Tyre having tread formed, in whole or in part, of composite material constructed by integral molding

Abstract

The invention relates to a tyre (10) having a tread (15) comprising a main composite material (30) having an integrally molded construction and comprising a thermoplastic polymer matrix and a fabric reinforcement component. The invention also relates to a method for manufacturing such a tyre, said method comprising hot-pressing a multi-layer assembly comprising a hot-meltable fabric part and a non-hot-meltable fabric part.

Description

Technical Field

[0001] This invention relates to the technical field of vehicle tires (e.g., bicycle tires). Tires typically comprise a carcass with two free longitudinal edges, each reinforced by a bead wire element. The carcass supports a tread for contact with the ground. Sidewalls, connected to the tread, extend along both sides of the tread.

[0002] A tire's grip on the ground, its puncture resistance and wear resistance, its weight, and its ability to absorb vibrations during riding all depend directly on the materials that make up the tire. In particular, to ensure the comfort and safety of vehicle users, the tire tread must meet stringent constraints. Background Technology

[0003] Traditional tire treads (especially bicycle tire treads) are primarily made of a composite material comprising vulcanized rubber and nylon fibers. The rubber provides grip and effectively absorbs vibrations experienced by the tire during rolling, ensuring rider comfort. The composite material provides the tire with durability and ensures good performance, namely, a good return of energy input by the cyclist under riding conditions.

[0004] The drawback of these traditional tires is that the vulcanized rubber is not recyclable or difficult to recycle because it cannot be melted and its manufacturing is irreversible. It is known that the rubber in tires (especially bicycle tires) is often embedded in composite layers, making it difficult to remove. Separating nylon from vulcanized rubber is particularly challenging. Therefore, recycling traditional tires is extremely complex and is generally not considered due to high processing costs. Consequently, current tires (especially bicycle tires) are destroyed after use and have a very strong environmental impact. Summary of the Invention

[0005] The purpose of this invention is to provide a tire that overcomes the aforementioned disadvantages, particularly by reducing its environmental impact and being recyclable.

[0006] Therefore, according to a first aspect, the present invention relates to a tire including a tread, characterized in that the tread includes a main composite material having an integrally molded structure and the main composite material including a thermoplastic polymer matrix and a fabric reinforcement component.

[0007] Advantageously, the tire according to the first aspect of the invention can be obtained by the tire manufacturing method according to the second aspect of the invention.

[0008] The tread is the part of the tire designed to contact the ground. It preferably has a thickness between 1 mm and 3 mm. The tread advantageously has a width between 18 mm and 120 mm. The tread may have embossing to improve its grip and performance.

[0009] A tire advantageously comprises a tire carcass that supports the tread.

[0010] The tires are preferably bicycle tires. A bicycle is a vehicle with one, two, or three wheels and a weight of less than 100 kg, such as a pedal bicycle or scooter.

[0011] The preferred tire is a bicycle tire.

[0012] Compared to car tires, bicycle tires have a reduced tread thickness, preferably approximately half the thickness of car tires. Furthermore, bicycle tires have a smaller tread width than car tires (preferably between 2 and 10 times).

[0013] Preferably, the tread and / or carcass and / or tire and / or multilayer components and / or composite materials described herein include (in particular, all of them) a first free longitudinal edge (in particular a substantially annular free longitudinal edge) and an optional second free longitudinal edge (in particular a substantially annular free longitudinal edge).

[0014] Preferably, the tread and / or carcass and / or tire and / or multilayer component and / or composite material described herein include (in particular, both include) a first end and a second end, the first end and the second end being free ends or integral with each other, and disposed between the first and second free longitudinal edges.

[0015] "Main composite material" should be understood as a material comprising at least two components of different properties, particularly including a main thermoplastic matrix and a fabric reinforcement component, and optionally one or more non-woven elements. Specifically, the fabric reinforcement component and optionally one or more non-woven elements are embedded in the main thermoplastic matrix.

[0016] The main composite material is preferably obtained by hot-pressing a multilayer assembly comprising a heat-fusible fabric portion (particularly a heat-fusible fabric portion forming a tire) and a non-heat-fusible fabric portion (particularly a non-heat-fusible fabric portion forming a tire), and optionally one or more non-heat-fusible non-woven elements (e.g., reinforcing glass fiber rods) and one or more heat-fusible non-woven elements (e.g., thermoplastic polymer films).

[0017] In one embodiment, the main composite material includes:

[0018] - One or more non-woven, non-fusible elements (e.g., reinforced fiberglass rods); and / or

[0019] - One or more non-woven, heat-fusible elements (e.g., thermoplastic polymer films).

[0020] Fabric is understood herein to mean any element / component / tube / part / section / structure obtained by manipulating (especially mechanically) at least one fiber and / or at least one yarn or at least one group of fibers.

[0021] Advantageously, the hot-melt fabric portion and optionally one or more hot-melt non-fabric elements form the main thermoplastic matrix.

[0022] Advantageously, the non-heat-meltable fabric portion forms the fabric reinforcement component.

[0023] Advantageously, the fabric reinforcement assembly includes one or more fabric reinforcement elements, particularly selected from: woven fabrics, knitted fabrics, nonwoven fabrics (e.g., spunbond nonwoven fabrics, meltblown nonwoven fabrics, or combinations thereof), one or more yarns, braids, sheets of optionally carded and / or needle-punched fibers, any element obtained by manipulating at least one yarn and / or at least one fiber, and mixtures thereof, preferably knitted fabrics, more preferably tubular knitted fabrics.

[0024] "Integral molded construction" should be understood as: any composite material obtained by molding at least one heat-fusible fabric portion and at least one non-heat-fusible fabric portion disposed in a molded assembly, and optionally at least one non-heat-fusible non-fabric portion (e.g., a reinforced glass fiber rod) and / or at least one heat-fusible non-fabric portion (e.g., a thermoplastic polymer film), in a single step including applying heat and pressure to melt or soften (one or more) heat-fusible portions.

[0025] Preferably, “non-heat-meltable fabric portion” or “non-heat-meltable non-fabric portion” is understood herein to mean any fabric portion or any non-fabric portion that is not intended to be heat-melted (i.e., not intended to be melted or softened) during the tire manufacturing method according to the invention and thus in the obtained tire.

[0026] The thermoplastic polymer matrix according to the present invention may include one or more thermoplastic polymers, such as thermoplastic polymers with different properties. For example, the thermoplastic polymer matrix includes polypropylene (PP) or thermoplastic polyurethane (TPU) or even mixtures thereof. In a non-limiting manner, the polymer may have different colors.

[0027] In this article, thermoplasticity is understood to mean any material that can be melted or softened by heating to form (and this can be done multiple times).

[0028] In particular, thermosetting or non-thermoplastic materials cannot be sufficiently softened by heating to be molded multiple times.

[0029] A thermoplastic polymer matrix forms an adhesive layer within which the fabric reinforcement assembly is disposed, and optionally one or more non-heat-fusible non-woven elements. The thermoplastic polymer matrix ensures that the forces experienced by the tread are transferred to the fabric reinforcement assembly.

[0030] Advantageously, in this document, "non-meltable" means any element / component / part / structure or part that is not configured to be in a molten state in the tire (i.e., during the hot pressing step for manufacturing the tire), which may be partially or completely thermoplastic, or partially or completely non-thermoplastic, preferably thermoplastic, but the highest heating temperature applied in the tire manufacturing method according to the invention is below the melting (or degradation) temperature of said element / component / part / structure or said part.

[0031] Preferably, the thermoplastic polymer matrix comprises one or more heat-fusible fabric elements, or even more preferably, it consists essentially of one or more heat-fusible fabric elements.

[0032] Preferably, the thermoplastic matrix is ​​formed of at least 50% or at least 60% or at least 70% or at least 80% or at least 90% or at least about 95% by weight of one or more hot-melt fabric elements and / or one or more hot-melt films.

[0033] The tread preferably includes one or more reinforcing elements, said one or more reinforcing elements including at least one fabric reinforcing element.

[0034] The fabric reinforcement element is advantageously a non-heat-meltable fabric portion, and optionally thermoplastic.

[0035] Preferably, but not limitingly, the tread has an inner surface, and the fabric reinforcement element is located on said inner surface of the tread.

[0036] Preferably, the fabric reinforcing element comprises one or more yarns. More preferably, the fabric reinforcing element comprises one or more knitted yarns.

[0037] Preferably, the fabric reinforcement assembly includes one or more fabric reinforcement elements, which are fabric tubular elements or fabric layers, especially knitted, braided, or woven. More preferably, the knitted tubular elements or the knitted layers include weft stitches (also known as weft-knitted fabrics in the prior art) or warp stitches (also known as warp-knitted fabrics in the prior art).

[0038] Preferably, the fabric reinforcement assembly comprises one or more tubular fabric elements, particularly knitted, woven, or interlaced, optionally substantially flat, or one or more fabric tubes, particularly knitted, woven, or interlaced, optionally substantially flat, each particularly comprising first and second longitudinal edges, particularly in a substantially annular shape.

[0039] Preferably, the optionally flattened fabric tube (e.g., a first or second fabric tube) or the optionally flattened fabric tubular element comprises:

[0040] - The first longitudinal edge, which coincides with or overlaps with the first free longitudinal edge of the tread and / or carcass and / or tire; and / or

[0041] - A second longitudinal edge that coincides with or overlaps with the second free longitudinal edge of the tread and / or carcass and / or tire. Preferably, the optionally flattened fabric tube (e.g., a first or second fabric tube) or the optionally flattened fabric tubular element comprises stacked first and second fabric layers.

[0042] Preferably, the first longitudinal edge and the second longitudinal edge of the composite material or the multilayer component described below coincide with or overlap with the first longitudinal edge and the second longitudinal edge of the carcass, tire or tread, respectively.

[0043] Preferably, the tubular knitted element is knitted on a circular knitting machine, particularly a small-diameter circular knitting machine, known as a sock knitting machine, or alternatively on a flat knitting machine with double beds.

[0044] The at least one fabric reinforcement element imparts high durability to the tread, particularly against the wear and shear forces it experiences during rolling. The at least one fabric reinforcement element also ensures grip of the tread relative to the surface on which it rolls (particularly the ground).

[0045] Therefore, the tires according to the present invention have technical performance similar to those of conventional tires made of vulcanized rubber, particularly in terms of grip, wear resistance and shear strength, and shock and vibration absorption.

[0046] The weight of the tire according to the invention is substantially similar to that of a conventional tire of the same size, but formed from a composite material based on vulcanized rubber and nylon. In other words, using the main composite material according to the invention, comprising a thermoplastic polymer matrix and at least one fabric reinforcement element, does not significantly increase the weight of the tread, and therefore does not significantly increase the weight of the tire.

[0047] Furthermore, the main composite material forming at least a portion of the tread of the tire according to the invention makes the tire more recyclable than conventional tires with treads formed of vulcanized rubber and nylon.

[0048] In fact, since the polymer matrix is ​​thermoplastic, it can be softened or melted by heating it to a temperature above a threshold temperature (e.g., melting temperature). Therefore, the manufacture of the polymer matrix is ​​reversible and allows for the recycling of the thermoplastic polymer matrix. In other words, by heating the tire (possibly after grinding), the thermoplastic polymer matrix bonded to the fabric reinforcement components can be recycled to produce, for example, new tires or tire parts. Furthermore, the thermoplastic polymer material forming the thermoplastic polymer matrix and the fabric reinforcement components can be easily separated from each other by heating the tread.

[0049] Furthermore, since the reinforcing component is made of fabric, it is also recyclable. In particular, the entire composite material is recyclable, making the tread portion formed from the main composite material easily recyclable.

[0050] Therefore, the tires according to the present invention are highly recyclable and significantly reduce their environmental impact.

[0051] The tread is preferably composed of a primary composite material so that it is essentially fully recyclable.

[0052] In a preferred embodiment, the main composite material having an integrally molded structure consists essentially of a thermoplastic polymer matrix and fabric reinforcement components, particularly at least one fabric reinforcement element, and optionally one or more non-fabric elements.

[0053] Preferably, it should be understood herein that the main composite material is substantially composed of a thermoplastic polymer matrix and a fabric reinforcement component, the thermoplastic polymer matrix and the fabric reinforcement component (considered together) being dominant in the main composite material by mass or by volume, preferably, the thermoplastic matrix and the fabric reinforcement component accounting for at least 50% by mass or by volume of the main composite material, more preferably at least 60% or at least 70% or at least 80% or at least 90% or at least 95% by mass or by volume of the main composite material.

[0054] In this article, "at least partially" means substantially the entire object or only a part of the object.

[0055] In a preferred embodiment, the main composite material accounts for at least 60% of the tread by volume or mass, preferably at least 70% by volume or mass, more preferably at least 80% by volume or mass, preferably at least 90% by volume or mass, particularly at least 95% by volume or mass, and even more particularly about 100% by volume or mass.

[0056] The main composite material preferably includes one or more reinforcing elements, which include one or more fabric reinforcing elements. In other words, without departing from the scope of the invention, the main composite material may include one or more reinforcing elements that are not fabric.

[0057] Without departing from the scope of the invention, the thermoplastic polymer matrix may include one or more thermoplastic (co) (ter) polymers selected from: polyolefins, thermoplastic styrene elastomers, thermoplastic olefin elastomers, polyurethanes (especially polyurethane elastomers), polyamides, polyesters, and mixtures thereof, preferably polyurethanes.

[0058] Advantageously, the polyolefin is selected from: polypropylene, polyethylene, high-density polyethylene and very high-density polyethylene.

[0059] Advantageously, the thermoplastic styrene elastomer is selected from thermoplastic elastomers comprising styrene repeating units (TPE-S) (especially styrene-based: CH(C6H5)-CH2), more preferably from thermoplastic elastomers comprising one or more styrene blocks and optionally one or more olefin blocks (optionally grafted), and preferably from poly(styrene-ethylene-butene-styrene) (SEBS); poly(styrene-butadiene-styrene) (SBS); poly(styrene-butadiene) (SBC); poly(styrene-isoprene-styrene) (SIS); poly(styrene-ethylene-propylene-styrene) (SEPS), for example, by Kuraray under the trade name Septon. Or by Kraton under the trade name Kraton Sale.

[0060] Advantageously, the thermoplastic olefin elastomer is selected from:

[0061] - Polyisobutylene (PIB); and / or

[0062] - terpolymers of ethylene, propylene, and diene (EPDM); copolymers of ethylene and propylene; copolymers of ethylene and α-olefins, such as copolymers of ethylene and butene or copolymers of ethylene and octene, and mixtures thereof; preferably EPDM and copolymers of ethylene and propylene; and / or

[0063] - A mixture of polyolefins (particularly polypropylene) with one or more unvulcanized thermoplastic olefin elastomers and optionally one or more plasticizers (e.g., mineral oils, naphthenic oils, or paraffin oils), wherein the thermoplastic olefin elastomers may be copolymers of ethylene and propylene, terpolymers of ethylene, propylene, and diene, or copolymers of ethylene and α-olefins (e.g., copolymers of ethylene and butene or copolymers of ethylene and octene).

[0064] Advantageously, the polyester is selected from polyethylene terephthalate and polybutylene terephthalate.

[0065] Advantageously, the polyamide is selected from PA 6, PA 66 and PA 4-6.

[0066] Advantageously, polyurethane also includes polyurethane elastomers.

[0067] Advantageously, the thermoplastic polymer matrix is ​​essentially composed of one or more hot-melt polymers.

[0068] "consistent with" should be understood to mean that (one or more) hot melt polymers constitute at least 80% by mass of the thermoplastic polymer matrix, preferably at least 90% by mass, and more preferably about 100% by mass.

[0069] In a variant embodiment, the primary composite material forms at least 80% of the tread by weight. Preferably, the primary composite material forms at least 90% of the tread by weight, particularly at least 95% by weight, and more particularly about 100% by weight. The advantage is that the tread is primarily (more particularly entirely) formed from recyclable materials, thus improving the tire's recyclability and further reducing its environmental impact.

[0070] In a variant embodiment, the fabric reinforcement component includes at least two fabric layers.

[0071] In a non-limiting manner, the first layer may be heat-fusible, while the second layer may be non-heat-fusible. Alternatively, each of the two fabric layers may be partially heat-fusible, and optionally, each of the two layers may include a non-heat-fusible portion.

[0072] In a variant embodiment, the main composite material includes at least a first fabric layer, a second fabric layer, a third fabric layer, and a fourth fabric layer.

[0073] Preferably, at least one of the fabric layers is partially heat-fusible. Preferably, at least one of the fabric layers has a heat-fusible portion and a non-heat-fusible portion.

[0074] Alternatively, and without departing from the scope of the invention, one or more of the fabric layers may be fully heat-fused, while another fabric layer or multiple fabric layers may not be heat-fused.

[0075] The presence of these four fabric layers improves the tire's grip and durability.

[0076] In a non-limiting manner, the main composite material may also include a fifth fabric layer and a sixth fabric layer.

[0077] In one embodiment, each of the fabric layers includes at least one heat-fusible portion and at least one non-heat-fusible portion.

[0078] In a variant embodiment, the fabric reinforcement assembly includes a first fabric tube comprising the first and second fabric layers, and the fabric reinforcement assembly further includes a second fabric tube comprising the third and fourth fabric layers.

[0079] The advantage is that the manufacturing of each tube allows for the creation of two fabric layers, which is particularly beneficial to the manufacturing method by avoiding errors when the layers overlap.

[0080] In a variant embodiment, the fabric reinforcement assembly includes a first knitted, braided, or interlaced tube portion comprising the first and second fabric layers, and the fabric reinforcement assembly further includes a second knitted, braided, or interlaced tube portion comprising the third and fourth fabric layers.

[0081] Advantageously, the first fabric tube is flat, thereby obtaining two stacked fabric layers formed by the first and second fabric layers. Preferably, the second fabric tube is flat, thereby obtaining two stacked fabric layers formed by the third and fourth fabric layers.

[0082] In a non-restrictive manner, the first and second tube sections can be different from each other.

[0083] Preferably, at least one of the first and second tubes is knitted into a circle on a circular knitting machine (especially a small-diameter circular knitting machine) or on a flat knitting machine including two needle beds.

[0084] In a non-limiting manner, the first tube can be obtained by knitting its longitudinal edges, for example, by a strip joined together by a longitudinal seam. Alternatively, and preferably, the first fabric tube can be knitted in a circular manner, in which case it is not necessary to longitudinally close the first tube. In a variant embodiment, the first and second tubes are arranged one on top of the other or one inside the other.

[0085] One advantage is that it allows for easier and more precise positioning of the four layers relative to each other, and also enables more precise zoning on the tread.

[0086] In this document, partitioning is understood to refer to any modification of at least one fabric parameter in one or more regions of a (particularly knitted) tubular portion of a fabric (also referred to herein as a fabric tube), said at least one parameter being selected from: yarn type (composition, fineness, partially or completely non-meltable, color, transparency) and bonding point (stitch pattern).

[0087] In an embodiment where the first and second tubes are arranged one on top of the other, the first and second fabric layers are continuous fabric layers, while the third and fourth fabric layers are continuous fabric layers.

[0088] In embodiments where the first and second tubes are arranged one inside the other, the second tube is preferably disposed inside the first tube. In this case, the third and fourth fabric layers extend between the first and second fabric layers. The first and second tubes are substantially coaxial.

[0089] Alternatively, and in a non-limiting manner, the first tube may be disposed inside the second tube, in which case the first and second fabric layers extend between the third and fourth fabric layers.

[0090] In a variant embodiment, the fabric reinforcement assembly includes a first fabric reinforcement element comprising a first fabric region and a second fabric region fabrically connected (particularly by knitting) to the first fabric region; the first fabric region and the second fabric region are distinguished by at least one characteristic selected from the following: stitch pattern (e.g., the presence of a looped sponge-like stitch or braided float or seam thread inclined relative to the longitudinal axis of the first fabric reinforcement element), the amount of yarn, the nature of the yarn, the mass fraction in the heat-melt fabric portion (particularly the mass fraction in the heat-meltable fabric portion), the mass fraction in the non-heat-melt fabric portion (particularly the mass fraction in the non-heat-meltable fabric portion), or the fineness (dtex) of the yarn.

[0091] Advantageously, the difference between the first knitted area and the second knitted area lies in at least one property that will affect, for example, mechanical behavior.

[0092] For example, the first knitted area includes elastic yarn, while the second knitted area does not include elastic yarn.

[0093] For example, the mass proportion of at least partially heat-melted yarn in the second knitted area is greater than the mass proportion of at least partially heat-melted yarn in the first knitted area.

[0094] In a variant embodiment, the first and second fabric layers are located in a first fabric reinforcement element having an integral fabric structure, and the third and fourth fabric layers are located in a second fabric reinforcement element having an integral fabric structure.

[0095] It should be understood that the first and third fabric layers have an integral fabric construction with the second and fourth fabric layers, such that they are at fabric joints, especially at knitted joints, and particularly in the same fabric piece obtained at the exit of a textile loom, especially a knitting machine, and are continuous. More specifically, there are no additional steps for their manufacture except for the finishing of their edges and / or the embroidery of at least one elongated element. This definition advantageously applies to any layer / element / piece having an integral fabric construction as described herein.

[0096] In other words, the first and second fabric layers are in the same fabric piece. The first and second fabric layers are interconnected by knitting or weaving to at least one yarn in both the first and second fabric layers. Similarly, the third and fourth fabric layers are in the same fabric piece. The third and fourth fabric layers are interconnected by knitting or weaving to at least one yarn in both the first and second fabric layers.

[0097] In a non-limiting manner, the first and second layers may be consecutive layers, such as stacked layers, or layers spaced apart from each other by other layers.

[0098] Preferably, the first, second, third and fourth fabric layers are at least partially overlapped with each other.

[0099] In a variant embodiment, the first, second, third, and fourth fabric layers are located within a first fabric reinforcement element having an integral fabric structure.

[0100] More preferably, the main composite material includes a tube comprising the first and second tube portions.

[0101] In a first embodiment, the tube is folded back so that the first and second tube portions are placed one on top of the other. In this embodiment, the first and second tube portions are connected to each other by a crease.

[0102] In another embodiment, the tube itself is folded back so that the second tube portion is placed inside the first tube portion.

[0103] In a variant embodiment, the main composite material includes at least one intermediate thermoplastic polymer layer disposed between two adjacent fabric layers.

[0104] The intermediate thermoplastic polymer layer is configured to partially form the thermoplastic polymer matrix. This intermediate thermoplastic polymer layer improves the impermeability and puncture resistance of the tread.

[0105] The intermediate thermoplastic polymer layer advantageously takes the form of a hot-melt polymer sheet (especially hot-melt before hot pressing).

[0106] Advantageously, the intermediate thermoplastic polymer layer may be disposed between two stacked tube sections, and / or may be disposed between the first and second fabric layers, and / or may be disposed between the third and fourth fabric layers, and / or may be disposed between the first and third fabric layers (when the first and second tube sections are coaxial), and / or may be disposed between the fourth and second fabric layers (when the first and second tube sections are coaxial).

[0107] In a variant embodiment, the primary composite material includes at least one outer thermoplastic polymer layer disposed in the outer portion of the tread intended to contact the ground.

[0108] The outer thermoplastic polymer layer is designed to contact the ground. This outer thermoplastic polymer layer forms a wear-resistant layer for the tire tread.

[0109] The hot-melt thermoplastic outer polymer sheet improves the tread's grip relative to the ground and its abrasion resistance.

[0110] The outer thermoplastic polymer layer advantageously takes the form of a polymer sheet that is at least partially or completely heat-melted.

[0111] In a variant embodiment, the main composite material includes at least one substantially continuous or discontinuous outer polymer coating, particularly at least partially or entirely thermoplastic outer polymer coating, which is disposed in the outer portion of the tread intended to contact the ground.

[0112] The outer polymer coating can advantageously form a wear-resistant layer on the tread.

[0113] The outer polymer coating may include a base surface, a first recessed pattern protruding inward from the base surface, and a second pattern protruding outward from the base surface in the form of a protrusion; preferably, the first and second patterns alternate.

[0114] The coating can be applied by applying at least one liquid composition as described below.

[0115] Preferably, the coating comprises polyurethane, especially a polyurethane elastomer.

[0116] In a variant embodiment, the mass fraction of thermoplastic material in the main composite material is greater than or equal to 80%, preferably greater than or equal to 90%, more preferably greater than or equal to 95%, and particularly about 100%.

[0117] This arrangement facilitates tire recycling. In fact, thermoplastic materials can be molded multiple times by heating.

[0118] In a variant embodiment, the mass fraction of the thermoplastic polymer matrix in the main composite material is greater than or equal to 50%, preferably greater than or equal to 60%, more preferably greater than or equal to 70%, and even more preferably greater than or equal to 80%.

[0119] In one embodiment, the mass fraction of the thermoplastic polymer matrix in the main composite material is less than or equal to 90%, preferably less than or equal to 85%. The mass fraction of the polymer matrix in the main composite material should be understood as the ratio of the total mass of the polymer (especially the hot melt polymer) forming the thermoplastic polymer matrix to the total mass of the main composite material having an integrally molded structure.

[0120] In a variant embodiment, the mass fraction of the fabric reinforcement components, particularly the fabric reinforcement elements, in the composite material is less than or equal to 50%, preferably less than or equal to 40%, particularly less than or equal to 30%, preferably greater than or equal to 5% and less than or equal to 20%, and even more preferably greater than or equal to 10% and less than or equal to 15%.

[0121] Preferably, the fabric reinforcement component forms a fabric reinforcement skeleton, more preferably a partially thermoplastic or fully thermoplastic and / or non-thermoplastic fabric reinforcement skeleton.

[0122] In a variant embodiment, the thermoplastic polymer matrix comprises polyurethane, particularly predominantly polyurethane by weight.

[0123] In a variant embodiment, the mass fraction of polyurethane (especially thermoplastic polyurethane) in the main composite material is greater than or equal to 5%, preferably greater than or equal to 10%, more preferably greater than or equal to 20%, preferably greater than or equal to 30%, particularly greater than or equal to 40%, and even more particularly greater than or equal to 50%.

[0124] In a variant embodiment, the mass fraction of polyurethane (especially thermoplastic polyurethane) in the main composite material is less than or equal to 90%, preferably less than or equal to 80%, and more preferably less than or equal to 70%.

[0125] In a variant embodiment, the mass fraction of thermoplastic material in the fabric reinforcement component is greater than or equal to 60% or 70% or 80% (optionally less than or equal to 90%), preferably greater than or equal to 90%, even more preferably greater than or equal to 95%, particularly about 100%.

[0126] This arrangement facilitates tire recycling. In fact, thermoplastic materials can be molded multiple times by heating.

[0127] In a variant embodiment, the primary composite material, preferably a thermoplastic polymer matrix, comprises: a first portion including a first aesthetic characteristic selected from a first color and a first design; and a second portion including a second aesthetic characteristic selected from a second color and a second design, wherein the first aesthetic characteristic differs from the second aesthetic characteristic.

[0128] Preferably, the first and second colors are not black.

[0129] Therefore, patterns and engravings can be formed on the surface of the tire.

[0130] Preferably, the tread comprises a plurality of substantially similar patterns spaced apart along the length of the tread.

[0131] Preferably, the main composite material, preferably a thermoplastic polymer matrix, comprises: a first portion comprising a first relief; and a second portion comprising a second relief different from the first relief.

[0132] The first and second reliefs are advantageously independent of the color of the thermoplastic polymer matrix.

[0133] Preferably, the main composite material includes a first fabric reinforcement element of a first color and a second fabric reinforcement element of a second color, the second color being different from the first color.

[0134] In a variant embodiment, the primary composite material, preferably a thermoplastic polymer matrix, includes a transparent or translucent portion forming an observation window through which at least a portion of the fabric reinforcement assembly can be seen from the outside of the tire.

[0135] In a variant embodiment, the primary composite material, preferably a thermoplastic polymer matrix, includes at least one light-reflecting pattern.

[0136] In a variant embodiment, the fabric reinforcement component comprises one or more yarns, the one or more yarns comprising at least one material selected from: polyester, especially high-tenacity polyester; polyamide; aramid; polyolefin; cellulose; glass; or mixtures thereof.

[0137] In a variant embodiment, the at least one fabric reinforcement component includes, in particular, one or more fabric reinforcement elements comprising one or more yarns made of at least one material selected from: polyester, especially high-toughness polyester; polyamide; aramid; polyolefin; glass, or mixtures thereof; preferably polyester; especially high-toughness polyester; polyamide; polyolefin; or mixtures thereof.

[0138] Advantageously, the polyester may be selected from polyethylene terephthalate (PET) and polybutylene terephthalate (PBT), polypropylene terephthalate (PTT) or mixtures thereof, preferably polyethylene terephthalate PET.

[0139] Advantageously, the polyolefin may be selected from polypropylene, polyethylene, copolymers of ethylene and propylene, high-density polyethylene (such as UHMWPE), preferably polypropylene and polyethylene, especially high-density or very high-density polyethylene (e.g., Dyneema).

[0140] Advantageously, the polyamide may be selected from: PA 6, PA 6-6, PA 4-6, PA 11 or 12, or mixtures thereof, preferably PA 6 or PA 6-6.

[0141] Advantageously, the aramid is selected from meta-aramid and para-aramid. Aramids are not preferred in the context of this invention because they are not thermoplastic.

[0142] Preferably, the fabric reinforcement assembly includes one or more fabric reinforcement elements, the one or more fabric reinforcement elements comprising one or more yarns selected from the foregoing list, particularly consisting of one or more yarns selected from the foregoing list.

[0143] Preferably, the fabric reinforcement component comprises multiple yarns, which may have the same or different properties.

[0144] In a variant embodiment, the main composite material comprises one or more yarns that are at least partially heat-fused.

[0145] In this article, at least partially heat-fused yarns can be either fully heat-fused or partially heat-fused.

[0146] The at least partially heat-melted yarn is the yarn that is at least partially heat-melted before being transformed in the tire manufacturing method according to the invention, particularly as described below according to the second aspect of the invention.

[0147] In this document, the at least partially heat-fused yarn may be either fully heat-fused or partially heat-fused.

[0148] At least partially heat-melting yarns can be core-spun yarns. Preferably, the core-spun yarn comprises a core having a melting or softening temperature T1 and a sheath having a melting or softening temperature T2, where T1 is greater than T2. ​​Advantageously, the sheath is configured to melt / soften at a temperature T2 below the core melting / softening temperature T1 during tire manufacturing.

[0149] At least partially heat-melting yarns can be side-by-side type yarns, with the first side formed of a material having a melting or softening temperature T1 as defined above, and the second side formed of a material having a melting or softening temperature T2 as defined above.

[0150] Specifically, the first and second sides are arranged longitudinally along the length of the yarn.

[0151] Therefore, in the main composite material, the sheath or second side of the yarn is melted into the thermoplastic polymer matrix, while the core or first side at least partially forms a fabric reinforcement element.

[0152] At least partially heat-melting yarns may be yarns made entirely or partially of heat-melting materials, i.e., having a melting or softening temperature lower than the hot-pressing temperature used to manufacture tires according to the invention.

[0153] In this case, the hot-melt yarn forms completely or partially a portion of the thermoplastic polymer matrix of the main composite material.

[0154] In a variant embodiment, the primary composite material specifically includes fabric reinforcement elements, each comprising one or more yarns that are at least partially non-thermothermal.

[0155] Advantageously, at least some of the non-meltable yarns can be (all) completely non-meltable or partially meltable.

[0156] Advantageously, at least a portion of the non-melting portion of the non-melting yarn forms the fabric reinforcing yarn, i.e., the elongated fabric reinforcing element.

[0157] Advantageously, the fabric reinforcement component includes one or more tubular knitted fabrics, each tubular knitted fabric including one or more partially non-thermal-melting yarns and / or one or more non-thermal-melting yarns.

[0158] In a variant embodiment, the main composite material comprises one or more core-spun yarns, each yarn comprising a metal core and a sheath, the sheath comprising at least one thermoplastic polymer material, particularly hot-melt (especially in tire manufacturing methods), for example, made of polyurethane.

[0159] This arrangement allows for a significant improvement in tire durability. Another advantage is that the metal core can be easily removed from the used tire and recycled separately from the rest of the tire before recycling. This facilitates the recycling of remaining tires.

[0160] In a variant embodiment, the tread, particularly at least one fabric reinforcement element, comprises at least one knitted pattern, such as multiple herringbone patterns. Preferably, the knitted pattern extends along the longitudinal direction (Lbr) of the tread (particularly the knitted reinforcement element) and extends repeatedly over a portion of the length of the tread or the knitted reinforcement element or over the entire length of the tread or the knitted reinforcement element.

[0161] The knitted pattern can also extend into the first sidewall and / or the second sidewall (as described below). In this case, preferably, the tread and the first sidewall, as well as optionally the second sidewall, are at least partially, and especially entirely, formed of the main composite material.

[0162] In a variant embodiment, the tread includes a longitudinal direction Lbr, and the main composite material (particularly at least one fabric reinforcing element) includes a plurality of knitted stitches arranged along the lines of the knitted stitches, the plurality of knitted stitches including one or more reinforcing yarns, at least one (or each) of the knitted stitches having a longitudinal direction Lmt intersecting the longitudinal direction Lbr.

[0163] Advantageously, the main composite material (in particular the at least one fabric reinforcing element) includes a longitudinal direction Lmc that is substantially parallel to the longitudinal direction Lbr of the tread.

[0164] Advantageously, the longitudinal direction Lbr of the tread and the longitudinal direction Lmc of the main composite material extend along the generally circumferential direction of the tire.

[0165] Advantageously, the longitudinal direction Lmt and the longitudinal direction Lbr form an angle β1 greater than 0° and less than or equal to 90°, particularly less than or equal to 60°, and even more particularly less than or equal to 50°.

[0166] Advantageously, β1 is greater than or equal to 10°, particularly greater than or equal to 20°, and even more particularly greater than or equal to 30°.

[0167] The plurality of knitted stitches arranged along the lines of the knitted stitches may also extend in the first sidewall and / or the second sidewall (as described below). In this case, preferably, the tread and the first sidewall, as well as optionally the second sidewall, are all at least partially formed of the main composite material.

[0168] In a variant embodiment, the tire further includes at least one sidewall, and the main composite material at least partially, and in particular completely, forms the at least one sidewall. One advantage is that the recyclability of the sidewall is also improved, thus improving the recyclability of the tire more generally.

[0169] The sidewall and the tread preferably have an integrally molded structure.

[0170] The tire preferably includes a first sidewall and a second sidewall, the plurality of sidewalls extending on both sides of the tread.

[0171] Preferably, the main composite material forms at least partially the first sidewall and at least partially the second sidewall; more preferably, the main composite material forms the first and second sidewalls and the tread.

[0172] The first and second sidewalls and the tread preferably have an integrally molded construction, especially in the main composite material.

[0173] Preferably, the tread and sidewall comprise at least one common yarn, preferably a knitted yarn.

[0174] In a variant embodiment, the mass fraction of the fabric reinforcement component in the tread is greater than that in the at least one sidewall, particularly by at least two or three times. One advantage is improved tread strength, especially abrasion resistance and impact resistance, while reducing tire weight. In effect, the sidewalls are not designed to have much contact with the ground (if any), thus subjecting them to less stress on grip and abrasion resistance.

[0175] The mass fraction (%) of the fabric reinforcement components in the tread and sidewall should be understood as the ratio of the total mass of the fabric reinforcement components in the tread and sidewall to the total mass of the tread and sidewall, respectively; in particular, this mass fraction may be calculated over a portion of the tire length or over the entire tire.

[0176] In a variant embodiment, the mass fraction of the fabric reinforcement component in at least one sidewall, particularly the first sidewall and / or the second sidewall, is greater than or equal to 20%, preferably greater than or equal to 30%, more preferably greater than or equal to 40%, preferably less than or equal to 80%, and especially less than or equal to 70% or 60%.

[0177] In a variant embodiment, the mass fraction of the fabric reinforcement component in the tread is less than or equal to 45%, particularly less than or equal to 30%, and even more particularly less than or equal to 20%.

[0178] In a variant embodiment, the mass fraction of the thermoplastic polymer matrix in the tread is greater than the mass fraction of the thermoplastic polymer matrix in the sidewall (particularly the first or second sidewall), particularly by at least two or three times.

[0179] Advantageously, the sidewalls allow the tire to be secured to the wheel without direct contact with the ground, thus requiring less fabric reinforcement.

[0180] Advantageously, in this invention, the mass fraction of the thermoplastic polymer matrix and the mass fraction of the fabric reinforcement in the tire, particularly between the tread and at least one sidewall, can be adjusted independently of each other by changing the mass fraction of the hot-melt fabric portion and the non-hot-melt fabric portion.

[0181] In a modified embodiment, the mass fraction of the thermoplastic polymer matrix in the tread is greater than or equal to 30%, preferably greater than or equal to 50%, and more preferably greater than or equal to 60%.

[0182] In a variant embodiment, the mass fraction of the thermoplastic polymer matrix in at least one sidewall, particularly in the first and / or second sidewall, is greater than or equal to 5%, preferably greater than or equal to 20%, more preferably greater than or equal to 30%, and particularly less than or equal to 60%.

[0183] In a variant embodiment, the tread includes at least one fabric reinforcement element ERBR, and the at least one sidewall includes at least one fabric reinforcement element ERPF that is different from the fabric reinforcement element ERBR of the tread.

[0184] Fabric reinforcement element ERPF advantageously has a linear density (dtex) that is different from that of fabric reinforcement element ERBR, especially by two to three times.

[0185] Fabric reinforcing elements ERBR and ERPF preferably comprise (or) one or more yarns of different properties. For example, ERBR may comprise (or) polyamide yarn, while ERPF may comprise (or) polyester yarn.

[0186] In a variant embodiment, the mass per unit area (g / m²) of the at least one sidewall 2 () smaller than the unit area mass of the tire tread (g / m) 2 One advantage is increased puncture resistance of the tread while limiting the weight of the sidewalls, thus limiting the weight of the tire.

[0187] In a variant embodiment, the mass fraction of the fabric reinforcement in the at least one sidewall is greater than the mass fraction of the fabric reinforcement in the tread.

[0188] In a variant embodiment, the tire includes two free longitudinal edges, at least one of which includes a bead wire element, and the main composite material at least partially, and especially completely, forms the bead wire element.

[0189] In one embodiment, a thermoplastic polymer matrix forms at least 50% by volume or by mass of the bead wire element, particularly at least 80% by volume or by mass of the bead wire element.

[0190] Compared to traditional tires, one advantage is the further improvement in tire recyclability, as the bead threads of traditional tires are metal and must be removed before the tire can be recycled. Furthermore, it should be understood that the bead threads and tread are integrally molded, which facilitates tire manufacturing.

[0191] In a variant embodiment, the tire comprises up to 10% by weight of vulcanized rubber and / or optionally vulcanized one or more thermosetting polymers. One advantage is the reduction in the amount of poorly recyclable or non-recyclable materials within the tire, thereby further improving the tire's recyclability.

[0192] Preferably, the tire comprises up to 5% by weight of vulcanized rubber and / or optionally vulcanized one or more thermosetting polymers.

[0193] More preferably, the tread and / or main composite material and / or tire does not include vulcanized rubber and / or optionally vulcanized thermosetting polymers.

[0194] When the tread and / or main composite material and / or tire comprises one or more vulcanized rubbers and / or one or more thermosetting polymers (optionally vulcanized), such polymers or polymers account for up to 10% of the total tire mass by weight, and in particular up to 5% of the total tire mass by weight.

[0195] In a variant embodiment, the tread comprises at least 50% polyurethane by weight, preferably at least 60% polyurethane by weight, more preferably at least 70% polyurethane by weight, and preferably at least 80% polyurethane by weight, particularly thermoplastic polyurethane.

[0196] In a variant embodiment, at least 50%, preferably at least 60%, 70%, or 80% by mass of the thermoplastic polymer matrix of the main composite material is composed of one or more hot-melt thermoplastic polyurethanes, and optionally, the main composite material includes one or more polyurethane-based fabric reinforcement elements, particularly non-hot-melt ones.

[0197] According to a second aspect, the present invention also relates to a method for manufacturing at least a portion of a tire, particularly a tire as described above with reference to a first aspect of the present invention, the method comprising the following steps:

[0198] a) Prepare a multilayer assembly comprising at least one heat-fusible fabric portion, particularly during hot pressing step b), and at least one non-heat-fusible fabric portion, particularly during hot pressing step b).

[0199] b) Using a mold configured to mold at least a portion of the tread of a tire (especially the tread or the tire), the multilayer assembly is hot-pressed by heating the multilayer assembly to melt the heat-fusible fabric portion, especially the non-heat-fusible fabric portion, in order to melt the heat-fusible fabric portion.

[0200] c) Obtaining a master composite material having an integrally molded structure, the master composite material comprising a thermoplastic polymer matrix and a fabric reinforcement component, the composite material at least partially forming the tread of a tire, particularly forming the tread and / or the tire.

[0201] Hot pressing causes the heat-fusible fabric portion of the multilayer component to melt and / or soften, such that the heat-fusible fabric portion melted by hot pressing forms at least a portion of the thermoplastic polymer matrix of the obtained composite material.

[0202] The non-meltable fabric portion does not melt during hot pressing, such that the non-meltable fabric portion at least partially forms the fabric reinforcement component of the obtained master composite material.

[0203] Advantageously, the fabric reinforcement component includes at least one non-meltable and / or non-meltable fabric portion, optionally at least partially thermoplastic or thermoplastic fabric portion.

[0204] Preferably, the multilayer assembly includes at least one partially heat-fused first fabric layer and optionally a second fabric layer, particularly a second fabric layer that is at least partially heat-fused.

[0205] In one embodiment, the multilayer assembly is produced by the use of elements (optionally such as polymer films or metal filaments) and / or one or more solid and / or dry fabric layers. No liquid resins or solvents are used.

[0206] Advantageously, the multilayer assembly has a general shape of a strip, which includes two free ends or joined ends, particularly joined together to form a torus, for example, the free ends joined together by a seam.

[0207] Advantageously, the multilayer assembly includes a strip, particularly having the form of a strip, and said strip has: first and second free ends, the longitudinal direction of the multilayer assembly extending between said first and second free ends; and a first lateral edge, particularly also referred to herein as a first longitudinal edge; and a second lateral edge, also referred to herein as a second longitudinal edge, the transverse direction of the multilayer assembly extending between the first lateral edge and the second lateral edge. Advantageously, the transverse direction of the multilayer assembly is substantially perpendicular to the longitudinal direction of the multilayer assembly.

[0208] Advantageously, the length of the strip-shaped multilayer component corresponds to the distance between the first and second free ends or the ends joined together of the multilayer component.

[0209] Advantageously, the width of the strip-shaped multilayer component corresponds to the distance between the first and second lateral (or longitudinal) edges.

[0210] Advantageously, the longitudinal direction of the multi-layer component extends along the generally circumferential direction of the tire (or toroidal surface).

[0211] Advantageously, the multi-layer component includes an inner surface and an outer surface, in particular, the outer surface is designed to contact the ground, the inner surface is opposite to the outer surface, and the inner surface faces the tire carcass in particular.

[0212] Preferably, the first fabric layer is oriented directly toward the outer surface of the multilayer assembly.

[0213] Preferably, the multilayer assembly includes one or more fabric layers, particularly knitted, braided, or interwoven, and / or one or more fabric tubes, particularly knitted, braided, or interwoven, optionally substantially flat, particularly each fabric tube including first and second longitudinal edges, particularly each longitudinal edge being substantially annular.

[0214] Preferably, the fabric tube (e.g., the first or second fabric tube) (optionally flat) or fabric layer (e.g., the first / second / third / fourth fabric layer) includes a first longitudinal edge that coincides with or overlaps with a first free longitudinal edge of the tread and / or carcass and / or tire and / or composite material.

[0215] Preferably, the fabric tube (e.g., the first or second fabric tube) (optionally flat) or fabric layer (e.g., the first / second / third / fourth fabric layer) includes a second longitudinal edge that coincides with or overlaps with a second free longitudinal edge of the tread and / or carcass and / or tire and / or composite material.

[0216] Preferably, the optionally flat fabric tube or the optionally flat fabric tubular element comprises two stacked fabric layers, such as the first and second fabric layers or the third and fourth fabric layers described herein.

[0217] The fabric layers (e.g., first / second / third / fourth fabric layers) may also include fabric portions that are thermoplastic and therefore essentially heat-melting, but are not intended to be heat-melted / softened during hot pressing step b). In the context of this invention, this type of fabric material is not considered heat-melting (referred to herein as non-heat-melting fabric sections / parts).

[0218] Advantageously, the non-heat-meltable parts (e.g., fabrics or non-fabricated parts) (whether for the first, second, third, fourth, or fifth aspects of the invention) are parts (e.g., fabrics or non-fabricated parts) not intended to be heat-melted in hot pressing step b), and / or parts (e.g., fabrics or non-fabricated parts) having a melting and / or softening or degradation temperature (e.g., if non-thermoplastic) greater than or equal to the highest heating temperature applied during hot pressing step b) and / or used in the tire manufacturing method.

[0219] Advantageously, the heat-melting parts / portions (e.g., fabric or non-fabric) mentioned herein (whether for the first, second, third, fourth, or fifth aspects of the invention) are parts / portions (e.g., fabric or non-fabric) intended to be heat-melted in hot pressing step b), and / or parts / components (e.g., fabric or non-fabric) having a melting and / or softening temperature less than or equal to the heating temperature (especially the highest temperature) applied during hot pressing step b) and / or used in the tire manufacturing method.

[0220] The multilayer components described herein may include first and second fabric layers, particularly including a first fabric tube (especially woven, knitted, or interwoven) comprising the first and second fabric layers (especially knitted) and optionally a third and fourth fabric layer, and more particularly including a second fabric tube (especially woven, knitted, or interwoven) comprising the third and fourth fabric layers (especially knitted).

[0221] The first and second fabric tubes can be two different fabric tubes, or they can be in the same fabric tube that is folded back, or for that fabric tube, one tube is inserted into the internal volume of the remaining tube.

[0222] In a variant embodiment, step a) includes preparing a multilayer assembly comprising: a first fabric layer including at least one at least partially heat-fusible yarn A; a second fabric layer including at least one at least partially heat-fusible yarn B; a third fabric layer including at least one at least partially heat-fusible yarn C; and a fourth fabric layer including at least one at least partially heat-fusible yarn D; and step b) includes hot-pressing the multilayer assembly with a mold configured to mold at least the tread of a tire by heating the multilayer assembly to at least partially melt the yarns A, B, C, and D of the first, second, third, and fourth fabric layers.

[0223] The molten portions of yarns A and / or B and / or C and / or D at least partially or wholly form the thermoplastic polymer matrix of the main composite material, while the unmolten portions of yarns A and / or B and / or C and / or D at least partially or wholly form the fabric reinforcement component of the main composite material.

[0224] Advantageously, the non-meltable portion, as defined herein, and therefore the non-meltable portion, may be at least partially thermoplastic or thermoplastic.

[0225] The fabric layer (whether it is the first, second, third, or fourth fabric layer) is advantageously at least partially heat-melted, i.e., it can be fully heat-melted (and therefore heat-melted / softened in the main composite material during step b) or it can be partially heat-melted (and therefore partially heat-melted / softened in the main composite material during step b).

[0226] In a variant embodiment, the non-meltable fabric portion comprises a first polyurethane having a melting or softening temperature T3, and the meltable fabric portion comprises a second polyurethane having a melting or softening temperature T4, where T3 is greater than T4.

[0227] The first polyurethane provides hardening properties to the tread and improves tread resistance, especially puncture resistance, abrasion resistance, and deformation resistance. Once melted, the second polyurethane enables the fabric reinforcement elements, including the fabric reinforcement components, to be bonded within the thermoplastic polymer matrix by providing cohesive forces between these reinforcement elements.

[0228] Specifically, T4 is higher than the highest heating temperature applied in the hot pressing step (b) and / or the highest heating temperature applied in the tire manufacturing method.

[0229] In particular, T3 is less than or equal to the heating temperature during the hot pressing step b), especially the highest temperature, and / or the highest heating temperature used in the tire manufacturing method.

[0230] In a variant embodiment, the multilayer assembly includes at least one fabric reinforcement element, which comprises a knitted loop or braided float, the knitted loop or braided float comprising one or more at least partially heat-fused yarns.

[0231] In a variant embodiment, the multilayer assembly is configured to obtain, in step c), a primary composite material that also forms at least a portion of the tire's sidewall.

[0232] In a variant embodiment, the first and second fabric layers are located in a first fabric element having an integral fabric structure, and the third and fourth fabric layers are located in a second fabric element having an integral fabric structure.

[0233] Advantageously, the multilayer assembly includes: a first fabric element having an integral fabric construction, the first fabric element including the first and second fabric layers; and a second fabric element having an integral fabric construction, the second fabric element including the third and fourth fabric layers.

[0234] In a variant embodiment, the primary composite material or multilayer assembly includes a first tube portion that is knitted, woven, or interlaced, the first tube portion including the first and second fabric layers, and the primary composite material or multilayer assembly further includes a second tube portion that is knitted, woven, or interlaced, the second tube portion including the third and fourth fabric layers.

[0235] In a preferred embodiment, the first knitted, braided, or interlaced tube portion is combined with the second knitted, braided, or interlaced tube portion by knitting, braiding, or interlacing. Preferably, the first knitted tube portion and the second knitted tube portion form an integral knitted structure.

[0236] When the first tube section is stacked relative to the second tube section to form a toroidal surface, this arrangement facilitates the correct placement of the first tube section relative to the second tube section.

[0237] Advantageously, the second fabric tube is folded over the first fabric tube or housed within the internal volume of the first fabric tube.

[0238] In another embodiment, the first tube and the second tube are independent of each other as first and second fabric tubes.

[0239] In a variant embodiment, during hot pressing step b), the multilayer assembly is heated to a temperature greater than or equal to 100°C and less than or equal to 250°C.

[0240] In a variant embodiment, during step b), the multilayer assembly is hot-pressed by applying a pressure greater than or equal to 1 bar and less than or equal to 200 bar, preferably less than or equal to 150 bar, 100 bar, or 50 bar.

[0241] In a variant embodiment, the method includes application (step e) using a device for spraying one or more liquid compositions onto the following:

[0242] - One or more surface portions of a multilayer component, particularly the inner and / or outer surfaces, and / or

[0243] - One or more surface portions of the tread and / or tire, particularly the inner and / or outer surfaces,

[0244] - Specifically, multi-layer components, treads, or tires are set in molds or on conveyors.

[0245] In order to form at least one coating area, and in particular, to form two or more coating areas, at least one coating area includes physicochemical and / or mechanical properties that are different from those of the remaining coating areas.

[0246] Specifically, the physicochemical and / or mechanical properties are selected from: thickness, abrasion resistance, grip on surfaces such as ground, Shore A or D hardness, type of liquid composition or applied pattern; more specifically, the type of liquid composition varies depending on the type of polymer, the type of fiber that may be present, and the solids content.

[0247] Preferably, step e) includes a drying step following the application of the at least one liquid composition, during which the solvent (organic solvent or water) of the liquid composition is evaporated to form one or more coating areas.

[0248] Preferably, the polymer type is natural rubber and / or polyurethane, especially polyurethane elastomer.

[0249] Preferably, the polymer type is a thermoplastic polymer and / or a thermoplastic elastomer.

[0250] In one embodiment, the liquid composition comprises at least one polymer dispersed in an organic solvent or water.

[0251] Aqueous dispersions that optionally include fibers are known in the prior art, such as aqueous polyurethane dispersions.

[0252] The solid content of the at least one polymer in the liquid composition may be greater than or equal to 5% or 10% and less than or equal to 60% or 55% or 50%, optionally less than or equal to 30% or 25% or 20%.

[0253] For example, the solid content is greater than or equal to 30% and less than or equal to 50%.

[0254] The solids content of at least one polymer is calculated by relating the total dry mass of one or more polymers in the liquid composition to the total dry mass of the liquid composition.

[0255] The mass fraction of fibers in the liquid composition can be greater than or equal to 5% or 10% and less than or equal to 30% or 25% or 20%.

[0256] The fiber mass fraction is calculated by relating the total mass of the fibers to the total mass of the liquid composition.

[0257] The liquid composition may include fibers, particularly fibers made of synthetic materials, especially polyester fibers (e.g., PET, PBT), polyamide fibers (e.g., PA 6 or 66), polyurethane fibers, polyolefin fibers (PP, PE, HMWPE, UHMWPE) or mixtures thereof; fibers made of natural materials (cotton, hemp, flax, etc.); regenerated fibers, reinforcing fibers, particularly mixtures derived from synthetic or natural fibers, such as those mentioned above, or mixtures thereof.

[0258] The fibers may be at least partially heat-fusible or at least partially non-heat-fusible (within the meaning of this document, and therefore optionally at least partially thermoplastic).

[0259] The liquid composition can be applied to multilayer components, especially substantially flat multilayer components, such as on a conveyor, or after step d) of pleating on a ring die, before step b) of hot pressing, or optionally after step b) of hot pressing on all or part of the tread and / or tire.

[0260] The spraying device may include one or more nozzles. The nozzles may spray liquid compositions that are similar to or different from the liquid composition sprayed by another nozzle.

[0261] The nozzle can simultaneously apply one or more liquid compositions to form at least one integrally formed coating area, and in particular multiple integrally formed coating areas, i.e., forming portions without boundaries or limits.

[0262] The liquid composition can be applied as described in European patents EP 2864536, EP 2262632 and EP 1807253.

[0263] The descriptions of European patents EP 2864536, EP 2262632 and EP 1807253 are incorporated herein by reference.

[0264] In a variant embodiment, the multilayer assembly includes a first fabric element, such as a fabric layer or fabric tube or fabric tubular element, comprising a first fabric region and a second fabric region fabrically connected (especially by knitting) to the first fabric region, the first fabric region being distinguished from the second fabric region by at least one characteristic selected from the following: stitch pattern (e.g., the presence of a looped sponge-like stitch or braided float or seam thread inclined relative to the longitudinal axis of the first fabric element), the amount of yarn, the nature of the yarn, the mass fraction of partially heat-fusible fabric (especially the mass fraction of the heat-fusible fabric portion), the mass fraction of the non-heat-fusible fabric portion, or the fineness (dtex) of the yarn.

[0265] Advantageously, the difference between the first knitted area and the second knitted area lies in at least one property that will affect, for example, mechanical behavior.

[0266] For example, the first knitted area includes elastic yarn, while the second knitted area does not include elastic yarn.

[0267] For example, the mass proportion of at least partially heat-melted yarn in the second knitted area is greater than the mass proportion of at least partially heat-melted yarn in the first knitted area.

[0268] In a variant embodiment, the multilayer assembly includes at least one fabric reinforcement element, such as a first fabric tube and / or a second fabric tube, the fabric reinforcement element comprising at least one knitted pattern, such as a herringbone pattern or yarn that is inclined relative to the longitudinal axis L of the strip and, in particular, parallel to each other.

[0269] Preferably, the knitted pattern extends along the longitudinal direction of the multilayer component, particularly in the shape of a generally stripe, and extends repeatedly over a portion of the length of the knitted reinforcing element or over the entire length of the knitted reinforcing element.

[0270] The knitted pattern may also extend over a portion of the width of the knitted reinforcing element, or over the entire width of the knitted reinforcing element.

[0271] Advantageously, the knitted pattern (e.g., V-shape or herringbone) or the slanted knitting yarn includes a first pattern (e.g., V-shape) and a second pattern (e.g., V-shape), the second pattern being knitted or woven with one or more yarns different from those of the first pattern (e.g., V-shape). The first pattern (e.g., V-shape) alternates with the second pattern (e.g., V-shape) over at least a portion of the length of the multi-layered assembly.

[0272] Advantageously, at least one first pattern (e.g., V-shape or herringbone) comprises a greater mass fraction of heat-fused fabric than at least one second pattern (e.g., V-shape or herringbone). In a variant, the multilayer assembly includes at least one fabric reinforcing element, such as a first fabric tube and / or a second fabric tube, comprising a plurality of knitted stitches having one or more reinforcing yarns, particularly at least partially non-heat-fused, the plurality of knitted stitches arranged along the lines of the knitted stitches, at least one of the lines of the knitted stitches having a longitudinal direction Lmt intersecting the longitudinal direction of the multilayer assembly.

[0273] Advantageously, the knitting stitches include knitting stitches that are inclined toward the first (longitudinal) side edge or the second (longitudinal) side edge.

[0274] Advantageously, the longitudinal direction Lmt forms an angle β1 with the longitudinal direction of the multilayer component that is greater than 0° and less than or equal to 90°, particularly less than or equal to 60°, and even more particularly less than or equal to 50°.

[0275] Advantageously, β1 is greater than or equal to 10°, particularly greater than or equal to 20°, and even more particularly greater than or equal to 30°.

[0276] The knitting stitches may extend over a portion of the width of the fabric reinforcing element, or over the entire width of the fabric reinforcing element.

[0277] In one variant, the multilayer components form at least 80% by weight or volume of the tread (particularly a tread having a first sidewall and / or a second sidewall), preferably at least 90% by weight or volume, and more preferably about 100% by weight or volume.

[0278] In one variation, the first and / or second and / or third and / or fourth fabric layers (especially knitted fabric layers) include at least one longitudinal fabric region (especially knitted fabric region), which includes a fabric pattern (especially knitted fabric pattern), particularly inclined fabric lines (especially knitted fabric lines), particularly along the longitudinal axis L of the strip. mt The slanted fabric threads, and the pattern includes at least one yarn (especially a knitted yarn) that is at least partially non-heat-fusible, and / or at least one yarn (especially a knitted yarn) that is at least partially heat-fusible.

[0279] The at least one longitudinal region extends along the entire or part of the length of the first tube and / or the fabric layer, particularly adjacent to one of the first and second longitudinal edges of the strip and / or the multilayer assembly.

[0280] For example, the surface area (cm) occupied by the at least one longitudinal region 2 The area should be less than or equal to 60% of the surface area of ​​the target fabric layer, especially between 20% and 40%.

[0281] For example, the surface area (cm) occupied by the at least one longitudinal region 2 (60% or greater, especially 80% or 90% or essentially 100%).

[0282] For example, the inclination of the fabric lines in at least one longitudinal fabric region of a given layer (e.g., the first or third layer) may be different from or similar to the inclination of the fabric lines in at least one longitudinal fabric region of another given layer (e.g., the second or fourth layer), for example, opposite.

[0283] L mt An angle is formed with the longitudinal axis L of the strip, which can be greater than 0° and less than or equal to 70°, particularly greater than or equal to 30° and less than or equal to 60°, for example, about 45°+ / -5°.

[0284] In a variant embodiment, the first and / or second and / or third and / or fourth fabric layers (especially knitted fabric layers) include (both include) two longitudinal fabric regions (especially knitted fabric regions) extending over all or part of the length of the fabric layer or the first fabric tube (especially the knitted fabric tube). One longitudinal fabric region includes fabric lines (especially knitted fabric lines) inclined relative to the axis L of the strip according to a first inclination, and the other longitudinal fabric region includes fabric lines (especially knitted fabric lines) inclined relative to the axis L of the strip according to a second inclination different from the first inclination.

[0285] This arrangement improves the mechanical properties of the tire tread.

[0286] For example, the surface area (cm²) occupied by the longitudinal region of the fabric. 2 It is between 45% and 65% of the surface area of ​​the target fabric layer, or between 25% and 35% of the surface area of ​​the target fabric layer if a third longitudinal fabric region exists.

[0287] In a variant embodiment, the first and / or second and / or third and / or fourth fabric layers (especially knitted fabric layers) include (all include) at least one longitudinal fabric region (especially a knitted fabric longitudinal region), which includes a fabric loop (especially a knitted fabric loop) comprising at least one at least partially heat-fused yarn. Preferably, the longitudinal fabric region is substantially located at the center of the first or second fabric layer.

[0288] Preferably, the surface area (cm²) occupied by the at least one longitudinal region 2 It should be less than or equal to 60% of the surface area of ​​the target fabric layer, especially between about 20% and 40%.

[0289] In one variation, the first fabric layer (especially knitted) of the first fabric tube (especially knitted) includes first, second, and third longitudinal fabric regions (especially knitted), at least one of the first and third longitudinal fabric regions including a fabric pattern (especially fabric yarn), especially knitted, which extends diagonally relative to the longitudinal axis L of the strip (e.g., along the axis Lmt defined above), and the fabric pattern includes at least partially non-heat-fusible yarns and / or at least partially heat-fusible yarns. The second longitudinal fabric region arranged between the first and third longitudinal regions includes a fabric loop or elongated fabric portion (especially knitted), which includes at least one at least partially heat-fusible yarn, and / or

[0290] - The second fabric layer (especially knitted) comprises at least one at least partially heat-melted yarn (especially knitted) so as to extend substantially along the entire width of the second fabric layer and substantially at least partially along the entire length of the second fabric layer, and / or

[0291] - The second longitudinal region of the first layer of fabric is intended to form at least a portion of the surface of the central region of the tire tread, particularly forming one or more regions that engage with the ground.

[0292] In one variant, the first fabric layer of the first fabric tube includes first, second, and third longitudinal fabric regions (especially knitted), and the second longitudinal region disposed between the first and third longitudinal regions includes a knitted loop comprising at least one at least partially heat-fused yarn, and the total mass fraction of the heat-fused fabric portion in the second longitudinal region is greater than the total mass fraction of the heat-fused fabric portion in the first longitudinal region or the total mass fraction of the heat-fused fabric portion in the third longitudinal region.

[0293] Preferably, the longitudinal region of the second fabric of the first layer is intended to form at least a portion of the surface of the central region of the tire tread, particularly forming one or more regions that engage with the ground.

[0294] In a variant embodiment, the at least one longitudinal region of the fabric layer (e.g., the first / second / third / fourth) (especially the first fabric layer) and / or the first longitudinal region and / or the third longitudinal region include / each include at least one at least partially heat-fusible yarn, especially a polyurethane yarn of 600 denier + / - 200 denier, particularly knitted with plating yarn, and more particularly a non-heat-fusible yarn, such as a polyamide yarn.

[0295] Preferably, at least partially heat-melted yarns knitted in the first and / or second and / or third longitudinal regions are made of polyurethane.

[0296] In one variant, the third and / or fourth knitted layers each comprise a pattern (e.g., diagonally knitted lines, such as along axis Lmt) that is knitted diagonally relative to the longitudinal axis L of the strip, extending substantially over the entire width of the second tube, and more particularly over the entire length of the second tube.

[0297] Preferably, the knitted pattern extends diagonally and forms an angle between 30° and 60° with the longitudinal axis L, for example, about 45°+ / -5°.

[0298] Preferably, the third and / or fourth layers are knitted with at least one at least partially heat-fusible yarn, especially a polyurethane monofilament yarn of 600 denier + / - 200 denier, and one or more at least partially non-heat-fusible yarns, especially one or more filler yarns.

[0299] In the variant embodiment:

[0300] - The multilayer assembly includes a strip comprising two ends joined together to form a toroidal surface.

[0301] - The strip includes a first longitudinal edge, which includes a plurality of folds at a first location, and the torus has a circumference C1 at the first location, and

[0302] - The method includes step d), which occurs before step b), and optionally after or before step e), which applies at least one liquid composition by spraying, and includes the step of setting the annular surface on the anti-mold at a second position, wherein at least a portion of the plurality of pleats, particularly substantially all of the pleats, are spaced apart from each other at the second position, and the annular surface has a circumference C2 greater than C1.

[0303] Advantageously, the plurality of pleats arranged along the first longitudinal edge allow the circumference of the torus to be varied between a first position corresponding to a resting position and a second position corresponding to an extended position, with the plurality of pleats unfolded in the second position and the first longitudinal edge in the extended position.

[0304] Advantageously, the strip also includes a second longitudinal edge that includes folds at a first location, at least some of which, in particular all of these folds, are spaced apart from each other at a second location.

[0305] Advantageously, this arrangement allows the toroidal surface (in particular, also in the form of a toroidal surface) to be held in the proper position on the die during the hot pressing step b) and optionally during the application step e) without causing the first longitudinal edge, and especially the second longitudinal edge, to move unintentionally on the die.

[0306] It has been observed that, without this arrangement, the first and second longitudinal edges of the strip, and therefore the first and second longitudinal edges of the toroidal surface, are not properly tensioned on the die, and the positioning of the strip on the die is also unreproducible.

[0307] The arrangement of the longitudinal edges of the first and second folds allows these problems to be overcome.

[0308] Preferably, the multiple folds are distributed over at least a portion of the length of the first longitudinal edge, and more preferably distributed substantially along the entire length of the first longitudinal edge.

[0309] Preferably, the multiple folds are distributed over at least a portion of the length of the second longitudinal edge, and more preferably, they are distributed substantially along the entire length of the second longitudinal edge.

[0310] Preferably, L2 and C2 are at least 10% or 20% larger than L1 and C1, more preferably at least 40% or 50%, and even more preferably at least 70% or 80%.

[0311] Advantageously, the strip has a length L1 at a first position, or the torus has a circumference C1 at a first position and a length L2 at a second position, or the torus has a circumference C2 at a second position.

[0312] Preferably, the length L1 corresponds to the length of the first or second longitudinal edge.

[0313] In a variant, the first longitudinal edge and / or the second longitudinal edge of the strip includes (both include) one or more elongated pleating elements arranged along all or part of the length of the first longitudinal edge and / or the second longitudinal edge to create the plurality of pleats, at least one of the elongated elements being a pleating yarn comprising a heat-fusible polymer material, particularly polyurethane.

[0314] By joining at least one elongated element (e.g., an elastic cord) together along at least a portion of the length of the first longitudinal edge and optionally the second longitudinal edge (particularly substantially along the entire length), multiple folds can be formed along the first longitudinal edge and optionally along the second longitudinal edge to bring portions of the strip closer together and create folds.

[0315] In a variant, the first longitudinal edge and / or the second longitudinal edge of the strip include (both include): an elongated pleating element, which is a first knitted pleating yarn comprising a heat-fusible polymer material, particularly polyurethane; and an elongated pleating element, which is a second knitted pleating yarn and includes floats, optionally comprising a heat-fusible polymer material, particularly polyurethane.

[0316] Advantageously, the first pleating yarn and the second pleating yarn are knitted along at least a portion (particularly over the entire length) of the length of the first longitudinal edge and optionally the second longitudinal edge, the pleating yarn being knitted such that at the first resting position of the strip, the first pleating yarn applies tension to the second pleating yarn at regular intervals, thus bringing portions of the strip closer together to create pleats.

[0317] Advantageously, both the first pleated yarn and the second pleated yarn are knitted on the first and / or second longitudinal edges of the first knitted tubular portion, and optionally on the first and / or second longitudinal edges of the second knitted tubular portion.

[0318] Advantageously, the width of the fold or pleat corresponds to the length of the float.

[0319] Advantageously, the knitting float corresponds to the portion of the second pleated yarn that extends substantially in a straight line over a certain number of stitch rows, in particular not forming loop stitches, and optionally not forming loaded stitches.

[0320] Preferably, the first pleated yarn is at least partially heat-melting yarn (optionally substantially heat-melting yarn), particularly made of polyurethane.

[0321] Preferably, the first pleated yarn includes a hot melt portion having a melting temperature between 120°C and 170°C.

[0322] Preferably, the first pleated yarn has a toughness of approximately 1.50 cN / dtex + / - 1 cN / dtex.

[0323] Preferably, the first pleated yarn has an elongation at break of 10% or more, particularly less than or equal to 100% or 30%.

[0324] Preferably, the first pleated yarn is core-spun and has: a non-heat-fusible core, which is optionally thermoplastic, for example made of polyethylene terephthalate (PET) (or polybutylene terephthalate (PBT)) or polyamide (PA6 or 6-6); and a heat-fusible sheath, for example made of polyurethane. More preferably, the mass fraction of the sheath in the yarn is between 60% and 90%, and the mass fraction of the core is between 10% and 40%.

[0325] Preferably, the first pleating yarn is a monofilament yarn, particularly having a diameter of greater than or equal to 0.10 mm and less than or equal to 0.60 mm, particularly about 0.35 mm + / - 0.20 mm.

[0326] Preferably, the second pleated yarn is a multifilament yarn or spunyarn of PET, PBT or polyamide fibers.

[0327] Preferably, the second pleated yarn is not a heat-fusible yarn, but optionally a thermoplastic yarn.

[0328] Advantageously, the first and second pleated yarns are knitted in such a way that in the first resting position, the first pleated yarn shrinks and thus brings the float portions closer together, thereby creating folds or wrinkles.

[0329] In addition to the inherent elasticity of the first pleated yarn, it can also be knitted by applying high tension to amplify its shrinkage and pleat formation in the first position.

[0330] The properties (elongation at break, toughness, etc.) are preferably measured using UNI EN ISO 2062-2010, and the linear density is measured using DIN EN ISO 2060.

[0331] According to a third aspect, the present invention also relates to a method for recycling tires, the method advantageously comprising:

[0332] - Collect at least one tire, particularly a tire according to the first aspect of the present invention, or a tire obtained according to the method described with reference to the second aspect of the present invention;

[0333] - Grind at least one tire to obtain ground particles or fragments;

[0334] - A step of converting the ground particles or fragments into microparticles, the microparticles being convertible by a heated conversion process (e.g., by extrusion molding), the conversion step including an extrusion granulation step.

[0335] The definitions, alternative embodiments, and examples of the first aspect of the present invention may be combined with the second, third, or fourth aspects of the present invention.

[0336] According to a fourth aspect, the present invention relates to a multilayer assembly for manufacturing tires by hot pressing, and particularly to a method for manufacturing tires according to any alternative embodiment of the second aspect of the invention.

[0337] Multilayer components may include any variations, embodiments, or definitions described with reference to the manufacturing method according to the second aspect of the invention or the fabric reinforcement component according to the first aspect of the invention.

[0338] Advantageously, the multilayer component includes strips, particularly in the form of strips, which include two free ends or ends joined together, particularly joined together to form a toroidal surface.

[0339] Advantageously, the multilayer assembly includes at least one heat-melt fabric portion and at least one non-heat-melt fabric portion.

[0340] Advantageously, the multilayer assembly includes: a first fabric tube comprising first and second fabric layers; and optionally a second fabric tube comprising third and fourth fabric layers, wherein at least one of the first fabric tube and the optional second fabric tube comprises at least one heat-fusible fabric portion, particularly in a method of manufacturing a tire by hot pressing, and wherein at least one of the first fabric tube and the optional second fabric tube comprises at least one non-heat-fusible fabric portion, particularly in a method of manufacturing a tire by hot pressing.

[0341] Advantageously, the at least one non-heat-meltable fabric portion is at least partially thermoplastic.

[0342] In one variant, the major component by mass relative to the total mass of the multilayer assembly is thermoplastic polyurethane.

[0343] The term "major component by mass" should be understood to mean that, optionally, the component has the highest mass fraction in the multilayer assembly compared to one or more mass fractions of one or more other components present. This major mass fraction may be less than 50%, for example at least 20% or 30%, or may be greater than 50% or 60% or 70% or 80% or 90%.

[0344] In a variant embodiment, the mass fraction of one or more thermoplastic materials in the multilayer fabric assembly is greater than or equal to 60% or 70% or 80% (optionally less than or equal to 90%), preferably greater than or equal to 90%, even more preferably greater than or equal to 95%, particularly about 100%.

[0345] This arrangement facilitates tire recycling. In fact, thermoplastic materials can be molded multiple times by heating.

[0346] In a variant, the strip includes a first longitudinal edge, the first longitudinal edge including a plurality of folds at a first position, and the strip has a total length L1 at the first position, preferably the torus has a circumference C1, and the strip has a length L2 at a second position, preferably the torus has a circumference C2, wherein at least a portion of the plurality of folds, particularly substantially all of the folds, are spaced apart, L2 is greater than L1, and preferably C2 is greater than C1.

[0347] Advantageously, the total length L1 is the distance separating the first and second free ends or joint ends of the strip.

[0348] Advantageously, the strip has a longitudinal axis L extending between its first and second free ends joined together and a transverse axis T extending substantially perpendicular to axis L.

[0349] In a variant, the first longitudinal edge includes one or more elongated pleating elements arranged along all or part of the length of the first longitudinal edge to create the pleats. At least one of the elongated elements is a pleating yarn comprising a thermoplastic polymer material, particularly polyurethane, and optionally a polyurethane elastomer.

[0350] In particular, the (first or second) pleated yarn is a heat-fusible yarn (i.e., intended to be heat-fusible in the tire manufacturing method according to the invention).

[0351] Advantageously, the elongated pleated element is knitted in at least one of the first and second fabric tubes.

[0352] Alternatively, the first longitudinal edge and optionally the second longitudinal edge of the strip include (both include): an elongated pleating element, said elongated pleating element being a first knitted pleating yarn comprising a heat-fusible polymer material, particularly polyurethane; and an elongated pleating element being a second knitted pleating yarn and comprising floats.

[0353] Multi-layer strips or components, as described herein, particularly according to variant embodiments, appear independently of each other in the description of the tire manufacturing method with reference to the second aspect of the invention, particularly independent of the steps of the manufacturing method, or again with reference to the tire according to the first aspect of the invention.

[0354] According to a fifth aspect, the present invention also relates to the manufacture of tires by hot pressing using multilayer components as described herein, particularly according to variations that appear in the description of a tire manufacturing method with reference to a second aspect of the invention, particularly independent of the steps of the manufacturing method, and / or variations that appear in the description of a multilayer component with reference to a fourth aspect of the invention. Attached Figure Description

[0355] The invention will be better understood by referring to the accompanying drawings and by reading the following description of embodiments of the invention given by way of non-limiting examples, wherein:

[0356] [ Figure 1 ] Figure 1 A first example of a tire according to the invention is shown schematically;

[0357] [ Figure 2 ] Figure 2 A side view schematically illustrates a first example of a multi-layer assembly for manufacturing a tire according to the present invention;

[0358] [ Figure 3 ] Figure 3A side view schematically illustrates a second example of a multi-layer assembly for manufacturing a tire according to the present invention;

[0359] [ Figure 4 ] Figure 4 A side view schematically illustrates a third example of a multi-layer assembly for manufacturing a tire according to the present invention;

[0360] [ Figure 5 ] Figure 5 A side view schematically illustrates a fourth example of a multi-layer assembly for manufacturing a tire according to the present invention;

[0361] [ Figure 6 ] Figure 6 A side view schematically illustrates a fifth example of a multi-layer assembly for manufacturing a tire according to the present invention;

[0362] [ Figure 7 ] Figure 7 A side view schematically illustrates a sixth example of a multi-layer assembly for manufacturing a tire according to the present invention;

[0363] [ Figure 8 ] Figure 8 This schematically illustrates, for example, Figures 2 to 7 A plan view showing the arrangement of fabric layers in the fabric tube or fabric tube section according to the present invention;

[0364] [ Figure 9 ] Figure 9 A schematic plan view of the first and second fabric layers of a second example of a fabric tube according to the invention is shown;

[0365] [ Figure 10 ] Figure 10 A schematic plan view of the first fabric layer of a fifth example of a fabric tube according to the invention is shown;

[0366] [ Figure 11 ] Figure 11 A schematic plan view of a sixth example of a knitted tube according to the invention is shown, which forms all or part of a multilayer assembly for manufacturing a tire according to the invention;

[0367] [ Figure 12 ] Figure 12 The illustration shows the basis for folding into three parts. Figure 12 The sixth example of the tube is a plan view viewed from the outside;

[0368] [ Figure 13 ] Figure 13 The illustration shows the basis for folding into three parts. Figure 12 The sixth example of the tube is a plan view viewed from the outside;

[0369] [ Figure 14 ] Figure 14 A three-dimensional diagram schematically illustrates the following based on Figure 12 The sixth example of the tube is folded into three parts and its ends are joined together to form a toroidal surface;

[0370] [ Figure 15 ] Figure 15 A seventh example of a flat tube is schematically shown in a perspective view. The flat tube includes a second fabric tube portion that is designed to be folded back against the fabric tube portion to form a strip.

[0371] [ Figure 16 ] Figure 16 A three-dimensional diagram schematically illustrates... Figure 15 The strips, whose first and second free ends are joined to form a toroidal surface;

[0372] [ Figure 17 ] Figure 17 The diagram schematically illustrates the position in the first resting position. Figure 16 The stripes;

[0373] [ Figure 18 ] Figure 18 The diagram schematically illustrates the second position on the annular reverse die. Figure 16 and Figure 17 The stripes;

[0374] [ Figure 19 ] Figure 19 Along Figure 18 The cross section XIX-XIX schematically shows the elongated strip located at the second position. Detailed Implementation

[0375] Figure 1 A first example of a tire 10 according to the invention is schematically shown. The tire 10 includes a tread 15, a first sidewall 20, and a second sidewall 25. Advantageously, the first sidewall 20 and the second sidewall 25 include first and second free longitudinal edges 21, 26 that are reinforced and form first and second bead wire elements 22, 27. The first and second sidewalls 20, 25 advantageously extend on both sides of the tread 15. Advantageously, the general shape of the tire 10 is a longitudinally open annular surface (not shown) extending circumferentially according to the intended diameter of the tire 10. Advantageously, the tread 15, the first and second sidewalls 20, 25, and the bead wire elements 22, 27 have an integrally molded construction and are formed of a main composite material 30. The main composite material 30 has a longitudinal axis Lmc extending circumferentially along the length of the tire 10 and a transverse axis Tmc substantially perpendicular to the axis Lmc.

[0376] Figure 2A first example of a multilayer assembly 40 for manufacturing a tire according to the invention is schematically shown. The multilayer assembly includes a fabric tube 50 folded in half, thus forming a first fabric tube portion 42 and a second fabric tube portion 44 connected by a crease 45. The first fabric tube portion 42 includes a first fabric layer 42a and a second fabric layer 42b, and the second fabric tube portion 44 includes a third fabric layer 44a and a fourth fabric layer 44b. The first and / or second and / or third and / or fourth fabric layers may (all) comprise one or more fully or partially heat-fusible multifilament yarns and / or monofilament yarns and one or more non-heat-fusible monofilament yarns and / or multifilament yarns, particularly their linear density (dtex) and mass fraction varying depending on the fabric layer to be used. Preferably, the tube 50 is a tube knitted on a small-diameter circular knitting machine. Advantageously, the stitch pattern of the first knitted layer 42a may be the same as or different from the stitch pattern of the second knitted layer 42b or the third or fourth knitted layer 44a or 44b.

[0377] Advantageously, at least one physical property and / or one chemical property of the first tube 42 and the second tube 44 are different, and the at least one physical property and / or one chemical property is particularly selected from: yarn composition, yarn fineness, mass fraction of heat-fusible fabric material and mass fraction of non-heat-fusible fabric material.

[0378] The multilayer assembly 40 may further include one or more heat-fusible polymer sheets 46, which may be disposed on the outer surface of the first layer 42a and / or within the first tube portion 42 and / or between the first tube portion 42 and the second tube portion 44 and / or within the second tube portion 44 and / or on the outer surface of the fourth layer 44b. The heat-fusible sheets 46 may be made of at least one polyolefin or polyolefin elastomer or polyurethane (e.g., polyurethane elastomer). Advantageously, the multilayer assembly 40 is generally shaped as a toroid, particularly by fixing the free ends 48 and 49 of the folded tube 50 and then hot-pressing. The multilayer assembly 40 advantageously includes heat-fusible fabric portions and non-heat-fusible fabric portions, and optionally includes heat-fusible non-fabric portions formed from one or more heat-fusible sheets 46.

[0379] Advantageously, a multi-layer assembly 40 in the form of a toroidal surface is placed in a mold assembly comprising a defined molding volume, and then hermetically closed. Pressure or vacuum is applied to the multi-layer assembly to push / press the assembly against the inner wall of the mold, while simultaneously applying heating temperature, thereby melting and / or softening the target heat-fusible material in the multi-layer assembly 40. Pressure can advantageously be applied by means of a deformable and inflatable bladder disposed within the forming toroidal surface of the multi-layer assembly 40, which inflates during hot pressing. Hot pressing can also be performed using rigid inserts, thus non-inflatable anti-molds such as those disposed within the internal volume of the molding assembly. Advantageously, at the end of hot pressing, a tire comprising a tread, a first sidewall, a second sidewall, and possibly bead wire elements is obtained.

[0380] Advantageously, arranging sheets 46 in the thermoplastic elastomer of the multilayer component 40 to form at least a portion of the outer surface of the tread can improve the wear resistance and grip of the tread.

[0381] The fabric tube 50 has: a longitudinal axis L, which in this example corresponds to the direction of the stitch row or the warp direction, or to the direction of knitting or weaving; and a transverse axis T, which is substantially perpendicular to axis L. The transverse axis T preferably corresponds to the weft direction or the direction of the stitch row.

[0382] Advantageously, the fabric tube 50 has an integral fabric construction, particularly an integral knitted construction. Therefore, the fabric tube 50 is advantageously obtained at the exit of the knitting machine without requiring the additional step of attaching another fabric insert to the tube 50, except perhaps by finishing the edges of the tube 50 through a seam. Thus, the tubes 42 and 44 comprise at least one common yarn, particularly a knitted yarn.

[0383] Advantageously, the multilayer component 40 is generally shaped as a strip, which includes first and second free ends 48, 49, and a longitudinal axis corresponding to axis L and a transverse axis corresponding to axis T.

[0384] In the prior art, tire manufacturing involves numerous steps: creating the tread by impregnating a fabric support with rubber, then creating the carcass by coating the fabric support with resin, and then assembling the tread and carcass together during molding. Molding also allows for the vulcanization of the polymer impregnating the tread. Finally, bead wire elements, particularly metal elements, are assembled along the free longitudinal edges. In this invention, the main composite material forming the tread, first and second blanks, and optional bead wire elements is advantageously obtained from dry material (and therefore without solvent) in a single hot-pressing step, and this is obtained from a thermoplastic material that can be easily recycled together without separation.

[0385] Figure 3A side view schematically illustrates a second example of a multi-layer assembly 60 for manufacturing a tire according to the present invention. This multi-layer assembly may correspond to... Figure 1 The multi-layer component 40 differs in that tube 42 is inserted into the internal volume of tube 44. In this case, tubes 42 and 44 are... Figure 3 The two are coaxial. Figure 3 The tube section is also an integral fabric structure, especially knitted.

[0386] Figure 4 A side view schematically illustrates a third example of a multi-layer assembly 70 for manufacturing a tire according to the present invention. This multi-layer assembly may correspond to... Figure 2 The multi-layer component 60 differs in that tubes 42 and 44 are two separate tubes 42' and 44', and therefore are not a monolithic fabric construction. Tubes 42' and 44' are in... Figure 4 The images are shown as stacked, but they can also be arranged coaxially, like... Figure 3 As shown.

[0387] Figure 5 A side view schematically illustrates a fourth example of a multilayer assembly 80 for manufacturing tires according to the invention. The multilayer assembly comprises three stacked and distinct tubes 90, 94, and 96. Tubes 90, 94, and 96 are not integral fabric structures. Tubes 90, 94, and 96 are preferably knitted, particularly on a circular knitting machine. Advantageously, the first tube 90 comprises a first fabric layer 90a and a second fabric layer 90b, the second tube 94 comprises a third fabric layer 94a and a fourth fabric layer 94b, and the third tube comprises a fifth fabric layer 96a and a sixth fabric layer 96b.

[0388] Advantageously, the first fabric layer 90a and / or the second fabric layer 90b and / or the third fabric layer 94a and / or the fourth fabric layer 94b and / or the fifth fabric layer 96a and / or the sixth fabric layer 96b may (all) comprise one or more monofilaments and / or multifilaments at least partially heat-fusible yarns, and one or more monofilaments and / or multifilaments that are not heat-fusible. One or more heat-fusible polymer sheets 98 may be disposed between and / or inside the tubes 90, 94 and 96 and / or on the outer surface of the first layer 90a and / or on the outer surface of the sixth layer 96b.

[0389] Figure 6 A side view schematically illustrates a fifth example of a multi-layer assembly 100 for manufacturing tires according to the invention. This multi-layer assembly can be similar to multi-layer assembly 80, except that tubes 90, 94, and 96 are integral fabric constructions (parts 90', 94', and 96') and are formed within a single tube 110. Therefore, tube 110 advantageously includes two folds 112 and 114.

[0390] Figure 7 A side view schematically illustrates a sixth example of a multilayer assembly 120 for manufacturing a tire according to the invention. This multilayer assembly can be similar to multilayer assembly 100, except that tubes 90, 94, and 96 are coaxial. Tube 96 is inserted into tube 94, and tubes 94 and 96 are inserted into tube 90.

[0391] Figure 8 An example of a first fabric layer 130 of a fabric tube or portion 132 according to the invention is shown schematically in a plan view. A second fabric layer of the tube or portion 132 may be similar to the first fabric layer 130.

[0392] The first fabric layer 130 advantageously includes a central region 134 for the tread and first and second lateral regions 136 and 138 for the first and second sidewalls, respectively.

[0393] Advantageously, the first fabric layer 130 and the tube or tube 132 include a longitudinal axis L1 and a transverse axis T1 substantially perpendicular to axis L1. Advantageously, the central region 134 of the tread includes a V-shaped or herringbone pattern (or an inverted V-shaped pattern, not shown) of knitted stitches or braided floats 140, the arms of which are inclined relative to the longitudinal axis L1, particularly the first lateral arms extending in the longitudinal direction L2, forming an angle α1 between 15° and 50° with the transverse axis T1. Advantageously, the V-shaped pattern includes a first V-shaped pattern and a second V-shaped pattern, the second V-shaped pattern being knitted or braided with one or more yarns different from those of the first V-shaped pattern. The first V-shaped pattern alternates with the second V-shaped pattern along the length of the central tread region 134. For example, the first V-shaped pattern is knitted or woven with a composite yarn comprising two polyamide multifilament yarns (especially PA6) and a polyurethane heat-fusible monofilament yarn, while the second V-shaped pattern is knitted or woven with a composite yarn comprising two polyurethane heat-fusible monofilament yarns and a polyamide multifilament yarn (especially PA6). Advantageously, the mass fraction of heat-fusible fabric included in the first V-shaped pattern is greater than that in the second V-shaped pattern. The arrangement of the first and second patterns along the central region 134 enables improvement in the mechanical properties (tensile strength, etc.) of the fabric reinforcement in the tire.

[0394] Advantageously, the V-shaped or herringbone pattern (or inverted V-shaped pattern, not shown) of the knitted stitch or braided float 140 can extend into the first lateral region 136 and may extend into the second lateral region 138.

[0395] Figure 9The diagram schematically illustrates a fabric tube 147 or a flat first and second fabric layers 140, 142 of the fabric tube 147 having a longitudinal axis L3. Advantageously, the first fabric layer 140 includes threads of knitted stitches or braided floats extending along a first direction L4 and inclined relative to axis L3 in a central region 144, and the second fabric layer 142 includes threads of knitted stitches or braided floats 145 extending along a second direction L5 and inclined relative to axis L3 in a central region 144, direction L5 opposite to direction L4. Advantageously, the stitches 145 include first and second stitches 145, the first stitch 145 including more non-heat-meltable fabric portion than the second stitch 145. This arrangement allows for the orientation of fabric reinforcement threads in the final composite material, and thus in tires, to improve their mechanical properties.

[0396] The arrangement of the first and second fabric layers 140 and 142 may be repeated for the second tube section or the third and fourth fabric layers of the second tube, and may also be repeated for the third tube section or the fifth and sixth fabric layers of the third tube. The first, second, or third tubes (parts of the first, second, or third tubes) may be arranged as described herein, for example, they may be stacked or coaxial. Depending on the mechanical properties sought in the final fabric reinforcement in the master composite material, the inclination of the knitted stitches or braided floats may vary from fabric layer to fabric layer.

[0397] Advantageously, the knitted threads or braided floats 141, 145 may extend into the first lateral regions 144b, 146b, respectively, and may extend into the second lateral regions 144c, 146c, respectively.

[0398] Figure 10A schematic illustration shows a flat first fabric layer 150, representing an example of a fabric tube 160 or a portion thereof 160 according to the invention. The first fabric layer 150 includes a central fabric region 154 intended to form all or part of the tread of a tire according to the invention, and lateral regions 152, 153 intended to form all or part of the first and second sidewalls of the tire according to the invention, respectively. Advantageously, the central region 154 includes a central sub-region 154a disposed between the first and second lateral sub-regions 154b and 154c. Advantageously, the central sub-region 154a has a mass fraction F1 of heat-fusible material, and the lateral sub-regions 154b and 154c have mass fractions F2 and F3 of heat-fusible material, respectively; preferably, F1 is greater than F2 or F3, more preferably, F1 is at least twice as much as F2 or F3. This arrangement allows for the formation of longitudinal strips in the central sub-region 154a that include more heat-fusible material compared to the lateral sub-regions 154b and 154c. Specifically, the central sub-region 154a includes knitted loops or braided floats protruding from the outer surface of the fabric layer to provide more heat-fusible fabric material, such as sponge-type stitches (terry loops). The lateral fabric regions 152 and 153 include a mass ratio of heat-fusible fabric portions to non-heat-fusible fabric portions ranging from 20:70 to 45:45.

[0399] Advantageously, pipe section or pipe 160 may be associated with pipe section or pipe 132 or 147, possibly according to Figures 2 to 7 The arrangement described herein depends on whether the tubes are different or whether the tube section has an integral fabric construction.

[0400] In a variant example, the central region 154 can be formed by the central sub-region 154a, the first lateral region 152 can be formed by the sub-region 154b, and the second lateral region 153 can be formed by the sub-region 154c.

[0401] Figure 11 A sixth, flat example of a knitted tube 170 according to the invention is schematically shown, which is intended to form, wholly or only partially, a multi-layered assembly for manufacturing tires according to the invention. The knitted tube 170 includes first, second, and third knitted tube sections 180, 190, and 200, which thus have an integral knitted structure. Each knitted tube section 180, 190, 200 includes two stacked fabric layers.

[0402] The knitting tube 180 includes first and second stacked fabric layers 184, the knitting tube 190 includes third and fourth stacked fabric layers 194, and the knitting tube 200 includes fifth and sixth stacked fabric layers 204.

[0403] exist Figure 12 , Figure 13 and Figure 14In this configuration, tubes 180, 190, and 200 are stacked on top of each other; alternatively, tubes 180, 190, and 200 can be arranged coaxially. Thus, the triple-folded tube 170 advantageously forms a multi-layer assembly 210, wherein the free ends 170a and 170b of the folded tubes 170 are joined together to form a main torus 220. Therefore, the multi-layer assembly 210 comprises six stacked fabric layers.

[0404] Specifically, the first, second, third, and fourth fabric layers of the tubes 180 and 190 include knitted stitches that are inclined relative to the longitudinal axis L7 and extend in the longitudinal direction L8 over their entire width. The composition of these layers is preferably similar to... Figure 9 The composition of the central areas 144 and 146 of the fabric shown.

[0405] The composition of the fifth and sixth fabric layers 204 of the tube 200 is preferably similar to that described above. Figure 10 The composition of the variant example of the fabric layer 150 described.

[0406] The multilayer assembly 210, in the form of a main pipe 220, advantageously includes a fifth fabric layer 204 on its outer surface, such that a central region 204a, after hot pressing, at least partially forms the tread of the tire, and lateral regions 204b and 204c partially form the first and second sidewalls of the tire. Advantageously, the central region 204 may resemble a central sub-region 154a, the lateral region 204b may resemble a sub-region 154b, and the lateral region 204c may resemble a sub-region 154c. Advantageously, the multilayer assembly 210 is disposed in a mold assembly including an inflatable or otherwise arranged molding insert disposed within the main pipe 220. Pressure or vacuum is then applied to the molding volume including the multilayer assembly 210. The multilayer assembly 210 is heated to melt or soften its heat-fusible fabric portions to form a thermoplastic polymer matrix impregnated with non-heat-fusible fabric portions, which form a fabric reinforcement assembly.

[0407] Figures 15 to 19 A seventh example of a multilayer assembly 300 according to the invention is shown. The multilayer assembly 300 includes, in particular, a strip 310 having first and second free ends 312, 314 connected and secured together to form a torus 320.

[0408] The strip 310 includes a longitudinal axis L extending between its first and second free ends 312, 314 and a transverse axis T extending from the first longitudinal edge 316 to the second longitudinal edge 318 and substantially perpendicular to the axis L.

[0409] Advantageously, the strip 310 includes a first fabric tube 330 and a second fabric tube 340, the second fabric tube being folded over the first fabric tube 330 and connected to the fabric of the first tube 330, particularly by knitting.

[0410] The first fabric tube 330 includes first and second fabric layers 332, 334, and the second fabric tube 340 includes third and fourth fabric layers 342, 344. Advantageously, each of the first fabric tube 330 and the second fabric tube 340 includes at least one heat-fusible fabric portion and at least one non-heat-fusible fabric portion.

[0411] Advantageously, each of the first, second, third, and fourth fabric layers (332, 334, 342, 344) includes a heat-fusible fabric portion and a non-heat-fusible fabric portion. Advantageously, the first fabric layer 332 includes a first longitudinal region 332a, a second longitudinal region 332b, and a third longitudinal region 332c, at least one of the first and third longitudinal regions 332a, 332c (preferably each) including a knitted pattern extending diagonally relative to the longitudinal axis L of the strip 310. Alternatively, the first and third longitudinal regions 332a, 332c do not include a diagonal knitted pattern, and the third and fourth fabric layers (342, 344) include a diagonal knitted pattern extending substantially along the entire width and length of the second knitted tubular portion 340.

[0412] The knitted pattern is preferably knitted with at least one partially non-heat-meltable yarn, and the diagonal knitted pattern thus provides tensile strength.

[0413] Advantageously, the second knitted region 332b, located between the first and third knitted regions 332a and 332c, includes knitted loops that at least partially comprise heat-fusible yarn. These knitted loops allow for the provision of more heat-fusible material, thereby forming a tread with improved grip using said heat-fusible material.

[0414] Advantageously, the mass fraction of heat-fusible yarn (especially polyurethane) in the second longitudinal region 332b is greater than the mass fraction of heat-fusible yarn (especially polyurethane) in the first or third longitudinal regions 332a, 332c.

[0415] Advantageously, the second knitted layer 334 includes a heat-fusible yarn that is knitted to extend substantially along the entire width of the second layer 334 and substantially at least partially along the entire length of the second layer 334.

[0416] Advantageously, the second region 332b of the first layer is intended to form all or part of the tread of the tire, particularly forming one or more regions that engage with the ground.

[0417] Advantageously, both the first longitudinal edge 316 and the second longitudinal edge 318 include a plurality of folds 350 at the first position, such as Figure 16 and Figure 17 As shown. Therefore, in the first position, the strip 310 has a total length L1, and the toroidal surface has a circumference C1, and in the second position, the strip 310 has a length L2, and the toroidal surface has a circumference C2, wherein at least a portion of the plurality of pleats (in particular, substantially all pleats 350) are spaced apart from each other in the second position, and L2 is greater than L1; preferably, C2 is greater than C1. The second position is in Figure 18 and Figure 19 As shown in the image.

[0418] Advantageously, both the first and second longitudinal edges 316 and 318 include one or more elongated pleating elements arranged along their substantially entire length to create the plurality of pleats 350. Specifically, both the first and second longitudinal edges 316, 318 include an elongated pleating element as a first knitted pleating yarn comprising a heat-fusible polymer material (particularly polyurethane), and an elongated pleating element as a second knitted pleating yarn comprising floats. Advantageously, the first pleating yarn is knitted under tension such that at the exit of the knitting machine, the first pleating yarn brings the ends of each float together, thus forming pleats 350 or folds.

[0419] The annular strip 310 has a circumference C1 in its first reduced resting position, and is then tensioned as it is arranged around the reverse mold 360 (especially the annular flexible membrane) to achieve a circumference C2 greater than C1, such as... Figure 18 and Figure 19 As shown.

[0420] Therefore, the first and second longitudinal edges 316, 318 are extendable, which allows the toroidal surface 320 to be held in the second position on the mold 360, and makes it easier to hold the toroidal surface during the hot pressing step.

[0421] Advantageously, the first pleating yarn and preferably the second pleating yarn are fully or partially heat-fusible, allowing them to enter the composition of the polymer matrix and thus disappear within the tire. Once the hot-pressing step has been performed, the first pleating yarn and preferably the second pleating yarn no longer exert tension on the first and second longitudinal edges 316, 318 when the tire is demolded.

Claims

1. A tire (10) comprising a tread (15), characterized in that, The tread includes a main composite material (30) having an integrally molded construction and including a thermoplastic polymer matrix and a fabric reinforcement component.

2. The tire according to claim 2, characterized in that, The main composite material (30) forms at least 80% by mass of the tread (15).

3. The tire according to claim 1 or 2, characterized in that, The fabric reinforcement assembly includes at least two fabric layers (42a, 90a, 42b, 90b, 44a, 44b, 94a, 94b, 96a, 96b, 130, 140, 150).

4. The tire according to claim 3, characterized in that, The fabric reinforcement assembly includes at least: a first fabric layer (42a, 90a, 130, 140, 150), a second fabric layer (42b, 90b, 142), a third fabric layer (44a, 94a), and a fourth fabric layer (44b, 94b).

5. The tire according to claim 4, characterized in that, The fabric reinforcement assembly includes a first fabric tube (42, 42', 90, 90'), the first fabric tube (42a, 90a) including a first fabric layer and a second fabric layer (42b, 90b), and the fabric reinforcement assembly also includes a second fabric tube (44, 44', 94, 94'), the second tube including the third fabric layer (44a, 94a) and the fourth fabric layer (44b, 94b).

6. The tire according to claim 5, characterized in that, The first tube section (42, 42', 90, 90') and the second tube section (44, 44', 94, 94') are arranged either on top of each other or inside each other.

7. The tire according to any one of claims 4 to 6, characterized in that, The first fabric layer (42a, 90a) and the second fabric layer (42b, 90b) are located in a first fabric reinforcement element having an integral fabric structure, and the third fabric layer (44a, 94a) and the fourth fabric layer (44b, 94b) are located in a second fabric reinforcement element having an integral fabric structure.

8. The tire according to any one of claims 4 to 6, characterized in that, The first fabric layer (42a), the second fabric layer (42b), the third fabric layer (44a) and the fourth fabric layer (44b) are located in the first fabric reinforcement element of the overall fabric structure.

9. The tire according to any one of claims 3 to 8, characterized in that, The main composite material (30) includes at least one intermediate thermoplastic polymer layer (46, 98) disposed between two adjacent fabric layers.

10. The tire according to any one of claims 1 to 9, characterized in that, The main composite material (30) includes at least one outer thermoplastic polymer layer (46, 98) disposed in the outer portion of the tread (15) intended to contact the ground.

11. The tire according to any one of claims 1 to 10, characterized in that, The mass fraction of thermoplastic material in the main composite material (30) is greater than or equal to 80%.

12. The tire according to any one of claims 1 to 11, characterized in that, The thermoplastic polymer matrix includes polyurethane, and in particular, mainly includes polyurethane by mass.

13. The tire according to any one of claims 1 to 12, characterized in that, The main composite material (30), preferably the thermoplastic polymer matrix, comprises: a first portion, the first portion comprising a first aesthetic characteristic selected from a first color and a first design; and a second portion, the second portion comprising a second aesthetic characteristic selected from a second color and a second design, wherein the first aesthetic characteristic is different from the second aesthetic characteristic.

14. The tire according to any one of claims 1 to 13, characterized in that, The main composite material (30), preferably the thermoplastic polymer matrix, includes a transparent or translucent portion forming an observation window through which at least a portion of the fabric reinforcement assembly can be seen from the outside of the tire.

15. The tire according to any one of claims 1 to 14, characterized in that, The fabric reinforcement component comprises one or more yarns, the one or more yarns comprising at least one material selected from: polyester, especially high-tenacity polyester; polyamide; aramid; polyolefin; cellulose; glass; or mixtures thereof.

16. The tire according to any one of claims 1 to 15, characterized in that, The tire also includes at least one sidewall (20, 25), and the main composite material (30) at least partially forms the at least one sidewall.

17. The tire according to claim 16, wherein, The mass fraction of the fabric reinforcement component in the tread (15) is greater than the mass fraction of the fabric reinforcement component in at least one sidewall (20, 25), in particular at least two or three times greater.

18. The tire according to any one of claims 16 and 17, characterized in that, The tread (15) includes at least one fabric reinforcement element ERBR, and the at least one sidewall (20, 25) includes at least one fabric reinforcement element ERPF that is different from the fabric reinforcement element ERBR of the tread.

19. The tire according to any one of claims 16 to 18, characterized in that, Mass per unit area (g / m²) of at least one sidewall (20, 25) 2 The mass per unit area (g / m²) of the tire tread (15) is less than that of the tire tread (15). 2 ).

20. The tire according to any one of claims 1 to 19, characterized in that, The tire (10) includes two free longitudinal edges (21, 26) on the left and right sides, at least one of which includes a bead wire element (22, 27), and the main composite material (30) forms at least partially, and especially completely, the bead wire element.

21. The tire according to any one of claims 1 to 20, characterized in that, The tire (10) comprises up to 10% by weight of vulcanized rubber and / or optionally vulcanized one or more thermosetting polymers.

22. A method for manufacturing a tire, particularly according to any one of claims 1 to 21, characterized in that, The method includes the following steps: a) Prepare multilayer components (40, 60, 70, 80, 100, 120, 210), the multilayer components comprising at least one heat-fusible fabric portion and at least one non-heat-fusible fabric portion; b) Using a mold configured to at least partially mold the tread (15) of the tire (10), the multilayer assembly is hot-pressed by heating the multilayer assembly to melt the heat-fusible fabric portion; c) Obtaining a master composite material (30) having an integrally molded structure, the master composite material comprising a thermoplastic polymer matrix and a fabric reinforcement component, the composite material at least partially forming the tread of a tire.

23. The manufacturing method according to claim 22, characterized in that, Step a) includes preparing a multilayer assembly (40, 60, 70, 80, 100, 120, 210) comprising: a first fabric layer (42a, 90a, 130, 140, 150) comprising at least one at least partially heat-fusible yarn A; a second fabric layer (42b, 90b, 142, 184) comprising at least one at least partially heat-fusible yarn B; a third fabric layer (44a, 94a) comprising at least one at least partially heat-fusible yarn C; and a fourth fabric layer (44b, 94b, 194) comprising at least one at least partially heat-fusible yarn D; and step b) includes hot-pressing the multilayer assembly by heating the multilayer assembly to at least partially melt the yarns A, B, C and D of the first, second, third and fourth fabric layers using a mold configured to mold the tread (15) of a tire (10).

24. The manufacturing method according to any one of claims 22 or 23, characterized in that, The non-meltable fabric portion comprises a first polyurethane having a melting or softening temperature T3, and the meltable fabric portion comprises a second polyurethane having a melting or softening temperature T4, where T3 is greater than T4.

25. The manufacturing method according to any one of claims 22 to 24, characterized in that, The multilayer assembly (40, 60, 70, 80, 100, 120, 210) includes at least one fabric reinforcement element, which comprises a knitted loop or a braided float, the knitted loop or the braided float comprising at least partially one or more heat-fusible yarns.

26. The manufacturing method according to any one of claims 22 to 25, characterized in that, During step c), the multilayer components (40, 60, 70, 80, 100, 120, 210) are heated to a temperature greater than or equal to 100°C and less than or equal to 250°C.

27. The manufacturing method according to any one of claims 22 to 26, characterized in that: - The multilayer assembly includes a strip, the strip having two ends joined together to form a toroidal surface. The strip includes a first longitudinal edge, the first longitudinal edge including a plurality of folds at a first location, and the toroidal surface having a circumference C1 at the first location. - The method includes step d), which occurs before step b), and includes the step of setting the toroidal surface on the anti-mold at a second position, wherein at least a portion of the plurality of pleats, particularly substantially all of the pleats, are spaced apart from each other at the second position, and the toroidal surface has a circumference C2 greater than C1.

28. The manufacturing method according to claim 27, characterized in that, The first longitudinal edge includes one or more elongated pleating elements arranged along all or part of the length of the first longitudinal edge to create the plurality of pleats. At least one of the elongated elements is a pleating yarn comprising a heat-fusible polymer material, particularly polyurethane.

29. The manufacturing method according to claim 28, characterized in that, The first longitudinal edge includes: an elongated pleating element, the elongated pleating element being a first knitted pleating yarn comprising a heat-fusible polymer material, particularly polyurethane; and an elongated pleating element being a second knitted pleating yarn and comprising a plurality of floats.

30. A method for recycling tires, characterized in that, The method includes: - Collect at least one tire (10) according to any one of claims 1 to 21 or at least one tire (10) obtained according to any one of claims 22 to 29; - Grind at least one tire to obtain ground particles or fragments; - A step of converting the ground particles or fragments into microparticles, which can be converted by, for example, a conversion process of heated plastics by extrusion molding, the conversion step of heated plastics including an extrusion granulation step.

31. A multilayer assembly (40, 60, 70, 80, 100, 120, 210) for manufacturing tires (10) by hot pressing, particularly said multilayer assembly for use in the manufacturing method according to any one of claims 22 to 29, characterized in that, The multilayer assembly includes a strip with two free ends (48, 49, 170a, 170b) or ends joined together, particularly joined together to form an annular surface (220), and the multilayer assembly (40, 60, 70, 80, 100, 120, 210) includes a heat-fusible fabric portion, particularly in the method of manufacturing a tire (10) by hot pressing.

32. The multilayer assembly (40, 60, 70, 80, 100, 120, 210) for manufacturing a tire (10) by hot pressing according to claim 31, characterized in that, The multilayer assembly includes: a first fabric tube (42, 42', 90', 94', 96', 132, 147, 180), the first fabric tube including a first fabric layer (42a, 90a, 130, 140, 150) and a second fabric layer (42b, 90b, 142, 184); and optionally includes a second fabric tube (44, 44', 190), the second fabric tube including a third and a fourth fabric layer (44b, 94b, 194), and at least one of the first fabric tube and optionally the second fabric tube includes the at least one heat-fusible fabric portion, and at least one of the first fabric tube and optionally the second fabric tube includes the at least one non-heat-fusible fabric portion, preferably at least partially thermoplastic.

33. The multilayer component according to any one of claims 31 and 32, characterized in that, The main component by mass relative to the total mass of the multilayer component (210) is thermoplastic polyurethane.

34. The multilayer component according to any one of claims 31 to 33, characterized in that, The strip includes a first longitudinal edge, the first longitudinal edge including a plurality of folds at a first position, and the strip having a total length L1 at the first position, preferably the toroidal surface having a circumference C1, and the strip having a length L2 at a second position, preferably the toroidal surface having a circumference C2, wherein at least a portion of the plurality of folds, particularly substantially all of the folds, are spaced apart at the second position, L2 being greater than L1, and preferably C2 being greater than C1.

35. The multilayer component according to claim 34, characterized in that, The first longitudinal edge includes one or more elongated pleating elements arranged along all or part of the length of the first longitudinal edge to create the plurality of pleats. At least one of the elongated elements is a pleating yarn comprising a heat-fusible polymer material, particularly polyurethane.

36. The multilayer component according to claim 35, characterized in that, The first longitudinal edge includes: an elongated pleating element, the elongated pleating element being a first knitted pleating yarn comprising a heat-fusible polymer material, particularly polyurethane; and an elongated pleating element being a second knitted pleating yarn and comprising a plurality of floats.

37. The multilayer component according to any one of claims 31 to 36, characterized in that: - The first fabric layer of the first fabric tube includes a first longitudinal region, a second longitudinal region, and a third longitudinal region. At least one of the first and third longitudinal regions includes a plurality of knitted patterns extending diagonally relative to the longitudinal axis L of the strip, and each of the plurality of knitted patterns includes non-heat-fusible yarns. A second knitted region disposed between the first and third knitted regions includes a plurality of knitted loops, which at least partially include heat-fusible yarns. - The second knitted layer comprises heat-fusible yarns knitted to extend substantially along the entire width of the second layer and substantially at least partially along the entire length of the second layer, and - The second region of the first layer is intended to form all or part of the tread of the tire, particularly forming one or more regions that engage with the ground.

Images