CN100537206C - 用于制造可用作轮胎胎冠衬层的带的设备和方法 - Google Patents
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Abstract
一种设备和方法用来制造可用作轮胎胎体中的胎冠衬层、缓冲层和增强层的带。带通过将多根单端帘线浸渍于溶剂基胶浆中而制造。这些帘线在进入浸渍盘之前被会聚以便使得他们在浸渍时固定于单个平面中。胶浆包括溶剂和弹性体组合物,其受到烘干以便使得大部分溶剂蒸发。弹性体组合物保留,以便包封着帘线,从而形成带。
Description
技术领域
本发明涉及用于制造可用作轮胎胎体中的胎冠衬层、缓冲层和增强层的带的设备和方法。
背景技术
轮胎工业已经长期相当关注子午胎构造以寻求增强轮胎。轮胎增强层的一个实例在授予Kimble的美国专利No.3,720,569中进行了描述。这种增强层通过将多根帘线按照所需间隔关系穿过挤出机而形成。帘线可在多重浸渍操作中涂以胶乳以便形成整体式带条。此类增强层构造可为子午线和斜交帘布层构造两者都提供道路稳定性更好和轮胎行驶里程更长的优点。然而,因为增强层与轮胎用橡胶的粘合不够,所以此类构造易受带束层边缘分离破坏问题。
包封着子午线轮胎带束层的胎冠衬层可用来帮助将此类带束层边缘分离破坏情况减至最小。最初,胎冠衬层被用作带有叠接的全宽度带条。经验表明,这种叠接在固化期间可能拉开。此外,由于胎冠衬层施用于带束层上方,所以在带束层的伸展方面存在缺陷。而且,对于这种构型,必须跨过整个带束层施用相同宽度的材料。由于这些缺陷,在二十世纪九十年代开发了较窄的胎冠衬层带。这种带绕着带束层螺旋地缠绕。此类带通过切割胶布而制造。带的宽度取决于每英寸的帘线数量,其根据轮胎制造商而改变。人们发现此类带能够增加缠绕张力,因为没有叠接。此外,此类带能够被施用在带束层边缘处的加固层中以便改进轮胎性能。然而,这种方法取决于若干方法/步骤,即编织织物、处理织物以便实现良好粘合于压延橡胶上、化合橡胶、将橡胶擦于或压延于处理过的织物上以及将胶布切割成特定宽度。这些都是固有的高成本/劳动密集型方法。由于切割步骤,所以在带的边缘上可能有切下的帘线,这可能造成边缘磨损。因此,此类方法产生大量废料。而且,由于每个带条中的单端帘线的数量可能不同,所以这样生产的带可能不均匀。对于每个步骤,潜在的误差和累加方差要求轮胎成型方法中容许过大的公差。最后,为了保证织物与轮胎用橡胶的良好粘合而加入橡胶,这就增加了轮胎的总重量。
由于切割涂胶布方法中存在固有缺点,所以已经开发了用于使用十字头挤出机由单端帘线制备胎冠衬层带的方法。此类方法通常被称为方法”,并且示于图1中。在总体上示于1处的方法中,多根帘线2和橡胶3被送入模头4中,在这里用橡胶把帘线包封起来以得到与轮胎用橡胶的良好粘合。这样就形成了包括多根涂胶单端帘线的带。在帘线被送入模头之前,帘线必须利用间苯二酚(resourcinol)-甲醛胶乳浸渍液进行处理,以保证良好粘合于在挤压步骤中引入的橡胶上。
与切割涂胶布方法相比,方法改进了均匀性,因为不可能存在不均匀切割,因此准确控制着带中的单端帘线的数量。而且,与切割涂胶布方法相比,这个方法减少了废品,因为在带的边缘没有切下的帘线。此外,利用方法可以得到更长的带每卷长度。然而,这个方法中使用的挤出机和模头代表着较大的资本投资。而且,带自身仍然依赖于橡胶混合步骤以及加入/施用橡胶作为保证良好粘合于轮胎用橡胶混合物上的方法,因此增加了重量和成本。此外,方法需要超过环境压力和温度。因此,在轮胎工业中就需要开发一种用于制造可用作轮胎胎体中的胎冠衬层、缓冲层和增强层的带或带条的方法,与现有技术的方法相比,这种方法资本密集和劳动密集程度较小。而且,需要一种能生产更均匀的带而并不产生废物的方法。此外,需要生产包装的带或带条,其准备作为胎冠衬层应用于轮胎中或者可用作胎体中的缓冲层和增强层。
发明内容
申请人已经认识到胶浆比橡胶流动性好得多,并且使用胶浆来包封单端帘线优于方法中使用的橡胶。此外,申请人已经认识到与方法中橡胶必须在热挤出机中施用相反,胶浆可以在环境温度和环境压力下施用。这样,通过提供并不需要象在方法中那样使用挤出机模头的方法,本发明就克服了与现有技术相关联的问题。
此外,本发明的方法不象现有技术的切割涂胶布方法那样为劳动密集型,因为其不涉及织物的切割。此外,其不象切割涂胶布方法那样为资本密集型,因为其不需要压延机辊筒。而且,本发明的方法避免了潜在的误差,因为其不具有切割步骤,进而几乎消除了由于每个带条中的单端帘线数量可能变化而导致不均匀的可能性。此外,由于本发明的方法中没有切割步骤,所以就不会造成边缘磨损并且带的边缘上没有切下的帘线。因此,与切割涂胶布方法相比,本发明的方法产生的废品更少。最后,可以减少轮胎的总重量,因为不需要加入橡胶以保证织物与轮胎用橡胶的良好粘合。
因此,根据本发明,提供了用于由多根单端帘线制造带的设备与方法。这种设备包括用于将包括溶于溶剂中的弹性体组合物的溶剂基胶浆施用于单端帘线上的浸渍盘。这种设备还包括用于在帘线行进至浸渍盘之前会聚帘线的装置,以便使得这些帘线会聚于单个平面中。在浸渍盘中,当进行浸渍时,帘线固定于单个平面中。另外,这种设备包括用于固化胶浆以便使得大部分溶剂馏出并且使帘线包封于弹性体组合物中从而形成带的烘箱。
此外,根据本发明,提供了一种用于制造带的方法。这种方法包括将多根单端帘线浸渍于包括胶浆和弹性体组合物的浸渍液中;并且固化胶浆以便使得大部分溶剂蒸发,从而形成包括包封于弹性体组合物中的单端帘线的带。
附图说明
图2为用于由单端帘线制造轮胎加强带的本发明的方法的一部分的局部视图。
图3为本发明的一对梳的沿图2中的方向线3-3剖开的平面图或正视图,这对梳置于浸渍盘之前。
图4为本发明的压辊的透视图。
图5为用于在本发明的设备中引导带的导向辊的切开透视图。
图6为图2的设备的最终驱动单元的透视图。
图7为用于将本发明的带引导至卷绕器的梳的透视图。
图8为本发明的卷绕器的视图。
具体实施方式
根据本发明,提供了一种用于制造用作轮胎胎体中的胎冠衬层、缓冲层和增强层的带条或带的设备和方法。将在本发明设备的操作范围内相对于图2-8来对本发明的方法进行描述。带由多根单端帘线制成。与包装于辊上的织物相反,“单端帘线”是指作为单端包装于卷轴上的处理过的帘线。单端帘线在市场上可从多个供应商处买到,这些供应商如德国的Mehler Textile Industries of Fulda、Dan River,Inc.of Atlanta、Georgia and Southern Weaving Company ofGreenville,South Carolina。在这个优选实施例中,单端帘线的数量为十个的倍数或者十二的倍数,根据应用情况而定。用于胎冠衬层或胎体应用的每英寸端部的数量的变化取决于帘线构造,而对于特定构造而言,则取决于轮胎类型和轮胎制造商。
可用于本发明帘线的典型合成纤维纱由聚酰胺如6,6尼龙、6尼龙或者其任何共聚物制成。替代地,纱可包括聚酯、聚芳基酰胺纤维、人造纤维、玻璃或者碳等等。用于本发明的特别适用的纱为T-728,其为可从DUSA International of Wilmington,Delaware买到的热稳定66尼龙。为了满足轮胎应用的强度和耐久性要求,纱通常由包含稳定剂的高粘度聚合物制备并且以高拉伸比拉伸以便产生高韧性纱,如美国专利No.3,311,691中所公开。
在图2中总体上以10示出的单端帘线进入本发明的设备。为简化示出,在10处仅示出了单根帘线。本发明的设备包括具有多根垂直梁12、一对水平梁14以及一组支柱16的框架。这些帘线被送至一个单一型导向辊18,导向辊18可以任选,根据帘线必须行进的距离而定。本发明的设备包括在图2中总体上以20示出的浸渍站。浸渍站20包括取出装置22、浸渍盘24以及以便用于升高和放下浸渍盘的机构26。
根据本发明的设备还包括用于在帘线行进至浸渍盘之前会聚帘线的装置。用于会聚帘线的装置包括第一梳28和第二梳30,如图2和3中所示。第一梳在帘线行进至浸渍盘之前会聚帘线。第二梳置于第一梳与浸渍盘之间以便在帘线离开第一梳之后与其行进至浸渍盘之前进一步会聚帘线。图3中更详细地示出了这些梳,图3为梳的平面图或正视图。第一梳具有多个第一凹槽28a,如图3中所示。每个第一凹槽具有多个第一齿28b。第一空间28c形成于连续的齿之间。帘线穿过第一空间向第二梳行进。第二梳具有多个第二凹槽30a,如图3中所示。第二梳的每个第二凹槽具有多个第二齿30b。第二空间30c形成于连续的第二齿之间。帘线穿过第一空间向浸渍盘行进。每个第二凹槽的宽度小于每个第一凹槽的宽度,以便会聚帘线并且在帘线行进至浸渍盘时使这些帘线置于单个平面中。
显然,在不背离本发明的精神的情况下可对所述的这些设备进行改型。例如,不使用多个梳来会聚帘线,用于在帘线行进至浸渍盘之前会聚帘线的装置可以包括导向辊。此类导向辊不具有跨过辊的宽度等距离分布的凹槽。相反,凹槽将会成群分布以便使得当帘线跨过导向辊行进时,帘线会聚于这些成群的凹槽中。不论发生哪一种情况,不管使用梳或者导向辊,本发明的会聚装置都设计成用于会聚帘线并使其定位于单个平面中,以及保证预浸的完整性。在图3中以31示出了离开第二梳的帘线的会聚组。
特别是从图2可以看出,浸渍盘22包括多个容放辊32。辊保持单端帘线穿过浸渍盘前进并且保证单端帘线浸入浸渍盘中。辊32包括多个如图4中所示的凸部32a和多个如图3和4中所示的凹槽或凹部32b。所会聚的帘线安放于容放辊的凹槽32b中。压辊34置于辊32的中间浸渍盘辊上方。压辊34包括多个凸部34a和凹部34b。如图4中所示,凸部34a与容放辊32的凹部34b啮合。帘线留在压辊的凸部上和浸渍盘辊的凹部中以便当它们穿过浸渍盘时将胶浆压入帘线之间的间隙中。当施用浸渍液时,所会聚的帘线固定于单个平面中。图4中用33示出了从浸渍盘辊的凹槽中出来的溶剂化的或润湿的带。
此外,在不背离本发明的范围的情况下可以改变所使用的特定设备。举例来说,如果当帘线穿过浸渍盘时帘线中存在足够的张力,那么可以不需要使用压辊。在这种情况下,只是必须单端帘线中的张力足够以便保持其处于浸渍盘的容放辊的凹部中。在这种情况下,适当的支承件,如导向辊或玻璃条杆,可用于帘线。
浸渍盘中使用的浸渍液为溶剂基的胶浆。这种溶剂基的胶浆包括弹性体组合物,其溶于溶剂如甲苯中。例如,这种弹性体组合物可包括,但不限于天然橡胶或带有苯乙烯丁二烯的天然橡胶或带有聚丁二烯的苯乙烯丁二烯。弹性体组合物中的这些组成材料可以根据最终用户需要而与增强剂、活化剂和/或增塑剂混合。胶浆中的溶剂的百分比取决于帘线穿过设备的速度。这种百分比通常介于10-30%的范围内。
随后,溶剂化的或润湿的带被送到导向辊36而后送到另一个如图2中所示并且特别如图5中的所示的导向辊38。图5为示出了本发明的示例性双型导向辊的一部分的剖视图。从图5中可以看出,凹槽40形成于导向辊中。这些凹槽40比容放单端帘线的凹槽如单一型导向辊18中的凹槽更宽,以便容放溶剂化的带。应当指出,与其在带离开浸渍盘之后使用导向辊来引导带,不如在浸渍盘之后使用绕着导向辊的套筒。导向辊或套筒的用途是在带离开图2所示的设备时保持带对齐并且防止其滚动。
随后将溶剂化的或润湿的带送到烘箱42,在这里其穿过一条通道,到达另一个双型导向辊44,然后穿过另一个条贯穿烘箱的通道。在烘箱中,帘线必须保持固定于单个平面上。这点通过保持帘线中的张力来实现,并且为保持带的完整性所需要。包括溶剂和弹性体组合物的胶浆在烘箱中烘干。这种烘干通常在大约110℃进行一定时间,这取决于在这点上帘线或带被传送过设备的速度。这种烘干馏出或蒸发大部分溶剂,如甲苯。剩余的是固定于单个平面中且包封于弹性体组合物中的帘线,从而形成带,图6中以46示出了这种带。在最终产品中,部分少量的残留溶剂留作带的组分。溶剂可以包括带重量的0.0009-5%。
离开烘箱,带通过导向辊38被送回到一组导向辊46、48和50,以及在图2和6中总体上以52示出的驱动装置。另一个包括轴54a和辊54b、54c的驱动装置54为任选,并且只有当驱动装置52不运转时才使用驱动装置54。从图2中可以看出,驱动装置52包括轴52a和齿轮传动辊52b、52c,用于驱动带通过设备。如图6中所示,驱动装置支承于框架56中,框架56包括支承杆件58以便当带穿过设备运动时呈送带。支承辊保持于一对支承件60之间。
随后,图6中以62示出的带被送到一对两个型导向辊62和64以及机构66处,以便将带呈送给如图7中所示的任选的梳68。机构66包括立式支座66a、水平杆66b以及辊66c。杆和辊通过端盖66d保持在一起。带在辊66c上方滚动并且前进至梳68。图7的梳类似于已知单端帘线方法中用于保持帘线分离所使用的梳,但是图7的梳齿数更少,并且与已知单端帘线方法中使用的梳相比,齿间距更宽,以便容纳带。于是带被送到如图8中所示的卷绕器70,卷绕器70由如图7中所示的框架72支承。在卷绕器之后,带被送到卷轴74,带在卷轴74上缠绕并存储。图7中示出了一对卷轴。
在梳之后,带被送到如图8中所示的导向轮76。导向轮通过紧固件78保持于卷绕器的框架72上。离开导向轮76后,带被送到另一个导向轮80。类似的导向轮可以见于用于制造单端帘线的已知设备中;然而,此类导向轮具有用于容纳单端帘线的凸部和凹部。相反,在本发明的设备中,导向轮76和80的表面都不具有凸部和凹部,而是保持平滑以便容纳带。此类导向轮在本发明中可任选地使用,并且用来保证带停留就位。当带从导向轮76运动到导向轮80进而运动到最终包装(即,带有卷绕于其上的带的卷绕器70)时,带中的张力通过松紧调节臂82来保持。松紧调节臂的端部绕着上枢轴点84和下枢轴点86做枢轴转动。松紧调节臂的运动由阻止松紧调节臂碰撞于卷轴上的下限动装置88来限制。上枢轴点84和下限动装置88通过板90而保持于框架上,其中板90紧固于卷绕器的框架上。导向辊92引导带至导向器94,带通过导向器94行进至最终包装。
对于本发明,因为各个帘线浸渍于胶浆中,所以帘线最好更易于接近胶浆而非现有技术中的橡胶,因为橡胶并不具有像胶浆那样好的流动性。因此与现有技术的方法相比,可以更完全地覆盖单根帘线或织物中的帘线。因此,与切割织物或方法相比,使用本发明可以生产出更优质的带。尽管可以在高温和高压下实现弹性体组合物如橡胶的所需封装特征,但是本发明能够在正在施用胶浆时在环境温度和环境压力下实现这些所需封装特征。
本发明的带可现成用作轮胎用胎冠衬层。当用于这种应用时,带直接缠绕于轮胎上。带中的单端帘线于是在轮胎固化方法中粘附于橡胶上。替代地,如上文所指出,带可以在轮胎胎体中用作缓冲层和增强层。本发明的带一般地为1/4"至3/8"左右宽。
将参看以下实例对本发明进行更详细地描述,该实例用来示例说明本发明而非限制其范围。
实例
可以使用图2的设备由多根单端帘线,如可从DUSA,International处买到的T-728,来制造带。然后,可以将帘线送到预浸盘,在预浸盘处施用rf1浸渍液。这种浸渍液可以通过向箱中加入水、氢氧化钠(NaOH),或苛性碱小球、间苯二酚薄片和甲醛而制成,从而形成固体含量约为6%的溶液。应当将这种溶液混合约30分钟。然后,可以使这种溶液陈放至少约3小时(最小为2小时,最大为4小时)。在另一个箱中,加入胶乳。然后使水与氢氧化铵NH4OH混合并被缓慢加到胶乳中。随后加入消泡剂以便形成溶液,应当缓慢进行混合。这种溶液的固体含量约为35%。随后,将这种溶液与来自第一箱的溶液化合。在使用之前应将化合的溶液在一起混合约30分钟。应将帘线浸渍于这种化合溶液中约3秒钟。然后,应将浸渍液在约226℃的温度下固化介于100和200秒范围内的停留时间。随后应将帘线送到另一个烘箱,浸渍液在这个烘箱中以165℃的温度被固化。帘线可以随后浸渍于胶浆浸渍盘中。胶浆浸渍盘中的胶浆可以是溶剂的混合物,如甲苯(85kg)和橡胶基弹性体组合物(15kg)的混合物,所述橡胶基弹性体组合物如天然橡胶,天然橡胶与苯乙烯丁二烯,或苯乙烯丁二烯与聚丁二烯。其任何一个均可以与增强剂、活化剂和/或增塑剂混合。胶浆应在烘箱中以110℃的温度烘干,以便使得甲苯被馏出。这样就形成了宽为1/2英寸的带。
Claims (6)
1.一种子午线轮胎,包括
带;和
包封着该带的非压延胎冠衬层,其中胎冠衬层包括多个单端帘线(10)、由rf1浸渍液形成的粘合物和包括溶于溶剂中的弹性体组合物的溶剂基胶浆,其中单端帘线在环境温度时被包封于弹性体组合物和微量溶剂中。
2.根据权利要求1所述的子午线轮胎,其中溶剂占该带重量的0.0009-5%。
3.根据权利要求1或2所述的子午线轮胎,其中溶剂为甲苯。
4.根据权利要求1或2所述的子午线轮胎,其中弹性体组合物选自天然橡胶、带有苯乙烯丁二烯的天然橡胶或带有聚丁二烯的苯乙烯丁二烯。
5.包封着子午线轮胎带束层的方法,包括:
a)在子午线轮胎上提供带束层;
b)形成非压延的胎冠衬层,通过:
i)浸渍多个单端帘线(10)于rf1浸渍液中;
ii)烘干已浸渍的帘线;
iii)在环境温度时,浸渍已rf1浸渍的帘线在包括溶剂和弹性体组合物的溶剂基胶浆中;和
iv)烘干胶浆,以便使得大部分溶剂蒸发,且弹性体组合物保留,以便包封着帘线,从而形成胎冠衬层;
c)使胎冠衬层绕着带束层螺旋地缠绕。
6.根据权利要求5所述的方法,其中还包括会聚所述多个单端帘线,以便在帘线行进至浸渍盘时使这些帘线置于单个平面中。
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2004
- 2004-08-24 JP JP2006524781A patent/JP4452718B2/ja not_active Expired - Fee Related
- 2004-08-24 WO PCT/US2004/027399 patent/WO2005023531A1/en active Application Filing
- 2004-08-24 DE DE602004017022T patent/DE602004017022D1/de not_active Expired - Lifetime
- 2004-08-24 AT AT04781980T patent/ATE410298T1/de not_active IP Right Cessation
- 2004-08-24 EP EP04781980A patent/EP1660312B1/en not_active Expired - Lifetime
- 2004-08-24 PT PT04781980T patent/PT1660312E/pt unknown
- 2004-08-24 ES ES04781980T patent/ES2315707T3/es not_active Expired - Lifetime
- 2004-08-24 CN CN200480032041.3A patent/CN100537206C/zh not_active Expired - Fee Related
- 2004-08-24 CA CA002536777A patent/CA2536777A1/en not_active Abandoned
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2009
- 2009-04-20 US US12/426,649 patent/US7879391B2/en not_active Expired - Fee Related
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GB868954A (en) * | 1957-03-08 | 1961-05-25 | Olympic Tyre & Rubber Company | Method and apparatus for processing cord |
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Also Published As
Publication number | Publication date |
---|---|
US7879391B2 (en) | 2011-02-01 |
EP1660312A1 (en) | 2006-05-31 |
ATE410298T1 (de) | 2008-10-15 |
DE602004017022D1 (de) | 2008-11-20 |
EP1660312B1 (en) | 2008-10-08 |
CA2536777A1 (en) | 2005-03-17 |
ES2315707T3 (es) | 2009-04-01 |
JP4452718B2 (ja) | 2010-04-21 |
US20090317543A1 (en) | 2009-12-24 |
PT1660312E (pt) | 2008-11-24 |
WO2005023531A1 (en) | 2005-03-17 |
US20050048280A1 (en) | 2005-03-03 |
JP2007504368A (ja) | 2007-03-01 |
CN1874885A (zh) | 2006-12-06 |
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