Pneumatic vehicle tire and method for manufacturing a pneumatic vehicle tire

Abstract

The invention relates to a pneumatic vehicle tire comprising a tread, a carcass with carcass plies having a carcass reinforcement, and a cap ply with a cap ply reinforcement (8b), wherein the carcass ply is turned up around bead cores so that a carcass turn-up is formed. According to the invention, - at least one carcass reinforcement made of a metal material extends in the carcass, - at least one cap ply reinforcement (8b) having an elongation at break of between 2% and 6% extends in the respective cap ply layer (8a) of the cap ply, wherein gaps (L) which each have a gap width (BL) are situated between at least some windings of the at least one cap ply reinforcement (8b) that are adjacent in the axial direction (aR), wherein the gap width (BL) of the respective gaps (L) is at least 0.5 times a cap ply reinforcement diameter of the at least one cap ply reinforcement (8b), and - the pneumatic vehicle tire has a load index in the range of 71 to 126.

Description

[0001] 202404649

[0002] Description

[0003] Vehicle pneumatic tires and methods for manufacturing a vehicle pneumatic tire

[0004] The invention relates to a vehicle pneumatic tire for passenger cars and / or light commercial vehicles according to the preamble of claim 1, and to a method for manufacturing such a vehicle pneumatic tire.

[0005] Due to the large number of vehicle tires used worldwide, the amount of used tires accumulating over time is a growing environmental problem. Burning, burying, or dumping them are rightly not sustainable disposal methods, especially since used tires themselves are now considered a valuable resource.

[0006] Recycling used tires is not unknown, but it is a complex and costly process that currently achieves little to no complete recovery. One well-known method is thermal decomposition, also called pyrolysis, used to recover materials such as pyrolysis carbon black and pyrolysis oils, which can then be reused in the tire manufacturing process. However, even these methods typically do not achieve a fully circular economy.

[0007] A typical tire construction poses drastic challenges to such a desirable circular economy. For example, it is known that noise absorbers, adhesives used for noise absorbers, and sealants are a major problem due to their residual stickiness in almost every separation process. But even used tires that do not contain such noise absorbers, adhesives, and / or sealants, or that have already been stripped of them, pose a significant challenge for efficient separation and recycling processes. 202404649

[0008] For example, a used tire, especially for passenger cars and light commercial vehicles, contains, in addition to steel cords as belt reinforcement and in the bead, carcass reinforcement in the carcass and belt reinforcement in the wound band, if one is used, made of a textile material. Typically, all reinforcements are embedded in an encasing rubber compound (often also called a rubber compound), frequently with the aid of adhesion promoters. This ensures that a strong bond between the reinforcement and the rubber compound is often maintained throughout the tire's lifespan. The bond between the textile reinforcements and the encasing rubber compound is usually significantly stronger than that between the steel cords and their rubber compound.This means that subsequently separating textile reinforcements from the surrounding rubber compound is very difficult (if not impossible). In contrast, steel cords, i.e., reinforcements made of a metallic material, can be separated from a rubber compound much more easily.

[0009] Furthermore, pneumatic tires with coiled casings containing textile reinforcements have a limited lifespan, as retreading is typically not an option. Removing the worn tread and applying a new one often fails because the coiled casing or its textile reinforcements are damaged during the mechanical removal of the worn tread. This usually renders the tire unusable, or at least unsuitable, for retreading.

[0010] Furthermore, in the conventional manufacturing of, for example, radial tires for passenger cars or light commercial vehicles, the contouring of the belt and the coil bandage, if a coil bandage is installed, generally only takes place during the vulcanization of the tire by forming the tire blank built on cylindrical drums using a 202404649

[0011] The inner layer of the inflated bellows inside the tire blank placed in the tire heating mold is a disadvantage. This can lead to material displacement and uneven axial expansion during vulcanization. To counteract this, DE 102004 058 522 A1 describes the use of a contoured construction drum. The method described therein uses a steel belt, and the contoured construction drum ensures uniform axial expansion and distortion-free forming. Furthermore, it allows the wound bandage to be applied close to the final contour, thus easily ensuring the desired bandage tension. This is achieved using a wound bandage with highly elastic nylon threads as the bandage's reinforcing material.A disadvantage of this is that, depending on the design of the vehicle's pneumatic tire, the highly elastic nylon threads can lead to an undesirable radial expansion of the material radially underneath.

[0012] WO 2023 / 090022 A1 further specifies carcass reinforcement bars made of an organic material in radial construction, coil bandage reinforcement bars made of a highly elongated organic material with an elongation at break of >10%, and belt reinforcement bars made of steel within two belt layers. The coil bandage covers the belt edges of the belt.

[0013] In JP 2023 544389 A, a single carcass ply with textile carcass reinforcing elements, a belt with two belt plies, each with steel reinforcing elements, is described. A coiled bandage is wound radially outwards on these plies. This bandage consists of coiled bandage reinforcing elements made of an organic material, running at an angle of less than 10° to the circumferential direction. The coiled bandage covers the belt edges.

[0014] KR 102352893 B1 further describes that radially above two carcass plies lie two belt plies with steel belt reinforcement elements, 202404649 whose angle to the circumferential direction changes along the longitudinal extent of the belt reinforcement elements, with a larger angle to the circumferential direction at the tire's zenith than in the shoulder areas. Furthermore, the belt reinforcement elements of different belt plies are arranged in such a way that they intersect in a cross pattern with opposite angles. The tread is directly adjacent to the radially above the belt plies.

[0015] KR 20050094681 A describes winding a coil bandage onto a belt, which consists of coil bandage reinforcement carriers made of a microfiber steel cord having a tensile strength of between 25kgf and 29kgf.

[0016] EP 1900549 A1 further describes that a coiled bandage made of curved coiled bandage reinforcement elements or coiled bandage reinforcement elements with a wave shape, each made of steel and exhibiting a tensile strength of between 2000 MPa and 5000 MPa, is arranged between the tread and a belt ply. This is intended to compensate for the circumferential growth in the coiled bandage during vulcanization. No metallic material is provided for the carcass or the belt. Furthermore, the coiled bandage covers the belt edges of the belt plies.

[0017] US Patent 11179970 B2 describes a belt with steel reinforcing bars arranged in a cross pattern, the angle of which varies longitudinally and is a maximum of 35° to the circumferential direction. A coil bandage covers the belt, the reinforcing bars of which are made of a highly ductile organic material. The coil bandage does not cover the belt edges of the radially underlying belt.

[0018] In JP 6798273 B2, a carcass with carcass reinforcements made of an organic material with an angle between 75° and 90° to 202404649

[0019] Circumferential direction is described. Radially above this, a belt with high-tensile-strength reinforcing belts, especially made of steel, is provided, which intersect and whose angles vary along the longitudinal extent, with smaller angles at the tire zenith than at the tire shoulders. A coiled bandage is not provided.

[0020] KR 101467464 B1 describes a belt with layers whose reinforcing belts are arranged in a cross pattern and have an angle of less than 25° to the circumferential direction. A coil bandage is not included.

[0021] US Patent 5365988 A describes a belt with steel belt reinforcements, wherein a radially overlying coil bandage with non-metallic coil bandage reinforcements covers the belt edges. The belt reinforcements are arranged in a cross pattern. Radially beneath this is a carcass with carcass reinforcements made of a rubberized fabric.

[0022] In JP 6538520 B2, a belt made of reinforcing belts of a metallic material is provided, with the coil bandage covering the belt edges. The coil bandage consists of organic coil bandage reinforcing belts running at an angle of between 0° and 5° to the circumferential direction. The carcass has carcass reinforcing belts made of an organic material.

[0023] CN 211663006 U describes a coil bandage that covers the belt edges of the radially underlying belt. Additional coil bandage strips run in the shoulder area, and at the tire's zenith, adjacent coil bandage strips may be wound with a gap. 202404649

[0024] US 2019160874 A1 describes a coil bandage made of organic coil bandage reinforcement carriers, wherein the coil bandage also extends over belt edges of the belt.

[0025] JP 2010095057 A describes a belt that is not covered by the circumferentially running coil bandage, wherein the belt reinforcement members are coiled in a wavy manner in the circumferential direction. The coil bandage, made of metallic or organic reinforcement members, is placed only on the sides and next to the belt, wherein the coil bandage reinforcement members have a lower modulus of elasticity than the circumferentially running belt reinforcement members.

[0026] EP 1094956 B1 describes a run-flat tire which has a non-metallic, circumferentially extending reinforcing layer between the carcass and the belt, or alternatively, above the belt. The reinforcing materials of the layer are wound spirally around the circumference of the carcass or belt.

[0027] DE 4208705 A1 describes a steel belt whose belt edges are covered by a textile-reinforced strip.

[0028] KR 100976580 B1 describes a pneumatic tire for heavy vehicles, such as trucks or buses, with a corrugated, coiled belt reinforcement. This type of tire does not have a coiled band.

[0029] In GB 770673 A, CN 114056007 A and WO 2018 / 125181 A1, a carcass is provided which is designed as an angled carcass, i.e. the carcass reinforcement bars run at an angle of between 70° and 90° to the circumferential direction. 202404649

[0030] In US 5058649 A, KR 100187594 B1, US 5524688 A and WO 2019105620 A1, it is stipulated that there is no apex radially above the bead cores in the bead area between these and the carcass plies with carcass reinforcement made of a non-metallic material.

[0031] The following invention is based on the objective of providing a vehicle pneumatic tire that exhibits high load-bearing capacity, is stable and durable, and has an increased service life. A further objective of the invention is to provide a method for manufacturing such a vehicle pneumatic tire.

[0032] This problem is solved by a vehicle pneumatic tire and a method according to the independent claims. The dependent claims specify preferred embodiments.

[0033] Accordingly, a pneumatic tire for passenger cars and / or light commercial vehicles is provided, comprising a tread, a carcass and a coiled bandage consisting of one or more than one coiled bandage layer with an axial coiled bandage extension, wherein

[0034] - the coil bandage is arranged radially above the carcass, i.e. directly partially covering the carcass or with additional layers of material in between, and radially below the tread, i.e. directly covered by the tread or with additional layers of material in between, and the coil bandage has at least one coil bandage reinforcement carrier, and

[0035] - the carcass (2) has at least one carcass ply, wherein each carcass ply has at least one carcass reinforcement element and each carcass ply runs between bead areas of the vehicle pneumatic tire, wherein at least one bead core is arranged in each bead area and each carcass ply is folded over around the at least one bead core in the respective bead area, so that a carcass fold is formed, wherein 202404649

[0036] - at least one carcass reinforcement beam made of a metallic material runs through the carcass,

[0037] - in the respective coil bandage position of the coil bandage, at least one coil bandage reinforcement carrier with an elongation at break of between 2% and 6%, preferably between 3% and 5.5%, particularly preferably between 3% and 5%, runs independently of one another, wherein gaps with a gap width of at least one coil bandage reinforcement carrier are arranged between at least some axially adjacent windings of the at least one coil bandage reinforcement carrier, wherein the gap width of the respective gaps is at least 0.5 times the diameter of the coil bandage reinforcement carrier of the at least one coil bandage reinforcement carrier, and

[0038] - the vehicle tire has a load index in the range of 71 to 126.

[0039] According to the invention, an "interrupted" wound bandage is produced, for example, by so-called "gap spooling." This means that in certain areas, at least some of the wound bandage reinforcement carriers or individual windings thereof do not touch, as they are wound with interruptions. This advantageously prevents excessive compression by the respective wound bandage reinforcement carrier in certain areas of the vehicle tire, for example, at the tire's apex and / or in the shoulder sections, as these areas are "thinned out" by the formation of gaps. Furthermore, this "gap spooling" saves material and weight.

[0040] Furthermore, this thinning, particularly at the tire's zenith, allows the tire to exhibit a certain degree of compliance at high speeds. This results in a rounder profile at high speeds, leading to improved tire performance. Manufacturing is also optimized, as the high-tensile-strength coiled bandage reinforcements already possess a degree of compliance, especially when the tire blank is formed into the vulcanization mold (see 202404649), thus preventing excessive tensile stress after forming. This, in turn, promotes the use of such high-tensile-strength coiled bandage reinforcements.

[0041] Furthermore, a coil bandage with high tensile stiffness or high elongation strength can effectively suppress radial expansion of the underlying radial material, particularly the carcass ply, or circumferential growth of the tire, thus reducing compression on the carcass. This is also advantageous when reduced longitudinal stiffness or reduced elongation strength of the underlying radial plies needs to be compensated for, for example, in the case of an angled or diagonal carcass design, or in the case of a belt (if present) with a cross-stitch pattern.

[0042] Furthermore, the use of high-tensile-strength coiled bandage reinforcement and metallic reinforcement in the carcass layer enables the development of a pneumatic tire specifically designed for passenger cars and / or light commercial vehicles, offering increased stability, stiffness, and durability. Conventionally, such pneumatic tires utilize only non-metallic carcass reinforcement. Moreover, a correspondingly equipped pneumatic tire exhibits a higher load capacity, for example, in the form of a higher load index (also known as load-carrying capacity index or load rating), compared to pneumatic tires of the same design and size but with conventionally used textile reinforcement. This would be advantageous in the future, particularly with regard to the increasing weight of electric vehicles, as tire dimensions would not necessarily need to be enlarged.

[0043] Within the scope of the present invention, an elongation at break with the above percentage values ​​is understood to mean that the respective coil bandage reinforcement carrier, which is neither rubberized nor installed in the vehicle pneumatic tire, has a maximum elongation of 202404649

[0044] The elongation at break must be 6%, preferably a maximum of 5.5%, and in particular a maximum of 5%. Such an elongation at break can be achieved through appropriate design (stranding, twisting) of the respective reinforcing element and / or by selecting an appropriate material for the respective reinforcing element. The elongation at break is specified in accordance with ASTM D2969-04 from 2010 (for steel filaments / cords) and ASTM D885 from 2023 (for textile filaments / cords and for hybrid filaments / cords (steel and textile)).

[0045] It is clear to those skilled in the art whether a particular element is considered a structural element in a given position or not. For example, in the context of the present invention, threads or filaments that typically serve for the classical distribution and / or conduction of electrical voltages are not structural elements within the meaning of the present invention. This applies equally to conventional threads or filaments for air drainage and other auxiliary components. This is particularly advantageous whenever such auxiliary components are not explicitly described as having a function designated as structural elements.

[0046] Furthermore, the feature "made of a metallic material" in the context of the present invention means that a corresponding metallic reinforcement consists essentially of the respective metallic material, for example, steel. The feature "made of steel" also means that a small proportion of a metal / metal alloy not typically referred to as steel is not excluded. For example, steel provided with a brass coating is included in this feature. Preferably, a metallic reinforcement made of steel comprises 90 percent or more by weight of steel, based on the total mass of the metallic reinforcement, preferably 92 percent or more by weight, particularly preferably 95 percent or more by weight, most preferably 97 percent or more by weight, and most preferably 99 percent or more by weight. 202404649

[0047] In the context of the present invention, the term "light commercial vehicles" refers to vehicles typically described as vans. Vehicle tires are typically assigned to a vehicle class by their dimensions, a load index (corresponding to a load capacity in kg per tire), and a speed rating. The load index of the vehicle tire according to the invention generally ranges from 71 to 126, covering both passenger cars and light commercial vehicles. This typically corresponds to a load capacity of 345 kg to 1700 kg. The vehicle tire according to the invention is therefore either a passenger car tire or a light commercial vehicle tire. In the context of the present invention, the load index is referenced to a tire pressure of 2.5 bar for single tires.

[0048] A vehicle tire with a load index in the range of 74 (375 kg) to 114 (1180 kg), preferably from 77 (412 kg) to 109 (1030 kg), more preferably from 80 (450 kg) to 107 (975 kg), and most preferably from 83 (487 kg) to 104 (900 kg) is particularly preferred. This applies preferably to vehicle tires for passenger cars. A vehicle tire with a load index in the range of 105 (925 kg) to 126 (1700 kg), preferably from 110 (1060 kg) to 124 (1600 kg), more preferably from 115 (1215 kg) to 122 (1500 kg), and most preferably from 116 (1250 kg) to 120 (1400 kg) is also particularly preferred. This applies particularly to pneumatic tires for light commercial vehicles.

[0049] Preferably, the vehicle pneumatic tire according to the invention comprises tires of category C1 and / or C2 according to the classification of tires based on Regulation (EC) No. 661 / 2009 of the European Parliament and of the Council of 13 July 2009. Accordingly, the vehicle pneumatic tire according to the invention is preferably not a tire of category C3. The vehicle pneumatic tire according to the invention is also not a bicycle tire or a motorcycle tire, preferably not a two-wheeler tire, and not a truck tire or a heavy-duty tire. 202404649

[0050] The at least one high-tensile-strength reinforcement layer in the wound bandage is preferably incorporated within an encasing rubber compound (individual sheathing or the rubber strip), whereby this rubber compound can in turn form a strong bond with other rubber compounds in the vehicle pneumatic tire (e.g., in the underlying belt (if present), the underlying carcass, or the tread above). However, it is also possible for the at least one high-tensile-strength reinforcement layer to be incorporated into the wound bandage without rubber or only partially rubberized. Preferably, the radially underlying belt (if present), the radially underlying carcass, and / or the radially above tread can have an adhesive compound to create a sufficient bond with the respective reinforcement layer in the wound bandage.

[0051] The invention further relates to a method for manufacturing a vehicle pneumatic tire for passenger cars and / or light commercial vehicles, in particular with a load index in the range of 71 to 126, in particular a vehicle pneumatic tire according to the invention, comprising at least the following steps:

[0052] - Providing a construction drum that can be rotated about a drum axis, wherein the construction drum has an outer surface facing radially outwards on which a tire package can be fully accommodated;

[0053] - Positioning and fixing a ring-shaped tire package in a radial direction above the provided construction drum, wherein the tire package comprises at least: a ring-shaped inner layer; a ring-shaped carcass arranged radially above it, consisting of at least one carcass ply with at least one carcass reinforcement made of a metallic material, and 202404649

[0054] Bead areas with bead cores;

[0055] - Expanding the provided construction drum in a radial direction so that the provided and fixed tire package lies flat against the outside of the construction drum, at least in some areas;

[0056] - Providing at least one coil bandage reinforcement carrier with an elongation at break of between 2% and 6%, preferably between 3% and 5.5%, particularly preferably between 3% and 5%, and

[0057] - Forming a coil bandage in a radial direction above the tire package by winding the at least one provided coil bandage reinforcement carrier in at least one coil bandage layer over an axial coil bandage extension such that gaps with a gap width of at least one are formed between at least some axially adjacent windings of the at least one coil bandage reinforcement carrier, wherein the gap width of the respective gaps is at least 0.5 times the diameter of the coil bandage reinforcement carrier of the at least one coil bandage reinforcement carrier;

[0058] - Applying a tread strip in a radial direction above the formed coil bandage and completing a tire blank;

[0059] - Molding the finished tire blank into a vulcanization mold and vulcanizing the tire blank;

[0060] - Removing the vehicle tire from the vulcanization mold after completion of vulcanization.

[0061] Using such a method, a vehicle pneumatic tire according to the invention with an "interrupted" coil bandage can be produced in a simple manner.

[0062] Preferably, the gap widths are further provided that the gap widths are between 0.5 times and 2 times the diameter of the coil bandage reinforcement carrier of the at least one coil bandage reinforcement carrier when the at least one coil bandage reinforcement carrier is wound individually, or, for example, the gap widths are between 0.5 times and 1.5 times the width of a rubber strip, but preferably between 3 mm and 10 mm when the at least one provided coil bandage reinforcement carrier is wound embedded in the rubber strip.

[0063] For gap widths of this size, depending on the construction of the coil bandage, a sufficiently high tensile stiffness or tensile strength can still be ensured to provide adequate stability, rigidity, and resistance. At the same time, thinning the bandage can also reduce compression in the respective area of ​​the tire with these gaps.

[0064] It can also be provided that the gap widths are identical or that the gap widths change with increasing axial distance of the respective gap from the tire's apex. With a changing gap width, a correspondingly adapted transition between areas with interrupted and continuous coil banding can be achieved, so that the compression and tensile stiffness do not change abruptly in the axial direction.

[0065] For example, it may be stipulated that

[0066] - the gap widths increase with increasing axial distance of the respective gap to the tire zenith when the gaps are arranged in side sections of the coil bandage, and / or

[0067] - the gap widths become smaller with increasing axial distance to the tire zenith when the gaps are arranged in the area of ​​the tire zenith, preferably over an axial extent of between 10% and 70% of the coil bandage extent around the tire zenith.

[0068] This (alternatively or additionally to a shortened version of the coil bandage above the belt edges of any existing belt 202404649 or in the sidewalls) prevents excessive compression in the shoulder sections of the vehicle tire by the respective coil bandage reinforcement carrier, for example by "thinning" them through the formation of gaps in the area of ​​the belt edges or in the sidewalls. Alternatively or additionally, such "thinning" in the area around the tire's zenith can also reduce the compression on the radially underlying layers in this area below the coil bandage and optimize the manufacturing process, particularly during molding into the vulcanization mold.

[0069] Preferably, the at least one reinforcing layer of the coiled bandage runs at a first angle to the circumferential direction within the coiled bandage, wherein the first angle is between 0° and 5°, preferably between 0° and 4°, particularly preferably between 0° and 3°, and most preferably between 0° and 2°. This allows for even better prevention of undesirable circumferential growth of the vehicle tire at high speeds, in addition to the high tensile strength of the coiled bandage, since the highly tensile-strength structure of the coiled bandage is then also less compliant. This is particularly advantageous when the radially underlying layers have reduced longitudinal stiffness or reduced tensile strength, as circumferential growth can be less effectively prevented by these layers, but this can be compensated for by the less compliant coiled bandage.However, the "gap-spooling" process also ensures that the vehicle's pneumatic tire can assume a round shape at high speeds at its zenith, or exhibit a certain degree of flexibility when being molded into the vulcanization mold.

[0070] Preferably, it is further provided that the at least one coil bandage reinforcement carrier with an elongation at break of between 2% and 6%, preferably between 3% and 5.5%, particularly preferably between 3% and 5%, is made of a textile material, in particular aramid, and / or of a metallic 202404649

[0071] The material is made of steel, in particular. Therefore, different materials are possible as reinforcing elements in the coil bandage, with which these elongations at break can be achieved through appropriate stranding. In order to make the construction less complex and / or to achieve a defined tensile strength across the entire coil bandage, the coil bandage preferably comprises exclusively coil bandage reinforcing elements with an elongation at break of between 2% and 6%, preferably between 3% and 5.5%, and particularly preferably between 3% and 5%.

[0072] When the spool band reinforcement is made of a metallic material, or even exclusively of a metallic material, recyclability can be improved and the effort required for retreading reduced, especially if the reinforcement in the carcass is also made exclusively of a metallic material or is free of textile reinforcement. The use of metallic reinforcement in the respective layer (spool band, carcass) reduces the susceptibility to damage when removing, for example, a worn tread. This allows the tire to be retreaded by applying a new tread, thus significantly increasing the overall lifespan of the tire. This can be considered a significant first step towards a circular economy, at least in principle.

[0073] Furthermore, it may be provided that the at least one high-tensile-strength coil bandage reinforcement layer exhibits an elongation behavior that differs from the elongation behavior of the at least one metallic carcass reinforcement layer. Thus, different implementations in the respective layers are possible.

[0074] Preferably, the vehicle pneumatic tire further comprises a belt that is radially covered on the outside by the coiled casing, and the belt 202404649 has one, two, or three belt layers, wherein the belt has at least one belt reinforcement element. Thus, depending on the desired design, a variable construction with or without a belt is possible, whereby, depending on the construction, a belt can additionally provide for holding the carcass together or reducing its circumferential growth under reduced compression. It is particularly preferred that a belt with one or two belt layers is provided. This is preferably intended for vehicle pneumatic tires for passenger cars. A belt with two or three belt layers is also particularly preferred. This is preferably intended for vehicle pneumatic tires for light commercial vehicles.

[0075] Preferably, it is further provided that at least one belt reinforcement layer made of a metallic material, in particular steel, runs independently of one another in each belt layer of the belt; preferably, only belt reinforcement layers made of a metallic material, in particular steel, run, i.e., the belt is free of or has no textile reinforcement layers. This also improves recyclability.

[0076] Preferably, the belt is further provided to have at least two belt layers, in particular a radially inner first belt layer and a radially above it a second belt layer, wherein the axial coil bandage extension

[0077] - is less than or equal to a first axial belt extension of the first belt layer of the belt, and / or

[0078] - is larger than a second axial belt extension of the second belt layer of the belt, or

[0079] - less than or equal to the second axial belt extension of the second belt layer of the belt.

[0080] A variable construction is therefore possible, in which all belt edges, or at least some belt edges, are covered by the coil bandage to protect them or the belt reinforcement elements from unwanted movement within the vehicle tire, which could otherwise lead to internal damage or material weakening. However, depending on the vehicle tire design, it is also preferable that excessive compression by the coil bandage reinforcement elements, which typically cover the belt edges in this area, does not occur in the shoulder sections of the vehicle tire. To achieve this, the coil bandage reinforcement elements can be wound or laid onto the belt in such a way that the coil bandage does not protrude axially beyond the belt edges. This also results in a reduction of mass and less heat generation at the belt edges.Depending on the design of the vehicle tire, this can also be combined with "gap spooling", i.e., the belt edges remain at least partially covered by the spool bandage to prevent the belt edges from lifting, but the spool bandage is wound with interruptions.

[0081] Preferably, it is further provided that the carcass reinforcement elements within at least one carcass layer of the carcass run at a third angle to the circumferential direction, wherein

[0082] - the carcass has at least two carcass plies, each carcass ply having at least one carcass reinforcement beam made of a metallic material, the respective carcass reinforcement beam running at a third angle of between 40° and 50°, preferably 45°, to the circumferential direction, and the carcass reinforcement beams of radially superimposed carcass plies having opposite directions of inclination, so that radially superimposed carcass reinforcement beams cross over each other to form a cross-laminated structure (diagonal carcass) or

[0083] - the carcass has only one carcass ply, wherein the carcass ply has at least one carcass reinforcement made of a metallic material, the carcass reinforcement running at a third angle of greater than 70° and less than or equal to 90° to the circumferential direction. 202404649

[0084] The carcass can therefore be designed as a two-ply diagonal carcass, which offers the advantage of improved rolling resistance and efficiency, resulting in overall increased efficiency and reduced fuel consumption. In the case of a driven wheel, a driving or braking torque is present at that wheel. These torques are transmitted through the sidewalls of the tire, via the respective components of the ply-structured tire, to the rim. A portion of these torques is transferred as tensile forces to the carcass's reinforcing elements. Since these reinforcing elements are made of a metallic material, particularly steel, and run at the aforementioned angle to the circumferential direction, the driving or braking torques in the form of tensile forces can be reliably absorbed by the reinforcing elements.

[0085] By choosing the third angle, the cross-bracing, and the metallic material of the carcass reinforcement, it is possible to prevent adjacent reinforcement from being subjected to shear stress under applied torque and thus heating up, as can happen with carcass reinforcement made of organic or textile materials. Energy dissipation and the resulting increase in power loss can therefore be avoided or at least minimized, thereby increasing the efficiency of the pneumatic tire. Due to the cross-bracing arrangement of the carcass reinforcement, the pneumatic tire not only has higher efficiency during acceleration but also during braking, leading to increased range, especially in electric vehicles. During braking, a larger portion of the braking energy can be recuperated and fed back into the battery because less energy is dissipated in the tire.

[0086] Furthermore, with such a carcass design, the omission of the belt (if present) can be compensated for, particularly with regard to stability, stiffness, and resistance, thus saving weight and material. The recyclability of the pneumatic tire can also be improved by the absence of the belt.

[0087] In contrast, a radial construction with a single-ply design and a 90° angle effectively prevents circumference growth. With a radial construction using a single-ply design and a third angle between 70° and less than 90° (angled carcass), the efficiency and rolling resistance of the tire can be improved, for the same reasons as with a bias-ply carcass. Furthermore, the number of belt plies (if present) can then be reduced, thus saving material and weight.

[0088] Preferably, the method further provides that a construction drum is provided whose outer surface has a radial axial distance from the drum axis, wherein the radial axial distance is maximal at a zenith of the construction drum and decreases from the zenith in the axial direction towards the shoulder regions of the construction drum, so that a construction drum with an axially contoured outer surface, for example a rounded outer surface, in particular a convexly curved outer surface, is provided, so that the provided and fixed tire package, when the provided construction drum expands radially, at least partially conforms to the axially contoured outer surface of the construction drum, so that the tire package also assumes an axially contoured shape at least partially; and thereby the wound bandage also assumes an axially contoured shape at least partially.

[0089] The contoured drum allows the high-tensile-strength material in the spool casing to adapt to, or approximate, the shape of the finished pneumatic tire even before vulcanization, and especially before being molded into the vulcanization mold. This results in a smaller residual raised area between the tread and the mold, leading to lower tensile forces on the spool casing and its reinforcing elements during molding. These forces can be absorbed without damage by the high-tensile-strength material. Therefore, in addition to gap spooling, this optimizes the production of pneumatic tires specifically for passenger cars and / or light commercial vehicles, featuring a high-tensile-strength spool casing and metallic carcass reinforcing elements.

[0090] Preferably, it is further provided that the at least one provided coil bandage reinforcement carrier with an elongation at break of between 2% and 6%, preferably between 3% and 5.5%, particularly preferably between 3% and 5%, has a waveform with a wavelength and a wave amplitude, wherein the formation of the coil bandage in the radial direction above the tire package is carried out by winding the at least one provided wave-shaped coil bandage reinforcement carrier in at least one coil bandage layer over an axial coil bandage extension in such a way that the at least one provided coil bandage reinforcement carrier retains its waveform in the circumferential direction and the waveform preferably changes during the forming of the tire blank into the vulcanization mold.

[0091] In addition to a contoured construction drum and gap spooling, a wave shape can also be provided for the high-tensile-strength coil bandage reinforcement elements. This wave shape can absorb or reduce the tensile forces that develop during expansion during molding. During molding into the vulcanization mold, the wave shape approximates a straight line, thus optimizing the tensile forces on the at least one high-tensile-strength coil bandage reinforcement element.

[0092] Preferably, the expansion of the provided construction drum is carried out radially and / or the outer surface of the provided construction drum is designed axially such that, after the finished tire blank is inserted into the vulcanization mold, the residual protrusion of the tire blank is less than or equal to 4%, preferably less than or equal to 2%, and particularly less than or equal to 1%, wherein the tire blank expands radially by this residual protrusion during vulcanization. The design of the tire blank is thus optimized to ensure that only a minimal residual protrusion remains, which can be compensated for without damage by the high-tensile-strength material of the spool band and the corresponding design, particularly with the "gap spooling" process.

[0093] The drawings show:

[0094] Fig. 1 shows a sectional view of a vehicle pneumatic tire;

[0095] Fig. 2A-2E Detail views of a coil bandage of the vehicle pneumatic tire according to Fig. 1;

[0096] Fig. 3A, 3B Detail views of the belt of the vehicle pneumatic tire according to Fig. 1;

[0097] Figs. 3C-3F show further embodiments of the coil bandage of the vehicle pneumatic tire according to Fig. 1;

[0098] Figs. 4A, 4B Detail views of a carcass of the vehicle pneumatic tire according to Fig. 1; 202404649

[0099] Fig. 4C shows a detailed view of a bead area of ​​the vehicle pneumatic tire in a further embodiment;

[0100] Fig. 5 shows a flowchart of a process for manufacturing the vehicle pneumatic tire according to Fig. 1;

[0101] Fig. 6A-6E shows a tire assembly plant for carrying out the procedure according to Fig. 5.

[0102] Figure 1 schematically shows a vehicle pneumatic tire 50 in a radial cross-section, which is intended for passenger cars or light commercial vehicles and accordingly has a load index (corresponding to a load capacity in kg per tire) in the range of 71 to 126.The vehicle pneumatic tire 50 comprises at least: a largely airtight inner layer 1; a carcass 2, which, for example, extends in a conventional manner from a tire zenith Z of the vehicle pneumatic tire 50 over sidewalls 3 to bead areas 4 and is anchored there by wrapping around tensile-resistant bead cores 5; a profiled tread 6 located radially outside the carcass 2, which is preferably formed by a cap and a base and has a profile with an application-specific tread depth; a belt 7 arranged in the radial direction rR between the tread 6 and the carcass 2, which has at least one belt layer 7a, preferably two belt layers 7a (as shown, a first belt layer 7a1 and a second belt layer 7a2) or also three belt layers 7a (not shown); and a coil bandage 8 covering the belt 7 radially outwards, which has at least one coil bandage layer 8a.

[0103] The coil bandage 8 covers, according to the embodiment shown in Fig. 1, belt edges 9 of the belt 7, i.e., both a first belt edge 9a of the first belt layer 7a1 and a second belt edge 9b of the second belt layer 7a2. The coil bandage 202404649

[0104] 8 extends axially aR to both sides beyond these belt edges 9; 9a, 9b, or rather, the axial spool bandage extension A8 of the spool bandage 8 is greater than the axial belt extension A7 of the belt 7. In the illustrated embodiment, the axial belt extension A7 is defined by a first axial belt extension A71 of the axially wider first belt layer 7a1. This allows the belt edges 9; 9a, 9b to be held down and protected for high-speed resistance and durability.

[0105] According to the detail shown in Fig. 2A, the coil bandage 8 further comprises, within the respective coil bandage layer 8a, one or more coil bandage reinforcement carriers 8b in the form of individual wires or filaments 10 or in the form of cords C made up of several twisted or intertwined filaments 10 (see Fig. 2B), wherein the one or more coil bandage reinforcement carriers 8b run parallel to each other and substantially along a circumferential direction U of the vehicle tire 50. The one or more coil bandage reinforcement carriers 8b are applied in a ring-like manner to the outer circumference of the belt 7 over the entire axial coil bandage extension A8 of the coil bandage 8, preferably wound onto it in a spiral fashion, although this is only partially shown in Fig. 2A. Furthermore, the one or more coil bandage reinforcement carriers 8b are coated with rubber or embedded in a rubber layer.As explained later, either a single rubberized coil bandage reinforcement carrier 8b can be wound in a ring shape on the outer circumference of the belt 7, or several coil bandage reinforcement carriers 8b running side by side can be wound within a rubber strip G wound in a ring shape on the outer circumference of the belt 7.

[0106] As shown in a schematic top view in Fig. 2C, the one or more coil bandage reinforcement carriers 8b within the respective coil bandage layer 8a extend at a first angle al to the circumferential direction U, wherein this first angle al in the vulcanized state of the vehicle pneumatic tire 50 202404649 is preferably between 0° and 5°, more preferably between 0° and 4°, particularly preferably between 0° and 3°, and most preferably between 0° and 2°. In this embodiment, this small first angle al relative to the circumferential direction U is intended to prevent undesirable circumferential growth of the vehicle pneumatic tire 50 at high speeds.

[0107] To achieve this, in addition to selecting a small first angle al of one or more coil bandage reinforcement elements 8b, it is further provided that the coil bandage 8 as a whole has a high tensile stiffness or high tensile strength in order to effectively suppress radial expansion of the radially underlying material. For this purpose, the respective coil bandage reinforcement element 8b is designed and / or manufactured from such a material that the elongation at break D of the respective coil bandage reinforcement element 8b is between 2% and 6%, preferably between 3% and 5.5%, and particularly preferably between 3% and 5%. The elongation at break D is determined in accordance with ASTM D2969-04 from 2010 (for steel cords) or ASTM D885 from 2023 (for textile cords and hybrid cords (steel and textile)), i.e.The respective coil bandage reinforcement carrier 8b, which is neither rubberized nor installed in the vehicle pneumatic tire 50, can be stretched by a maximum of 6%, preferably by a maximum of 5.5%, and in particular by a maximum of 5%, before it breaks. In this way, a highly tensile-strength coil bandage reinforcement carrier 8b, and thus also a highly tensile-strength coil bandage 8, is provided.

[0108] For example, a metallic material mM can be selected for the respective coil bandage reinforcement carrier 8b, preferably steel. The metallic material mM is in the form of individual filaments 10 or, preferably, in the form of cords C made up of twisted filaments 10, as illustrated by way of example in Fig. 2B. Accordingly, at least two, preferably three (as shown), metallic filaments 10 are individually twisted together to form several strands 11, wherein the individual strands 11 are in turn also twisted together to form a single cord-like coil bandage reinforcement carrier 8b. Thus, for example, a single coil bandage reinforcement carrier 8b can be constructed in a 3 x 3 structure (three twisted strands 11, each with three twisted filaments 10). A cord C can also consist of only one strand 11 with a corresponding number of filaments 10 twisted together.

[0109] In the case of such a cord C, the filament diameter D10 of the individual twisted or stranded metallic filaments 10 is, for example, between 0.1 mm and 0.3 mm, preferably between 0.14 mm and 0.25 mm. Depending on the type of twisting or stranding, this results in a cord diameter DC of, for example, between 0.3 mm and 1.2 mm, preferably between 0.5 mm and 1 mm. A single metallic filament 10 already exhibits an elongation at break D of, for example, approximately 2%. However, if the individual filaments 10 are twisted, the elongation at break D of the respective coil bandage reinforcement carrier 8b, designed as a cord C, increases to, for example, between 3.5% and 6%, depending on the type of twisting or stranding. The elongation at break D is therefore not only determined by the material, but also by the structural design of the respective coil bandage reinforcement carrier 8b.

[0110] However, a textile material tM can also be used, for example aramid, from which the respective coil bandage reinforcement carrier 8b is preferably formed in the form of a multifilament cord or a cord C made of several intertwined filaments 10, for example aramid fibers, as shown in cross-section in Fig. 2D. Accordingly, a plurality, for example more than 100, preferably more than 200, intertwined textile filaments 10 are combined to form a cord C. The cord diameter DC of the respective textile cord C is, as with the metallic filaments 10, for example between 0.3 mm and 1.2 mm, preferably between 0.5 mm and 1.2 mm. In such a form as a textile multifilament yarn or as a textile cord C, such a coil bandage strength carrier 8b exhibits, depending on the type of twisting or stranding, i.e., whether as an x1 cord, as in Fig.The design is represented in 2D, or as an x2 cord (with two such twisted textile cords C), or, depending on the twist level, exhibits an elongation at break D of, for example, between 2% and 6%. For a textile material tM, x2 cords are preferred because they offer better fatigue resistance.

[0111] Hybrid variants are also possible. For example, textile filaments 10 can be combined with metallic filaments 10 within a coil bandage reinforcement carrier 8b. In such hybrid variants, the material and / or the structural design of the respective coil bandage reinforcement carrier 8b must be selected such that an elongation at break D of between 2% and 6%, preferably between 3% and 5.5%, and particularly preferably between 3% and 5%, is achieved.

[0112] In a preferred embodiment, however, it is provided that mainly, preferably exclusively, coil bandage strength carriers 8b made of a metallic material mM are used in order to enable, in addition to the high tensile strength, an improved recyclability of the vehicle pneumatic tire 50 or also a retreading of the vehicle pneumatic tire 50 without increased effort.

[0113] The targeted selection of the material and / or the construction of the respective coil bandage reinforcement layer 8b to achieve the required elongation at break D (or high tensile strength) as well as the targeted selection of the small first angle al is particularly advantageous when a reduced longitudinal stiffness or a reduced tensile strength of the radially underlying belt 7 needs to be compensated for. In some embodiments of the vehicle pneumatic tire 50, it may be provided that the belt reinforcement layers 7b shown schematically in Fig. 3A 202404649 are located in the one or more belt layers 7a; 7a1 , 7a2 of the belt 7 do not run under a shallow second angle a2 of less than 35° to the circumferential direction U as is conventional, but run under a second angle a2 to the circumferential direction U as shown in a schematic top view in Fig. 3B, which lies between 35° and 55°, preferably between 40° and 45°.In such a design, the tensile strength or longitudinal stiffness of the entire belt 7 is limited, so that the belt 7 itself can only partially prevent the circumferential growth of the vehicle tire 50 at higher speeds. This is compensated for in the above design by the construction of the coil bandage 8, in particular by an appropriate selection of D and al.

[0114] In the case of two belt layers 7a; 7a1 , 7a2, as exemplified in Figs. 1 , 3A and 3B, the belt reinforcement bars 7b run within the respective belt layer 7a; 7a1 , 7a2 at the specified second angle 2 to the circumferential direction U, whereby the belt reinforcement bars 7b in each belt layer 7a; 7a1 , 7a2 have a different slope direction, so that the radially superimposed belt reinforcement bars 7b cross each other or form a so-called cross bond.

[0115] The belt reinforcement elements 7b, like the respective coil bandage reinforcement element 8b, can be made of a metallic material mM, preferably steel. Metallic belt reinforcement elements 7b can also be combined with belt reinforcement elements 7b made of a textile material tM, for example, polyester, nylon, rayon, aramid, or the like. However, it is preferred to use only belt reinforcement elements 7b made of a metallic material mM in order to enable improved recyclability of the vehicle pneumatic tire 50. The belt reinforcement elements 7b are also in the form of individual wires or filaments 10 and / or in the form of cords C made of several twisted or intertwined strands.

[0116] Filaments 10. Furthermore, the belt reinforcement carriers 7b are also preferably coated with rubber or embedded in a rubber layer.

[0117] The second angle a2 of the belt reinforcement elements 7b, between 35° and 55°, preferably between 40° and 45°, can be selected, for example, when the radially underlying carcass 2 has carcass reinforcement elements 2b in the individual carcass layers 2a in the form of wires or filaments 10 embedded or sheathed in rubber, or cords C consisting of several filaments 10, which, according to the invention, are at least partially, preferably exclusively, made of a metallic material mM, particularly preferably steel. This allows not only the provision of a robust pneumatic tire 50, but also improved recyclability.

[0118] In the case of a carcass 2 made of metallic carcass reinforcement members 2b, it is also necessary to ensure that the carcass reinforcement members 2b are compressed less during operation of the vehicle pneumatic tire 50, particularly to achieve good durability of the carcass reinforcement members 2b under dynamic loads. This is achieved precisely by the belt reinforcement members 7b running, as described, at the largest possible second angle α2 of between 35° and 55°, preferably between 40° and 45°, to the circumferential direction U. In this case, the belt reinforcement members 7b can yield more easily under dynamic load, and less compression acts on the radially underlying carcass 2.

[0119] In summary, a pneumatic tire 50 for passenger cars and / or light commercial vehicles utilizes a carcass 2 with metallic carcass reinforcement elements 2b, and the resulting properties are addressed by a corresponding design of the belt 7 and the wound band 8 as described. Depending on the design and application of such a pneumatic tire 50 for passenger cars 202404649 and / or light commercial vehicles, when using a carcass 2 with metallic carcass reinforcement elements 2b, it may also be possible to construct the belt 7 and / or the wound band 8 differently from the designs described above, as illustrated below:

[0120] According to one embodiment, for example, the axial spool bandage extension A8 may be less than or equal to the axial belt extension A7 or the first axial belt extension A71 of the axially wider or radially lower first belt layer 7a1, as indicated by dashed lines in Fig. 3C for various variants. Accordingly, the axial spool bandage extension A8 of the spool bandage 8

[0121] - be equal to the first axial belt extension A71, or

[0122] - smaller than the first axial belt extension A71 but larger than a second axial belt extension A72 of the radially upper second belt layer 7a2, or

[0123] - be less than or equal to the second axial belt extension A72.

[0124] The belt 7, which runs axially aR between shoulder sections 12 of the vehicle tire 50, is then no longer completely covered by the coil bandage 8 at the first belt edge 9a of the first belt layer 7a1 and possibly also at the second belt edge 9b of the second belt layer 7a2. Compared to the embodiment in Fig. 1, side sections 8c of the coil bandage 8 are therefore omitted, or the respective coil bandage reinforcement carrier 8b wound onto the belt 7 extends, if at all, only a small portion into the shoulder sections 12 of the vehicle tire 50.

[0125] This, in combination with the selected larger second angle a2 of the belt reinforcement 7b (lower longitudinal tensile strength) and in conjunction with the metallic material mM of the carcass reinforcement 2b, prevents excessive compression in the shoulder sections 12 of the vehicle pneumatic tire 50 by the respective coil bandage. 202404649

[0126] Reinforcing beam 8b is coming. Furthermore, the lower mass and low weight have an effect.

[0127] Heat development at the belt edges 9a, 9b has a positive effect on the high-speed behavior of the vehicle pneumatic tire 50.

[0128] This embodiment can also be used for certain applications of the vehicle pneumatic tire 50 with a coiled bandage 8, where the respective coiled bandage reinforcement carrier 8b does not exhibit an elongation at break D of between 2% and 6%, preferably between 3% and 5.5%, and particularly preferably between 3% and 5%. In this case as well, excessive compression by the respective coiled bandage reinforcement carrier 8b in the shoulder sections 12 of the vehicle pneumatic tire 50 can be prevented. However, this compression occurs more frequently with highly tensile-strength coiled bandage reinforcement carriers 8b, so that the reduced axial elongation offers an even greater advantage.

[0129] Instead of or in addition to this shortened version of the coil bandage 8, it can be provided that the respective coil bandage reinforcement carrier 8b is wound onto the radially underlying belt 7 in such a way that at least in the side sections 8c of the coil bandage 8 a gap L with a gap width BL is formed between axially adjacent windings of the coil bandage reinforcement carriers 8b. The gap width BL can be constant or it can increase with increasing axial distance from the tire zenith Z. In the side sections 8c of the coil bandage 8, a gap width BL of, for example, between 0.5 times and 2 times a coil bandage reinforcement carrier diameter D8b, i.e., the cord diameter DC of the coil bandage reinforcement carriers 8b designed as cords C or the filament diameter D10 of the coil bandage reinforcement carriers 8b designed as individual filaments 10, can be selected.

[0130] In the radial direction rR above the first belt edge 9a of the first belt layer 7a1 and possibly also the second belt edge 9b of the second belt layer 7a2, the windings of the respective coil bandage reinforcement carrier 8b are thus 202404649

[0131] "Thinned out". This also prevents excessive compression by the respective coil bandage strength carrier 8b in the shoulder sections 12 of the vehicle pneumatic tire 50, in combination with the selected larger second angle a2 of the belt strength carrier 7b (lower longitudinal tensile strength) and in conjunction with the metallic material mM of the carcass strength carrier 2b. Furthermore, material can be saved and the weight of the vehicle pneumatic tire 50 reduced.

[0132] According to a further embodiment, it is provided that the carcass reinforcement elements 2b of the carcass 2 running between the two bead areas 4 enclose a third angle a3 to the circumferential direction U, which in the case of a radial construction of the vehicle pneumatic tire 50 (in the vulcanized state of the vehicle pneumatic tire 50) is between 70° and 90°, or in the case of a diagonal construction of the vehicle pneumatic tire 50 (in the vulcanized state of the vehicle pneumatic tire 50) is between 40° and 50°, preferably 45°.

[0133] The design as a 50-series pneumatic tire with a diagonal construction offers the advantage that drive and braking forces in the form of tension can be absorbed by the carcass reinforcement elements 2b with only minimal energy losses. This is because, due to their angle relative to the circumferential direction U, these elements are displaced less during acceleration and braking, resulting in less energy loss as heat. This is particularly relevant for electric vehicles, as it not only achieves higher efficiency during acceleration but also allows a larger portion of the braking energy to be recuperated and fed back into the energy storage system, since less energy is dissipated in the 50-series pneumatic tire. Overall, this results in increased efficiency during operation.

[0134] According to a preferred embodiment, also shown in Fig. 4A, two carcass plies 2a are provided within the carcass 2, each carcass ply 2a having carcass reinforcement bars 2b extending at the third angle α3 to the circumferential direction U. The carcass ply 2a is folded over or folded up around the tensile-resistant bead cores 5, as shown in Fig. 1, i.e., a carcass fold 2f is formed on the axially outer side of the respective bead area 5. However, in each carcass ply 2a, the carcass reinforcement bars 2b have a different direction of slope, so that the radially overlapping carcass reinforcement bars 2b intersect or form a so-called cross-lamination. As a result, the carcass reinforcement elements 2b made of metallic material remain relatively flexible overall, resulting in lower rolling resistance at high speeds.

[0135] In the standard construction shown in Fig. 1, the carcass fold 2f does not extend to the sidewalls 3. In a different so-called C-construction (not shown), the carcass fold 2f can, however, extend to below the belt 7 or below the winding band 8.

[0136] In an optional embodiment, in such a carcass 2 consisting of two carcass layers 2a with metallic carcass reinforcement bars 2b in a cross bond, the radially overlying belt 7, for example with metallic belt reinforcement bars 7b in a cross bond (see Fig. 3B), can be omitted. This saves material and therefore also improves the recyclability of the vehicle pneumatic tire 50. However, if a belt 7 is provided, a second angle α2 of the belt reinforcement bars 7b of between 20° and 55°, preferably between 30° and 35°, can be selected due to the design of the carcass 2 as a diagonal carcass, since the diagonal carcass already experiences less compression due to the third angle α3 of the carcass reinforcement bars 2b. 202404649

[0137] To optimize the compression on the carcass 2, the coil bandage 8, which continues to lie radially above it, can be shortened in its side sections 8c and / or have coil bandage reinforcement carriers 8b which, as described above with reference to Fig. 3D, have a correspondingly enlarged gap L, so that the coil bandage reinforcement carriers 8b are “thinned” in the side sections 8c of the coil bandage 8.

[0138] Furthermore, in a design as a vehicle pneumatic tire 50 in radial construction or in diagonal construction, it can be provided that between adjacent carcass reinforcement carriers 2b in edge areas 2c of carcass strips 2S, from which the respective carcass layer 2a is composed in circumferential direction U, a reinforcement carrier spacing A2b is left, which corresponds between 1 times and 1.5 times a carcass reinforcement carrier diameter D2b of the carcass reinforcement carriers 2b, as shown in Fig. 4B. This can be achieved, for example, by omitting every second carcass reinforcement carrier 2b in the two edge regions 2c of a calendered material web, within which the parallel carcass reinforcement carriers 2b are embedded in rubber, i.e., a correspondingly large space 13 is formed between the carcass reinforcement carriers 2b with the reinforcement carrier spacing A2b.From this calendered material web, the carcass strips 2S are then cut to the appropriate length and with the corresponding angle of the carcass reinforcement elements 2b, and joined at their edge regions 2c by overlap splicing with further carcass strips 2S. Several carcass strips 2S joined in this way then form the carcass layer 2a, which extends in the circumferential direction U.

[0139] The edge regions 2c extend over an edge length L2c of, for example, between 3 mm and 10 mm, preferably over 5 mm, starting from an edge edge 2d of the respective carcass strip 2S. With edge regions 2c of the respective carcass strip 2S designed in this way, it can be achieved that during overlap splicing during the preparation of the respective carcass layer 2a, i.e., during the surface overlapping of the two edge regions 2c of adjacent carcass strips 2S in an overlap area 2e, the carcass reinforcement carriers 2b in the radially overlapping edge regions 2c are offset from each other in the circumferential direction U. In particular, these are arranged such that a carcass reinforcement carrier 2b is arranged within a carcass strip 2S in the radial direction rR adjacent to a space 13 within the respective radially adjacent carcass strip 2S.

[0140] In this way, unlike conventional overlap splicing, the overlap area 2e between two carcass strips 2S does not contain twice as many carcass reinforcement elements 2b as outside the overlap area 2e within the respective carcass strip 2S, but rather a similar number of carcass reinforcement elements 2b as outside the overlap area 2e within the respective carcass strip 2S. This results in the additional advantage, particularly with the carcass reinforcement elements 2b made of a metallic material mM used here, that the modulus and the flexural strength (and thus the restoring moments) within the multiple overlap areas 2e on the circumference of the carcass layer 2a largely correspond to the modulus and the flexural strength outside the overlap areas 2e within the respective carcass strip 2S or the carcass layer 2a formed from it.This also prevents the unintentional opening of the carcass flap 2f of the carcass 2.

[0141] In a radial-construction vehicle tire 50 with only one carcass ply 2a, it can also be provided that the carcass reinforcement members 2b run at a third angle α3 to the circumferential direction U of greater than 70° but less than 90°, so that a so-called angled carcass is formed. Such a slight angulation of the carcass reinforcement members 2b relative to the circumferential direction U can increase the efficiency of the vehicle tire 50 and also improve rolling resistance due to the metallic carcass reinforcement members 2b. For example, a standard carcass high-profile construction 2f, as shown in Fig. 1, or preferably a C-construction of the carcass high-profile construction 2f, which extends at least to below the belt 7 or to below the coil band 8, can be provided.In the case of such an angled carcass, a belt layer 7a can be omitted in the radially above belt 7, whereby the technical effect can already be compensated by a slight angulation of the carcass reinforcement carriers 2b.

[0142] Furthermore, as shown in Fig. 4C, it is provided that in the case of the carcass reinforcement members 2b made of a metallic material mM, the carcass rim 2f does not extend into the sidewall 3 in a standard design, but is only arranged within a bead strip 4a (rim strip) that protects the bead area 4 from the rim. In the bead area 4, the inflated pneumatic tire 50 is generally pressed against the rim by the more robust bead strip 4a, so that the pneumatic tire 50 is protected from damage in this area. At a transition edge F, the bead strip 4a transitions radially rR into the sidewall 3, with a radially upper end 2g of the carcass rim 2f lying radially below this transition edge F.

[0143] In particular, the radially upper end 2g of the carcass high-profile section 2f also lies radially below a radially lower end 3a of the sidewall 3, which in cross-section represents the radially lowest point of the sidewall 3 on the respective tire side. This results in a length between a bead core top surface 5a of the bead core 5, formed by the radially uppermost layer of the bead core 5, and the radially upper end 2g of the carcass high-profile section 2f of, for example, between 10 mm and 30 mm. 202404649

[0144] In this design, the carcass high-profile section 2f is additionally protected, since this area radially below the transition edge F is already less compressed, especially in the tire contact patch when the vehicle tire 50 rolls on a surface. Furthermore, the material of the bead 4a is more robust than, for example, the sidewall 3, so that forces are absorbed more effectively.

[0145] Furthermore, in this design, no apex 4b (as in Fig. 1 with radially longer carcass rise 2f) is arranged radially above the bead core 5 between it and the carcass ply 2a. To avoid excessively sharp bends in the carcass ply 2a in the area of ​​the bead core's upper surface 5a, the bead core 5 has a teardrop-shaped cross-section. This can be achieved, for example, by constructing the bead core 5 in several layers 5b, each with a layer height H5b (or a wire thickness of the wires forming the bead core 5) of, for example, between 1.2 mm and 1.7 mm, according to one of the following configurations or arrangements: 3-4-3-2-1 (as shown).

[0146] 3-4-5-4-3-2-1 ,

[0147] 2-3-2-1 ,

[0148] 4-5-4-3-2-1 or

[0149] 3-4-5-4-3-2-1 .

[0150] This makes the bead core 5 increasingly pointed radially outwards, thus compensating for the absence of the apex 4b. The carcass high-cut 2f can therefore terminate with a smaller radial extension compared to the embodiment in Fig. 1 and thus run entirely within the bead band 4a to achieve the aforementioned advantages.

[0151] The tire construction process is described below with reference to Figures 5 and 6A-6E, by which in particular the pneumatic tire 50 shown in Fig. 1 for a passenger car and / or for light vehicles is produced.

[0152] Commercial vehicles with a carcass 2 made of metallic carcass reinforcement members 2b as described above can be manufactured in the individual embodiments. The problem here is that the tire blank 50R (“green tire”, i.e., in the unvulcanized state), assembled from the individual components (inner layer 1, carcass 2, belt 7, coil bandage 8, tread 6, bead core 5, etc.), expands by up to 4% (in the radial direction rR) at the tire zenith Z and also to a lesser percentage in the shoulder sections 12 due to the action of pressure and temperature during insertion into the vulcanization mold 27, before the final vehicle pneumatic tire 50 made of elastic rubber, with its components permanently bonded together and the incorporated tread pattern, is completed in the vulcanization tool.

[0153] However, such radial expansion of up to 4% is problematic with a tire blank 50R, which, as described, has at least a carcass 2 with metallic carcass reinforcement members 2b and, in certain embodiments, also a coiled bandage 8 with high-tensile-strength coiled bandage reinforcement members 8b, which run at a small first angle oc1 to the circumferential direction U of preferably between 0° and 5°, preferably between 0° and 4°, particularly preferably between 0° and 3°, and most preferably from 0° to 2°. Particularly across the tire cross-section, this results in uneven expansion of the respective materials, which can lead to material displacements relative to the surrounding components as well as to an uneven stress distribution in the respective reinforcement members 2b, 7b, 8b.Furthermore, changing the first angle oc1 of the coil bandage reinforcement carriers 8b to compensate for radial expansion during vulcanization is only possible to a limited extent, especially with small first angles oc1, as described. Therefore, the manufacturing process described below is used to enable such a construction of the tire blank 50R or the vehicle pneumatic tire 50 in a simple and reliable manner: 202404649.

[0154] As shown in Figures 5 and 6A, in a first step ST1 a construction drum 20 is provided as part of a tire building system 100, which can be rotated about a drum axis 21. The construction drum 20 generally consists of segments distributed around its circumference, each of which is movable in the radial direction rR to allow the outer diameter of the construction drum 20 to be reduced or increased.

[0155] According to a preferred embodiment, the construction drum 20 is surface contoured, i.e., its outer surface 22 is not planar but has a convexly curved shape or a rounded cross-sectional contour, as shown in Fig. 6A. The outer surface 22 thus has a radial axial distance rA to the drum axis 21, which is at its maximum at the zenith 20Z of the construction drum 20. This radial axial distance rA decreases from the zenith 20Z on both sides in the axial direction aR towards the shoulder regions 20S of the construction drum 20. The outer surface 22 of the construction drum 20 is thus largely or almost completely adapted to the cross-sectional contour of the components of the finished pneumatic tire 50, i.e., the carcass 2, the belt 7, or the spool band 8.

[0156] In a second step ST2, a ring-shaped tire package 23 is positioned radially rR above the build drum 20. This package consists at least of the inner layer 1, the carcass 2, and the bead sections 4 with the bead cores 5 and optionally other components, each of which runs ring-shaped. The tire package 23 is preferably assembled from its individual components on a separate drum (not shown) and positioned radially above the outer surface 22 of the build drum 20 via a transfer device (not shown). Alternatively, the individual components can be wound directly onto the build drum 20 to assemble the tire package 23 directly on the drum.

[0157] The carcass 2 is constructed according to the respective embodiment as described above, i.e. with one or two carcass layers 2a each with carcass- 202404649

[0158] Reinforcing elements 2b made of a metallic material, in particular steel. The carcass plies 2a are folded over or folded up around the tensile-resistant bead cores 5 in a standard construction as shown in Fig. 1 or 4C, i.e., the carcass fold 2f is formed on the axially outer side of the respective bead area 5, either with apex 4b (see Fig. 1) or without apex (see Fig. 4C). However, a C-construction as described above is also possible. The carcass plies 2a themselves are then, for example, as described above, in the case of two carcass plies 2a in a cross bond (Fig.4A) (diagonal construction) or in the case of a carcass layer 2a in radial construction with carcass reinforcement members 2b running at 90° or in radial construction with greater than 70° and less than 90° (angle carcass) wherein the carcass reinforcement members 2b in the case of a radial construction with an angle carcass or in the case of a diagonal construction are located in edge areas 2c of the carcass strips 2S forming the carcass layer 2a with the widened reinforcement member spacing A2b to each other.

[0159] In a third step ST3, the assembled tire package 23 is fixed centrally, for example in a conventional manner using clamping devices 24 arranged (axially) on both sides of the construction drum 20, on which the side walls 3 may already be positioned. In this state, which is shown in Fig. 6B, the construction drum 20 (or its segments) is still in its retracted state, in which the tire package 23 is clamped between the clamping devices 24 and the outer surface 22 of the construction drum 20 only touches it tangentially at the zenith 20Z.

[0160] In a fourth step ST4, the belt 7, comprising individual belt layers 7a, 7a1, 7a2, which is assembled on a separate belt drum (not shown) away from the construction drum 20, is provided via a transfer device 25 and positioned centrally above the construction drum 20. The belt 7 is constructed according to one of the respective embodiments as described above, i.e., it can have one or more belt layers 7a, 7a1, 7a2 with belt reinforcement elements 7b made of a metallic material mM or a textile material tM, 202404649 which preferably run at the second angle a2 of between 35° and 55° to the circumferential direction U and, in the case of two belt layers 7a, 7a1, 7a2, may also be positioned in a cross pattern relative to each other.

[0161] In a fifth step ST5, the construction drum 20 is enlarged radially rR, as shown in Fig. 6C, while the clamping devices 24 are simultaneously moved axially aR. This causes the tire package 23, particularly in its central region, to conform to the convexly curved shape of the outer surface 22 of the construction drum 20 in the illustrated embodiment, so that the tire package 23 also assumes a curved shape. At the same time, this radial expansion of the construction drum 20 presses the radially upper carcass 2 of the tire package 23 against the belt 7 positioned radially above it.

[0162] Through appropriate measures, the belt 7 conforms fully to the curved tire package 23 or the radially upper carcass 2 over its entire axial belt extension A7, so that in this embodiment the belt 7 is also adapted to the curved shape of the outer surface 22 of the construction drum 20. The full-surface conformity of the belt 7 to the tire package 23 or the carcass 2 can be achieved, for example, by an inflatable cuff on the transfer device 25, by radial deformability of the transfer device 25, or by other means that cause the belt 7 to be pressed fully and over its entire axial belt extension A7 against the already contoured or curved tire package 23.

[0163] In some of the embodiments described above, the belt 7 can also be omitted, particularly in the case of a carcass 2 made of metallic carcass reinforcement members 2b in a cross bond (see Fig. 4A). In this case, the fourth step ST4 is omitted, and the tire package 23 is then simply expanded by the radial expansion of the construction drum 20 in the fifth step ST5.

[0164] The means are adapted to the convexly curved shape of the outer surface 22 of the construction drum 20.

[0165] In a sixth step ST6, at least one coil bandage reinforcement carrier 8b is provided, and a coil bandage 8 with one or more coil bandage layers 8a is then applied radially above the contoured or curved belt 7 (or, if the belt 7 is omitted, directly radially above the contoured or curved tire package 23 or the contoured or curved carcass 2). In this embodiment, the coil bandage 8 thus also conforms fully to the curved belt 7, the curved tire package 23, or the radially superior carcass 2 over its entire axial coil bandage extent A8, so that the coil bandage 8 is also adapted to the curved shape of the outer surface 22 of the construction drum 20.

[0166] The application of the coil bandage 8 is preferably achieved by winding one or more rubber strips G over an arbitrary winding head 26, as exemplified in Fig. 6D, so that one or more coil bandage layers 8a are formed within the coil bandage 8. Accordingly, several, for example between three and five, coil bandage reinforcement carriers 8b are embedded in the respective rubber strip G. The rubber strip G therefore has a rubber strip width BG of, for example, between 3 mm and 10 mm, in particular between 4 mm and 7 mm. The winding of the rubber strips G can be carried out overlapping or butt-to-butt. However, it can also be provided that a single coil bandage reinforcement carrier 8b is wound over the winding head 26 in one or more coil bandage layers 8a, wherein this coil bandage reinforcement carrier 8b is then correspondingly rubberized, i.e., encased in a rubber coating. 202404649

[0167] According to a further embodiment, which is preferably used in addition to the surface-contoured construction drum 20, the coil bandage reinforcement carrier(s) 8b are wound in the region of the tire zenith Z in such a way that a gap L with a specific gap width BL forms between at least some of the axially adjacent windings aR of the coil bandage reinforcement carrier(s), as shown in an enlarged view in Fig. 3E and Fig. 3F. This is comparable to the winding of the coil bandage reinforcement carrier(s) 8b in the side sections 8c of the coil bandage 8, as described with reference to Fig. 3D. The gaps L are preferably located on both sides of the tire zenith Z over an axial extent of between 10% and 70% of the coil bandage extent A8, preferably symmetrically around the tire zenith Z.

[0168] As shown in Fig. 3E, several coil bandage reinforcement elements 8b are wound onto the rubber strips G. In this embodiment, the gap L is formed by advancing the coiling head 26 axially aR, winding adjacent rubber strips G with a gap width BL apart from each other. Therefore, a gap L does not form between each winding of the coil bandage reinforcement elements 8b, but only between the axially outer and axially inner coil bandage reinforcement elements 8b of axially adjacent rubber strips G. The gap width BL can be between 0.5 and 1.5 times the rubber strip width BG, but preferably between 3 mm and 10 mm.

[0169] As shown in Fig. 3F, a single coil bandage reinforcement carrier 8b is wound up, whereby a gap L with a specific gap width BL is preferably formed between each axially adjacent winding of the coil bandage reinforcement carrier 8b by a corresponding feed of the coiling head 26. The gap width BL can in this case be between 0.5 times and 2 times the coil bandage width.

[0170] Strength carrier diameter D8b, i.e., the cord diameter DC of the coil bandage strength carriers 8b designed as cords C, or the filament diameter D10 of the coil bandage strength carriers 8b designed as individual filaments 10.

[0171] In both designs, the gap width BL of all formed gaps L can be constant or decrease with increasing distance from the tire's apex Z. Such gaps L also allow for material and weight savings. Furthermore, they can reduce compression on the radially underlying layers.

[0172] The provided coil bandage 8 is constructed according to one of the respective embodiments as described above, i.e., with highly tensile-strength coil bandage reinforcement carriers 8b, which have an elongation at break D of between 2% and 6%, preferably between 3% and 5.5%, and particularly preferably between 3% and 5%. The respective coil bandage reinforcement carrier 8b is thus, for example, made of a metallic material mM or a textile material tM, and the coil bandage 8 has an axial coil bandage extension A8, which, depending on the application, is greater than, less than, or equal to the first and / or second axial belt extension A71, A72.

[0173] The design and stranding of the coil bandage reinforcement elements 8b must be adapted according to the respective embodiment to the material used for the coil bandage reinforcement elements 8b and the extent to which the finished tire blank 50R expands radially rR during subsequent molding into the vulcanization mold due to the effects of pressure and temperature, since this radial expansion, as already described, acts as tensile forces in the circumferential direction U on the coil bandage 8 or the individual coil bandage reinforcement elements 8b. 202404649

[0174] In its simplest form, for small radial expansions during forming, for example 1% (relative to the radius of the tire blank 50R), a coil bandage reinforcement carrier 8b can be selected which has a straight shape FG, as shown in Fig. 2C for a small first angle oc1. In this case, the small radial expansion of the tire blank 50R can be absorbed by the respective coil bandage reinforcement carrier 8b without damage in the form of tensile forces in the circumferential direction U, even if the respective coil bandage reinforcement carrier 8b runs at the small first angle oc1 described above and / or has the elongation at break D described above of between 2% and 6%, preferably between 3% and 5.5%, and particularly preferably between 3% and 5%. For further optimization, the gap L described above can additionally be formed between individual coil bandage reinforcement carriers 8b in the area of ​​the tire zenith Z.

[0175] According to an alternative embodiment, however, it can also be provided that the individually wound rubberized coil bandage reinforcement carrier 8b or the multiple coil bandage reinforcement carriers 8b embedded in the wound rubber strips G run in a wave shape FW in the circumferential direction U, as shown by way of example in Fig. 2E. The tensile forces in the circumferential direction U caused by the radial expansion on the coil bandage reinforcement carriers 8b then cause the wavelength WL of the coil bandage reinforcement carrier 8b to increase and the wave amplitude WA to decrease, i.e. the “wave” to be pulled apart.

[0176] The coil bandage reinforcement carrier 8b thus approaches a straight shape FG with increasing radial expansion of the tire blank 50R during the forming process in order to absorb the increased tensile forces, whereby at this stage with an almost straight course a very high circumferential stiffness is present in the coil bandage 8, particularly when a small first angle oc1 of between 0° and 5°, preferably between 0° and 4°, particularly preferably between 0° and 3°, most preferably from 0 to 2°, is selected for the coil bandage reinforcement carrier 8b.

[0177] Preferably, the waveform FW is selected with respect to its wavelength WL and wave amplitude WA such that, after completion of vulcanization, and in particular after molding, an almost straight shape FG is present or at least approximates one. This not only achieves the aforementioned very high circumferential stiffness but also enables the selection of a high-tensile-strength coil bandage reinforcement element 8b, even when a very small first angle oc1 for the coil bandage reinforcement element 8b is chosen, between 0° and 5°, preferably between 0° and 4°, particularly preferably between 0° and 3°, and most preferably between 0° and 2°.

[0178] In principle, this design can also be combined with corrugated coil bandage reinforcement carriers 8b with the gap L described above between individual corrugated coil bandage reinforcement carriers 8b in the area of ​​the tire zenith Z in order to achieve reduced compression both centrally on the belt 7 and on the carcass 2.

[0179] In principle, for such coiled bandage reinforcement elements 8b with a circumferential waveform FW U, a construction drum 20 that is planar and uncontoured on the outside 22 or less contoured in the axial direction aR can also be used. The increased radial expansion during molding, which can then amount to up to 4%, for example, can be compensated for by a waveform FW with a correspondingly selected wavelength WL and wave amplitude WA, in which an almost straight shape FG is present after completion of vulcanization, and in particular after completion of molding, or is approached as such. For optimal compensation, the gap L described above between individual corrugated coiled bandage reinforcement elements 8b in the area of ​​the tire zenith Z can also be provided in an uncontoured construction drum 20.

[0180] In a seventh step, ST7, the remaining components, particularly the tread 6, are provided, and the tire blank 50R is assembled in subsequent steps. The completed tire blank 50R is then placed in a vulcanization mold 27 in an eighth step, ST8, and subsequently heated under pressure to create the final pneumatic tire 50 made of elastic rubber with its permanently bonded components and integrated tread pattern. The pneumatic tire 50 can then be removed from the vulcanization mold 27 in a ninth step, ST9, after vulcanization is complete.

[0181] The advantage of using a construction drum 20 that is already contoured in the axial direction aR is that, before the finished tire blank 50R is inserted into the vulcanization mold 27, only a small gap S remains in the radial direction rR between the tire blank 50R and the vulcanization mold 27, as schematically indicated in Fig. 6E (dashed line: the state with an uncontoured construction drum). This is because the individual components of the tire blank 50R were already adapted to the shape of the finished vehicle tire 50 during its construction via the convexly curved outer surface 22. In the subsequent vulcanization process, the heating during insertion results in a minimized residual protrusion R in the radial direction rR, which corresponds to the gap S through which the components of the vehicle tire 50 yield. This residual protrusion R is preferably in the range of 1% (relative to the radius of the tire blank 50R).

[0182] Such radial expansions around the remaining residual elevation R are present in the components used, in particular the carcass 2 made of metallic carcass reinforcement members 2b and, depending on the design, also of coil bandages. 202404649

[0183] Reinforcing elements 8b, which run at the first angle oc1 of between 0° and 5°, preferably between 0° and 4°, particularly preferably between 0° and 3°, and most preferably between 0° and 2°, to the circumferential direction U, can generally be accommodated without difficulty. This is particularly advantageous for an embodiment of the vehicle pneumatic tire 50 in which highly tensile-strength coiled bandage reinforcing elements 8b are used, as described above. In this case, the coiled bandage reinforcing elements 8b can only absorb a limited tensile force due to the significantly reduced compliance in the circumferential direction U, but this is generally sufficient with a residual elevation R in the range of 1% during molding into the vulcanization mold 27.

[0184] As described, however, instead of or in addition to the contoured construction drum 20, a circumferentially U-shaped coiled bandage reinforcement carrier 8b can also be used to generate additional compliance even with a residual protrusion R greater than 1%, whereby the waveform FW, with its wavelength WL and wave amplitude WA, is adapted as described to the residual protrusion R or the gap S remaining before molding, so that after completion of vulcanization or even after molding, a largely straight course of the coiled bandage reinforcement carrier 8b results at the correspondingly selected first angle oc1. The formation of the gap L can also be combined accordingly.

[0185] 202404649

[0186] Reference symbol list

[0187] 1 inner layer

[0188] 2 Carcass

[0189] 2a Carcass layer

[0190] 2b Carcass reinforcement

[0191] 2c Edge areas of the carcass layer 2a

[0192] 2d edge of the carcass ply 2a

[0193] 2e Overlap area

[0194] 2f Carcass high impact

[0195] 2g radial upper end of the carcass high spot 2f

[0196] 3 side wall

[0197] 3a radial lower end of the side wall 3

[0198] 4 bead area

[0199] 4a Bead band

[0200] 4b Apex

[0201] 5 bead core

[0202] 5a Top of bead core

[0203] 5b Layers of the bead core

[0204] 6 treads

[0205] 7 belts

[0206] 7a Belt position

[0207] 7a1 first belt layer

[0208] 7a2 second belt layer

[0209] 7b Belt reinforcement

[0210] 8 coil bandage

[0211] 8a Coil bandage placement

[0212] 8b Coil bandage reinforcement

[0213] 8c Side sections of the coil bandage 8

[0214] 9a first belt edge of the first belt layer 7a1

[0215] 9b second belt edge of the second belt layer 7a2 202404649

[0216] 10 Filament

[0217] 11 strand

[0218] 12 Shoulder section

[0219] 13 spaces

[0220] 20 construction drum

[0221] 20S Shoulder area of ​​the construction drum 20

[0222] 20Z Zenith of the construction drum 20

[0223] 21 Drum axle

[0224] 22 Outside of the construction drum 20

[0225] 23 tire package

[0226] 24 clamping device

[0227] 25 Transfer facility

[0228] 26 spool head

[0229] 27 Vulcanization form

[0230] 50 vehicle pneumatic tires

[0231] 50R tire blank

[0232] 100 tire assembly system al first angle a2 second angle a3 third angle

[0233] A2b Strength beam spacing

[0234] A7 axial belt extension

[0235] A71 first axial belt extension of the first belt layer 7a1

[0236] A72 second axial belt extension of the second belt layer 7a2

[0237] A8 axial coil bandage extension aR axial direction

[0238] BG rubber strip width

[0239] BL gap width

[0240] C Cord

[0241] D Elongation at break 202404649

[0242] D2b Carcass Reinforcing Belt Diameter

[0243] D8b coil bandage reinforcement carrier diameter

[0244] D10 Filament Diameter

[0245] DC cord diameter

[0246] F Transition flank

[0247] FG straight-line shape

[0248] FW waveform

[0249] G rubber strips

[0250] H5b Layer height of the layers 5b mm metallic material

[0251] L gap

[0252] L2c edge length

[0253] R residual elevation rA radial axis distance rR radial direction

[0254] S Spalt tM textile material

[0255] U circumferential direction

[0256] WL wavelength

[0257] WA wave amplitude

[0258] Z Tire zenith

Claims

202404649 Patent claims 1. Vehicle pneumatic tire (50) for passenger cars and / or light commercial vehicles, comprising a tread (6), a carcass (2) and a coiled bandage (8) consisting of one or more than one coiled bandage layer (8a) with an axial coiled bandage extension (A8), wherein - the coil bandage (8) is arranged radially (rR) above the carcass (2) and radially (rR) below the tread (6) and the coil bandage (8) has at least one coil bandage reinforcement carrier (8b), and - the carcass (2) has at least one carcass ply (2a), wherein each carcass ply (2a) has at least one carcass reinforcement carrier (2b) and each carcass ply (2a) runs between bead areas (4) of the vehicle pneumatic tire (50), wherein at least one bead core (5) is arranged in each bead area (4) and each carcass ply (2a) is folded over the at least one bead core (5) in the respective bead area (4) so ​​that a carcass fold (2f) is formed, characterized in that - in the carcass (2) at least one carcass reinforcement carrier (2b) made of a metallic material (mM) runs, - in the respective coil bandage position (8a) of the coil bandage (8), at least one coil bandage reinforcement carrier (8b) with an elongation at break (D) of between 2% and 6%, preferably between 3% and 5.5%, particularly preferably between 3% and 5%, extends, wherein gaps (L) with a gap width (BL) are arranged between at least some axially adjacent windings (aR) of the at least one coil bandage reinforcement carrier (8b), wherein the gap width (BL) of the respective gaps (L) is at least 0.5 times the coil bandage reinforcement carrier diameter (D8b) of the at least one coil bandage reinforcement carrier (8b), and - the vehicle pneumatic tire (50) has a load index in the range of 71 to 126. 202404649 2. Vehicle pneumatic tire (50) according to claim 1, characterized in that the gap widths (BL) are between 0.5 times and 2 times the diameter (D8b) of the spool bandage reinforcement carrier (8b) when the at least one spool bandage reinforcement carrier (8b) is wound individually, or the gap widths (BL) are, for example, between 0.5 times and 1.5 times the width (BG) of a rubber strip (G), preferably between 3 mm and 10 mm when the at least one provided spool bandage reinforcement carrier (8b) is wound embedded in the rubber strip (G).

3. Vehicle pneumatic tire (50) according to claim 1 or 2, characterized in that the gap widths (BL) of the gaps (L) are identical or the gap widths (BL) change with increasing axial distance of the respective gap (L) to a tire zenith (Z) of the vehicle pneumatic tire (50).

4. Vehicle pneumatic tire (50) according to claim 3, characterized in that - the gap widths (BL) become larger when the gaps (L) are arranged in side sections (8c) of the coil bandage (8) with increasing axial distance of the respective gap (L) to the tire zenith (Z), and / or - the gap widths (BL) become smaller with increasing axial distance to the tire zenith (Z) when the gaps (L) are arranged in the area of ​​the tire zenith (Z), preferably over an axial extent of between 10% and 70% of the coil bandage extent (A8) around the tire zenith (Z).

5. Vehicle pneumatic tire (50) according to one of the preceding claims, characterized in that 202404649 the at least one coil bandage reinforcement carrier (8b) runs in a first angle (a1) to the circumferential direction (U) within the coil bandage (8), wherein the first angle (a1) is between 0° and 5°, preferably between 0° and 4°, particularly preferably between 0° and 3°, most preferably from 0° to 2°.

6. Vehicle pneumatic tire (50) according to one of the preceding claims, characterized in that the at least one coil bandage strength carrier (8b) with an elongation at break (D) of between 2% and 6%, preferably of between 3% and 5.5%, particularly preferably of between 3% and 5%, is made of a textile material (tM), in particular aramid, and / or of a metallic material (mM), in particular steel.

7. Vehicle pneumatic tire (50) according to one of the preceding claims, characterized in that the coil bandage (8) comprises exclusively coil bandage strength carriers (8b) with an elongation at break (D) of between 2% and 6%, preferably of between 3% and 5.5%, particularly preferably of between 3% and 5%.

8. Vehicle pneumatic tire (50) according to one of the preceding claims, characterized in that the carcass (2) comprises exclusively carcass reinforcement members (2b) made of a metallic material (mM), preferably steel.

9. Vehicle pneumatic tire (50) according to one of the preceding claims, characterized in that the vehicle pneumatic tire (50) further comprises a belt (7) which is radially covered on the outside by the coil bandage (8) and the belt (7) has one, two or three belt layers (7a; 7a1 , 7a2), wherein the belt (7) has at least one belt reinforcement carrier (7b). 202404649 10. Vehicle pneumatic tire (50) according to claim 9, characterized in that at least one belt reinforcement element (7b) made of a metallic material (mM), in particular steel, runs in each of the respective belt layer (7a) of the belt (7), preferably exclusively belt reinforcement elements (7b) made of the metallic material (mM).

11. Vehicle pneumatic tire (50) according to claim 9 or 10, characterized in that the belt (7) has at least two belt layers (7a; 7a1 , 7a2), in particular a radially inner first belt layer (7a1 ) and a radially above it a second belt layer (7a2), wherein the axial coil bandage extension (A8) - is less than or equal to a first axial belt extension (A71 ) of the first belt layer (7a1 ) of the belt (7), and / or - is larger than a second axial belt extension (A72) of the second belt layer (7a2) of the belt (7), or - less than or equal to the second axial belt extension (A72) of the second belt layer (7a2) of the belt (7).

12. Vehicle pneumatic tire (50) according to one of the preceding claims, characterized in that the carcass reinforcement elements (2b) extend within at least one carcass layer (2a) of the carcass (2) at a third angle (oc3) to the circumferential direction (U), wherein - the carcass (2) has at least two carcass plies (2a), each carcass ply (2a) having at least one carcass reinforcement layer (2b) made of a metallic material (mM), wherein the respective carcass reinforcement layer (2b) runs at a third angle (oc3) of between 40° and 50°, preferably 45°, to the circumferential direction (U), and the carcass reinforcement layers (2b) of radially superimposed carcass plies (2a) have opposite slope directions exhibit 202404649, such that superimposed carcass reinforcement elements (2b) cross in the radial direction (rR) to form a cross-shaped structure, or - the carcass (2) has only one carcass layer (2a), wherein the carcass layer (2a) has at least one carcass reinforcement carrier (2b) made of a metallic material (mM), wherein the carcass reinforcement carrier (2b) extends at a third angle (oc3) of greater than 70° and less than or equal to 90° to the circumferential direction (U).

13. Method for manufacturing a vehicle pneumatic tire (50) for passenger cars and / or light commercial vehicles, in particular with a load index in the range of 71 to 126, in particular a vehicle pneumatic tire (50) according to one of the preceding claims, comprising at least the following steps: - Providing a construction drum (20) (ST1) which can be rotated about a drum axis (21) wherein the construction drum (20) has an outer surface (22) extending radially outwards (rR) on which a tire package (23) can be fully accommodated; - Positioning and fixing a ring-shaped tire package (23) in a radial direction (rR) above the provided construction drum (20) (ST2) (ST3), wherein the tire package (23) comprises at least: a ring-shaped inner layer (1), a ring-shaped carcass (2) above it in a radial direction (rR) consisting of at least one carcass layer (2a) with at least one carcass reinforcement carrier (2b) made of a metallic material (mM), and bead areas (4) with bead cores (5); - Expanding the provided construction drum (20) in a radial direction (rR) (ST5) so that the provided and fixed tire package (23) lies flat against the outside (22) of the construction drum (20), at least in some areas; - Providing at least one coil bandage reinforcement carrier (8b) with an elongation at break (D) of between 2% and 6%, preferably between 3% and 5.5%, particularly preferably between 3% and 5%, and 202404649 - Forming a coil bandage (8) in a radial direction (rR) above the tire package (23) by winding the at least one provided coil bandage reinforcement carrier (8b) in at least one coil bandage layer (8a) over an axial coil bandage extension (A8) such that gaps (L) with a gap width (BL) are formed between at least some axially adjacent windings (aR) of the at least one coil bandage reinforcement carrier (8b), wherein the gap width (BL) of the respective gaps (L) is at least 0.5 times a coil bandage reinforcement carrier diameter (D8b) of the at least one coil bandage reinforcement carrier (8b) (ST6); - Applying a tread strip (6) in a radial direction (rR) above the formed coil bandage (8) and completing a tire blank (50R) (ST7); - Molding the finished tire blank (50R) into a vulcanization mold (27) and vulcanizing the tire blank (50R) (ST8); - Removal of the vehicle pneumatic tire (50) from the vulcanization mold (27) after completion of vulcanization (ST9).

14. Method according to claim 13, characterized in that a construction drum (20) is provided, the outer surface (22) of which has a radial axial distance (rA) to the drum axis (21), wherein the radial axial distance (rA) is at its maximum at a zenith (20Z) of the construction drum (20) and decreases from the zenith (20Z) in the axial direction (aR) towards shoulder regions (20S) of the construction drum (20), so that a construction drum (20) with an outer surface (22) contoured in the axial direction (aR), for example a rounded outer surface (22), in particular a convexly curved outer surface (22), is provided, so that the provided and fixed tire package (23) expands in the radial direction (rR) of the provided construction drum (20) at least partially conforms to the outer surface (22) contoured in the axial direction (aR). 202404649 The construction drum (20) is laid flat so that the tire package (23) also assumes a contoured shape in the axial direction (aR) at least in some areas; and thereby the coiled bandage (8) wound on it also assumes a contoured shape in the axial direction (aR) at least in some areas.

15. Method according to claim 13 or 14, characterized in that the at least one provided coil bandage reinforcement carrier (8b) with an elongation at break (D) of between 2% and 6%, preferably between 3% and 5.5%, particularly preferably between 3% and 5%, has a waveform (FW) with a wavelength (WL) and a wave amplitude (WA), wherein the formation of the coil bandage (8) in the radial direction (rR) above the tire package (23) is carried out by winding the at least one provided wave-shaped coil bandage reinforcement carrier (8b) in at least one coil bandage layer (8a) over an axial coil bandage extension (A8) such that the at least one provided coil bandage reinforcement carrier (8b) retains its waveform (FW) in the circumferential direction (U).

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