Method of forming a tire that has three reinforcement layers

Abstract

A method of making a tire is provided in which first and second reinforcement plies are brushed to reduce their stickiness. The reinforcement plies are assembled with an inner liner and they are turned around a rod. A third reinforcement ply (80) is assembled with the inner liner, first reinforcement ply (32), second reinforcement ply (74), and the rod (72). The assembly results in the third reinforcement ply being located outboard from the second reinforcement ply in an axial direction.

Description

[0001] Description

[0002] TITLE: METHOD OF FORMING A TIRE THAT HAS THREE REINFORCEMENT LAYERS

[0003] FIELD OF THE INVENTION

[0004] The subject matter of the present invention relates to a method of making a tire that includes brushing of two or more components of the tire. More particularly, the present application involves a method of making a tire that includes brushing first and second reinforcement plies to reduce stickiness so that when they are placed together and turned up in the formation process they will separate from one another in the turn-up to reduce or eliminate the formation of creases.

[0005] BACKGROUND OF THE INVENTION

[0006] The manufacturing process of tires involves the placement of various products onto a forming drum. Some of these components can be folded / turned on the drum to adjust their positions relative to one another to create the desired tire architecture. Some of the various components may be made of materials that are sticky so that they are attached to one another and remain in their desired positions during this build process. Once all of the desired products have been assembled, the resulting tire is referred to as a green tire. This green tire is subsequently transferred to a mold for curing and for imparting a tread pattern into the tread products.

[0007] Fig. 1 is a perspective view of a tire during its building process at a stage of construction in which tire components are being assembled on a drum 62. Two tire building components are first and second reinforcement plies 32, 74 that are products that provide strength and flexibility to the tire and support its inflation pressure. The first and second reinforcement plies 32, 74 may include cables embedded into a matrix that is sticky to the touch. In Fig. 1, the second reinforcement ply 74 is placed onto the drum 62, and then subsequently the first reinforcement ply 32 is placed onto the second reinforcement ply 74. In order to achieve the desired tire architecture, the ends of the two reinforcement plies 32, 74 are turned-up (folded) back towards the center of the drum 62. This action causes both ends of the reinforcement plies 32, 74 to be folded simultaneously with one another. The second reinforcement ply 74 is longer so it covers the first reinforcement ply 32 in the folded section as shown in Fig. 1. Due to the fact that both reinforcement plies 32, 74 are made of a sticky material, they will stick against one another which may cause some problems in the turning step. In this regard, creases 56 may be made in the folded-up sections of the reinforcement plies 32, 74 which can impact the uniformity of the resulting tire architecture and which can cause problems in the automated building process. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

[0009] [Fig 1]

[0010] Fig. 1 is a perspective view of a prior process of forming a tire.

[0011] [Fig 2]

[0012] Fig. 2 is a cross-sectional view of a radial cut of a truck tire with all items in cross-section as the tire would look when mounted to a rim.

[0013] [Fig 3]

[0014] Fig. 3 is a cross-sectional view of the bead of Fig. 2 as it would look when mounted to a rim.

[0015] [Fig 4]

[0016] Fig. 4 is a side view of a step of the process in which a second reinforcement ply is brushed.

[0017] [Fig 5]

[0018] Fig. 5 is a side view of a step of the process in which the brushed second reinforcement ply is applied to an inner liner.

[0019] [Fig 6]

[0020] Fig. 6 is a side view of a step of the process in which a first reinforcement ply is brushed.

[0021] [Fig 7]

[0022] Fig. 7 is a side view of a step of the process in which the brushed first reinforcement ply is applied to the brushed second reinforcement ply.

[0023] [Fig 8]

[0024] Fig. 8 is a side view of a step of the process in which bead filler is applied.

[0025] [Fig 9]

[0026] Fig. 9 is a side view of a step of the process in which rods are applied.

[0027] [Fig 11]

[0028] Fig. 11 is a side view of a step of the process in which additional components such as a third reinforcement ply, anti-abrasive strips, and bead layers are applied.

[0029] [Fig 12]

[0030] Fig. 12 is a perspective view of a first reinforcement ply being brushed.

[0031] [Fig 13]

[0032] Fig. 13 is a perspective view of a second reinforcement ply being brushed. The use of identical or similar reference numerals in different figures denotes identical or similar features.

[0033] DETAILED DESCRIPTION OF THE INVENTION

[0034] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations.

[0035] The present invention provides for a method of making a tire 10 in which first and second reinforcement plies 32, 74 are brushed at strategic locations to reduce folding creases upon turning of the first and second reinforcement plies 32, 74. The brushing reduces stickiness between the two plies 32, 74 at the point of their interaction at the turning location so that they slide smoothly against one another at this point. The surfaces of the two plies 32, 74 that engage one another will not stick to one another so that as they are folded together their surfaces can separate and / or slide relative to one another to result in a turn-up that lacks or reduces creases 56 and increases uniformity.

[0036] Fig. 2 shows a tire 10 that is a heavy duty truck tire 10. The tire 10 may be a steer tire, a drive tire, a trailer tire, or an all position tire. The tire 10 includes a casing 22 onto which a tread 20 is disposed thereon. The bead 24 is a part of the casing 22 that is at the inner radial end of the casing 22 closest to the central axis. The central axis of the tire 10 extends through the center of the casing 22, and the axial direction 16 of the tire 10 is parallel to the central axis. The radial direction 14 of the tire 10 is perpendicular to the central axis, and the tread 20 is located farther from the central axis in the radial direction 14 than the casing 22. The tread 20 extends all the way around the casing 22 in the circumferential direction of the tire 10 and circles the central axis 360 degrees. Although described as being in use with heavy duty truck tires 10, the tire 10 as provided in accordance with the present invention may be any type of tire 10 such as a light duty vehicle tire, a light truck tire, a passenger car tire, or any other type of tire 10. However, certain embodiments exist in which the tire 10 is a heavy duty truck tire 10. As used herein, the directions described as being outward or inward in the radial direction 14 mean farther or closer to something relative to the central axis 12 in the radial direction 14. The directions described as being inboard or outboard in the axial direction 16 mean closer to or farther from the center line of the tire 10 in the axial direction 16 that is designated as the radial direction 14 line in Fig. 2. Although shown as being used with a heavy duty truck tire 10, it is to be understood that the present method may be used with any type of tire 10 such as a light duty truck tire or a passenger car tire. Description with reference to a heavy duty truck tire 10 is with only one exemplary embodiment, and other types of tires 10 can be used with the present method.

[0037] Fig. 2 is a radial cut of a tire 10 in accordance with one exemplary embodiment. Various tissues, sometimes called products, composed of different materials can be present throughout the tire 10. The tread 20 of the tire 10 is shown as being located farthest from the axial center of the tire 10 in the radial direction 14. A first belt layer 64 and a second belt layer 66 are located below the tread 20 in the radial direction 14 and comprise belts for use in strengthening and holding the form of the tire 10. The reinforcement belts of the layers 64, 66 may be crossed relative to one another, and in some instances they can be arranged at an angle of 20 degrees to one another. The casing 22, or carcass, extends from the tread 20 and includes sidewalls of the tire 10 terminating in a pair of beads 24 that are arranged for mounting onto the rim of the wheel of the vehicle. A bead core 28 is located in each one of the beads 24 and is present to provide strength and a gripping force in the bead 24 for retention onto the rim. The left hand side bead 24 can be a mirror image of the right hand side bead 24 and both beads 24 can have products that are made of the same material. Some of the tissues / products are located only in the bead 24, while others are located in the bead 24 and extend therefrom. For instance, an inner liner 68 is inside of the bead 24 and extends to an inner, exterior side of the bead 24 before extending up the sidewall of the casing 22. The inner liner 68 then extends across the entire inner side of the crown in the axial direction 16 before extending into and forming the inner side of the right hand side wall of the casing 22. The inner liner 68 then terminates inside of the right hand side bead 24 and is arranged in a similar mirror-image manner to its presence in the left hand side bead 24. The inner liner 68 is a product of the tire 10 that extends all the way from one bead 24 to the other bead 24 and is made of a material that is fluid tight so that fluid between the tire 10 and rim is maintained therein for purposes of maintaining inflation pressure of the tire 10.

[0038] The tire 10 includes a tissue designated as a first reinforcement ply 32 that is located within one of the beads 24 and extends through the casing 22 and crown to the other bead 24. The first reinforcement ply 32 wraps around the bead core 28 to a location that is outward in the axial direction 16 from the rod 72. The first reinforcement ply 32 has a main portion that is in the bead 24 and is inboard from the return casing ply of the first reinforcement ply 32 in the axial direction 16. The main portion extends to the bead core 28 to a location of the first reinforcement ply 32 that is closest to the central axis 12 in the radial direction 14. At this location closest to the central axis 12 in the radial direction 14, the first reinforcement ply 32 is then designated as a return casing ply which extends from this point to an outward first terminal end 104 of the return casing ply which is the part of the return casing ply of the first reinforcement ply 32 farthest from the central axis 12 in the radial direction 14. It is thus the case that both the main portion and the return casing ply of the first reinforcement ply 32 are wrapped around the bead core 28 and both may engage the bead core 28 in some embodiments. The main portion and return casing ply can be continuous with one another with no interruption in the first reinforcement ply 32 from one to the other.

[0039] Relative positions in the axial direction 16 can be described with respect to inboard and outboard positions. The most inboard point of the tire 10 may be the radial direction line 14 shown in Fig. 2 in its location in Fig. 2 as it is located at the center of the tire 10 in the axial direction 16. The center of the tire 10 is inboard of both of the beads 24 in the axial direction 16. As used herein, an object described as inboard in the axial direction 16 to another object means that it is located closer to the radial direction line 14 as shown in Fig. 2. Further, as used herein an object described as being located outboard from another object in the axial direction 16 means that it is located farther from the radial direction line 14 in the axial direction 16 as shown in Fig. 2. As another example, the bead layer 42 is outboard of the bead core 28 in the axial direction 16. Relative positioning in the radial direction 14 may be described in relation to the central axis in which objects may be closer to or farther from the central axis in the radial direction 14 than other objects.

[0040] Fig. 3 is a close-up view of the left hand side bead 24 in accordance with another exemplary embodiment. The bead core 28 is made up of one or more steel rods 72. The bead core 28 is surrounded by bead filler 36, which in some embodiments may include padding gum with a wrapping tissue that surrounds the entire bead core 28. This padding gum and wrapping tissue are not shown in Fig. 3, and instead only bead filler 36 completely surrounds the rod 72, but is to be understood that other arrangements of the bead 24 are possible. The rod 72 making up the bead core 28 is shown as a single piece and has a rectangular cross-sectional shape. This single piece can actually be many rods arranged together in the shape of a rectangle. In other embodiments the bead core 28 can be made of multiple components and these components could have any cross-sectional shape. The wrapping tissue, if present, may have a stiffness of 14 MPa and can be made of a rubber mix and textile which in some instances can be a nylon ply. The padding gum, if present, can be a rubber mix and may have a stiffness of 28 MPa, and the rod 72 can be made of steel or aluminum and can have a stiffness of 30,000,000 MPa in some embodiments. The bead core 28 can be lightened so that a smaller rod 72 can be used to improve performance properties of the tire 10. Although shown as being a rectangular rod 72, the rod 72 could be circular in other embodiments. In yet further arrangements, the rod 72 could be variously shaped and need not be a rectangular or circular in shape.

[0041] The bead 24 includes bead filler 36 that can engage and completely surround the rod 72, and may also engage the first reinforcement ply 32 and be between the main portion and the return casing ply of the first reinforcement ply 32. The bead filler 36 also engages the second reinforcement ply 74 and the third reinforcement ply 80. First terminal ends 104 and 118 of the first and second reinforcement plies 32, 74 engage the bead filler 36. The bead filler 36 may be placed into the bead 24 as a single layer, or it may be made of multiple layers within the bead 24. The bead filler 36 can be a rubber mix that can have a stiffness in the range from 3.6 MPa to 5.6MPa. The bead filler 36 ends in the bead 24, or in some instances may extend into the sidewall of the tire 10. However, the bead filler 36 does not extend all the way under the belt layers 64, 66 to the other sidewall of the tire 10. The first reinforcement ply 32 is a composite material that includes metal cords and a rubber mix. The first reinforcement ply 32 in the direction of its cords is stiffer than the bead fillers 36. The first reinforcement ply 32 extends from the bead 24, through the sidewall, under the belt layers 64, 66, and then into the opposite sidewall and down into the bead 24 on the righthand side of the tire 10.

[0042] The bead 24 includes an anti-abrasive strip 46 that is on the outside of the bead 24 and is designed to engage the rim. The anti-abrasive strip 46 engages the inner liner 68, the second reinforcement ply 74, the bead layer 42, and the sidewall product 70. The bead layer 42 is a product of the tire 10 made of rubber that has a portion that engages the anti-abrasive strip 46, sidewall product 70, second reinforcement ply 74, and third reinforcement ply 80. The bead layer 42 extends outward in the radial direction 14 to an outward radial terminal end that is the farthest outward position of the bead layer from the central axis 12 in the radial direction 14. The bead layer 42 may terminate in the bead 24, and may or may not extend to the sidewall of the tire 10. However, the bead layer 42 does not extend to be under the belt layers 64, 66, and does not extend to the right-hand side sidewall or right hand side bead 24. The bead layer 42 engages the sidewall product 70, the anti-abrasive strip 46, the first reinforcement ply 32, and the third reinforcement ply 80. A sidewall product 70 is in the sidewall and may have a stiffness that is 3.6 to 5.6 MPa. The bead layer 42 is free from engagement with the bead filler 36 and the bead core 28 and is an interior product of the tire 10 and does not have any portion that forms the outer surface of the tire 10.

[0043] The present application describes the stiffness of a product or material. The stiffness that is being referred to is the Young’s modulus which is the stiffness of an elastic material, or elastic modulus. The stiffness is provided in measurements of mega pascals (MPa). The stiffness material property in question that is being referred to is MA10. This stiffness property can be calculated using French standard NF T 46-002, September 1988.

[0044] The tire 10 includes three reinforcement plies 32, 74, and 80 that extend from the left-hand bead 24 across the crown of the tire 10 under the belt layers 64, 66 and into the right-hand bead 24. The first and second reinforcement plies 32, 74 wrap around the bead cores 28 of the beads 24, but the third reinforcement ply 80 does not wrap around the two bead cores 28. The second and third reinforcement plies 74, 80 can be configured as previously discussed with respect to the first reinforcement ply 32 and a repeat of this information is not necessary. The reinforcement plies 32, 74, 80 provide strength and flexibility to the tire 10, and provide a support structure for the inflation pressure of the tire 10 which carries the tire 10 load. The third reinforcement ply 80 engages the second reinforcement ply 74 and is spaced from and not in engagement with the first reinforcement ply 32, and the third reinforcement ply 80 is located outboard from the second reinforcement ply 74 in the axial direction 16. The third reinforcement ply 80 engages the second reinforcement ply 74 both in the bead 24 and the sidewall of the tire 10, and is spaced from and not in engagement with the second reinforcement ply 74 between these sections and is instead in engagement inboard in the axial direction 16 with the bead filler 36.

[0045] The second reinforcement ply 74 is in engagement with the first reinforcement ply 32 through most of its length, and these two plies 32, 74 both wrap around the bead core 28 and act together to provide strength and flexibility benefits. The second reinforcement ply 74 extends a longer length than does the first reinforcement ply 32 such that when it wraps around it extends a greater distance outward in the radial direction 14. The second reinforcement ply 74 engages on opposite sides the first and third reinforcement plies 32, 80 and a minor portion of the bead filler 36 on its inner side. The outer side of the second reinforcement ply 74 touches the bead filler 42. It is to be understood that the arrangement of the components making up the tire 10 are only exemplary and others are possible in other embodiments.

[0046] A method of making the tire 10 that has three reinforcement plies 32, 74, and 80 is disclosed. Fig. 4 shows the second reinforcement ply 74 and identifies a first side 90 and an oppositely disposed second side 92. The sides 90 and 92 make up the two largest sides of the second reinforcement ply 74. The method involves brushing the first side 90 with a brush 52 so that the tackiness or stickiness of the first side 90 is removed. The brush 52 can include bristles that are made of metal, fabric, or any other material capable of wearing down the first side 90 so that it is smooth enough to reduce its tackiness or stickiness. The entire first side 90 is not brushed. The brush 52 brushes the portion of the first side 90 that extends from the first terminal end 118 of the second reinforcement ply 74 to a first inner location 120 of the second reinforcement ply 74. The distance 128 is the distance from the first terminal end 118 to the first inner location 120, and this entire distance 126 may be brushed. This brushing creates a second brushing zone 94 of the second reinforcement ply 74 that extends from the first terminal end 118 to the first inner location 120.

[0047] On an opposite end of the second reinforcement ply 74, a second terminal end 122 is present and a distance 130 extends from this second terminal end 122 to a second inner location 124 of the first side 90. The distances 120 and 130 may be the same as one another. The brush 52 may also be used to brush the first side 90 from the second terminal end 122 to the second inner location 124 along the entire distance 130 so that the stickiness or tackiness of the first side 90 is reduced at this portion of the first side 90. An additional distance 126 extends from the first inner location 120 to the second inner location 124 along the first side 90, and the first side 90 along this distance 126 is not brushed such that it retains a higher degree of stickiness than does the first side along distance 128 or distance 130. This portion of the first side 90 is designated as an unbrushed region 102 that extends from the first inner location 120 to the second inner location 124. The entire length of the first side 90 may be calculated as the combined distances 128, 126 and 130. The second side 92 which is opposite from the first side 90 is not brushed and retains the same degree of stickiness as does the first side 90 along distance 126.

[0048] The next step in the method may involve the placement of the brushed second reinforcement ply 74 onto the inner liner 68 and this step is shown with reference to Fig. 5. The inner liner 68 engages the second side 92 and is free from engagement with the first side 90. The second side 92 is relatively sticky and the placement of the inner liner 68 thereon will result in the two components being stuck to one another such that they will not easily slide relative to one another. The length of the inner liner 68 is made so that its length is not greater than the length of the second reinforcement ply 74, and in fact the length of the inner liner 68 is less than the distance 126.

[0049] Fig. 6 show another step in the method of making the tire 10 in which a brush 54 is used to brush the first side 84 of the first reinforcement ply 32. In this regard, the first reinforcement ply 32 has a first side 84 and an oppositely disposed second side 86 that make up the two longest sides of the first reinforcement ply 32. The second side 86 is completely unbrushed and retains its initial stickiness. The brush 54 brushes the first side 84 from a first terminal end 104 to a first inner location 106 to create a first brushing zone 88 that has reduced stickiness from the unbrushed portions of the first reinforcement ply 32. A distance 114 of the first brushing zone 88 is defined as being the distance that extends from the first terminal end 104 to the first inner location 106. The brush 54 can also be used to brush an oppositely disposed portion of the first reinforcement ply 32 that extends from the second terminal end 108 to a second inner location 110. This part of the first side 84 is brushed to again make it less sticky than it otherwise would be, and to be smoother than other unbrushed portions of the first reinforcement ply 32. A distance 116 is defined as being the distance from the second inner location 110 to the second terminal end 108, and this distance 116 is brushed at the first side 84. An unbrushed region 100 is a portion of the first side 84 that is not brushed and has a higher stickiness than does the brushed first brushing zone 88. The length of the unbrushed region 100 is designated as distance 112 which extends from the first inner location 106 to the second inner location 110. The distance 112 is greater than the combined distances 114 and 116. The second side 86 is not brushed and is of the same stickiness as the unbrushed region 100. Fig. 7 shows the next step in the method of making the tire 10 in which the brushed first reinforcement ply 32 from Fig. 6 is applied to the subassembly of Fig. 5. Here, the first side 84 is placed into engagement with the first side 90. This engagement causes the first brushing zone 88 to be placed into engagement with the second brushing zone 94. The unbrushed region 100 is placed into engagement with the unbrushed region 102 and since both of these unbrushed regions 100, 102 are sticky, they are held and stuck against one another to some degree. On the opposite end, the brushed areas of the first and second reinforcement plies 32, 74 at the second terminal ends 108, 122 are placed into engagement with one another. The inner liner 68 is not placed into engagement with the first reinforcement ply 32. The engagement is made so that the first inner location 106 engages the first inner location 120, and so that the second inner location 110 engages the second inner location 124. In other embodiments these locations 106, 120 and 110, 124 need not engage one another.

[0050] As can be seen, engagement of the brushing zones 88, 94 results in an area of the two reinforcement plies 32, 74 that can slide relative to one another, or become separated from one another, because neither of them at this point are tacky or sticky. This sliding or separation can be at these locations of the two plies 32, 74 and not at the other locations of the two plies 32, 74 that are in engagement and are not brushed and hence stick to one another. The oppositely disposed brushed sections of the two plies 32, 74 that are on the opposite ends and are associated with the terminal ends 108, 122 and the inner locations 110, 124 can also slide relative to one another because the sides 84 and 90 at this location are brushed and smooth and do not stick onto one another. The second reinforcement ply 74 has a length that is longer than the length of the first reinforcement ply 32, and is longer than the length of the inner liner 68. A portion of the second brushing zone 94 is uncovered by the first reinforcement ply 32 and is exposed, and all of the unbrushed region 102 is covered by the first side 84 and is not exposed.

[0051] Fig. 8 shows another step in the method in which the bead filler 36 is placed onto the subassembly of Fig. 7. The bead filler 36 is put onto the second side 86, and two sections of the bead filler 36 are placed thereon. At this point, the first and second reinforcement plies 32, 74 are not turned and are flat. Fig. 9 shows the advancement of the method in which two rods 72 are placed onto the bead filler 36 so that each rod 72 is in engagement with one of the bead fillers 36. The rod 72 does not engage the second side 86, or any other portion of the first or second reinforcement plies 32, 74 and are free from engagement therewith. Fig. 10 shows the turn up portion of the method in which the first and second reinforcement plies 32, 74 are turned around the rod 72. In this regard, the first and second plies 32, 74 are turned from their position in Fig. 9 to the one shown in Fig. 10 in which they extend around the rod 72 so that the first terminal ends 104, 118 are moved past the rod 72. This turning causes the ends of the first and second plies 32, 74 to be formed into a curved shape and for the second side 86 and the first side 90 to engage the bead filler 36. The inner liner 68 is moved slightly on its end to assume a somewhat curved shape but not as much as the ends of the reinforcement layers 32, 74. The first and second reinforcement plies 32, 74 do not engage the rod 72 but are still turned around it as can be seen in Fig. 10. The opposite ends of the first and second reinforcement plies 32, 74 associated with the second terminal ends 108, 122 are likewise turned around the second rod 72 in a similar manner. The engagement between the first brushing zone 88 and the second brushing zone 94 allows these components at these areas to slide relative to one another upon the turning action being executed. This sliding prevents the formation of creases 56 as would otherwise be the case if the engagement of the reinforcement layers 32, 74 was a sticky engagement brought about by not brushing the engagement surfaces. The first and second reinforcement plies 32, 74 may stretch somewhat at the areas of the first and second brushing zones 88, 94 and smooth sliding or separation between them will prevent or reduce creases 56. Alternatively, the reinforcement plies 32, 74 may not stretch at the first and second brushing zones 88, 94 and turning of them around the rod 72 may still achieve a more uniform turn up without creases 56 due to the sliding action allowed via the brushing. The turning process may involve the separation of the reinforcement plies 32, 74 at the area where they turn around their own neutral fiber.

[0052] In order to remove or reduce creases 56, constant pressure 360 degrees completely around the first and second reinforcement plies 32, 74 may be applied. However, with the brushing step, the turn-up step may be accomplished by using less than constant pressure 360 degrees completely around the first and second reinforcement plies 32, 74 to achieve the fold. In this regard, the sliding and / or separation of the two reinforcement plies 32, 74 may allow for an automated process of turning to be employed in which force is applied to the products 32, 74 to fold them that is less than 360 degrees around, or is less than 180 degrees around.

[0053] After the turn-up of the ends of the reinforcement plies 32, 74, additional components may be laid upon the now turned-up assembly. Fig. 11 shows a subsequent step in the process in which additional materials such as a pair of anti-abrasive strips 46, a pair of bead layers 42, and a single third reinforcement ply 80 and a single sidewall product 70 are placed onto the turn-up subassembly of Fig. 10. Additional products could be placed onto the sub-assembly as needed and the tire 10 green products built up for eventual curing in a mold.

[0054] Fig. 12 is a perspective view of the first reinforcement ply 32 and shows a pair of brushes 54, 60 brushing the first side 84 so that brushed zones 88 are present along distance 114 and along distance 116. This brushing may extend along the entire length of the first side 84 and thus along then entire length of the first terminal end 104 and along the entire length of the second terminal end 108. The unbrushed region 100 is present along distance 112 and likewise extends along the entire length of the first reinforcement ply 32. The distance 112 between the brushing zones may be longer than the combined distances 114 and 116. Although two different brushes 54, 60 are shown creating the brushed sections of the first side 84, the same brush may be used in other embodiments.

[0055] A pair of brushes 52, 58 may be used to create the second brushing zones 94 as shown in Fig. 13 which is a perspective view of the second reinforcement ply 74. The brushed zones 94 extend along the entire length of the second reinforcement ply 74 and thus along the entire length of the terminal ends 118, 122. The distance 126 of the unbrushed region 102 is longer than the combined distances 128, 130 of the brushed regions. Although a pair of brushes 52, 58 are used to brush the first side 90, only a single brush 52 or 58 may be used in other embodiments. The brushes 52, 54, 58, 60 can be variously configured and need not be of a roller type as shown, but could be a linear brush or variously shaped and can include bristles of any type.

[0056] Although described as brushing the reinforcement plies 32, 74 so that they are smooth and do not demonstrate any tackiness, this is not always the case in other embodiments. In other embodiments the brushed zones 88, 94 of the reinforcement plies 32, 74 that result from the brushing action may still display some degree of tackiness. However, these brushed zones 88, 94 will not be as tacky as the other unbrushed regions 100, 102 and will enhance sliding of their engaged surfaces to reduce or eliminate creases 56 in the turned up assembly. Further, the current process may result in creases 56 that are formed, but these creases 56 may be less in number or severity upon application of the brushing step. The method allows for an automated process of turning to be employed in which the application of this turning force may be less than 360 degrees completely around the reinforcement plies 32, 74 if desired. The method of building the tire 10 can also include other steps such as placement of additional components into the green tire 10, moving the green tire 10 to a mold and curing the green tire 10 into a cured tire 10, and subsequent cooling and inspection and processing of the cured tire 10.

[0057] Although illustrated and described as being a heavy duty truck tire 10, it is to be understood that the tire 10 that is build can be any type of tire 10 and need not be a heavy duty truck tire 10 in other embodiments. In this regard, some tissues can be modified and elements such as the rod 72 could be modified to be circular or multiple component in configuration. As such, the method could be adapted for building other types of tires 10, both different kinds of heavy duty truck tires, car tires, light truck tires, etc., from those disclosed and is to be understood that the disclosed elements types are only exemplary and others are possible. While the present subject matter has been described in detail with respect to specific embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and / or additions to the present subject matter as would be apparent.

Claims

CLAIMS1. A method of making a tire, comprising: providing an inner liner; providing a first reinforcement ply; providing a second reinforcement ply; brushing the first reinforcement ply to reduce stickiness of the first reinforcement ply; brushing the second reinforcement ply to reduce stickiness of the second reinforcement ply; assembling the inner liner, the first reinforcement ply, and the second reinforcement ply; providing a rod; turning the first reinforcement ply and the second reinforcement ply around the rod; providing a third reinforcement ply; and assembling the third reinforcement ply with the inner liner, the first reinforcement ply, the second reinforcement ply, and the rod such that the third reinforcement ply is located outboard from the second reinforcement ply in an axial direction.

2. The method as set forth in claim 1 , further comprising providing bead filler, wherein the bead filler is placed onto the first reinforcement ply before turning the first reinforcement ply and the second reinforcement ply, and wherein the rod is placed onto the bead filler before turning the first reinforcement ply and the second reinforcement ply.

3. The method as set forth in claim 1 or 2, further comprising: providing an anti-abrasive strip, wherein the anti-abrasive strip engages the second reinforcement ply; providing a bead layer, wherein the bead layer engages the anti-abrasive strip; and providing a sidewall product, wherein the sidewall product is located outboard from the third reinforcement ply in the axial direction.

4. The method as set forth in any one of claims 1-3, wherein the brushing of the first reinforcement ply and the brushing of the second reinforcement ply takes place before the assembling of the inner liner, the first reinforcement ply, and the second reinforcement ply.

5. The method as set forth in claim 4, wherein brushing of the first reinforcement ply creates a first brushing zone on a first side of the first reinforcement ply; wherein the brushing of the second reinforcement ply creates a second brushing zone on a first side of the second reinforcement ply; and wherein the assembling of the inner liner, the first reinforcement ply, and the second reinforcement ply causes the first brushing zone to engage the second brushing zone.

6. The method as set forth in claim 5, wherein the first reinforcement ply has a second side that is oppositely disposed from the first side of the first reinforcement ply, wherein the second side of the first reinforcement ply is unbrushed; and wherein the second reinforcement ply has a second side that is oppositely disposed from the first side of the second reinforcement ply, wherein the second side of the second reinforcement ply is unbrushed.

7. The method as set forth in any one of claims 1-6, wherein the assembling of the inner liner, the first reinforcement ply, and the second reinforcement ply includes placement of the second reinforcement ply onto and into engagement with the inner liner and then subsequently placement of the first reinforcement ply onto and into engagement with the second reinforcement ply.

8. The method as set forth in claim 1 , wherein brushing of the first reinforcement ply creates a first brushing zone on a first side of the first reinforcement ply, and wherein the first side of the first reinforcement ply has an unbrushed region wherein the brushing of the second reinforcement ply creates a second brushing zone on a first side of the second reinforcement ply, and wherein the first side of the second reinforcement ply has an unbrushed region; wherein the unbrushed region of the first reinforcement ply and the unbrushed region of the second reinforcement ply are located inboard in an axial direction from the first brushing zone of the first reinforcement ply and the second brushing zone of the second reinforcement ply; wherein the first brushing zone of the first reinforcement ply and the second brushing zone of the second reinforcement ply are located outward in a radial direction from the rod.

9. The method as set forth in any one of claims 1-8, wherein the third reinforcement ply is completely unbrushed and engages the second reinforcement ply at an unbrushed second side of the second reinforcement ply.

10. The method as set forth in any one of claims 1-9, wherein the brushing the first reinforcement ply includes brushing from a first terminal end of the first reinforcement ply to a first inner location of the first reinforcement ply, and wherein the brushing the first reinforcement ply includes brushing from a second terminal end of the first reinforcement ply to a second inner location of the first reinforcement ply, and wherein the first reinforcement ply is unbrushed from the first inner location of the first reinforcement ply to the second inner location of the first reinforcement ply; wherein the distance from the first inner location of the first reinforcement ply to the second inner location of the first reinforcement ply is greater than the distance from the first terminalend of the first reinforcement ply to the first inner location of the first reinforcement ply, and wherein the distance from the first inner location of the first reinforcement ply to the second inner location of the first reinforcement ply is greater than the distance from the second terminal end of the first reinforcement ply to the second inner location of the first reinforcement ply; wherein the brushing the second reinforcement ply includes brushing from a first terminal end of the second reinforcement ply to a first inner location of the second reinforcement ply, and wherein the brushing the second reinforcement ply includes brushing from a second terminal end of the second reinforcement ply to a second inner location of the second reinforcement ply, and wherein the second reinforcement ply is unbrushed from the first inner location of the second reinforcement ply to the second inner location of the second reinforcement ply; and wherein the distance from the first inner location of the second reinforcement ply to the second inner location of the second reinforcement ply is greater than the distance from the first terminal end of the second reinforcement ply to the first inner location of the second reinforcement ply, and wherein the distance from the first inner location of the second reinforcement ply to the second inner location of the second reinforcement ply is greater than the distance from the second terminal end of the second reinforcement ply to the second inner location of the second reinforcement ply.

11. The method as set forth in claim 1 , wherein the brushing the first reinforcement ply includes brushing a portion but not all of a first side of the first reinforcement ply, and wherein a second side of the first reinforcement ply is oppositely disposed from the first side of the first reinforcement ply and is completely unbrushed; and wherein the brushing the second reinforcement ply includes brushing a portion but not all of a second side of the second reinforcement ply, and wherein a second side of the second reinforcement ply is oppositely disposed from the first side of the second reinforcement ply and is completely unbrushed.

12. The method as set forth in any one of claims 1-11, wherein the wrapping of the first reinforcement ply and the wrapping of the second reinforcement ply occur at a bead of the tire.

13. The method as set forth in any one of the preceding claims, wherein the tire is a heavy duty truck tire.

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