A tire having a continuous turn woven carcass ply structure and a method of manufacturing the same
By employing a continuous folded weave structure in the tire manufacturing process, the problem of interface adhesion defects caused by the cut points in traditional tires has been solved, thereby improving the tire's load-bearing capacity and service life.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-06-29
- Publication Date
- 2026-07-28
AI Technical Summary
Traditional radial tires suffer from interface adhesion defects due to the cutting points created during the manufacturing process of the tire carcass cords, which reduces tire lifespan and load-bearing capacity.
The tire carcass ply structure is made by continuously folding and weaving rubber-coated cords around the outer surface of the drum to form a tire carcass ply tube without cut points. The cords and rubber are effectively bonded, eliminating interface adhesion defects in the cut point area.
It improves the tire's load-bearing capacity and service life, ensures continuous tension within the cords, and strengthens the force transmission between the tire carcass and the steel bead.
Smart Images
Figure CN122463585A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of tire technology, and specifically to a tire with a continuous folded woven carcass ply structure and a method for manufacturing the same. Background Technology
[0002] Cut-off point issues are one of the most serious problems limiting the lifespan of radial tires. In traditional radial tires, the carcass ply is made by calendering cords and rubber. During tire manufacturing, the carcass ply needs to be cut and then spliced on a molding drum to form the carcass ply layers. During the cutting process, continuous cut-off points are created. Since the cut sections of the cords lack a coating, they cannot effectively bond with the rubber, resulting in interface bonding defects at the cut-off points. Furthermore, shearing occurs between the cords and the rubber at these cut-off points, easily causing holes and cracks in these areas during tire use, ultimately damaging the tire bead area and significantly reducing tire lifespan. Summary of the Invention
[0003] The main objective of this invention is to provide a tire with a continuous folded woven carcass ply structure and a method for manufacturing the same, so as to overcome the problem of cut points during tire manufacturing and avoid shortened tire life and low load-bearing capacity caused by cut points.
[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: A tire with a continuously folded braided carcass ply structure includes a continuously folded braided carcass ply structure. The continuously folded braided carcass ply structure is a carcass ply tube without cut points formed by continuously folding rubber-coated cords around the outer surface of a molded drum. The circumferential length of the carcass ply tube is L, and the axial length is expressed as D+2h. The formula for calculating the total length M of the rubber-coated cords used is:
[0005] Where D is the distance between the two wire rings after they are placed on the forming drum, h is the length of the carcass ply wrapping, b represents the spacing between the centers of a single rubber-coated cord, a is the overlap length after the cut end of the rubber-coated cord is connected to the starting end, and θ is the angle between the arrangement direction of a single rubber-coated cord and the axis of the tire.
[0006] Furthermore, the cords in the continuously folded braided tire cord layer structure are made of steel wire cords, nylon cords, aramid cords, nylon and aramid blended cords, polyester cords, or carbon fiber cords.
[0007] Furthermore, the angle between the arrangement direction of the single rubber-coated cord in the continuous folded braided tire carcass ply structure and the axial direction of the tire is -3° to 3°.
[0008] Furthermore, in the continuous folded braided tire cord layer structure, the rubber-coated cords are composed of 1 to 2 cords arranged at equal intervals and coated with rubber.
[0009] Furthermore, it also includes the steel wire ring, lower triangle rubber layer, upper triangle rubber layer, sidewall rubber layer, belt cord layer, upper tread layer, lower tread layer, shoulder pad rubber layer, airtight layer, steel ring wrapping layer, and bead protection layer. The airtight layer is located inside the continuous zigzag tire carcass ply structure. The sidewall rubber layer, belt ply layer, shoulder pad rubber layer, and bead wrapping layer are all located outside the continuous zigzag tire carcass ply structure and are all in contact with it. The belt ply layer and shoulder pad rubber layer are sequentially attached to the outer side of the tread lower layer and the tread upper layer. The bead wrapping layer is attached to the outer side of the bead wrapping layer. The bead ring, lower triangular rubber layer, and upper triangular rubber layer are located inside the continuous zigzag tire carcass ply structure.
[0010] A tire manufacturing method having a continuous folded braided carcass ply structure includes the following steps: S1. First, attach the inner end cap protective layer, airtight layer, and steel ring cloth layer to the outer surface of the molded drum in sequence from the inside to the outside. S2. Fix the starting end of the rubber-coated cord to the steel ring covering layer, and then wind it along the axis of the forming drum at a certain angle. When it reaches the other end of the forming drum, fold the rubber-coated cord back and continue winding. Repeat this folding and turning until it winds 360° around the surface of the forming drum. Then cut the rubber-coated cord and connect it to the pre-fixed starting end to form a continuous folding braided tire cord layer structure. S3. Then, the steel wire ring, lower triangular rubber layer, upper triangular rubber layer, sidewall rubber layer, and shoulder pad rubber layer are sequentially pasted onto the upper surface of the continuous folded woven tire carcass ply structure. Then, the rubber layer on the outside of the steel wire ring is reversed and inflated in the forming drum to bulge the rubber layer and form a semi-finished tire component. S4. Finally, the belt ply, the lower tread layer, and the upper tread layer are glued and pressed onto the surface of the semi-finished tire components to form a green tire. The green tire is then removed from the forming drum and vulcanized to obtain a tire with a continuous folded ply ply structure.
[0011] Furthermore, in step S2, after the rubber-coated cord in the continuously folded braided tire cord layer structure is continuously folded back and woven 360°, the rubber-coated cord is cut off, and its cut end is connected to the starting end. The position of the connecting end is located below the position of the steel wire ring.
[0012] Furthermore, the connection between the cut end and the starting end of the coated cord is achieved by butt joint, lap joint, or welding.
[0013] Compared with the prior art, the present invention has the following beneficial effects: The tire of this invention adopts a continuous folded braided carcass ply structure. This structure is formed by continuously folding and weaving rubber-coated cords around a molding drum to create an endless carcass ply tube. This can solve the problem of cord breakage points in the carcass ply during the manufacturing process of existing conventional tires, eliminate adhesion defects at the interface between the carcass cords and rubber, ensure continuous internal tension of the carcass cords, strengthen the force transmission between the carcass and the bead wire, improve the strength of the carcass ply, and increase the tire's load-bearing capacity and service life. Attached Figure Description
[0014] Figure 1 This is a two-dimensional cross-sectional schematic diagram of a tire with a continuously folded braided carcass ply structure according to the present invention.
[0015] Figure 2 For the present invention Figure 1 A schematic diagram of the tire cords in the continuously folded braided tire cord layer structure.
[0016] Figure 3 This is a schematic diagram of the arrangement of the tire cords in the continuous folded braided tire cord layer structure of the present invention.
[0017] Figure 4 This is a schematic diagram of the tire cord arrangement of the continuous folded braided tire cord layer structure with a certain arrangement angle according to the present invention.
[0018] Figure 5 This is a planar unfolded schematic diagram of the continuous folded braided tire cord layer structure of the present invention, which is woven from rubber-coated cords.
[0019] Figure 6 This is a three-dimensional schematic diagram of the continuous folded weave fabric layer structure of the present invention.
[0020] Figure 7 This is a three-dimensional schematic diagram of a tire with a continuously folded braided carcass ply structure according to the present invention.
[0021] Among them, the steel wire ring 1, lower triangular rubber layer 2, upper triangular rubber layer 3, sidewall rubber layer 4, continuous folded woven carcass ply structure 5, belt ply layer 6, upper tread layer 7, lower tread layer 8, shoulder pad rubber layer 9, airtight layer 10, steel ring covering layer 11, and bead protection layer 12. Detailed Implementation
[0022] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.
[0023] Example 1
[0024] Combination Figures 1 to 7This embodiment provides a tire with a continuous folded woven carcass ply structure, including a steel wire bead 1, a lower triangular rubber layer 2, an upper triangular rubber layer 3, a sidewall rubber layer 4, a continuous folded woven carcass ply structure 5, a belt ply 6, an upper tread layer 7, a lower tread layer 8, a shoulder pad rubber layer 9, an airtight layer 10, a steel bead covering layer 11, and a bead protection layer 12.
[0025] Specifically, the airtight layer 10 is located inside the continuously folded braided tire carcass ply structure 5. The sidewall rubber layer 4, belt ply layer 6, shoulder pad rubber layer 9, and rim wrapping layer 11 are all located outside the continuously folded braided tire carcass ply structure 5 and are all in close contact with it. The belt ply layer 6 and the shoulder pad rubber layer 9 are successively attached to the outer side of the lower tread layer 8 and the upper tread layer 7. The rim wrapping layer 11 is attached to the outer side of the bead protector layer 12. The bead ring 1, lower triangular rubber layer 2, and upper triangular rubber layer 3 are located inside the continuously folded braided tire carcass ply structure 5. The continuously folded braided tire carcass ply structure 5 is a tire carcass ply tube without cut points formed by continuously folding rubber-coated cords around the outer surface of the molded drum. The circumferential length of the tire carcass ply tube is L, and the axial length is expressed as D+2h. The formula for calculating the total length M of the rubber-coated cords used is:
[0026] Where D is the distance between the two wire rings 1 after they are placed on the forming drum, h is the length of the carcass ply wrapping, b represents the spacing between the centers of a single rubber-coated cord, a is the overlap length after the cut end of the rubber-coated cord is connected to the starting end, and θ is the angle between the arrangement direction of a single rubber-coated cord and the axis of the tire.
[0027] like Figure 3-4 As shown, in this embodiment, the angle between the arrangement direction of the single rubber-coated cord in the continuous folded braided tire carcass ply structure 5 and the axial direction of the tire is -3° to 3°.
[0028] In this embodiment, the adhesive-coated cords in the continuous folded braided tire cord layer structure 5 consist of 1-2 cords arranged at equal intervals and coated with adhesive. The cords in the continuous folded braided tire cord layer structure 5 are steel wire cords, nylon cords, aramid cords, nylon and aramid blended cords, polyester cords, or carbon fiber cords.
[0029] Example 2
[0030] This embodiment provides a tire manufacturing method with a continuous folded braided carcass ply structure, including the following steps: S1. First, attach the inner end protective layer 12, the airtight layer 10, and the steel ring cloth layer 11 to the outer surface of the molded drum from the inside out. S2. Fix the starting end of the rubber-coated cord to the steel ring covering layer 11, and then wind it along the axis of the forming drum at a certain angle. When the cord reaches the other end of the forming drum, fold it back and continue winding. Repeat this folding and turning until the cord is wound 360° around the surface of the forming drum. Then cut the rubber-coated cord and connect it to the pre-fixed starting end to form a continuous folding braided tire cord layer structure 5. Here, 360° means that the rubber-coated cord covers the entire cylindrical surface of the forming drum, that is, it is circumferentially covered. S3. Then, the steel wire ring 1, the lower triangular rubber layer 2, the upper triangular rubber layer 3, the sidewall rubber layer 4, and the shoulder pad rubber layer 9 are sequentially pasted onto the upper surface of the continuous folded woven carcass ply structure 5. Then, the rubber layer on the outside of the steel wire ring 1 is reversed and inflated in the forming drum to make the rubber layer bulge to form a semi-finished tire component. S4. Finally, the belt ply 6, the lower tread layer 8, and the upper tread layer 7 are glued and pressed onto the surface of the semi-finished tire components to form a green tire. The green tire is then removed from the forming drum and vulcanized to obtain a tire with a continuous folded ply ply structure.
[0031] In this embodiment, after the rubber-coated cord in the continuously folded braided tire cord layer structure 5 in step S2 is continuously folded back and woven 360°, the rubber-coated cord is cut, and its cut end is connected to the starting end. The position of the connecting end is located below the position of the steel wire ring 1. The method of connecting the cut end of the rubber-coated cord to the starting end is by butt joint, overlap, or welding.
[0032] The above description is merely a preferred embodiment of the present invention and does not constitute any limitation on the technical scope of the present invention. Therefore, any minor modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the technical solution of the present invention.
Claims
1. A tire with a continuous folded woven carcass ply structure, characterized in that, The tire carcass ply structure (5) includes a continuously folded braided tire carcass ply structure (5), which is a tire carcass ply tube without cut points formed by continuously folding and braiding rubber-coated cords around the outer surface of the molding drum. The circumferential length of the tire carcass ply tube is L, and the axial length is expressed as D+2h. The formula for calculating the total length M of the rubber-coated cords used is: Where D is the distance between the two wire rings (1) after they are placed on the forming drum, h is the length of the carcass ply wrapping, b is the distance between the centers of a single rubber-coated cord, a is the overlap length after the cut end of the rubber-coated cord is connected to the starting end, and θ is the angle between the arrangement direction of a single rubber-coated cord and the axial direction of the tire.
2. A tire with a continuous folded woven carcass ply structure as described in claim 1, characterized in that, The cords in the continuous folded braided fabric layer structure (5) are made of steel wire cords, nylon cords, aramid cords, nylon and aramid mixed cords, polyester cords or carbon fiber cords.
3. A tire with a continuous folded woven carcass ply structure as described in claim 1, characterized in that, In the continuous folded braided tire carcass ply structure (5), the angle between the arrangement direction of the single rubber-coated cord and the axial direction of the tire is -3° to 3°.
4. A tire with a continuous folded woven carcass ply structure as described in claim 1, characterized in that, In the continuous folded braided tire cord layer structure (5), the rubber-coated cords are composed of 1 to 2 cords arranged at equal intervals and coated with rubber.
5. A tire with a continuous folded woven carcass ply structure as described in claim 1, characterized in that, It also includes the wire ring (1), lower triangular rubber layer (2), upper triangular rubber layer (3), sidewall rubber layer (4), belt cord layer (6), upper tread layer (7), lower tread layer (8), shoulder pad rubber layer (9), airtight layer (10), wire ring covering layer (11), and bead protection layer (12). The airtight layer (10) is located on the inner side of the continuous folded braided tire carcass ply structure (5). The sidewall rubber layer (4), belt ply layer (6), shoulder pad rubber layer (9), and rim wrapping layer (11) are all located on the outer side of the continuous folded braided tire carcass ply structure (5) and are all in contact with the continuous folded braided tire carcass ply structure (5). The belt ply layer (6) and the shoulder pad rubber layer (9) are successively attached to the outer side of the tread lower layer (8) and the tread upper layer (7). The rim wrapping layer (11) is attached to the outer side of the bead protection layer (12). The wire bead (1), lower triangular rubber layer (2), and upper triangular rubber layer (3) are located inside the continuous folded braided tire carcass ply structure (5).
6. A method for manufacturing a tire with a continuous folded braided carcass ply structure, based on the tire according to any one of claims 1-5, characterized in that, Includes the following steps: S1. First, attach the inner end cap protective layer (12), airtight layer (10), and steel ring cloth layer (11) to the outer surface of the forming drum from the inside out. S2. Fix the starting end of the rubber-coated cord to the steel ring covering layer (11), and then wind it along the axial direction of the forming drum at a certain angle. When it reaches the other end of the forming drum, fold the rubber-coated cord back and continue winding. Repeat this process until it winds around the surface of the forming drum 360°. Then cut the rubber-coated cord and connect it to the pre-fixed starting end to form a continuous folded braided tire cord layer structure (5). S3. Then, the wire ring (1), lower triangular rubber layer (2), upper triangular rubber layer (3), sidewall rubber layer (4), and shoulder pad rubber layer (9) are sequentially pasted onto the upper surface of the continuous folded woven tire carcass ply structure (5). Then, the rubber layer on the outside of the wire ring (1) is reversed and inflated in the forming drum to make the rubber layer bulge to form a semi-finished tire component. S4. Finally, the belt ply (6), the lower tread layer (8), and the upper tread layer (7) are glued and pressed onto the surface of the semi-finished tire parts to form a green tire. The green tire is then removed from the forming drum and vulcanized to obtain a tire with a continuous folded ply ply structure.
7. A tire manufacturing method with a continuously folded woven carcass ply structure as described in claim 6, characterized in that, In step S2, after the rubber-coated cord in the continuously folded braided tire cord layer structure (5) is continuously folded back and woven 360°, the rubber-coated cord is cut off, and its cut end is connected to the starting end. The position of the connecting end is located below the position of the wire loop (1).
8. A tire manufacturing method with a continuously folded woven carcass ply structure as described in claim 7, characterized in that, The ends of the coated cord are connected to the starting ends by butt joint, lap joint, or welding.