CN110561979A - polyurethane pneumatic tire and manufacturing method thereof - Google Patents

Abstract

the invention discloses a polyurethane pneumatic tire and a manufacturing method thereof, wherein the tire comprises a polyurethane tread, a polyurethane belt layer, a polyurethane sidewall, a polyurethane tire body, a polyurethane soft triangle, a polyurethane hard triangle, a steel wire ring and a bead protection rubber which are sequentially arranged from outside to inside. Compared with the traditional tire, the polyurethane pneumatic tire and the manufacturing method thereof provided by the invention have the advantages that the polyurethane material is used for replacing the rubber material, so that the tire performance is more excellent, and the service life is greatly prolonged. Meanwhile, the polyurethane material has more comprehensive performance than a natural rubber material, and thus is simpler in structure than a rubber tire. The characteristics determine that the manufacturing process of the polyurethane tire can be greatly simplified compared with the traditional tire. The polyurethane tire is suitable for various types of inflatable tires, including car tires, truck tires, engineering tires, giant tires, various special tires and the like, and is particularly suitable for engineering tires and giant tires with low speed and high load.

Description

Polyurethane pneumatic tire and manufacturing method thereof

Technical Field

The invention relates to the technical field of tires, in particular to a polyurethane pneumatic tire and a manufacturing method thereof.

Background

at present, the truck tire is mainly an all-steel radial tire released by Michelin in the fifties of the twentieth century. As shown in fig. 1, the all-steel radial tire structure comprises a tread, a base rubber, a belt ply, a tire body, a soft triangle, a hard triangle, a bead filler, a sidewall rubber, an inner liner, a transition layer and the like. The used materials mainly comprise natural rubber, styrene butadiene rubber, butyl bromide rubber and the like. Through the development of nearly 70 years, all-steel radial tires have obvious advantages in the aspects of performance, energy consumption and the like, and are popularized in the global range at present.

The stress of the tire in the rolling process is extremely complex, the functions of all parts are different, and the requirement is difficult to meet only by using one or two rubber materials, so that the tire structure evolves to supplement the parts mutually. The functions of all parts are different, and the requirements on materials are also different, for example, the tire side needs ultraviolet resistance, wear resistance, fatigue resistance and other performances, and the air-tight layer has higher requirements on air tightness.

Meanwhile, the formula and the structural characteristics of the all-steel radial tire also determine that the manufacturing process is complex. The main process comprises banburying, extruding, rolling, cutting, molding, vulcanizing and the like.

The traditional tire manufacturing mainly has the following characteristics:

in the aspect of factory construction:

1, the number of the procedures is large and complicated: dozens of working procedures, the quality control is complicated, any one working procedure has problems, and the product quality is directly influenced.

2, large occupied area: the length and width of a general tire factory workshop are about 1 kilometer respectively, and the characteristic severely restricts the development of tire factories and can only be built in suburbs or areas with cheap and remote land.

3, large investment amount: because of the complex workshop, equipment, working procedures and the like, the investment for building a common tire factory is generally 10 hundred million RMB as a unit, which reaches 20 to 40 hundred million, and the construction period is long, which is generally at least 3 to 5 years.

4, the number of workers is large: the numerous processes of tire production determine the need for sufficient technical workers to maintain production, and a minimum of 500-800 workers are required in a common tire factory to ensure production in one production line.

5, serious pollution: pollution sources such as dust, waste gas, noise and the like in the processes of banburying, calendering and vulcanizing in the process of manufacturing the tire exist all the year round, and a plurality of measures are also adopted by the nation to limit the expansion and new building of the traditional tire factory.

6, the energy consumption is huge: the production line is long, the equipment is more, the energy consumption is extremely high, especially the vulcanization process is the most serious, and a large amount of steam stripping heat supply sources are needed.

The technical aspect is as follows: because some parts of the tire are extremely thick, various technical defects are inevitable during the molding and vulcanization. For example, rubber has slow heat conduction, and the tread is too thick, so that the vulcanization time is long, the vulcanization degree inside and outside is not uniform, the inside and outside characteristics of the material are different, and the material is very easy to break during the running process. The problems are caused by the properties of the rubber material, and although the overall technology is continuously improved by adjusting the formula, the structure and the process of each manufacturer, the problems cannot be fundamentally solved. In addition, the rubber material has poor wear resistance and puncture resistance under severe mine working conditions, so that the service life of the engineering tire and the mine giant tire is extremely short, and the service life is only thousands of hours or even hundreds of hours, so that the engineering tire becomes the main consumption of the mining cost of the mine.

disclosure of Invention

The present invention has an object to provide a polyurethane pneumatic tire and a method for manufacturing the same, which are superior in tire performance to conventional tires by replacing a rubber material with a polyurethane material. Meanwhile, the polyurethane material has more comprehensive performance than a natural rubber material, and thus is simpler in structure than a rubber tire. The characteristics determine that the manufacturing process of the polyurethane tire can be greatly simplified compared with the traditional tire. The polyurethane tire is suitable for various types of inflatable tires, including car tires, truck tires, engineering tires, giant tires, various special tires and the like, and is particularly suitable for engineering tires and giant tires with low speed and high load.

In order to achieve the above purpose, the invention provides the following technical scheme:

Comprises a polyurethane tread, a polyurethane belt layer, a polyurethane sidewall, a polyurethane tire body, a polyurethane soft triangle, a polyurethane hard triangle, a steel wire ring and a bead protection rubber which are arranged from outside to inside in sequence; wherein, the polyurethane tread is the part of the tire which is directly contacted with the ground; the polyurethane belt layer is used for improving the support and stress of the tire; the polyurethane tire body is a framework component of the tire, and the polyurethane tire side is used for providing protection for the polyurethane tire body; the polyurethane tire tread, the polyurethane belt layer, the polyurethane tire side and the polyurethane tire body are connected with each other through polyurethane filling glue; the steel wire ring is bonded with a polyurethane tire body through the hanging glue of the polyurethane steel wire ring, the polyurethane hard triangle provides support for the steel wire ring, and the polyurethane soft triangle is a transition part between the polyurethane tire side and the polyurethane hard triangle; the bead part of the polyurethane pneumatic tire is provided with bead wear-resistant glue which is used for contacting with a rim and protecting the bead part.

Preferably, the polyurethane tread is provided with patterns with different shapes.

preferably, the polyurethane belt layers are arranged at different angles between the polyurethane tread and the polyurethane carcass with steel wires.

Preferably, the shore hardness of each component is:

55-95 degrees of polyurethane tread, 50-80 degrees of polyurethane filling glue, 75-95 degrees of polyurethane belt layer, 50-80 degrees of polyurethane sidewall, 75-95 degrees of polyurethane carcass, 50-70 degrees of polyurethane soft triangle, 85-99 degrees of polyurethane hard triangle, 85-99 degrees of polyurethane steel wire ring hanging glue and 80-95 degrees of bead wear-resistant glue.

the polyurethane pneumatic tire according to any one of the above claims, wherein the manufacturing method comprises:

first, the manufacture of the components.

Polyurethane tread: the method adopts a tread centrifugal pouring process, a tread direct pouring type pouring process, an injection molding/injection molding process, an extrusion process, a block pouring and then combination circular process, a polyurethane foaming process, a 3D printing process, a processing and molding process, any lap joint mode or a direct cylindrical molding process and combination thereof;

Polyurethane tape layer: the method adopts a calendering oblique cutting lapping process, a belt type direct casting process, an extrusion molding process, a magnetic adsorption process, an injection/injection molding process, a 3D printing process, any lapping mode or a direct cylindrical molding process and combination thereof;

A polyurethane sidewall: the method adopts a direct pouring process, a multilayer laminating process, an injection molding/injection molding process, an extrusion process, a polyurethane foaming process, a 3D printing process, a processing and molding process and combination thereof;

the soft polyurethane triangle, the hard polyurethane triangle and the steel wire ring are processed by adopting a steel wire ring winding process. When the steel wire is glued, besides the rolling mode, a glue hanging process, a glue spraying process, a glue brushing process and a dipping process can be adopted. In the dipping process, the surface of the steel wire is treated and then dipped by a trough filled with glue; in addition, the polyurethane soft triangle and the polyurethane hard triangle are prepared by direct pouring and multiple pouring; a polyurethane carcass: the method adopts a carcass direct pouring molding process, a cylinder carcass molding process, a shuttle-shaped steel wire layered pouring process, an electromagnetic steel wire adsorption process, a 3D printing process, a calendering/extrusion molding process, an injection molding/injection molding process and combination thereof;

Bead wear-resistant glue: after the tire body is prepared, opening an outer mold of the tire body mold, installing a bead rubber protecting mold at the bead part of the molded tire body, directly pouring, and finally finishing the manufacture of bead rubber protection on the tire body;

secondly, an integral forming process.

Compounding a polyurethane tread and a polyurethane belt layer, namely compounding each belt layer of a tire on a belt layer forming drum in a winding mode, after the belt layers are completely compounded, moving the belt layer forming drum to a centrifugal vehicle with a prepared tread, integrally inserting the belt layer forming drum into the central position of the prepared annular tread, filling gaps between the belt layer and the tread with filling glue by pouring, and finally forming an integral tread-belt layer assembly;

And (2) integrally compounding, namely closing a polyurethane tire body (comprising a polyurethane soft triangle, a polyurethane hard triangle, a steel wire ring and a seam allowance wear-resistant adhesive component which are compounded with the tire body) with an inner core and a side plate mold with a polyurethane tire side and a tire tread-belted layer component into a closed mold cavity through the movement of equipment and a mold, and injecting and filling adhesive to finally form the whole tire through a material injection hole reserved on the side plate mold.

preferably, the belt layers of the tire are combined on the belt building drum in a winding mode, and the aim of tight combination is achieved by coating special materials among the belt layers in the combining process.

Preferably, in the integral molding process, after the integral compounding step, the integral molding process further comprises:

curing and molding, namely maintaining the design temperature for a specified time after all pouring is finished; in the curing stage, the heat preservation curing process can be directly carried out on the equipment, and the mold and the whole product can be detached from the equipment and placed in a constant temperature chamber for curing after the product meets the movable requirement.

preferably, in the integral molding process, after the curing molding, the method further comprises:

And (3) post-vulcanizing and taking out the product, opening the mold after the product is cured, taking out the product and the inner core, putting the product and the inner core into a constant temperature chamber for post-vulcanizing, and removing the inner core after the post-vulcanizing is finished to obtain the whole product.

Compared with the traditional tire, the polyurethane pneumatic tire and the manufacturing method thereof provided by the invention have the advantages that the polyurethane material is used for replacing the rubber material, so that the tire performance is more excellent. Meanwhile, the polyurethane material has more comprehensive performance than a natural rubber material, and is simpler in structure than a rubber all-steel radial tire. The characteristics determine that the manufacturing process of the polyurethane tire can be greatly simplified compared with the traditional tire. The polyurethane tire is suitable for various types of inflatable tires, including car tires, truck tires, engineering tires, giant tires, various special tires and the like, and is particularly suitable for engineering tires and giant tires with low speed and high load.

The polyurethane material has outstanding performance, the wear resistance and the puncture resistance are 3-8 times of those of natural rubber, and the polyurethane material also has extremely high bearing property, and is more suitable for mine giant tires with higher requirements on wear resistance, puncture resistance and bearing. Different from natural rubber, the liquid rubber vulcanization mode is from inside to outside vulcanization, the material is more uniform after being cured, various symptoms caused by uneven rubber vulcanization are solved, and the service life of the tire is prolonged.

The liquid polyurethane material overturns the prior tire production, adopts a pouring process and avoids most technical problems of the traditional tire production. As shown in Table 1, the investment amount of the pneumatic polyurethane tires is about 1/10 of that of the conventional tires, the floor area is about 1/20, the labor is 1/10, and the number of processes is 3/10. Therefore, the patent technology converts the traditional tire production into a project with small investment, small occupied area and less labor force, avoids the defects of the traditional tire, greatly reduces the threshold of entering the tire industry, and makes it possible to realize large output value and high profit with small investment in the tire manufacturing industry.

TABLE 1 comparison of polyurethane pneumatic tires with conventional rubber tires in terms of technical investment, floor area, labor intensity, and process sequence

	Investment (Yi Yuan)	Floor area (m)2)	Labor force	Procedure (ii)
					polyurethane	0.5-1	2000	40	3
Rubber tyre	5-10	40000	400	10
					Ratio of	1/10	1/20	1/10	3/10

Tire enterprises are environment pollution households, and countries set more admittance environmental protection terms, so that the influence of tire factories on the environment is reduced, but the tire factories cannot get rid of the figure of three wastes no matter how. These pollution sources seriously affect physical and psychological health of workers, and complaints from residents around tire factories to environmental protection departments often occur. The pollution sources of the traditional tire enterprises mainly include dust (carbon black and the like) from an internal mixing workshop, waste gas during vulcanization, noise and the like (figure 2). In addition, in the aspect of energy consumption, a series of admission thresholds and various new energy-saving technologies are also proposed by the nation, but the effect is not obvious. For example, in the vulcanization process, the rubber tire can normally generate the vulcanization reaction only by heating to 150-160 ℃, and no matter how energy is saved, the real green development can not be realized without changing the characteristics of the material.

The technical vulcanization temperature of the polyurethane pneumatic tire is only about 100 ℃, the vulcanization temperature is greatly lower than 150 ℃, the vulcanization time is only 2 hours, the efficiency is improved by 3-6 times, the vulcanization pressure is reduced to 1/9 of the original vulcanization pressure, and the energy consumption is greatly reduced (Table 2). In the aspect of environmental protection, dust, waste gas and noise pollution are eliminated, and the method conforms to the current major trends of green development, energy conservation and emission reduction.

TABLE 2 comparison of polyurethane pneumatic tire technology with conventional tire technology and three wastes

	Pressure of vulcanization	temperature of vulcanization	Vulcanization time	Three wastes
					polyurethane tire	0.2MPa	100℃	2-4h	is free of
Rubber tyre	1.8MPa	150℃-160℃	12h	dust, exhaust gas, noise

The polyurethane pneumatic tire produced by using the polyurethane elastomer to replace natural rubber and other materials has the following characteristics. (1) The polyurethane pneumatic tire has excellent wear resistance and puncture resistance, is improved by 3-8 times compared with common rubber, can greatly prolong the service life of the tire, and particularly has high requirements on wear resistance, puncture resistance and load for engineering tires (R25-R35) and giant tires (R49-R63 or more than R63). The improvement of the service life means that the cost of the engineering tire is greatly reduced, and (2) the polyurethane is used as a liquid raw material, so that the traditional natural rubber tire process is overturned, the investment cost is greatly reduced, the occupied area is reduced, and a large amount of labor force is saved. (3) The weight of the polyurethane pneumatic tire can be reduced by 10-20%, so that the manufacturing cost of the tire is greatly reduced. (4) The polyurethane material has excellent ultraviolet resistance and good air tightness, so that the polyurethane pneumatic tire has a simpler structure and lighter weight than a natural rubber tire. (5) The polyurethane material characteristics determine that the fuel is saved by about 5% -10% compared with the traditional rubber tire.

drawings

in order to more clearly illustrate the embodiments of the present application or technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments described in the present invention, and other drawings can be obtained by those skilled in the art according to the drawings.

FIG. 1 is a view showing the construction of a rubber all-steel radial tire;

FIG. 2 is a diagram of pollution sources and heat sources in a conventional tire enterprise;

FIG. 3 is a structural view of a pneumatic tire of polyurethane according to an embodiment of the present invention;

FIG. 4 is a schematic view of a centrifugal tread casting process;

FIG. 5 is a schematic view of a direct tread casting process;

FIG. 6 is a schematic view of a block casting process (block casting alone followed by splicing to form a circle);

FIG. 7 is a composite view of a multi-layer process for a tread;

FIG. 8 is a schematic view of a sidewall casting process;

FIG. 9 is a schematic view of a bead filler assembly manufacturing mold;

FIG. 10 is a schematic view of a carcass straight-pouring process;

FIG. 11 is a schematic view of a drum carcass building process;

FIG. 12 is a schematic view of a shuttle wire casting process;

FIG. 13 is a carcass belt tread composite schematic;

fig. 14 is a composite view of the whole tire.

Description of reference numerals:

1. A tread; 2. filling glue; 3. a belt ply; 4. a sidewall; 5. soft triangles; 6. a hard triangle; 7. a bead ring; 8. a carcass; 9. and (4) bead wear-resistant glue.

Detailed Description

In order to make the technical solutions of the present invention better understood, those skilled in the art will now describe the present invention in further detail with reference to the accompanying drawings.

It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or terminal that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or terminal. Without further limitation, an element defined by the phrases "comprising … …" or "comprising … …" does not exclude the presence of additional elements in a process, method, article, or terminal that comprises the element. Further, herein, "greater than," "less than," "more than," and the like are understood to exclude the present numbers; the terms "above", "below", "within" and the like are to be understood as including the number.

As shown in fig. 3, a polyurethane pneumatic tire comprises a tread 1, a belt 3, a sidewall 4, a soft triangle 5, a hard triangle 6, a bead ring 7, a tire body 8 and a bead filler 9 which are arranged in sequence from outside to inside; wherein, the tread 1 is the part of the tire directly contacting with the ground; the belt layer 3 is used for improving the support and stress of the tire; the carcass 8 is a carcass component of the tire, and the sidewalls 4 are used to provide protection for the carcass; the tire tread 1, the belt ply 3, the tire side 4 and the tire body 8 are connected with each other through filling rubber 2; the steel wire ring 7 is bonded with the tire body 8 through steel wire ring rubberizing, the hard triangle 6 provides support for the steel wire ring, and the soft triangle 5 is a transition part between the tire side 4 and the hard triangle 6; the bead part of the pneumatic tire is provided with bead wear-resistant rubber 9 which is used for contacting with a rim and protecting the bead part.

The tread 1, the filling rubber 2, the belted layer 3, the sidewall 4, the soft triangle 5, the hard triangle 6, the tire body 8 and the bead wear-resistant rubber 9 in the polyurethane pneumatic tire are all made of polyurethane materials. Polyurethane allows the inner liner (including the inner liner and the transition layer) of a conventional rubber tire to be omitted due to superior air-tightness. The number of the belt layers can be greatly reduced according to actual conditions.

The structure and the function of each component in the polyurethane pneumatic tire are specifically as follows:

The tread 1: the tread 1 is the part of the tire in direct contact with the ground, has patterns of different shapes according to different use conditions and different requirements, has the function of protecting the tire body, is also the part of the tire which is used most and has the largest loss, and provides the functions of driving, traction, braking, water drainage and skid resistance, shock absorption, steering and the like. The polyurethane tire can greatly improve the traction performance of vehicles on mud and snow. The strength and the wear resistance of the tread can be improved, and the daily wear loss of the tread can be reduced. The wear resistance of polyurethane is 3-8 times of that of rubber, so that the depth of tyre patterns can be reduced, and the whole weight of the tyre can be reduced by 5-20%.

Filling adhesive 2: the filling rubber 2 is a member connecting the tread 1, the belt 3, the carcass 8 and the sidewall 4 in the above-described pneumatic urethane tire. The buffer structure has the effects that each part contacted with the buffer structure can be tightly connected, gaps among all parts are filled, bubbles or vacant positions are prevented from appearing, and meanwhile, a good buffer effect is achieved on all stressed parts. The liquid polyurethane is used as filling glue, so that gaps among all parts can be completely filled, and the phenomena of air bubbles and delamination possibly caused in the traditional rubber process are avoided.

Belt layer 3: the belt 3 is arranged between the tread 1 and the tyre body 8 by steel wires according to different angles and is used for improving the supporting and stress parts of the tyre. The main functions are as follows: firstly, the tyre tread and the tyre body cord fabric resist centrifugal force, prevent the outward bulge phenomenon of the tyre crown caused by the action of the centrifugal force, and ensure stable tyre outer diameter and tyre circumference. Secondly, the desired shape of the tire footprint is controlled, thereby effectively providing grip/traction. Third, it provides rigidity required for the tire to oversteer and turn, and thus provides excellent handling. Fourthly, the invasion of foreign matters on the road surface is resisted. In the polyurethane pneumatic tire, the polyurethane and the steel wires have natural high viscosity, so carcinogenic toxic substances such as heavy metal, phenol and the like used in the traditional rubber belt layer manufacturing process are avoided in the production and manufacturing process, the operation environment of a workshop is improved, and the pollution and the damage to the natural environment in the life cycle of a tire product are reduced. Meanwhile, due to the high-strength material performance, the number of belted layers can be reduced to the maximum extent by the polyurethane all-steel tire, the weight and the thickness of the tire are reduced, and the heat generation is greatly reduced.

sidewall 4: the sidewall 4 is a portion for protecting the tire casing 8 from being scratched by foreign matter. The sidewall 4 needs to have strong wear resistance and aging resistance, and meanwhile, the portion needs to bear periodic stress strain for a long time and has strong bending resistance and flexibility. The wear resistance of the polyurethane is 3-8 times that of common rubber, the performance is almost unchanged after aging at 100 ℃ for 48 hours, and the polyurethane has good bending resistance flexibility, so that the polyurethane has more excellent performance after the polyurethane sidewall replaces rubber.

carcass 8: the carcass 8 is a tire frame member, and is mainly used for receiving tire impact force, such as tire load pressure, internal air pressure, and lateral shear force. The polyurethane has higher strength and stronger steel wire and cord thread adhesive force, is similar to the production of a polyurethane belt layer, ensures green production and can improve the bearing capacity of the tire in the manufacturing process.

It should be noted that, because the air tightness of the polyurethane material is better than that of the existing tire air-tight layer material of bromobutyl rubber and butylbenzene rubber, the existing air-tight layer and transition layer (inner liner layer) in the existing tire structure can be eliminated for the polyurethane all-steel radial tire. Therefore, the polyurethane tire body can simultaneously have the functions of supporting and air tightness. The structure can reduce the weight of the whole tire by 5-20%. The structure of the tubeless all-steel radial tire without the inner liner is also the innovation point of the structure of the patent. And are included as protection for this patent.

a soft triangle 5: the soft triangle 5 is the transition between the sidewall 4 and the hard triangle 6. The polyurethane has wider performance and hardness range and completely meets the requirement of soft triangle performance.

a hard triangle 6: the hard triangle 6 provides support for the steel wire ring 7 and has stronger rigidity. The polyurethane has wider performance and hardness range and completely meets the requirement of hard triangle performance. According to the related requirements, the soft and hard triangular glue can be combined into one part. This point is also the protection content of this patent.

and (3) a bead ring 7: the bead ring 7 is a member that ensures that the tire can be tightly fixed to the rim. The polyurethane is used as a natural steel wire adhesive, and can play a role in high-strength adhesion and protection.

Bead wear-resistant glue 9: the bead wear-resistant glue 9 is a component which is in contact with the rim and protects the bead part. The wear resistance and hardness of the polyurethane completely meet the requirements.

All the relevant improvements on the above structure of the polyurethane pneumatic tire belong to the protection content of the patent.

The polyurethane material has excellent wear resistance and puncture resistance, and the basic properties of the required raw materials are as follows (Table 3): the polyurethane material comprises various polyether or polyester polyols (PTMG, PCL and the like), isocyanate (MDI, TDI, NDI and the like), curing agent (Moca, BDO and the like), and the like, all the polyurethane materials (TPU, CPU, MPU) and raw materials thereof which can meet the following performance requirements, prepolymers synthesized by related raw materials, curing agents and catalysts, or related formulas relating to the raw materials are used for manufacturing the polyurethane tire, and the materials of the prepolymers prepared by taking MDI, TDI and NDI as the isocyanate belong to the protection range of materials of all parts of the polyurethane tire.

TABLE 3 Property requirements of the polyurethane tire formulation

	Hardness (shore A)	Wear-resistant and puncture-resistant	low heat generation	Adhesion of steel wire
					Tread	55°-95°	●●●	●●●	---
Filling adhesive	50°-80°	----	●●●	●
					belt layer	75°-95°	----	●●●	●●●
Tyre body	75°-95°	---	●●●	●●●
					Sidewall	55°-80°	●●	●●●	---
Soft triangle	50°-70°	---	●●●	---
					Hard triangle	80°-99°	---	●●●	●
steel wire ring coating rubber	85°-99°	---	●●●	●●●
					bead protection glue	80°-95°	●●●	●●●	---

the manufacturing method of the polyurethane pneumatic tire comprises the following steps:

Manufacturing of the component:

The tread 1: (1) the centrifugal casting process of the tire tread (figure 4) comprises the steps of heating a manufactured mold cavity (pattern block and outer fixing plate), then loading the mold cavity on a centrifugal vehicle, additionally installing a heat preservation cover outside the mold cavity, integrally rotating to a sufficient speed, detecting a casting head to a specified position, after casting is started, reciprocating the casting head along the axial direction of the centrifugal vehicle according to the calculated speed, finally, after the rubber material reaches the required weight, leaving the centrifugal vehicle, continuously rotating the centrifugal vehicle until the rated time reaches basic solidification, and finishing the manufacturing of the tire tread. The tread prepared by the process has uniform material and stable performance. The tread prepared by the process avoids the generation of air bubbles to the maximum extent. The thickness and the formula of different materials of the multilayer structure can be adjusted at any time according to the requirements of different products. And simultaneously pouring base rubber after the pouring of the tire tread is finished. The process can also prepare the tire tread with a certain thickness by centrifugation, and then attach two or three pieces of tire tread to make the tire tread reach the required thickness. The centrifugal casting process of the tire tread comprises horizontal centrifugation and vertical centrifugation, which belong to the protection content of the patent. (2) In the tread direct pouring type pouring process (figure 5), a mold cavity is a closed space, a plurality of pouring points are arranged on the mold, rubber material flowing out of a pouring machine is uniformly divided into a plurality of material flows after passing through a spreader cone, and a retention device is arranged at the feeding end of each rubber material flow passage and can be simultaneously fed or sequentially fed according to actual conditions so as to ensure the flowability and curing uniformity of the rubber material in the mold (or a plurality of pouring machines are used for pouring). After the material flow is full of the mold cavity, the material flow enters the waste bin through the overflow channel, the pressure is supplied to the waste bin in the curing process of the rubber material, and the rubber material can be supplemented through the waste bin, so that the manufacturing of the tire tread is completed. In addition, the injection molding/injection molding process (3) is adopted. (4) The polyurethane pneumatic tire tread rubber is prepared by an extruder through an extrusion process on any polyurethane. (5) And (3) combining the blocks after casting into a round process (figure 6). (6) A polyurethane foaming process. (7)3D printing technology. (8) The machining and forming process is to make the blank in any shape into the designed shape of the tread by machining (turning, milling, etc.) and bench work. (9) Any lap joint (belt) or direct cylindrical forming process. (10) The multilayer application process carried out by any method, including the case whether the number of layers and the material of each layer are one or more (figure 7), and the centrifugal casting process carried out in any form to achieve a tread made of the above multilayer material. (11) Vacuum, pressure feed processes using any of the above methods. (12) Any intersection of the above methods, a process used in combination, or a modified process. Are all protected by the present patent.

The manufacturing method of the belt ply 3 and the belt ply 3 component is divided into two main processes, wherein the first process is the arrangement of steel wires, and the steel wires are at 0 degree or other angles. And the other is the glue attaching process after the steel wire arrangement is finished. (1) Calendering and bias cutting, performing calendering and glue attaching after the steel wires are well arranged, performing bias cutting on the belt ply according to design requirements, and bonding the belt ply strips subjected to bias cutting through a special glue stock to finally form the whole belt ply. This process is similar to the conventional tire belt calendering and bias cutting process. (2) The belt type direct casting process has the advantages that the whole belt layer is integrally formed, and the problem of joints caused by oblique cutting and lapping of the traditional belt layer is avoided. (3) And (3) extrusion/calendaring molding, namely extruding or calendaring by using an extruder/calendar to attach rubber to the steel wire. In addition, other glue coating processes, such as glue spraying process, glue brushing process and the like, are also included in the protection content of the patent. (4) Magnetic adsorption, namely, a belt type or ring type belt ply formed by adsorbing a steel wire on the surface of a mould by using magnetic force and then pouring. (5) Injection molding, namely, a molding mode is carried out by adopting an injection molding machine or an injection machine. (6)3D printing, namely manufacturing the steel wire with the binding layer, the adhesive or the steel wire and the adhesive by adopting a 3D printing technology. (7) Any lap joint (belt) or direct cylindrical forming process. (8) And (3) carrying out a multilayer laminating process after the single-layer belt ply is prepared by adopting any process or a mixed crossing process. (9) Single or multiple belt layers prepared using any of the above processes or a hybrid crossing process. (10) The steel wire arrangement process of the polyurethane all-steel radial tire structure belt ply angle in the range of more than or equal to 0 degrees and less than or equal to 180 degrees. (11) Any intersection of the above methods, a process used in combination, or a modified process. Are all protected by the present patent.

And a sidewall 4 forming process: (1) the direct pouring process comprises the steps of directly pouring and molding the tire side according to the shape of a designed tire side part, directly opening a movable mold of a molded mold, retaining the tire side in a fixed mold (figure 8), and directly using for subsequent integral molding after manually trimming a pouring gate and rough edges. (2) The multilayer application process carried out by any method, including the case of one or more of the number of layers and the material of each layer, and the centrifugal casting process carried out in any form to reach the sidewalls constituted by the above multilayer materials. (3) Injection molding/injection molding process. (4) Sidewalls are made by an extrusion process using an extruder for any kind of polyurethane. (5) A polyurethane foaming process. (6)3D printing technology. (7) The machining and forming process uses blanks in any shape to form the designed shape through machining (turning, milling and the like) and bench work. (8) The sidewall component of the polyurethane pneumatic radial tire is produced by adopting the vacuum and pressure feeding of any method. (9) Any intersection of the above methods, a process used in combination, or a modified process. Are all protected by the present patent.

the soft triangle 5, the hard triangle 6 and the steel wire ring 7 are firstly processed by adopting the traditional steel wire ring winding process. When the steel wire is attached with glue, besides the traditional mode of extruding/rolling by a mouth plate, the steel wire can also adopt an impregnation process, the surface of the steel wire is treated and then is impregnated by a trough filled with special glue, and other similar glue hanging processes, glue spraying processes, glue brushing processes are adopted to prepare polyurethane triangular glue components, and the like, which also belong to the protection content of the patent. After the preparation of the steel wire ring is finished, the steel wire ring is placed into a mould, and is respectively made into a soft triangle 5 and a hard triangle 6 through one or more times of pouring, and finally a triangular glue component formed by combining the soft triangle 5, the hard triangle 6 and the steel wire ring 7 is made (figure 9).

The tyre body 8 (1) tyre body direct casting forming process (figure 10), the tyre body steel wire and the braided wire (including steel wire with any specification or high polymer material wire, such as Kevlar fiber, TPU wire and the like) made of special materials are uniformly braided on the inner core component (the inner core can be regarded as a closed inner contour shape inner mould of the tyre), after a triangle rubber component consisting of a soft triangle, a hard triangle and a steel ring is installed, the steel wire is reversely wrapped, and the whole tyre body is cast after an external mould is closed. The tyre body component (with the inner core) containing soft and hard triangles and steel rings is manufactured. (2) The drum type tyre body forming process (the process is similar to the existing tyre forming process, figure 11), uniformly arranging tyre body steel wires on a special forming drum and forming a cylindrical structure (or absorbing through magnetic force) through a knitting wire, pouring after mould closing to form a cylindrical tyre body coated on the forming drum, mounting a bead filler component consisting of a soft triangle 5, a hard triangle 6 and a steel wire ring 7 on the drum after mould opening, bulging a middle capsule of the forming drum after mounting, bulging two side turn-up capsules after the middle capsule is bulged to a certain position, withdrawing after the turn-up capsules are shrunk, continuously keeping pressure in the middle capsule, and finally manufacturing the tyre body component containing the soft triangle 5, the hard triangle 6 and the steel wire ring 7 as shown in figure 10(3) (wherein the special forming drum and the capsules are arranged). (3) The spindle-shaped steel wire is poured in a layered mode, and the process is schematically shown in figure 12. The well arranged steel wire is in a barrel shape, after the inner core enters the center of the barrel, the two ends of the steel wire move to the centers of the two sides of the inner core until the inner core is tightened, the soft and hard, triangular and steel wire ring components are arranged to complete the reverse wrapping, and the casting is carried out after the outer die is closed, thus completing the manufacture of the tire body. (4) And (4) pouring by an electromagnetic steel wire adsorption process. (5) And 3D printing, namely manufacturing the carcass steel wire or the adhesive, the steel wire and the adhesive by adopting a 3D printing technology. (6) Calendering \ extrusion molding of the tire body (7), injection molding \ injection molding (8), any lap joint mode or direct cylindrical molding process (9), and step-by-step laminating process of single-layer or partial tire body prepared by any process or mixed cross process. (10) A multilayer carcass process prepared using any of the above processes or a hybrid cross-over process. (12) Any process used in combination with any of the above methods may include vacuum, pressure casting, etc., or modified processes based on the above processes. Are all protected by the present patent.

Bead wear-resistant glue 9: after the tire body 8 is prepared, the outer mold of the tire body mold is opened, soft and hard triangular glue and a steel wire ring assembly are assembled, a bead rubber protecting mold is installed at the bead part on the molded tire body, direct pouring is carried out, and finally bead rubber is formed on the tire body.

And (3) integral forming process:

Compounding between tread 1 and belt 3:

According to different design requirements, firstly, the belt layers 3 of the tire are compounded on a belt layer building drum in a winding mode, and the aim of tight combination is achieved by coating special materials among the belt layers in the compounding process. After the belt layer 3 is completely compounded, the belt layer forming drum moves to a centrifugal vehicle position (or a directly poured tire tread mold position) of the prepared tire tread, the belt layer forming drum is integrally inserted into the central position of the prepared annular tire tread, and the gap between the belt layer 3 and the tire tread 1 is filled with the poured filling glue 2. Eventually forming an integral tread-belt assembly (fig. 13).

integral compounding:

By the movement of the equipment and the mould, a polyurethane matrix with an inner core (comprising a soft triangle 5, a hard triangle 6, a steel wire ring 7 and a bead wear-resistant glue 9 component which are compounded with the matrix), a side plate mould with a side wall and a tread-belted layer component are closed into a closed mould cavity, and filling glue is injected to finally form the whole tyre through a material injection hole reserved on the side plate mould. (FIG. 14).

Curing and forming

After all the casting is finished, keeping the design temperature for a specified time; in the curing stage, the heat preservation curing process can be directly carried out on the equipment, and the mold and the whole product can be detached from the equipment and placed in a constant temperature chamber for curing after the product meets the movable requirement.

And after post-vulcanization and product taking-out and product curing are completed, opening the mold, taking out the product and the inner core, putting the product and the inner core into a constant temperature chamber for post-vulcanization, and removing the inner core after the post-vulcanization is completed to obtain the whole product.

Compared with the traditional tire, the polyurethane pneumatic tire and the manufacturing method thereof have the advantages that the polyurethane material is used for replacing the rubber material, so that the all-steel tire has more excellent performance. Meanwhile, the polyurethane material has more comprehensive performance than a natural rubber material, and is simpler in structure than a rubber all-steel radial tire. The characteristics determine that the manufacturing process of the polyurethane tire can be greatly simplified compared with the traditional tire. The polyurethane tire is suitable for various types of inflatable tires, including car tires, truck tires, engineering tires, giant tires, various special tires and the like, and is particularly suitable for engineering tires and giant tires with low speed and high load.

The polyurethane material has outstanding performance, the wear resistance and the puncture resistance are 3-8 times of those of natural rubber, and the polyurethane material also has extremely high bearing property, and is more suitable for mine giant tires with higher requirements on wear resistance, puncture resistance and bearing. Different from natural rubber, the liquid rubber vulcanization mode is from inside to outside vulcanization, the material is more uniform after being cured, various symptoms caused by uneven rubber vulcanization are solved, and the service life of the tire is prolonged.

The liquid polyurethane material overturns the prior tire production, adopts a pouring process and avoids most technical problems of the traditional tire production. As shown in Table 1, the investment amount of the pneumatic polyurethane tires is about 1/10 of that of the conventional tires, the floor area is about 1/20, the labor is 1/10, and the number of processes is 3/10. Therefore, the patent technology converts the traditional tire production into a project with small investment, small occupied area and less labor force, avoids the defects of the traditional tire, greatly reduces the threshold of entering the tire industry, and makes it possible to realize large output value and high profit with small investment in the tire manufacturing industry.

TABLE 1 comparison of polyurethane pneumatic tires with conventional rubber tires in terms of technical investment, floor area, labor intensity, and process sequence

Tire enterprises are environment pollution households, and countries set more admittance environmental protection terms, so that the influence of tire factories on the environment is reduced, but the tire factories cannot get rid of the figure of three wastes no matter how. These pollution sources seriously affect physical and psychological health of workers, and complaints from residents around tire factories to environmental protection departments often occur. The pollution sources of the traditional tire enterprises mainly include dust (carbon black and the like) from an internal mixing workshop, waste gas during vulcanization, noise and the like (figure 2). In addition, in the aspect of energy consumption, a series of admission thresholds and various new energy-saving technologies are also proposed by the nation, but the effect is not obvious. For example, in the vulcanization process, the rubber tire can normally generate the vulcanization reaction only by heating to 150-160 ℃, and no matter how energy is saved, the real green development can not be realized without changing the characteristics of the material.

The technical vulcanization temperature of the polyurethane pneumatic tire is only 100 ℃, the vulcanization temperature is greatly lower than 150 ℃, the vulcanization time is only 2 hours, the efficiency is improved by 3-6 times, the vulcanization pressure is reduced to 1/9 of the original vulcanization pressure, and the energy consumption is greatly reduced (Table 2). In the aspect of environmental protection, dust, waste gas and noise pollution are eliminated, and the method conforms to the current major trends of green development, energy conservation and emission reduction.

TABLE 2 comparison of polyurethane pneumatic tire technology with conventional tire technology and three wastes

	Pressure of vulcanization	Temperature of vulcanization	Vulcanization time	three wastes
					Polyurethane tire	0.2MPa	100℃	2-4h	Is free of
Rubber tyre	1.8MPa	150℃-160℃	12h	Dust, exhaust gas, noise

The polyurethane pneumatic tire produced by using the polyurethane elastomer to replace natural rubber and other materials has the following characteristics. (1) The polyurethane pneumatic tire has excellent wear resistance and puncture resistance, is improved by 3-8 times compared with common rubber, can greatly prolong the service life of the tire, and particularly has high requirements on wear resistance, puncture resistance and load for engineering tires (R25-R35) and giant tires (R49-R63 or more than R63). The improvement of the service life means that the cost of the engineering tire is greatly reduced, and (2) the polyurethane is used as a liquid raw material, so that the traditional natural rubber tire process is overturned, the investment cost is greatly reduced, the occupied area is reduced, and a large amount of labor force is saved. (3) The weight of the polyurethane pneumatic tire can be reduced by 10-20%, so that the manufacturing cost of the tire is greatly reduced. (4) The polyurethane material has excellent ultraviolet resistance and good air tightness, so that the structure of the polyurethane pneumatic tire is simpler than that of a natural rubber all-steel radial tire and the weight is lighter. (5) The polyurethane material characteristics determine that the fuel is saved by about 5% -10% compared with the traditional rubber tire.

While certain exemplary embodiments of the present invention have been described above by way of illustration only, it will be apparent to those of ordinary skill in the art that the described embodiments may be modified in various different ways without departing from the spirit and scope of the invention. Accordingly, the drawings and description are illustrative in nature and should not be construed as limiting the scope of the invention.

Claims (8)

1. A polyurethane pneumatic tire is characterized by comprising a polyurethane tread, a polyurethane belt layer, a polyurethane sidewall, a polyurethane tire body, a polyurethane soft triangle, a polyurethane hard triangle, a steel wire ring and a polyurethane bead filler which are sequentially arranged from outside to inside; wherein, the polyurethane tread is the part of the tire which is directly contacted with the ground; the polyurethane belt layer is used for improving the support and stress of the tire; the polyurethane tire body is a framework component of the tire, and the polyurethane tire side is used for providing protection for the polyurethane tire body; the polyurethane tire tread, the polyurethane belt layer, the polyurethane tire side and the polyurethane tire body are connected with each other through polyurethane filling glue; the steel wire ring is bonded with a polyurethane tire body through the hanging glue of the polyurethane steel wire ring, the polyurethane hard triangle provides support for the steel wire ring, and the polyurethane soft triangle is a transition part between the polyurethane tire side and the polyurethane hard triangle; the bead part of the polyurethane pneumatic tire is provided with bead wear-resistant glue which is used for contacting with a rim and protecting the bead part.

2. the polyurethane pneumatic tire of claim 1, wherein the polyurethane tread is provided with patterns of different shapes.

3. The polyurethane pneumatic tire of claim 1, wherein the polyurethane belt layers are arranged at different angles with steel wires between the polyurethane tread and the polyurethane carcass.

4. A pneumatic polyurethane tire as claimed in claim 1, wherein all components are made of polyurethane-based material, and the shore hardness of each component is:

55-95 degrees of polyurethane tread, 50-80 degrees of polyurethane filling glue, 75-95 degrees of polyurethane belt layer, 50-80 degrees of polyurethane sidewall, 75-95 degrees of polyurethane carcass, 50-70 degrees of polyurethane soft triangle, 85-99 degrees of polyurethane hard triangle, 85-99 degrees of polyurethane steel wire ring hanging glue and 80-95 degrees of bead wear-resistant glue.

5. The pneumatic polyurethane tire according to any one of claims 1 to 4, which is produced by the following method:

Firstly, manufacturing a component;

polyurethane tread: the method adopts a tread centrifugal pouring process, a tread direct pouring type pouring process, an injection molding/injection molding process, an extrusion process, a block pouring and then combination circular process, a polyurethane foaming process, a 3D printing process, a processing and molding process, any lap joint mode or a direct cylindrical molding process and combination thereof;

Polyurethane tape layer: the method adopts a calendering oblique cutting lapping process, a belt type direct casting process, an extrusion molding process, a magnetic adsorption process, an injection/injection molding process, a 3D printing process, any lapping mode or a direct cylindrical molding process and combination thereof;

a polyurethane sidewall: the method adopts a direct pouring process, a multilayer laminating process, an injection molding/injection molding process, an extrusion process, a polyurethane foaming process, a 3D printing process, a processing and molding process and combination thereof;

Regarding three components of a polyurethane soft triangle, a polyurethane hard triangle and a steel wire ring, the steel wire ring is processed by adopting a winding process; when the steel wire is attached with glue (including the tire body and the belted layer), besides adopting a rolling mode, a glue hanging process, a glue spraying process, a glue brushing process and a dipping process can also be adopted; in the dipping process, the surface of the steel wire is treated and then dipped by a trough filled with glue; in addition, the polyurethane soft triangle and the polyurethane hard triangle are prepared by direct pouring and multiple pouring;

a polyurethane carcass: the method adopts a carcass direct pouring molding process, a cylinder carcass molding process, a shuttle-shaped steel wire layered pouring process, an electromagnetic steel wire adsorption process, a 3D printing process, a calendering/extrusion molding process, an injection molding/injection molding process and combination thereof;

bead wear-resistant glue: after the tire body is prepared, opening an outer mold of the tire body mold, assembling a soft triangle-steel wire ring assembly, installing a bead rubber protecting mold at a bead part on the molded tire body, directly pouring, and finally finishing the manufacture of bead rubber protection on the tire body;

Secondly, an integral forming process;

Compounding a polyurethane tread and a belt ply, namely compounding each belt ply of a tire on a belt ply forming drum in a winding mode, moving the belt ply forming drum to a centrifugal vehicle with a prepared tread, integrally inserting the belt ply forming drum into the center of the prepared annular tread, filling gaps between the belt ply and the tread with filling glue by pouring, and finally forming an integral tread-belt ply assembly;

The whole combination is carried out, a polyurethane tire body with an inner core (comprising a polyurethane soft triangle, a polyurethane hard triangle, a steel wire ring and a seam allowance wear-resistant glue component which are combined with the tire body well), a side plate mold with a polyurethane tire side and a tire tread-belted layer component are closed into a closed mold cavity through the movement of equipment and a mold, and filling glue is injected through a material injection hole reserved on the side plate mold to finally form the whole tire.

6. A method of manufacturing a pneumatic polyurethane tire as in claim 5, wherein the belt layers of the tire are assembled onto the belt building drum by winding, and the belt layers are bonded together by coating with a special material.

7. The method of manufacturing a pneumatic tire of polyurethane as claimed in claim 5, wherein the integral molding process further comprises, after the integral compounding step:

Curing and molding, namely maintaining the design temperature for a specified time after all pouring is finished; in the curing stage, the heat preservation curing process can be directly carried out on the equipment, and the mold and the whole product can be detached from the equipment and placed in a constant temperature chamber for curing after the product meets the movable requirement.

8. The method of manufacturing a pneumatic tire of polyurethane as claimed in claim 7, wherein the integral molding process further comprises, after the curing molding:

And (3) post-vulcanizing and taking out the product, opening the mold after the product is cured, taking out the product and the inner core, putting the product and the inner core into a constant temperature chamber for post-vulcanizing, and removing the inner core after the post-vulcanizing is finished to obtain the whole product.