Tire with recycled rubber in bead

Abstract

A tire is provided having a bead with a reinforcing ply having a main portion (32) and a turn-up carcass ply (34) extending from the main portion. The bead also includes a reinforcement layer (38). There is a native bead filler (86, 84) comprising native rubber and a recycled bead filler (80, 82, 92) made of recycled rubber. An outward radial end (76) of the turn-up carcass ply is closer to the native bead filler than the recycled bead filler, and the outward radial end of the turn-up carcass ply is not engaged with the recycled bead filler. The outward radial end of the reinforcement layer is closer to the native bead filler than the recycled bead filler, and the outward radial end of the reinforcement layer is not engaged with the recycled bead filler.

Description

[0001] STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] This invention was made with government support under Advanced Manufacturing Office Award No. DE-EE0007897 awarded by the Office of Energy Efficiency and Renewable Energy (EERE) of the U.S. Department of Energy. The government has certain rights in this invention. Technical Field

[0003] The present subject matter relates to a tire comprising recycled rubber. More particularly, the present application relates to a bead design characterized by both virgin and recycled bead filler being strategically placed to maintain tire performance. Background Art

[0004] Once tires exceed their useful life, they are removed from service and enter the scrap phase. Approximately 50% of tires at the end of their life are burned to produce tire-derived fuel. Of the remaining scrap tires, some are reused in crumb rubber products, others are used in civil engineering applications, and the remainder are ground up and sent to landfills. To reduce the environmental impact of scrap tires, it may be desirable to reuse the rubber from scrap tires in the manufacture of new tires. However, only a relatively small amount of recycled rubber is used in new tires, as adding larger amounts of recycled rubber to new tires has been shown to degrade functional properties such as strain modulus and tensile strength. Therefore, using recycled rubber in place of new virgin rubber in newly manufactured tires may reduce tire performance. This disadvantage limits the applicability of recycled rubber in newly manufactured tires. Therefore, it is desirable to design a tire that allows the incorporation of recycled rubber into newly manufactured tires without degrading the performance of the newly manufactured tire due to the incorporation of recycled rubber. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] A complete and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification with reference to the accompanying drawings, wherein:

[0006] Figure 1 is a perspective view of a heavy truck tire.

[0007] Figure 2 This is a cross-sectional view of a truck tire in a radial section, where the cross-section of everything is what the tire will look like when mounted on the rim.

[0008] Figure 3 is a cross-sectional view of what a bead may look like when mounted to a rim, according to an exemplary embodiment.

[0009] Figure 4 is a cross-sectional view of a bead according to another exemplary embodiment.

[0010] Figure 5 is a cross-sectional view of a bead according to yet another exemplary embodiment.

[0011] The use of the same or similar reference numbers in different drawings denotes the same or similar features. DETAILED DESCRIPTION

[0012] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided for illustration of the invention and is not meant to limit the invention. For example, features shown or described as part of one embodiment can be used with another embodiment to yield a third embodiment. The present invention is intended to include these and other modifications and variations.

[0013] The present invention provides a tire 10 having recycled rubber incorporated into the bead 24 in a manner that does not compromise durability and longevity. In this regard, the recycled bead filler 78 is not engaged with the outward radial ends 76 of the turnup carcass ply 34 of the reinforcement ply 32, and is not engaged with the outward radial ends 58 of the reinforcing ply 38. These ends 76 and 58 are positioned closer to the virgin bead filler 36 than to the recycled bead filler 78. This arrangement allows recycled rubber to be incorporated into newly manufactured tires without degrading the tire's performance. In some embodiments, a multi-layer strategy is used to construct the virgin bead filler 36 and the recycled bead filler 78 to further ensure product performance while incorporating a certain amount of recycled material.

[0014] Figure 1A tire 10 is shown, which is a heavy-duty truck tire 10. The tire 10 can be a steer tire, a drive tire, a trailer tire, or an all-position tire. The tire 10 includes a carcass 22 on which a tread 20 is disposed. The beads 24 are the portions of the carcass 22 located at the inner radial ends of the carcass 22 closest to the central axis 12. The central axis 12 of the tire 10 extends through the center of the carcass 22, and the axial direction 16 of the tire 10 is parallel to the central axis 12. The radial direction 14 of the tire 10 is perpendicular to the central axis 12, and in the radial direction 14, the tread 20 is located farther from the central axis 12 than the carcass 22. The tread 20 extends around the entire carcass 22 in the circumferential direction 18 of the tire 10 and surrounds the central axis 12 360 degrees. Although described for use with a heavy-duty truck tire 10, the tire 10 provided according to the present invention can be any type of tire 10, such as a light vehicle tire, a light truck tire, a passenger car tire, or any other type of tire 10. However, there are certain embodiments in which the tire 10 is a heavy truck tire 10. As used herein, a direction described as outward or inward in a radial direction 14 means farther away from or closer to something in the radial direction 14 relative to the central axis 12. A direction described as inboard or outboard in an axial direction 16 means closer to or farther away from the centerline of the tire 10 in the axial direction 16, which is at the centerline 12. Figure 2 In the figure, the radial direction is represented as 14 lines.

[0015] Figure 2is a radial section through a tire 10 according to an exemplary embodiment. Various structures, sometimes referred to as products, composed of different materials, may be present throughout the tire 10. The tread 20 of the tire 10 is shown as being furthest from the axial center of the tire 10 in the radial direction 14. A first belt layer 64 and a second belt layer 66 are positioned below the tread 20 in the radial direction 14 and comprise belts that strengthen and maintain the shape of the tire 10. The reinforcement belts of layers 64, 66 may cross relative to one another, and in some cases, may be arranged at a 20-degree angle to one another. A carcass 22, or skeleton, extends from the tread 20 and comprises the sidewalls of the tire 10, which terminate in a pair of beads 24 arranged for mounting on a rim of a vehicle wheel. A bead core 28 is located in each of the beads 24 and is present to provide strength and gripping force within the beads 24 to maintain the tire 10 on the rim. The left bead 24 may be a mirror image of the right bead 24, and both beads 24 may contain products made from the same material. Some structures / products are located only in the bead 24, while others are located in and extend from the bead 24. For example, the inner liner 68 is located inside the bead 24 and extends to the inside and outside of the bead 24, then extends upward along the sidewall of the carcass 22. The inner liner 68 then extends across the entire inside of the crown in the axial direction 16, then extends into the right sidewall of the carcass 22 and forms the inside of that sidewall. The inner liner 68 then terminates inside the right bead 24 and is arranged in a mirror-image manner similar to its presence in the left bead 24. Thus, the inner liner 68 is a product of the tire 10 that extends from one bead 24 to the other and is made of a fluid-impermeable material, thereby maintaining fluid between the tire 10 and the rim to maintain the inflation pressure of the tire 10.

[0016] The tire 10 includes a structure, designated as a reinforcement ply 32, that is positioned within one of the beads 28 and extends through the carcass 12 and the crown to the other bead 28. The reinforcement ply 32 is wound around the bead core 28 and, outwardly from the bead core 28 in the axial direction 16, is designated as a turnup carcass ply 34. The reinforcement ply 32 has a main portion 74 that is positioned within the bead 24 and inboard of the turnup carcass ply 34 in the axial direction 16. The main portion 74 extends to the bead core 28 to a position of the reinforcement ply 32 that is closest to the center axis 12 in the radial direction 14. At this location closest to the center axis 12 in the radial direction 14, the reinforcement ply 32 is designated as a turnup carcass ply 34, which extends from this point to an outward radial end 76 of the turnup carcass ply 34, which is the portion of the turnup carcass ply 34 that is furthest from the center axis 12 in the radial direction 14. Thus, in some embodiments, both the main portion 74 and the turnup carcass ply 34 are wrapped around the bead core 28 and can both engage the bead core 28. In the bead 24, the turnup carcass ply 34 can be completely outboard of the main portion 74 in the axial direction 16, but this arrangement need not always be the case. The main portion 74 and the turnup carcass ply 34 can be continuous with one another, with no interruption between them in the reinforcement ply 32.

[0017] Relative positions in the axial direction 16 can be described with respect to an inner position and an outer position. The innermost point of the tire 10 can be Figure 2 The radial direction line 14 shown in FIG is located at the center of the tire 10 along the axial direction 16. Figure 2 The center of the tire 10 is located inwardly of the two beads 24 in the axial direction 16. Therefore, as used herein, an object is described as being located inwardly of another object in the axial direction 16 to mean that it is located closer to the radial direction line 14, such as Figure 2 Furthermore, as used herein, an object is described as being outside another object in the axial direction 16 to mean that it is positioned further away from the radial direction line 14 in the axial direction 16, as shown or as will be positioned in other figures. Figure 2 As shown or as will be positioned in other figures. As another example, the bead layer 42 is located outside the bead core 28 in the axial direction 16. Relative positioning in the radial direction 14 can be described with respect to the central axis 12, wherein objects can be closer to or farther away from the central axis 12 in the radial direction 14 than other objects. Although the central axis 12 is not shown in every figure due to size limitations, it should be understood that when something is described as being closer or farther away in the radial direction 14, reference should be made to the position of the central axis 12 as will be seen in order to determine the relative positioning.

[0018] Figure 3 is a close-up view of the left bead 24 according to another exemplary embodiment. The bead core 28 is composed of one or more steel rods 72. The bead core 28 is surrounded by the filler 30, and in some cases can be completely surrounded by the filler 30 on all sides. In some embodiments, surrounding the bead core 28 is a winding tissue 44 that can be made of nylon. The rod 72 that makes up the bead core 28 is shown as a single piece and has a rectangular cross-sectional shape. The single piece can actually be many rods arranged together in a rectangular shape. In other embodiments, the bead core 28 can be composed of multiple parts, and these parts can have any cross-sectional shape. The winding tissue 44 is wrapped around the filler 30 to isolate the rod 72 and the filler 30 from other elements of the tire 10 (such as the reinforcing cord layer 32 and the filler). The wrap 44 may have a stiffness of 14 MPa and may be made of a rubber compound and fabric (in some cases, it may be a nylon cord ply), the filler 30 may be a rubber compound and may have a stiffness of 28 MPa, and the rod 72 may be made of steel or aluminum and may have a stiffness of 30,000,000 MPa in some embodiments. The bead core 28 may be lightened so that a smaller rod may be used to improve the performance characteristics of the tire 10.

[0019] The tire bead 24 includes a virgin bead filler 36 and a recycled bead filler 78, both sometimes referred to as filler, positioned between and joining the reinforcement ply 32, the main portion 74, and the turn-up carcass ply 34. A wrapping 44 joins the recycled bead filler 78, the main portion 74, the turn-up carcass ply 34, and the wrapping 44. The virgin bead filler 36 does not join the wrapping 44. The wrapping 44 serves to stabilize the geometry of the filler 30 and the rod 72. Without the wrapping 44, the filler 30 would assume a more square shape when formed and a more elliptical shape when the tire 10 is in use. Thus, the wrapping 44 shapes the structures of the tire bead 24 in a desired manner, enabling them to function as intended. It should be understood that other truck tires 10 can be made without the wrapping 44 and still function in a completely normal and safe manner. The addition of the wrapping 44 can provide even greater durability performance for the bead 24 than would be possible without the wrapping 44 in the bead 24. However, there are a variety of truck tire 10 designs that are fully functional and safe according to the present design, both designs that include the wrapping 44 and designs that do not.

[0020] The recycled bead filler 78 is also located between the reinforcement layer 38 and the turnup carcass ply 34 and engages the reinforcement layer and the turnup carcass ply. The virgin bead filler 36 does not engage the bead core 28. The virgin bead filler 36 is located between the main portion 74 and the reinforcement layer 38 and engages both elements. The virgin bead filler 36 also engages the turnup carcass ply 34, the strip 48, and the recycled bead filler 78. The turnup carcass ply 34 has an outward radial end 76 that is the portion of the turnup carcass ply 34 that is most outward from the center axis 12 in the radial direction 14 and is the portion of the turnup carcass ply 34 that is farthest from the center axis 12 in the radial direction 14. The outward radial end 76 engages the virgin bead filler 36 and is the only element of the tire 10 that is engaged with the outward radial end 76. The outward radial end 76 is closer to the virgin bead filler 36 than to the recycled bead filler 78. The recycled bead filler 78 does not engage the outward radial end 76. The turn-up carcass ply 34 extends into and terminates within the virgin bead filler 36. The reinforcement layer 38 has an outward radial end 58, which is the portion of the reinforcement layer 38 farthest from the center axis 12 in the radial direction 14. The outward radial end 58 is closer to the virgin bead filler 36 than to the recycled bead filler 78, and the outward radial end 58 does not engage the recycled bead filler 78. The strip 48 surrounds the outward radial end 58 so that it does not engage the virgin bead filler 36, but it can be said that the reinforcement layer 38 extends outward in the radial direction 14 and terminates in the virgin bead filler 36. The reinforcement layer 38 joins the bead layer 42 , the virgin bead filler 36 , the recycled bead filler 78 , and the turnup carcass ply 34 .

[0021] The virgin bead filler 36 is located within the bead 24 and is positioned so that the recycled bead filler 78 is divided into a first region 92 and a second region 94 positioned more radially outward. Thus, the recycled bead filler 78 is discontinuous in the radial direction 14 such that it is not continuous along its entire length in the radial direction 14. The first region 92 engages the winding tissue 44, the virgin bead filler 36, the reinforcing ply 38, and the reinforcement ply 32 including the turnup carcass ply 34. The second region 94 engages the virgin bead filler 36, the main portion 74 of the reinforcement ply 32, the strip 48, the bead layer 42, and the sidewall product 70. The volume of material in the first region 92 may be different from the volume of material in the second region 94.

[0022] During construction of the tire 10, the recycled bead filler 78 and the virgin bead filler 36 may be placed into the bead 24 as separate, unitary components. Alternatively, these structures 78, 36 may be formed into one or more layers during the construction of the tire 10. Figure 3, the recycled bead filler 78 and the virgin bead filler 36 are each composed of two layers. The recycled bead filler 78 is composed of a first recycled bead filler layer 80 and a second recycled bead filler layer 82, and both layers 80, 82 are located in a first region 92 and a second region 94. The first recycled bead filler layer 80 joins the bead ply 42, the strip 48, the sidewall product 70, and the virgin bead filler 36 in the second region. The second recycled bead filler layer 82 joins the reinforcement ply 38, the turnup carcass ply 34, and the virgin bead filler 36 in the first region 92. The second recycled bead filler layer 82 in the second region 94 joins the sidewall product 70, the main portion 74, and the virgin bead filler 36. The second recycled bead filler layer 82 in the first region 92 joins the winding tissue 44, the main portion 74, and the turnup carcass ply 34.

[0023] In the second region 94, the first layer 80 of recycled bead filler and the second layer 82 of recycled bead filler are joined to each other by an interface 88 defined at their junction. Interface 88 joins the sidewall product 70 and extends from it to interface 90 of the virgin bead filler 36. The first region 92 does not have an interface 88 because the first layer 80 of recycled bead filler is separated from and not joined to the second layer 82 of recycled bead filler due to the presence of the turn-up carcass ply 34. Therefore, in the first region 92, the first layer 80 of recycled bead filler does not join the second layer 82 of recycled bead filler. The volume of recycled bead filler in the first layer 80 of recycled bead filler can be the same as or different from the volume of material present in the second layer 82 of recycled bead filler. The material comprising the first layer 80 of recycled bead filler can be identical to the material comprising the second layer 82 of recycled bead filler. During the construction process of the tire 10, the layers 80 and 82 can be laid up as separate layers onto other structures.

[0024] The virgin bead filler 36 is comprised of a first virgin bead filler layer 84 and a second virgin bead filler layer 86, with an interface 90 formed at the junction between the two layers 84, 86. Interface 90 joins interface 88 and extends from interface 88 to and joins the outward radial end 76. The first layer 84 joins the strip 48, the reinforcement layer 38, the first recycled bead filler layer 80, and the turnup carcass ply 34, including the outward radial end 76. The second virgin bead filler layer 86 joins the main portion 74, the second recycled bead filler layer 82, and the turnup carcass ply 34, including the outward radial end 76. The two layers 84, 86 can be made of the same material and can have the same volume or different volumes from each other. The layers 84, 86 can be applied at different times during the construction process of the tire 10 and need not be applied immediately sequentially. The presence of the turnup carcass ply 34 separates a portion of the virgin bead filler first layer 84 from the virgin bead filler second layer 86. The native bead filler 36 engages and separates both the first region 92 and the second region 94 , and the first region 92 is not engaged with the second region 94 .

[0025] The virgin bead filler 36 and the recycled bead filler 78 are a different rubber mix than the rubber mix that constitutes the rubber filler 30. The material that constitutes the virgin bead filler 36 and the recycled bead filler 78 can be more flexible than the material that constitutes the rubber filler 30. The bead fillers 36, 78 can have a stiffness in the range of 3.6 MPa to 5.6 MPa. The bead fillers 36, 78 terminate in the bead 24 or, in some cases, may extend into the sidewall of the tire 10. However, the bead fillers 36, 78 do not extend all the way beneath the belt layers 64, 66 to the other sidewall of the tire 10. The reinforcing ply 32 is a composite material comprising metal cords and a rubber mix. The reinforcing ply 32 is more rigid in the direction of its cords than the wound tissue 44, the bead fillers 36, 78, and the rubber filler 30. The reinforcing ply 32 extends from the bead 24 beneath the belts 64 , 66 , through the sidewall, and then into the opposing sidewall and down into the bead 24 on the right side of the tire 10 .

[0026] The reinforcement layer 38 is located outside the turnup carcass ply 34 in the axial direction 16 and contacts the turnup carcass ply along a portion of its length. The reinforcement layer 38 terminates in the bead 24 so that a portion of the reinforcement layer is located inward from a portion of the bead core 28 in the radial direction 14. The remaining portion of the reinforcement layer 38 is outward from the bead core 28 in the radial direction 14. The reinforcement layer 38 can be made of a combination of steel and rubber, and the rubber can have a stiffness of 10 MPa. The bead 24 includes a wear strip 46 located on the outside of the bead 24 and designed to engage the rim. The wear strip 46 engages the reinforcement layer 38, but no other arrangement is required. Figure 3The reinforcing layer 38 in the radial direction 14 extends outwardly to have a portion on the outside of the bead core 28 and the turn-up carcass ply 34 in the radial direction 14 .

[0027] Bead layer 42 is a product made of rubber of tire 10, and it has the part that joins reinforcing layer 38 and is positioned between reinforcing layer 38 and wear strip 46.Bead layer 42 extends outwardly to outward radial end 56 and joins strip 48, recycled bead filler first layer 80 and sidewall product 70 in radial direction 14, and this outward radial end is the outward position of bead layer 42 farthest from center axis 12 in radial direction 14.Outward radial end 56 is positioned slightly inward toward a part of recycled bead filler 78 in radial direction 14.Bead layer 42 can terminate in bead 24, and may or may not extend to the sidewall of tire 10.However, bead layer 42 does not extend to below belt layer 64, 66, and does not extend to right sidewall or right side bead 24.Sidewall product 70 is located in sidewall, and can have the stiffness of 3.6MPa to 5.6MPa. The bead layer 42 is not engaged with the turnup carcass ply 34 and the bead core 28 , is an internal product of the tire 10 , and does not have any portion forming the outer surface of the tire 10 .

[0028] This application describes the stiffness of a product or material. The stiffness referred to is Young's modulus, which is the stiffness of an elastic material, or the modulus of elasticity. The stiffness values ​​provided are measured in megapascals (MPa). The stiffness material property in question is MA10. This stiffness property can be calculated using the French standard NF T 46-002, dated September 1988.

[0029] The strip 48 is located in the bead 24 and engages the reinforcing layer 38, the bead layer 42, and both the virgin bead filler 36 and the recycled bead filler 78. When the reinforcing layer 38 is assembled into the green tire 10 prior to curing, the strip 48 may be present on the end of the reinforcing layer 38. In this regard, the strip 48 may be wrapped around the outward radial end 58 before and after the reinforcing layer 38 is assembled into the tire 10. Although the strip 48 is shown as being present, it should be understood that in other exemplary embodiments of the tire 10, the strip 48 is not present in the tire 10. The provided configuration of the bead 24 allows for the elimination of the strip 48 at the end of all products, thereby reducing the cost of the tire 10 and reducing the complexity of the tire 10.

[0030] An alternative design of the bead 24 is Figure 4 , which again shows a cross-section of the left bead 24 (the right bead 24 is a mirror image). Figure 4 The product design and its arrangement are the same as previously discussed and there is no need to repeat that information. However, there are some differences in the configuration of the bead 24 and those will be discussed in detail. Figure 3Differences in implementation plans. Figure 4 A recycled bead filler 78 is included that is not divided into a first region 92 and a second region 94 such that two regions do not exist. The recycled bead filler 78 does not engage the bead core 28, but the virgin bead filler 36 engages the bead core 28. The turnup carcass ply 34 is located within the virgin bead filler 36, with the first layer 84 located on one side in the axial direction 16 and the second layer 86 located on the other side in the axial direction 16. An interface 90 engages the interface 88 and extends therefrom to the outward radial end 76. The virgin bead filler 36 has two layers 84, 86 that engage the turnup carcass ply 34, and the two layers 84, 86 engage the outward radial end 76. The first layer 84 engages the reinforcement ply 38 and the strip 48.

[0031] There is no recycled bead filler 78 between the reinforcement layer 38 and the turnup carcass ply 34, and the recycled bead filler 78 does not join the outward radial end 76, the turnup carcass ply 34, the outward radial end 58, or the reinforcement layer 38. The virgin bead filler 36 is continuous in the radial direction 14, and the recycled bead filler 78 is also continuous in the radial direction 14. A majority of the recycled bead filler 78 is outward from a majority of the virgin bead filler 36 in the radial direction 14. However, due to the geometry of the interface between the bead fillers 36, 78, some portions of the recycled bead filler 78 are actually closer to the center axis 12 in the radial direction 14 than some portions of the virgin bead filler 36.

[0032] In various embodiments of the tire 10, the volume of material comprising the virgin bead filler 36 is equal to, greater than, or less than the volume of material comprising the recycled bead filler 78. In this regard, when a cross-section of the bead 24 is taken, such as Figures 2 to 5 ), the volume can be determined as the size of the area of ​​one bead filler 36 compared to the area of ​​the other bead filler 78.

[0033] Another exemplary embodiment of the tire 10 is Figure 5 is shown in FIG, which includes a configuration similar to Figure 3 of those products, making it unnecessary to repeat that information. Figure 5The difference in FIG relates to the configuration of the recycled bead filler 78 and the native bead filler 36. Here, the recycled bead filler 78 engages the winding tissue 44 of the bead core 28 and extends from the bead core 28 to a portion located at an outward position of the bead 24 in the radial direction 14. The recycled bead filler 78 is continuous from the bead 24 to an upward portion of the bead 24 in the radial direction 14. The recycled bead filler 78 extends in a continuous manner from the bead core 28 to a position outward from the native bead filler 36 in the radial direction 14, such that the recycled bead filler 78 extends to a position further outward from the center axis 12 in the radial direction 14 than the native bead filler 36.

[0034] The native bead filler 36 extends inward from the bead layer 42 in the axial direction 16 toward the main portion 74, but does not reach the main portion 74 and does not engage the main portion. The native bead filler 36 is located between the turnup carcass ply 34 and the reinforcement ply 38 and engages these two products, such that no other products of the tire 10 other than the native bead filler 36 are located between the turnup carcass ply 34 and the reinforcement ply 38. There is no strip 48, although it may be present in other embodiments. The entire outward radial end 58 engages only the native bead filler 36 and no other products. The native bead filler first layer 84 engages the reinforcement ply 38, but the native bead filler second layer 86 does not engage the reinforcement ply 38. In a similar manner, the outward radial end 76 engages only the native bead filler 36, and specifically engages the interface 90, such that both the native bead filler first layer 84 and the native bead filler second layer 86 engage the outward radial end 76.

[0035] Different configurations of the beads 24 with the virgin bead filler 36 and the recycled bead filler 78 are possible, and it should be understood that the configurations illustrated herein are merely exemplary and that other configurations are possible. Furthermore, while both fillers 36, 78 are illustrated as being comprised of two layers 84 / 86 and 80 / 82, it should be understood that both fillers 36, 78 may include any number of layers or no layers according to different exemplary embodiments.

[0036] In the various disclosed embodiments, it can be seen that the outward radial end 58 and the outward radial end 76 do not engage the recycled bead filler 78, but rather contact or are closer to the virgin bead filler 36. This arrangement protects the ends of the reinforcement layer 38 and the ends of the turn-up carcass ply 34 to maintain the desired durability performance of the cured tire 10 against crack initiation, formation, and propagation. Thus, the ends of the reinforcement layer 38 and the ends of the turn-up carcass ply 34 are protected from the effects of the recycled rubber product, thereby maintaining the durability performance of the tire 10 against crack initiation, formation, and propagation. The ends of the reinforcement layer 38 and the ends of the turn-up carcass ply 34 can be positioned so that the majority of the reinforcement layer 38 and the turn-up carcass ply 34 extending from their ends 58, 76 are closer to the virgin bead filler 36 than to the recycled bead filler 78.

[0037] As disclosed in various embodiments herein, the bead 24 includes a filler 36, 78 having a plurality of layers 80, 82, 84, 86. The plurality of layers 80, 82, 84, 86 may be layered into the bead 24 using a co-extrusion process. Other combinations of layering may be created by mixing and matching the disclosed arrangements.

[0038] Various embodiments disclosed herein can incorporate any type of recycled rubber into the recycled bead filler 78, such that the bead 24 can incorporate any type of recycled rubber. The recycled rubber can be included only in the bead 24 of the tire 10 and need not be included in other portions of the tire 10, such as the sidewall, tread 20, or undertread layer. In other embodiments, recycled rubber can be included in other portions of the tire 10, such as the sidewall, tread 20, or undertread layer, in addition to the bead 24. The volume of the bead 24 can include 1% to 10%, 10% to 30%, 12% to 15%, 5% to 15%, 15% to 25%, 20% to 30%, 25% to 35%, 12%, 15%, 20%, 10%, or 12% to 20%, or up to 15% recycled rubber. In other embodiments, the volume of the bead 24 may include 30% to 50%, 50% to 70%, 70% to 90%, 90% to 100%, or 100% recycled rubber. Thus, in other arrangements, recycled rubber may constitute any portion of the volume of the bead 24. The volume can be determined by taking a cross-section of the bead 24 and measuring the area of ​​the recycled rubber compared to the total area of ​​the cross-section of the bead 24. In some embodiments, a new tire 10 for light vehicles may include 12% recycled rubber in the bead 24, and a new tire 10 for commercial vehicles may include 15% recycled rubber in the bead 24. Recycled rubber can be incorporated into the bead 24 in the geometries described herein without reducing the performance of the tire 10 or increasing manufacturing costs. In some embodiments, by using a multi-layer 80 / 82 and 84 / 86 strategy as discussed herein, the durability and long-lasting performance of the existing bead 24 can be maintained by incorporating recycled rubber. The multi-layered arrangement and placement of the recycled bead filler 78 allows the beads 24 of the tire 10 to maintain product performance even with the inclusion of recycled material therein.

[0039] The recycled bead filler 78 can be any type of recycled rubber, which is a rubber product that has been cured and previously used in products such as tires or rubber hoses. The rubber in the recycled bead filler 78 is always vulcanized rubber and can be reprocessed vulcanized rubber from a tire that is placed in the current tire 10. In some embodiments, the recycled rubber is micronized rubber powder (MRP) obtained from old tires. In some embodiments, the micronized rubber powder is a micronized rubber composition having a particle size in the range of 40 mesh to 200 mesh, wherein the micronized rubber composition contains at least 10 weight percent solution styrene-butadiene rubber. The micronized rubber powder can be a micronized rubber powder as provided in U.S. Patent No. 9,815,974, entitled "recycled micronized rubber formulation having improved abrasion resistance," the contents of which are incorporated herein by reference for all purposes.

[0040] Although the subject matter of the present invention has been described in detail with respect to specific embodiments and methods thereof, it should be understood that those skilled in the art, upon understanding the foregoing, may readily conceive of modifications, variations, and equivalents of such embodiments. Accordingly, the scope of the present disclosure is by way of example and not by way of limitation, and the present disclosure does not exclude the inclusion of such obvious modifications, variations, and / or additions to the subject matter.

Claims

1. A tire having a central axis, a radial direction and an axial direction, the tire comprising: tread; a carcass carrying the tread, wherein the carcass has beads having: A bead core having a rod and a filler; a reinforcement ply wrapped around a portion of the bead core, wherein the reinforcement ply has a main portion, wherein the reinforcement ply has a turnup carcass ply extending from the main portion and located outboard of the bead core in the axial direction, wherein the turnup carcass ply has an outward radial end; a virgin bead filler having a portion radially outward from the bead core in the radial direction and axially outward of the reinforcing ply in the axial direction, wherein the virgin bead filler comprises virgin rubber; a recycled bead filler having a portion radially outward from the bead core in the radial direction and axially outward of the reinforcing ply in the axial direction, wherein the recycled bead filler comprises recycled rubber; a reinforcing layer having a portion located outside the turnup carcass ply in the axial direction, wherein the reinforcing layer has an outward radial end; wherein the outward radial end of the turnup carcass ply is closer to the virgin bead filler than to the recycled bead filler, and wherein the outward radial end of the turnup carcass ply is not engaged with the recycled bead filler; wherein the outward radial end of the reinforcement layer is closer to the virgin bead filler than to the recycled bead filler, and wherein the outward radial end of the reinforcement layer does not engage the recycled bead filler.

2. The tire of claim 1 further comprising a strip engaging the outward radial end of the reinforcing layer, wherein the outward radial end of the reinforcing layer does not engage the native bead filler.

3. The tire of claim 1 wherein the outward radial ends of the reinforcement layers engage the native bead filler, and wherein the outward radial ends of the turnup carcass plies engage the native bead filler.

4. The tire according to any one of claims 1 to 3, wherein the bead core has a winding structure engaging the rubber filler, wherein the winding structure engages the reinforcing cord layer.

5. The tire according to claim 1 , wherein the bead has a bead layer that engages the reinforcing layer and has a portion located outside the reinforcing layer in the axial direction, The bead has a wear strip having a portion located outside the bead layer in the axial direction, wherein the wear strip has a portion located radially inward from the bead core, wherein a portion of the bead layer is located between the reinforcing layer and the wear strip in the axial direction.

6. The tire of any one of claims 1 to 5, wherein the recycled bead filler is not engaged with the bead core, wherein the recycled bead filler is not engaged with the turnup carcass ply, wherein the recycled bead filler is not engaged with the reinforcement layer, and wherein the virgin bead filler is located between the turnup carcass ply and the reinforcement layer.

7. The tire of any one of claims 1 to 5, wherein the recycled bead filler engages the bead core, wherein the recycled bead filler engages the turn-up carcass ply, wherein the recycled bead filler is continuous from the bead core to a position outward from the native bead filler in the radial direction such that the recycled bead filler extends to a position further outward in the radial direction than the native bead filler.

8. The tire of claim 7, wherein the native bead filler is located between the reinforcement layer and the turnup carcass ply, and wherein the native bead filler is not engaged with the major portion of the reinforcement ply.

9. The tire according to any one of claims 1 to 5, wherein the recycled bead filler is discontinuous such that the recycled bead filler is located radially inwardly and radially outwardly from the virgin bead filler, wherein the virgin bead filler extends in the axial direction from the main portion of the reinforcement ply to a position outboard of the outward radial end of the turnup carcass ply in the axial direction; wherein said recycled bead filler engages said bead core; wherein a portion of the recycled bead filler is located between the turn-up carcass ply and the reinforcement layer; A portion of the primary bead filler is located between the turn-up carcass ply and the reinforcement layer.

10. The tire according to any one of claims 1 to 9, wherein the recycled bead filler has a first layer of recycled bead filler and a second layer of recycled bead filler, The native bead filler comprises a first native bead filler layer and a second native bead filler layer.

11. The tire of claim 10, wherein the interface between the first layer of recycled bead filler and the second layer of recycled bead filler engages the interface between the first layer of virgin bead filler and the second layer of virgin bead filler.

12. The tire of claim 10 or 11, wherein the interface between the first and second layers of virgin bead filler engages the outward radial ends of the turnup carcass ply.

13. The tire according to any one of claims 1 to 12, wherein 10% to 30% of the volume of the bead is made of micronized rubber powder present in the recycled bead filler.

14. The tire of claim 13, wherein 12% to 15% of the volume of the bead is made from micronized rubber powder present in the recycled bead filler.

15. The tire of any one of claims 1 to 14, wherein the recycled bead filler comprises a micronized rubber composition having a particle size ranging from 40 mesh to 200 mesh, wherein the micronized rubber composition comprises at least 10 weight percent solution styrene-butadiene rubber.

16. The tire according to any one of the preceding claims, wherein the tire is a heavy truck tire.

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