameter D.

[0086] Further optimize the technical solution, with the triangular adhesive layer 2 arranged circumferentially along the steel wire ring structure 1, including directions along the radial and axial sides of the steel wire ring, such as... Figure 12As shown in (a) and 12(b).

[0087] To further optimize the technical solution, the braided carcass ply and the braided belt ply use a single rubber-coated cord (e.g., Figure 13 (a) or multiple coated cords (as shown) Figure 13 (b) The cord tapes are continuously and evenly wound to form a curtain tube.

[0088] Further optimize the technical solution. The cords in the cord belt composed of multiple rubber-coated cords are evenly distributed, and the distribution interval is determined by the tire structure design. The number of cords is 2 to 8.

[0089] To further optimize the technical solution, the cords of the woven body ply and the woven belt ply include materials such as steel wire, nylon, aramid, or a mixture of nylon and aramid.

[0090] To further optimize the technical solution, the tire carcass braiding unit and the braided belt ply can be directly bonded, or an adhesive layer can be provided, with the thickness H of the adhesive layer being greater than the diameter D of the tire carcass cord.

[0091] This invention not only improves tire stiffness and impact resistance but also suppresses standing wave phenomena generated during high-speed tire rotation, increasing tire lifespan during high-speed driving. It establishes a stable and continuous force transmission structure, strengthening force transmission between the steel wire ring and the tire carcass, and between the tire carcass and the belt layer, thus improving the overall structural stiffness of the tire. By incorporating a woven carcass ply, this invention eliminates the continuous cut points produced by the calendering, cutting, and splicing processes of traditional carcass ply manufacturing. This avoids situations where the lack of coating at the cut points prevents effective adhesion to the rubber, preventing damage such as holes and cracks at the cut points during tire operation, and the pull-out of carcass cords under impact loads. The continuous cord tension within the woven carcass ply and woven belt ply further enhances the tire's load-bearing capacity and lifespan.

[0092] Example 1:

[0093] This invention proposes a tire with a multi-layered carcass and belt layer cross-woven structure. Finite element analysis was performed on the proposed tire with this multi-layered carcass and belt layer cross-woven structure compared to a traditional multi-layered carcass ply tire. The traditional multi-layered carcass ply tire has 7 carcass plies and 8 belt plies. Two types of tires with a multi-layered carcass and belt layer cross-weave structure were used. Tire 1 has four woven carcass plies (seven radially), and is covered by eight belt plies. (This tire's structure is the same as the tire with a continuous cord tension structure.) Tire 2 has four woven carcass plies (seven radially) and three woven belt plies, and is covered by five belt plies. All tires use the same materials. The inflation pressure is set to 1.59 MPa. After inflation, a rigid road surface is applied, and the road surface is moved to compress the tires, reducing the inflation radius to 550 mm. The road surface reaction force is then measured. The stress cloud diagrams of the three tires after loading are shown below. Figure 14 (a) Figure 14 (b) and Figure 14 As shown in (c), where, Figure 14 (a) is a stress contour plot after traditional tire loading. Figure 14 (b) is a stress contour plot of the tire after loading. Figure 14 (c) is the stress cloud diagram after the tire is loaded twice, and its relevant data is shown in Table 1.

[0094]

[0095] Table 1

[0096] Analysis of the calculation data in Table 1 shows that, under the same inflation pressure, the outer diameter of tire 2, with its multi-layer carcass and belt layer cross-weave structure, is reduced by 2.24% compared to the traditional tire. When the tire is under load, the corresponding deflection and support reaction force are measured. Based on this data, the radial stiffness changes of the three types of tires can be obtained. Compared to the traditional multi-layer carcass ply tire, the radial stiffness of tire 1, with its multi-layer carcass and belt layer cross-weave structure, increases by 49.04%, and the radial stiffness of tire 2, with its multi-layer carcass and belt layer cross-weave structure, increases by 68.58%. In conclusion, the tire with a multi-layer carcass and belt layer cross-weave structure invented in this invention forms a continuous force transmission structure in its skeleton material, achieving continuous load transmission and significantly improving tire stiffness and load capacity.

[0097] Example 2:

[0098] To verify the impact of the number and type of woven belt ply layers on tire performance of the tire with a multi-layered carcass and belt ply cross-weave structure proposed in this invention, finite element analysis results were compared for tires with one, two, and three belt ply layers in the multi-layered carcass and belt ply cross-weave structure. The boundary conditions and load types were the same as in Example 1.

[0099] Among them, tires with a multi-layered carcass and belt ply cross-woven structure are defined as follows: tire three, with one belt ply and two carcass ply; tire four, with two belt ply and three carcass ply; and tire five, with three belt ply and four carcass ply. Finite element analysis is performed on these tires, and the results are as follows: Figure 15 (a) Figure 15 (b) and Figure 15 As shown in (c) Figure 15 (a) Figure 15 (b) and Figure 15 (c) are stress cloud diagrams of tires three, four and five after loading, respectively. The relevant data are shown in Table 2.

[0100]

[0101] Table 2

[0102] Analysis of the above results reveals that as the number of carcass plies and the belt plies they cover in the multi-layer carcass and belt plies cross-woven structure increases, the outer diameter and width of the inflated section gradually decrease, but the magnitude of the change is not large; at the same time, the radial stiffness of the tire also increases, but the magnitude of the change is also very small.

[0103] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.

Claims

1. A tire having a multi-layered carcass and belt layer cross-woven structure, characterized in that, It includes a wire bead structure (1), a triangular rubber layer (2), and a multi-layer carcass and belt layer cross-woven structure (3). The wire bead structure (1) and the triangular rubber layer (2) are both located inside the multi-layer carcass and belt layer cross-woven structure (3), and the triangular rubber layer (2) covers the outside of the wire bead structure (1). The multi-layer tire carcass and belt layer cross-woven structure includes multiple layers of tire carcass weaving units and woven belt ply layers that are cross-attached to the multiple layers of tire carcass weaving units. The multiple layers of tire carcass weaving units are divided into a single layer of tire carcass woven ply layer located at the center of the structure and multiple double layers of tire carcass woven ply layers covering the surfaces of the single layer of tire carcass woven ply layer and the woven belt ply layer. The single and double layers of tire carcass woven ply layers are tire carcass ply tubes without end formed by continuous zigzag weaving of rubber-coated cords. The woven belt ply layer is placed between every two layers of tire carcass woven ply layers and is formed by continuously winding rubber-coated cords around the tire circumference at a certain angle. The multi-layer tire carcass and belt layer cross-weaving structure (3) includes n+1 layers of tire carcass weaving units and n layers of woven belt ply that are cross-bonded with the n+1 layers of tire carcass weaving units, wherein n is 2 to 8; the first layer of tire carcass weaving unit is located at the center of the multi-layer tire carcass and belt layer cross-weaving structure (3), the first layer of woven belt ply is bonded to the first layer of tire carcass weaving unit, the second layer of tire carcass weaving unit is bonded to the lower surface of the first layer of tire carcass weaving unit and the upper surface of the first layer of woven belt ply; and so on, each layer of tire carcass weaving unit is cross-bonded with the woven belt ply, wherein the first layer of tire carcass weaving unit is a single layer of tire carcass woven ply, and the second to n+1 layers of tire carcass weaving units are upper and lower two layers of tire carcass woven ply, and finally a multi-layer tire carcass and belt layer cross-weaving structure is formed along the radial direction of the tire by cross-bonding n layers of woven belt ply and 2n+1 layers of tire carcass woven ply.

2. A tire with a multi-layered carcass and belt layer cross-woven structure as described in claim 1, characterized in that, It also includes a shoulder pad rubber layer (5), a sidewall rubber layer (4), and a bead protector layer (11). The inner side of the multi-layer carcass and belt layer cross-woven structure (3) is provided with an airtight layer (10), and the outer side of the multi-layer carcass and belt layer cross-woven structure (3) is provided with a multi-layer belt cord layer structure (9). The shoulder pad rubber layer (5), the sidewall rubber layer (4), and the bead protector layer (11) are all attached to the multi-layer carcass and belt layer cross-woven structure (3). The multi-layer belt cord layer structure (9) is covered with a tread underlayer (6), a tread toplayer (7), and a crown belt layer (8).

3. A tire with a multi-layered carcass and belt layer cross-woven structure as described in claim 2, characterized in that, When n is 3, the multi-layer tire carcass and belt layer cross-woven structure (3) is formed by cross-bonding 4 layers of tire carcass weaving units and 3 layers of woven belt cord fabric (16); wherein the tire carcass weaving units are the first layer of tire carcass weaving unit (12), the second layer of tire carcass weaving unit (13), the third layer of tire carcass weaving unit (14) and the fourth layer of tire carcass weaving unit (15).

4. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure, characterized in that, The method for preparing a tire with a multi-layered carcass and belt layer cross-woven structure as described in any one of claims 1-3 comprises the following steps: S1. A multi-layered tire body and belt layer cross-woven structure is formed by cross-bonding n+1 layers of tire body weaving unit and n layers of woven belt cord fabric layer (3). S2. On the upper surface of the prepared multi-layer carcass and belt layer cross-woven structure (3), weave a K layer of belt cord fabric, where K is 1 to 8. S3. Prepare other structural layers required for tire manufacturing: Cut the airtight layer, shoulder pad rubber layer, sidewall rubber layer, steel rim covering layer, and bead protection layer to the appropriate lengths, and attach them to the multi-layer carcass and belt layer cross-woven structure and K-layer belt ply according to the tire's structural dimensions and positions, to obtain a semi-finished component of a rubber tire with a multi-layer carcass and belt layer cross-woven structure; then press the tread rubber layer onto the K-layer belt ply structure to obtain an uncured green tire with a multi-layer carcass and belt layer cross-woven structure; S4. The prepared green tire is heated and pressurized using a vulcanizing machine. After vulcanization, a tire with a multi-layered carcass and belt layer cross-woven structure is obtained.

5. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure as described in claim 4, characterized in that, The manufacturing method of the multi-layer carcass and belt layer cross-woven structure includes: S11, First layer of tire carcass braiding unit: Two steel wire ring structures are fixed in parallel at a certain interval, so that the triangular rubber layer is wrapped around the steel wire ring structure in the circumferential direction. Select a cord with a rubber-coated surface, leave a certain length and fix it on one of the triangular rubber layers. Then, it is wound around the other triangular rubber layer with a certain tension and angle. This is done continuously for 360 degrees in the circumferential direction. At the same time, the rubber-coated cord is rolled into a layer using a pressing roller. Finally, the rubber-coated cords are connected at the calculated connection point to make the first layer of braided tire carcass cord tube. S12. Cover the upper and lower surfaces of the prepared first layer of woven tire cord with a rubber layer and inflate it with air so that its outer contour expands to the shape of the woven tire cord layer. S13, First layer of woven cord fabric: Prepare a cord, after coating the surface with adhesive, fix one end of it to the first layer of woven cord fabric of the tire carcass with adhesive coating. The fixing point is the position of the first end of the cord layer set in advance. Wrap it circumferentially along the outside of the first layer of woven unit of the tire carcass with adhesive coating with a certain tension and angle until the width of the weave reaches the set width of the cord layer, forming the first layer of woven cord fabric tube. S14, Second tire carcass braiding unit: The upper surface of the first layer of braided cord ply is covered with a rubber layer. A rubber-coated cord is selected, with a reserved length, and one end is fixed to the center line of the tread of the first layer of braided cord ply covered with rubber. It is braided with a certain tension and angle on the upper surface of the first layer of braided cord ply covered with rubber and the lower surface of the first layer of tire carcass braiding unit covered with rubber. At the same time, they are pressed together. Finally, the rubber-coated cord is connected at the calculated connection point. This makes the second layer of tire carcass braiding unit, which can be divided into upper and lower layers along the radial direction of the tire. The weaving methods of the braided belt ply and the carcass braided ply in steps S15, S13, and S14 involve sequentially cross-bonding n layers of braided belt ply and n+1 layers of carcass braided units, ultimately forming a multi-layered carcass and belt layer cross-woven structure in the radial direction of the tire, consisting of 2n+1 layers of carcass braided ply and n layers of braided belt ply cross-bonding.

6. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure as described in claim 5, characterized in that, In each layer of the tire carcass woven ply, the winding angle of a single cord is 0° to the tire's axial direction. ~ Or -0. ~- The included angle is 0° to the center plane of the tire tread. ~3 Or -0. ~-3 .

7. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure as described in claim 5 or 6, characterized in that, The angles of the tire carcass woven cord layers should be symmetrical. For double-layer tire carcass woven cord layers, the angles of the upper cords in each tire carcass layer are opposite to those of the lower cords; or the angles of the upper cords in each tire carcass layer are opposite to those of their adjacent upper cords, and the angles of the lower cords in each tire carcass layer are opposite to those of their adjacent lower cords.

8. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure as described in claim 7, characterized in that, In the multi-layer cross-bonded tire carcass braided unit and the K-layer belt cord fabric layer, the number of braided belt cord fabric layer structures is even, and the winding angles of adjacent braided belt cord fabric layers are opposite.

9. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure as described in claim 5, characterized in that, The woven cord fabric layer and the woven belt cord fabric layer are formed by continuously and evenly winding a cord tape consisting of a single rubber-coated cord or multiple rubber-coated cords to form a cord tube.

10. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure as described in claim 9, characterized in that, The cords of the woven fabric layer and the woven belt fabric layer include steel wire, nylon, aramid, or a mixture of nylon and aramid.

11. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure according to claim 5, characterized in that, The wire loop structure is formed by winding and weaving multiple steel wires. The core of the wire loop structure is a closed circular steel wire. The outer layer of the core is wound and woven with multiple layers of steel wires or nylon, aramid, or a blend of nylon and aramid. The circumferential cross-sectional shape of the wire loop structure includes triangle, rectangle, circle, and regular hexagon.

12. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure according to claim 5, characterized in that, After the cords in the tire body weaving unit are continuously woven with adhesive coating, the weaving end point will return to the starting position. The connection between the starting point and the end point is achieved by two methods: butt joint and lap joint.

13. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure according to claim 5, characterized in that, The starting position of the continuous weaving of the cords after being coated with adhesive in the tire body braiding unit is determined by finite element analysis or tension calculation formula.

14. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure according to claim 13, characterized in that, The stress distribution of a tire with carcass braiding units under inflation and load conditions was calculated using the finite element method, and the position with the minimum tension of the carcass cord was selected as the starting position for continuous braiding of the carcass braiding unit.

15. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure according to claim 5, characterized in that, The thickness of the rubber-coated cord continuously woven in the tire body braiding unit and the braided belt cord layer is 0.5-2 times the cord diameter D.

16. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure according to claim 5, characterized in that, The triangular adhesive layer (2) is arranged circumferentially along the wire ring structure (1), including radial and axial directions along the wire ring structure.

17. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure according to claim 9, characterized in that, The cord belt, composed of multiple rubber-coated cords, has cords that are evenly distributed, with the distribution interval determined by the tire structure design. The number of cords is 2-8.

18. A method for manufacturing a tire with a multi-layered carcass and belt layer cross-woven structure according to claim 5, characterized in that, The tire carcass braiding unit is directly bonded to the braided belt cord layer, or an adhesive layer is provided, the thickness H of which is greater than the diameter D of the tire carcass cord.

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