Dies for polymer mixers and tire plies manufactured therefrom

Abstract

To provide a technique in which a ply is formed by a polymer mixer and die such that cords are arranged in an array and coated with topping rubber, and the ply may be a thin array of cords.SOLUTION: A method for producing a corduroy ply comprises the steps of: concentrically attaching a first topping rubber to a periphery of each of a plurality of cords; forming an array of the cords coated with the first topping rubber; concentrically attaching a second topping rubber to a periphery of each of a plurality of cords; and forming a cord-ply having a corduroy first surface and a corduroy second surface opposite the first corduroy surface.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to extruding a ply that can enhance the performance of pneumatic or non-pneumatic tires.

Background Art

[0002] Conventionally, plies can be used in various rubber products such as tires.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] A ply can be formed by a polymer mixer and a die such that a plurality of cords are arranged in an array and can be coated with topping rubber. Thus, the ply may be a thin array of a plurality of cords.

Means for Solving the Problems

[0005] The die for a polymer mixer according to the present invention includes first and second opposing surfaces, each defining a plurality of cylindrical first portions and a plurality of V-shaped second portions spaced apart between each of the first portions. The first and second opposing surfaces form a ply having a first portion thicker than the second portion and a grooved portion therebetween.

[0006] According to another aspect of the die, each first portion is connected to an adjacent second portion to form a linear connection portion.

[0007] In yet another aspect of the die, each second part is defined by the midpoint between two cords in a ply on one side of one cord and the midpoint between two cords on the opposite side of that cord.

[0008] According to yet another embodiment of the die, the first and second opposing surfaces each have the appearance of inverted corduroy.

[0009] According to yet another embodiment of the die, each opposing surface has at least one concave cylindrical surface.

[0010] In yet another embodiment of the die, each opposing surface has at least one concave cylindrical surface that connects to another adjacent concave cylindrical surface, thereby forming a linear connection between them.

[0011] The die can manufacture a tire according to the present invention, which comprises a pair of annular bead cores spaced apart in the axial direction, carcass plies extending around both bead cores, a tread positioned radially outward from the carcass plies and engaging with the contact surface, and a belt structure positioned radially between the carcass plies and the tread. The carcass plies include a plurality of cords embedded in a polymer substrate. The carcass plies have a first surface at the radial upper end and a second surface at the radial lower end located opposite the first surface. The first surface defines a plurality of first portions and a plurality of second portions spaced apart between each of the first portions. Each of the first portions has a greater thickness than each of the second portions, thereby forming grooved portions between each of the plurality of cords.

[0012] In another embodiment of the die and tire, each of the first parts is connected to an adjacent second part, forming a linear connection.

[0013] According to yet another embodiment of the die and tire, each of the second parts is defined by the midpoint between two cords on one side of the cord and the midpoint between two cords on the opposite side of the cord.

[0014] According to yet another embodiment of the die and tire, the first surface has the appearance of corduroy.

[0015] According to yet another embodiment of the die and tire, the second surface has a second cylindrical portion, each of which is partially concentric with the cylindrical outer surface of an adjacent cord.

[0016] In yet another embodiment of the die and tire, each of the second cylindrical portions is connected to an adjacent second cylindrical portion, forming a linear connection.

[0017] According to yet another embodiment of the die and tire, each of the second cylindrical portions is defined by the midpoint between two cords on one side of the cord and the midpoint between two cords on the opposite side of the cord.

[0018] According to yet another embodiment of the die and tire, the second surface has the appearance of corduroy.

[0019] According to yet another embodiment of the die and tire, the belt structure has a first belt surface at the radial upper end and a second belt surface at the radial lower end located opposite the first belt surface, the first belt surface having a first belt cylindrical portion, each of which is partially concentric with the cylindrical outer surface of an adjacent belt cord.

[0020] According to yet another embodiment of the die and tire, the first belt surface has the appearance of corduroy.

[0021] The method according to the present invention manufactures a die and a corduroy ply. This method includes a step of concentrically attaching a first topping rubber to the outer circumference of each of a plurality of cords, a step of forming an array of cords coated with the first topping rubber, a step of concentrically attaching a second topping rubber to the outer circumference of each of the plurality of cords, and a step of forming a cord ply having a first corduroy surface and a second corduroy surface on the opposite side of the first corduroy surface.

[0022] According to another aspect of the die and the cordroy ply, an additional step includes changing the first flat surface and the second flat surface.

[0023] According to yet another aspect of the die and the cordroy ply, an additional step includes removing rubber from the first flat surface and the second flat surface of the cord ply.

[0024] According to yet another aspect of the die and the cordroy ply, an additional step includes calendering the first topping rubber and the second topping rubber.

[0025] According to yet another aspect of the die and the cordroy ply, an additional step includes removing the material of the grooved portion between each cord of the plurality of cords.

[0026] According to yet another aspect of the die and the cordroy ply, the pressure of the first topping rubber in the topping chamber is 5,000 kPa or more.

[0027] According to yet another aspect of the die and the cordroy ply, the pressure of the second topping rubber in the topping chamber is 5,000 kPa or more.

[0028] According to yet another aspect of the die and the cordroy ply, the time interval during the attachment step is 10 minutes or less.

[0029] According to yet another embodiment of the die and cordroy ply, the first topping rubber has the same rubber mixture as the second topping rubber.

[0030] According to yet another embodiment of the die and cordroy ply, the first topping rubber has a rubber mixture having a greater complex modulus than the rubber mixture of the second topping rubber.

[0031] [Definition] In this specification and in the claims, it is used as follows:

[0032] "Apex" refers to the elastomer filler material positioned between the ply and the folded ply in the radially upper part of the bead core.

[0033] "Ring-shaped" means that it is formed in a ring-like manner.

[0034] "Aspect ratio" refers to the ratio of the tire's cross-sectional height to its cross-sectional width.

[0035] "Bead cross-sectional aspect ratio" refers to the ratio of the bead's cross-sectional height to its cross-sectional width.

[0036] "Asymmetrical tread" refers to a tread pattern that is not symmetrical with respect to the tire's center plane or equatorial plane (EP).

[0037] "Axial" and "in the axial direction" refer to a line or direction parallel to the tire's axis of rotation.

[0038] "Bead" refers to a portion of a tire that is wrapped in ply cord and may or may not have other reinforcing elements such as flippers, chippers, apex, toe guards, and chafers, and includes an annular tension member molded to fit the design rim.

[0039] "Belt structure" means at least two annular layers or plies of parallel cords, which are located beneath the tread, are not fixed to the bead, and have cords inclined with respect to the equatorial plane of the tire, and may or may not be woven. The belt structure may also include plies of parallel cords inclined at a relatively small angle, which act as a restraining layer.

[0040] A "bias tire" (cross-ply) refers to a tire in which reinforcing cords within the carcass plies extend diagonally across the tire from bead to bead at an angle of approximately 25° to 65° relative to the tire's equatorial plane (EP). If multiple plies are present, the cords of the plies extend at opposite angles to each other in alternating layers.

[0041] A "breaker" refers to at least two annular layers or plies of parallel reinforcing cords that are at the same angle as the parallel reinforcing cords of the carcass ply with respect to the equatorial plane (EP) of the tire. Breakers are typically associated with bias tires.

[0042] The term "cable" refers to a cord formed by twisting together two or more pairs of pliers.

[0043] "Carcass" refers to the tire structure, including the bead, which is separate from the belt structure on the plies, the tread, the undertread, and the sidewall rubber.

[0044] "Casing" refers to the entire tire, excluding the carcass, belt structure, bead, sidewall, tread, and undertread.

[0045] "Chippa" refers to a narrow strip of fabric or steel cord located within the bead area, which serves to reinforce the bead area and stabilize the innermost radial portion of the sidewall.

[0046] "Circumferential" and "circumferential" refer to a line or direction that extends along the circumference of the annular surface of a tire parallel to the equatorial plane (EP) and perpendicular to the axial direction, and can also refer to the direction of a set of adjacent circular curves whose radius, when viewed in cross-section, defines the axial curvature of the tread.

[0047] "Code" refers to one of the reinforcing strands that make up the tire's reinforced structure.

[0048] "Cord angle" refers to the acute angle formed by the cords relative to the equatorial plane (EP) on the left or right side in a plan view of the tire. "Cord angle" is measured in a hardened but non-expanded tire.

[0049] "Corduroy" refers to a surface composed of straight cords (such as section 21) and grooves / throats between the cords. This surface appears to be made up of multiple cords placed parallel to each other.

[0050] "Crown" refers to the inner part of the tire at both ends of the tire's tread width.

[0051] "Denier" refers to the weight in grams per 9,000 meters (a unit representing linear density).

[0052] "Dtex" refers to the weight in grams per 10,000 meters.

[0053] "Density" refers to the weight per unit length.

[0054] "Elastomer" refers to an elastic material that can recover its dimensions and shape after deformation.

[0055] The "equator plane (EP)" refers to a plane perpendicular to the tire's axis of rotation and passing through the center of its tread, or a plane containing the circumferential centerline of the tread.

[0056] An "evolving tread pattern" refers to a tread pattern that is predetermined during the tire design process so that the running surface, intended to contact the road, evolves as the tread wears down due to the tire's movement on the road surface, and this evolution remains substantially unchanged throughout the entire lifespan of the tire, regardless of the degree of tread wear, resulting in superior grip and road handling performance.

[0057] "Fabric" essentially refers to a network of multiple cords that extend in one direction and may be twisted together, the cords being composed of multiple filaments (which may be twisted together) of a high modulus material.

[0058] A "fiber" is a unit of material, either natural or artificial, that forms the basic elements of a filament, and is characterized by having a length of at least 100 times its diameter or width.

[0059] "Filament count" refers to the number of filaments that make up a yarn. For example, 1000 denier polyester has approximately 190 filaments.

[0060] "Flipper" refers to the reinforcing fabric around the bead wire, used for strength and to secure the bead wire within the tire body.

[0061] "Footprint" refers to the section or area of ​​a tire's tread that is in contact with a flat surface under normal load and pressure at zero speed.

[0062] "Gauge" generally refers to a dimension, specifically a thickness dimension.

[0063] A “groove” refers to an elongated void within the tread that extends straight, curved, or zigzag around the tread in a circumferential or lateral direction. Grooves extending circumferentially and laterally may have common portions. “Groove width” may be the portion of the tread surface occupied by a groove or groove portion divided by the length of that groove or groove portion; therefore, groove width may be the average width over the length of that groove. Grooves may vary in depth within the tire. The depth of a groove may vary around the tread, and the depth of one groove may be constant and different from the depth of another groove within the tire. When such narrow or wide grooves have substantially less depth than the wider circumferential grooves with which they interconnect, they can be considered to form a “tie bar” that tends to maintain rib-like characteristics in the tread area in question. As used herein, grooves are intended to have a width large enough to remain open within the tire’s contact area, i.e., footprint.

[0064] "High-tensile steel (HT)" refers to carbon steel with a filament diameter of 0.20 mm and a tensile strength of at least 3400 MPa.

[0065] "Inside" refers to the direction towards the inside of the tire, and "outside" refers to the direction towards the outside.

[0066] "Inner liner" means one or more layers of elastomer or other material that form the inner surface of a tubeless tire and contain the expanding fluid inside the tire.

[0067] The "inboard side" refers to the side of the tire closest to the vehicle when the tire is mounted on the wheel and the wheel is mounted on the vehicle.

[0068] "LASE" is the load at a specific elongation.

[0069] "Horizontal direction" refers to the axial direction.

[0070] "Lay length" refers to the distance that a twisted filament or strand travels until it rotates 360 degrees around another filament or strand.

[0071] "Load range" refers to the load and inflation limits of a given tire used for a specific type of driving, as defined in the Tire & Rim Association's table.

[0072] "Mega high-tensile steel (MT)" refers to carbon steel with a filament diameter of 0.20 mm and a tensile strength of at least 4500 MPa.

[0073] "Net contact area" refers to the total area of ​​the contact elements between defined boundary edges, measured around the entire circumference of the tread.

[0074] The "net-gross ratio" refers to the value obtained by dividing the total area of ​​the tread contact elements between the lateral edges of the tread around the entire circumference by the total area of ​​the tread around the entire circumference between the lateral edges.

[0075] A "non-directional tread" refers to a tread that does not have a preferred direction of travel and does not need to be positioned on the vehicle at a specific wheel position to ensure that the tread pattern aligns with the preferred direction of travel. Conversely, a directional tread pattern has a preferred direction of travel that requires specific wheel positioning.

[0076] "Normal load" refers to the specific design inflation pressure and load specified by the appropriate standardization body for the tire's operating conditions.

[0077] "Normal tensile steel (NT)" refers to carbon steel with a filament diameter of 0.20 mm and a tensile strength of at least 2800 MPa.

[0078] The "outboard side" refers to the side of the tire that is furthest from the vehicle when the tire is mounted on the wheel and then mounted on the vehicle.

[0079] "Ply" refers to a cord reinforcement layer consisting of multiple parallel cords that are covered with rubber and arranged radially or in other ways.

[0080] "Radial" and "radially" refer to the direction toward or away from the tire's axis of rotation.

[0081] "Radial ply construction" means one or more carcass plies, or at least one ply having reinforcing cords oriented at an angle between 65° and 90° with respect to the equatorial plane (EP) of the tire.

[0082] "Radial ply tire" means a belted or circumferentially constrained pneumatic tire having a bead-to-bead cord, with at least one ply positioned at a cord angle between 65° and 90° with respect to the tire's equatorial plane (EP).

[0083] A "rib" means a circumferentially extending strip of rubber on the tread defined by at least one circumferential groove and such a second groove or lateral edge, the strip not being laterally divided by a groove of full depth.

[0084] "Rivet" refers to the open space between codes within a layer.

[0085] "Sectional height" refers to the radial distance from the nominal rim diameter to the outer diameter of the tire at the tire's equatorial plane (EP).

[0086] "Sectional width" refers to the maximum straight-line distance parallel to the tire axis between the outer surfaces of the sidewalls, excluding any sidewall bulges caused by labels, decorations, or protective bands, when the tire has been inflated to normal pressure for 24 hours or thereafter in an unloaded state.

[0087] "Self-supporting run-flat" refers to a type of tire that has a structure strong enough to support the vehicle load on its own when operated for a limited time, at a limited speed, and in an unrestrained state. The tire's sidewall and inner surface will not collapse or buckle due to the tire structure alone (e.g., without an internal structure).

[0088] "Sidewall insert" refers to an elastomer or cord reinforcement located in the sidewall region of the tire. The insert may be added to the carcass reinforcement ply and the outer sidewall rubber that forms the outer surface of the tire.

[0089] "Sidewall" refers to the part of the tire between the tread and the bead.

[0090] A "sipe" or "notch" refers to a small slot molded into the tread element of a tire that further divides the tread surface to improve traction. Sipes may be configured to close when within the contact area, or footprint, to distinguish them from grooves.

[0091] The "spring constant" refers to the stiffness of a tire, expressed as the slope of the load deflection curve at a given pressure.

[0092] "Stiffness ratio" refers to the value obtained by dividing the stiffness of the belt structure being tested by the stiffness of another belt structure, when the value is determined by a fixed three-point bending test in which the cord is supported at both ends and a load is applied to the center between the fixed ends to cause bending.

[0093] "Ultra-high-strength steel (ST)" refers to carbon steel with a filament diameter of 0.20 mm and a tensile strength of at least 3650 MPa.

[0094] "Tenacity" is a stress expressed as force per unit linear density (gm / tex or gm / denier) in an unstrained sample.

[0095] "Tension" is a stress expressed as force / cross-sectional area. Strength (psi) = 12,800 × specific gravity × tenacity (g / denier).

[0096] "Toe guard" refers to the circumferentially arranged elastomer rim contact portion of the tire, located on the axially inner side of each bead.

[0097] "Tread" refers to the molded rubber component that is bonded to the tire casing and includes the portion of the tire that contacts the road when the tire is properly inflated and under normal load.

[0098] "Tread element" or "traction element" refers to a rib or block element.

[0099] "Tread width" refers to the arc length of the tread surface in a plane containing the tire's axis of rotation.

[0100] The "folded end" refers to the portion of a carcass ply that is folded upward (i.e., radially outward) from the bead around which the ply is wrapped.

[0101] "Ultra-high-strength steel (UT)" refers to carbon steel with a filament diameter of 0.20 mm and a tensile strength of at least 4000 MPa.

[0102] "Vertical deflection" refers to the amount of deflection a tire experiences under load.

[0103] "Yarn" is a general term for a continuous strand of woven fibers or filaments. Yarn can be produced in the following forms: (1) a number of twisted fibers; (2) a number of untwisted filaments; (3) a number of filaments that are partially twisted together; (4) a single filament (monofilament) that may or may not be twisted; and (5) a narrow strip of material that may or may not be twisted. [Brief explanation of the drawing]

[0104] [Figure 1] This figure schematically shows an apparatus for manufacturing an exemplary ply according to the present invention. [Figure 2] This is an enlarged perspective view schematically showing a part of the exemplary apparatus in Figure 1. [Figure 3] This figure schematically shows an exemplary cross-sectional structure of a ply according to the present invention. [Figure 4] This is a schematic perspective view showing an exemplary die according to the present invention. [Modes for carrying out the invention]

[0105] The present invention will be described with reference to the attached drawings and with examples.

[0106] Figure 1 shows an example of apparatus 1 for manufacturing a ply according to the present invention. The ply can be used for any structure of a tire, such as the carcass, belt, overlay, flipper, chipper, etc. Apparatus 1 is merely an example, and the apparatus is not limited to the specific structures shown in Figures 1-2. The cord 2 may be drawn from spools 3 arranged parallel to each other and fed into a first topping apparatus 5. The structure suitable for the cord 2 is not limited, and the structure may be selected depending on the ply, such as 1×5, 1×4, 1×3, 2+2, 2+3, monofilament, etc. Although the cord 2 is shown as a monofilament in Figures 1-3, a strand cord containing multiple strands / filaments may be used instead. The cord 2 may be made of steel, carbon fiber, resin, rayon, aramid, glass fiber, and / or other suitable material.

[0107] When the cords 2 pass through the array rolls 4, the cords 2 may be substantially parallel to each other. The array rolls 4 may include rotatable roll bodies 4A, 4B that sandwich the cords 2 from above and below. In the illustrated example, guide grooves may be formed on the outer circumferential surface of at least one roll body into which a portion of the cords 2 can be fitted. The guide grooves may be formed in the circumferential direction of the roll bodies 4A, 4B. This allows multiple cords 2 to be discharged smoothly from the array rolls 4 without resistance. Alternatively, instead of the rolls 4, a comb-like body with slit-shaped guide holes may be provided.

[0108] In the embodiments shown in Figures 1 and 2, the first topping device 5 includes a small rubber extrusion unit 5A and a rubber attachment 5B attached to the tip of the rubber extrusion unit. The rubber extrusion unit 5A may include an inlet port 5A1 into which the material for the first topping rubber is supplied, and an extrusion port 5A2 into which the kneaded and softened first topping rubber is discharged toward the cord 2. The rubber extrusion unit 5A may include a screw-type rubber extruder equipped with a screw shaft rotated by a motor M. The rubber attachment 5B may include a pipe-shaped body 6 connected to the extrusion port 5A2 of the rubber extrusion unit 5A.

[0109] The tubular body 6 may include a hollow topping chamber 6C. The distal end 6A of the tubular body 6 may be closed, and the rear end 6B of the tubular body 6 may include an opening that can communicate with the extrusion port 5A2. For example, if the rear end 6B of the tubular body 6 is fixed to the rubber extrusion section 5A using a flange, the first topping rubber can be supplied to the topping chamber 6C of the tubular body 6 under a predetermined pressure. The tubular body 6 may be divided into two longitudinal sections to facilitate maintenance of the topping chamber 6C.

[0110] As shown in Figure 2, the pipe-shaped body 6 may include a plurality of first guide holes 9 on the upstream wall surface through which the cord 2 passes. The first holes 9 may be formed spaced apart from each other in the longitudinal direction of the pipe-shaped body 6. The base body 6 may have second covering holes 10 on the downstream wall surface corresponding to the first holes 9. The second holes 10 may be concentric with the first holes 9 and may have a larger diameter than the diameter of the first holes 9. The rubber fitting 5B may further include a pressure sensor 8 for detecting the pressure in the topping chamber 6C. The signal from the pressure sensor 8 may be transmitted to a control device (not shown) of the rubber extrusion unit 5A. This allows the amount of rubber supplied to the rubber extrusion unit 5A to automatically control the rubber pressure in the topping chamber 6C and maintain the pressure at a predetermined optimal value.

[0111] The cords 2 may be positioned parallel to each other by the rolls 4, thereby passing through the topping chamber 6C from the first hole 9 to the second hole 10 of the pipe-shaped body 6. The cords 2 may be drawn straight out so that they are aligned with the corresponding centers of the first hole 9 and the second hole 10, respectively. Within the topping chamber 6C, the first topping rubber r1 supplied under a predetermined rubber pressure may permeate / fill the gaps between the cords 2 and adhere to the outer circumference of the cords. Within the second hole 10, the first topping rubber r1 adhering to the cords 2 may be scraped off, except for a thin coating layer 11 that adheres concentrically to the outer circumference of the cords.

[0112] Since the cord 2 passes through the high-pressure first topping rubber r1, even if the passage speed is fast, the first topping rubber r1 can sufficiently and effectively penetrate into the minute gaps between the cords 2. As mentioned above, the pressure in the topping chamber 6C can be controlled within a desired range by the pressure sensor 8. Thus, efficient adhesion of the first topping rubber r1 to the cords 2 can be achieved.

[0113] The pressure in the topping chamber 6C may be 5,000 kPa, 10,000 kPa, or higher. If the pressure in the topping chamber 6C is less than 5,000 kPa, the effect of the first topping rubber r1 on the cord 2 may be unacceptably small. If the pressure is excessively high, the first topping rubber r1 may undesirably flow out of the first and second holes 9,10. Also, the resistance generated when the cord 2 passes through the first topping rubber r1 may increase, potentially reducing productivity. The speed of the cord 2 may be in the range of 5 to 30 m / min, or in the range of 10 to 30 m / min.

[0114] The diameter of the first hole 9 may be within the range of 101% to 107% of the outer diameter of the cord 2, or within the range of 103% to 105%. If the diameter of the first hole 9 is less than 101% of the outer diameter of the cord 2, the cord may break. If the diameter exceeds 107%, centering of the cord 2 becomes problematic, and an excessive amount of topping rubber may leak out from the gaps between the cords.

[0115] The diameter of the second hole 10 may be within the range of 102% to 110% of the outer diameter of the cord, or within the range of 103% to 105%. If the diameter of the second hole 10 is less than 102% of the outer diameter of the cord, the covering thickness of the first topping rubber r1 will be excessively small, which may lead to delamination of the first topping rubber. If the diameter exceeds 107%, the covering thickness will be excessively thick, which may undesirably increase the overall thickness of the ply. The covering thickness may be between 0.1 mm and 0.5 mm.

[0116] Next, the second topping step may involve attaching the second topping rubber r2 to the surface of the cord array 12 on which the multiple cords 2 and the covering of the first topping rubber r1 are arranged. Four calender rolls 13 may be used (Figure 1). Both sides of the rubber-covered cord array 12 may be covered with the second topping rubber r2, forming a sheet-like cord ply 15 as shown in Figure 3.

[0117] As shown in Figures 1 and 3, according to the present invention, an auxiliary die 14 may be further included downstream of the calender roll 13. The die 14 may include die plates for modifying the flat upper and lower surfaces of the sheet ply 15 so that the grooved ply 16 of Figure 3 is realized. The die 14 may remove rubber r2 from the sheet ply 15 so that the upper surface 18 and lower surface 19 of the grooved ply 16 have cylindrical portions 21, each of which is partially concentric with the cylindrical outer surface of its adjacent cord 2. The joining of each cylindrical portion 21 with an adjacent cylindrical portion may form a linear connection with each cylindrical portion, defined by the midpoint 23 between two cords on one side of the cord 22 and the midpoint 23 between two cords on opposite sides of the cord 22.

[0118] The grooved ply 16 has rubber on the upper and lower parts of the cords 22 and has notches or grooves between each cord 2, which can produce a ply of medium size (compared to a conventional sheet-like ply 15). This can result in a more uniform strain distribution of the rubber within the ply 16 during tire molding, thereby resulting in a more uniform cord spacing in the cured tire. Thus, the upper and lower surfaces 18,19 of the ply 16 can have an appearance similar to corduroy fabric, in one example (Figure 3). Furthermore, any geometry that produces a ply 16 with a varying gauge along the upper and lower surfaces 18,19 can result in the aforementioned uniform strain distribution.

[0119] Consequently, any example of a ply 16 having additional topping gauges located directly above and / or directly below each code 22, and smaller gauges located between the codes 22, can have such a geometry. Examples of geometry may further include serrated, square-toothed, rectangular-toothed, non-concentric cylindrical, or any suitable repeating geometry to conform to this description. Such a ply 16 can be used with any suitable tire, such as those disclosed in U.S. Patent Application Publication 2002 / 0134482, which is incorporated herein by reference in whole.

[0120] An exemplary die 100 for a rubber mixer according to the present invention can produce an exemplary ply 16 (Figure 4). The exemplary die 100 can operate with an extruder, calender, gear pump, and / or other suitable rubber / polymer mixer. As previously stated, the die 100 can produce a ply such as the exemplary ply 16, having a plurality of cords 22 embedded in a polymer substrate (Figure 3). The ply 16 may have a first cylindrical surface 18 at the radial upper end and a second cylindrical surface 19 at the radial lower end located opposite the first surface. Accordingly, the die 100 may have a cylindrical surface 102 defining a plurality of cylindrical first portions and a plurality of V-shaped second portions spaced apart between each of the cylindrical first portions (one is shown) (Figure 4). Each of the cylindrical first portions of the ply 16 has a greater thickness than each of the V-shaped second portions (at position 23), thereby forming a ply with a plurality of opposing V-shaped grooved portions between each of the plurality of cords 22 (Figure 3).

[0121] Modifications of the present invention are possible in consideration of the description presented herein. While representative specific embodiments and details have been shown to illustrate the present invention, it will be apparent to those skilled in the art that various changes and modifications can be made thereto without departing from the scope of the invention. Accordingly, it should be understood that the specific embodiments described may be modified within the full intended scope of the invention as defined by the claims appended below.

Claims

1. In a method for manufacturing corduroy ply, The process involves attaching the first topping rubber concentrically to the outer circumference of each of the multiple cords, The process involves forming an array of cords covered with the first topping rubber, The process involves further covering the array of cords covered with the first topping rubber with a second topping rubber, A step of forming a cord ply having a first corduroy surface and a second corduroy surface opposite to the first corduroy surface, A method characterized by including the following.

2. The method according to claim 1, further characterized by including the step of changing a first flat surface and a second flat surface.

3. The method according to claim 1, further characterized by including a step of removing rubber from a first flat surface of the cord ply and a second flat surface of the cord ply.

4. The method according to claim 1, further characterized by including a step of calendering the first topping rubber and the second topping rubber.

5. The method according to claim 1, further characterized by including a step of removing material from the grooved portions between each of the plurality of cords.

6. The method according to claim 1, characterized in that the pressure of the first topping rubber in the topping chamber is 5,000 kPa or more.

7. The method according to claim 6, characterized in that the pressure of the second topping rubber in the topping chamber is 5,000 kPa or more.

8. The method according to claim 1, characterized in that the time interval between adhesion steps is 10 minutes or less.

9. The method according to claim 1, characterized in that the first topping rubber has the same rubber mixture as the second topping rubber.

10. A first topping device that attaches a first topping rubber concentrically to the outer circumference of each of a plurality of cords to form an array of cords covered with the first topping rubber, A calender roll for further covering the array of cords covered with the first topping rubber with a second topping rubber, A die for forming a cord ply having a first corduroy surface and a second corduroy surface opposite to the first corduroy surface, Includes, Apparatus for manufacturing corduroy plies, wherein the die includes first and second opposing surfaces, each defining a first portion and a second portion spaced apart between the first portions, and the two opposing surfaces form a ply having a first portion thicker than the second portion and a grooved portion between them.

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