A method for forming a tire carcass based on continuous steel wire winding and a tire comprising a tire carcass formed by the forming method

Abstract

This invention discloses a tire carcass forming method based on continuous steel wire winding and a tire containing a carcass formed by this method, belonging to the field of tire manufacturing technology. The method includes the following steps: S10, a first steel wire bead and a second steel wire bead, which are fixed relative to each other at predetermined positions in a forming device; S20, providing at least one continuous, unbroken, high-strength steel wire prepreg tape; S30, fixing the starting end of the continuous steel wire to the first steel wire bead; S40, guiding the continuous steel wire to reciprocate between the first and second steel wire beads according to a predetermined winding path and density; S50, weaving the prepreg tape into a single layer using steel wire on both sides near the first and second steel wire beads, utilizing the adhesiveness of the prepreg tape to form a complete carcass; S60, subjecting the wound carcass to subsequent tire forming and vulcanization processes. This invention eliminates the main failure mode of carcass-rubber separation caused by end stress concentration.

Description

Technical Field

[0001] This invention belongs to the field of tire manufacturing technology, and more specifically relates to a tire carcass forming method based on continuous steel wire winding and a tire containing a carcass made by the forming method. Background Technology

[0002] In applications such as aircraft tires, heavy-duty tires, engineering tires, and new energy vehicle tires, tires need to serve for extended periods under their respective extreme conditions. For example, aircraft tires withstand large impact loads during takeoff, landing, and taxiing; heavy-duty tires are under high loads for extended periods; engineering tires are frequently subjected to punctures and cuts; and new energy vehicle tires must cope with the instantaneous high torque output by the motor during start-up and braking. These harsh conditions place extremely high demands on the structural integrity and durability of the tires.

[0003] Traditional radial tires are made by calendering, cutting, and bonding cords and rubber together. This process creates a series of break points at the cut points of the cord layers, resulting in interfacial bonding defects and structural discontinuities in these areas. When traditional tires are used under extreme conditions, stress concentration and insufficient interfacial bonding strength at these break points can easily lead to premature tire failure, severely reducing tire lifespan.

[0004] Chinese patent CN119682440A (Wound Carcass) proposes a tire with continuously wound carcass ply to solve the problem of carcass cord breakage points during the manufacturing process of traditional tire carcass ply. However, there is a gap in the existing technology regarding the molding method of tires with continuously wound carcass ply structures. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A tire carcass forming method based on continuous steel wire winding includes the following steps: S10. Prepare two wire rings, which are respectively designated as the first wire ring and the second wire ring, and fix them relative to each other at a predetermined position of the forming device, which corresponds to the position of the wire ring in the finished tire. S20. Provide at least one continuous, unbroken high-strength steel wire prepreg tape as a reinforcing material; S30. Fix the starting end of the continuous steel wire to the first steel wire loop; S40. Drive the winding head on the forming device to guide the continuous steel wire to reciprocate between the first steel wire loop and the second steel wire loop according to a predetermined winding path and density; S50. During or after the winding process, the prepreg tape is woven into a single layer using steel wire on both sides near the first and second steel wire rings, and the adhesiveness of the prepreg tape is used to form a complete tire carcass. S60. The wound tire blank is then subjected to subsequent tire forming and vulcanization processes to produce the finished tire.

[0006] Furthermore, in step S40, the winding path causes the wire to pass sequentially through the following key areas: Starting from the first wire bead, passing through the bead area, sidewall area, and crown area, extending to the second wire bead and wrapping or fixing it, then returning through the crown area and sidewall area, and back to the first wire bead.

[0007] Furthermore, the winding path of the continuous steel wire covers and tightly wraps the first steel wire loop and the second steel wire loop, and extends to form a reinforcing structure for the tire's bead region, sidewall region and crown region.

[0008] Furthermore, the winding process is completed by a computer-controlled precision winding device, which can precisely control the winding angle, spacing / density, and pretension of the steel wire.

[0009] A tire, wherein the tire carcass reinforcement layer is made by the tire carcass forming method based on continuous steel wire winding as described in any of the preceding claims, the reinforcement layer being formed by at least one continuous steel wire being wound back and forth between two steel wire loops, and without any cord fabric cut-off joints in the entire circumferential direction of the tire.

[0010] Furthermore, the continuous steel wire is a high-carbon steel wire or a high-strength alloy steel wire cord, and the surface of the continuous steel wire is covered with a plating or coating that is bonded to rubber.

[0011] Compared with the prior art, the present invention has the following beneficial effects: Completely eliminates the risk of delamination failure: Because the carcass reinforcement layer is made of continuously wound steel wires, there is no reverse-wrapped end of the cord fabric as in traditional processes. Therefore, it fundamentally eliminates the main failure mode of delamination between the carcass and rubber caused by stress concentration at the end.

[0012] Significantly enhances structural integrity and fracture resistance: The continuous steel wire structure allows stress to be transmitted evenly and smoothly throughout the entire tire carcass, avoiding abrupt stress changes at the junctions of the steel wire loops, filler rubber, and cord layers. The steel wire loops are tightly wrapped by continuous steel wire layers, resulting in a stronger bond and significantly reducing the risk of cord breakage and interlayer delamination around the steel wire loops.

[0013] Weight reduction and improved uniformity: Continuous winding technology enables optimal material distribution, reducing overlap and the need for additional material to reinforce specific areas, potentially reducing tire weight. Simultaneously, the high degree of structural uniformity improves tire dynamic balance and durability.

[0014] Simplified process and improved reliability: The process reduces multiple steps such as multi-layer cutting, bonding, and reverse wrapping, which lowers the probability of defects introduced by process complexity and improves tire reliability from the source of manufacturing. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0016] Figure 1 This is a partial schematic diagram of the traditional cut cord fabric body structure (showing the reverse-wrapped end).

[0017] Figure 2 This is a schematic diagram of the continuous wire winding process of the present invention.

[0018] Figure 3 This is a schematic diagram of the continuously wound tire structure of the present invention.

[0019] Figure 4 This is a schematic diagram of the radial section of a tire made using traditionally cut cord fabric.

[0020] Figure 5 This is a schematic diagram of the radial cross-section of a tire manufactured using the molding method of the present invention.

[0021] Among them, 1. Cord steel wire; 2. Tire steel rim; 3. Cord layer; 4. Continuous steel wire; 5. First steel wire ring; 6. Second steel wire ring. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Example 1

[0024] A tire carcass forming method based on continuous steel wire winding includes the following steps: S10. Prepare two wire rings, which are respectively designated as the first wire ring 5 and the second wire ring 6, and fix them relative to each other at a predetermined position of the forming device, which corresponds to the position of the wire ring in the finished tire. S20. Provide at least one continuous, unbroken high-strength steel wire prepreg tape as a reinforcing material; S30. Fix the starting end of the continuous steel wire 4 to the first steel wire loop 5; S40. Drive the winding head on the forming device to guide the continuous steel wire 4 to reciprocate between the first steel wire loop 5 and the second steel wire loop 6 according to the predetermined winding path and density. The winding path causes the steel wire to pass through the following key areas in sequence: Starting from the first wire bead 5, passing through the bead area, sidewall area, and crown area, it extends to the second wire bead 6 and is wrapped or fixed thereon, then returns to the crown area and sidewall area, and returns to the first wire bead 5.

[0025] Through repeated winding, a uniform and continuous reinforcing layer network is constructed in the tire's bead, sidewall, and crown areas, forming a complete closed-loop structure.

[0026] In this embodiment, the winding path of the continuous steel wire 4 covers and tightly wraps the first steel wire loop 5 and the second steel wire loop 6, and extends to form a reinforcing structure of the tire bead area, sidewall area and crown area.

[0027] S50. During or after the winding process, the prepreg tape is woven into a single layer on both sides near the first wire loop 5 and the second wire loop 6 using steel wire, and the adhesiveness of the prepreg tape is used to form a complete tire carcass. S60. The wound tire blank is then subjected to subsequent tire forming and vulcanization processes to produce the finished tire.

[0028] In this embodiment, the winding process is completed by a computer-controlled precision winding device, which can precisely control the winding angle, spacing / density, and pretension of the steel wire.

[0029] Example 2

[0030] A tire, wherein the tire carcass reinforcement layer is made by the tire carcass forming method based on continuous steel wire winding provided in Example 1, wherein the reinforcement layer is composed of at least one continuous steel wire reciprocatingly wound between two steel wire loops, and there are no cord cut joints in the entire circumferential direction of the tire.

[0031] In this embodiment, the continuous steel wire 4 is a high-carbon steel wire or a high-strength alloy steel wire cord, and the surface of the continuous steel wire is covered with a plating or coating that is bonded to rubber.

[0032] This invention abandons the traditional process of cutting and bonding fabric, and uses one or more continuous high-strength steel wires (or steel wire cords) to cross two steel wire loops through a specific winding path to achieve seamless and continuous forming of the carcass reinforcement layer, thereby fundamentally eliminating the structural weaknesses that lead to peeling and breakage failure.

[0033] The technical solutions of the present invention have been fully described above. It should be noted that the specific embodiments of the present invention are not limited to the above description. All technical solutions formed by those skilled in the art based on the spirit and essence of the present invention by adopting equivalent transformations or equivalent transformations in terms of structure, method or function fall within the protection scope of the present invention.

Claims

1. A tire carcass forming method based on continuous steel wire winding, characterized in that, Includes the following steps: S10. Prepare two wire rings, which are respectively designated as the first wire ring and the second wire ring, and fix them relative to each other at a predetermined position of the forming device, which corresponds to the position of the wire ring in the finished tire. S20. Provide at least one continuous, unbroken high-strength steel wire prepreg tape as a reinforcing material; S30. Fix the starting end of the continuous steel wire to the first steel wire loop; S40. Drive the winding head on the forming device to guide the continuous steel wire to reciprocate between the first steel wire loop and the second steel wire loop according to a predetermined winding path and density; S50. During or after the winding process, the prepreg tape is woven into a single layer using steel wire on both sides near the first and second steel wire rings, and the adhesiveness of the prepreg tape is used to form a complete tire carcass. S60. The wound tire blank is then subjected to subsequent tire forming and vulcanization processes to produce the finished tire.

2. The tire carcass forming method based on continuous steel wire winding according to claim 1, characterized in that, In step S40, the winding path causes the wire to pass through the following key areas in sequence: Starting from the first wire bead, passing through the bead area, sidewall area, and crown area, extending to the second wire bead and wrapping or fixing it, then returning through the crown area and sidewall area, and back to the first wire bead.

3. The tire carcass forming method based on continuous steel wire winding according to claim 2, characterized in that, The winding path of the continuous steel wire covers and tightly wraps the first and second steel wire loops, and extends to form a reinforcing structure for the tire's bead area, sidewall area, and crown area.

4. The tire carcass forming method based on continuous steel wire winding according to claim 1, characterized in that, The winding process is completed by a computer-controlled precision winding device, which can precisely control the winding angle, spacing / density, and pretension of the steel wire.

5. A tire, characterized in that, The tire carcass reinforcement layer is made by the tire carcass forming method based on continuous steel wire winding as described in any one of claims 1 to 4. The reinforcement layer is formed by at least one continuous steel wire being wound back and forth between two steel wire loops, and there are no cord fabric cut joints in the entire circumferential direction of the tire.

6. The tire according to claim 5, characterized in that, The continuous steel wire is a high-carbon steel wire or a high-strength alloy steel wire cord, and the surface of the continuous steel wire is covered with a plating or coating that is bonded to rubber.

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