WO2018211430A1

WO2018211430A1 - A process for manufacturing tubeless tyre having integrated envelope(s) and a product thereof

Info

Publication number: WO2018211430A1
Application number: PCT/IB2018/053422
Authority: WO
Inventors: Sameer Panda; K.n. PANDA
Original assignee: Sameer Panda
Priority date: 2017-05-16
Filing date: 2018-05-16
Publication date: 2018-11-22
Also published as: ZA201907374B

Abstract

The present invention relates to a manufacturing process of envelope(s) integrated tubeless tyre. More specifically, the invention provides a manufacturing process for integrating envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre. The invention aims to provide a manufacturing process that overcomes the drawbacks and enables effective and efficient integration of envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre. The manufacturing process of envelope(s) integrated tubeless tyre is limited to high quality semi vulcanized tubeless tyres and envelope(s) made as per specification for undergoing further manufacturing processes. Though the rubber of the tyre and envelope(s) is semi-vulcanised and ready to use, still they are soft with some flowability for superior grip and further processing.

Description

A Process for Manufacturing Tubeless Tyre Having Integrated Envelope(s) And A

Product Thereof

FIELD OF THE INVENTION

The present invention relates to manufacturing process of envelope(s) integrated tubeless tyre. More specifically, the invention provides a manufacturing process for integrating envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre.

BACKGROUND OF THE INVENTION

Manufacturing a multi chambered tubeless tyre is difficult utilizing the present available manufacturing processes which provides mere extrusion and joining. Once a tyre is manufactured and vulcanised it is not possible to make alterations in structure as per the existing knowledge. After vulcanisation, attaching and fixing of any external rubber part is not possible. Therefore, the joining has to be done before vulcanisation as after vulcanization, property of the rubber changes and plasticity is developed, these restrictions further restricts modifications that improves longevity and robustness of the tyre by incorporating materials like sealant, coolant, sensor etc. directly inside the tyre.

Incorporating sealant inside a tyre is well known to allow the tyres to function, even after punctures. However, in the current technology there are several problems associated with it like leakage, deterioration of property due to interaction with air, wheel balancing as the sealant tends to be at the bottom of the tyre due to gravity, rubber hardening etc. Apart from that it is seen that sealant is ineffective in case of side wall puncture. Further, it is required that at regular intervals the sealant has to be changed. As in existing system of tubeless tyres there is no separate chamber for sealant, hence sealant is exposed to air. This tends to decreases the life of sealant along with life of tyre and causes environmental hazard and cost of ownership is also increased. U.S. Patent No. 8360122B2, discloses an invention relates to sealant material compositions for use in pneumatic tires. More specifically, relates to incorporation of uncured sealant material composition into a tire during a tire building process. In the method of this invention, the sealant material is assembled into the unvulcanized rubber tire and the tire is vulcanized using any technique, such as any standard method, capable of depolymerizing the non-halogenated butyl rubber in the sealant composition into a layer including the sealant material. Drawback associate to the method is that, when sealant comes in contact with moisture and air pressure during vulcanization the property of sealant will degrade, thus tends to decreases the life of sealant along with life of tyre.

U.S. Patent No. 20060169393A1, discloses a method and apparatus for making and applying a puncture sealant to tire components mounted upon a tire building drum. The method of making a tire with a built in sealant comprising the steps of: mounting an inner liner onto a tire building drum, extruding a sealant composition into strips having tapered sidewalls, cutting the strip to a desired length, mounting the sealant over the inner liner, layering a tire component over the sealant. Since the introduction of sealant is prior to vulcanisation process, so when sealant comes in contact with moisture and air pressure during vulcanization the property of sealant will degrade, thus tends to decreases the life of sealant along with life of tyre.

European Patent No. EP2567802A1, discloses a method for making a compartmentalized sealant strip and barrier assembly. It comprises the steps of co- extruding a barrier strip of a non-sealant elastomeric material with a plurality of projecting extending walls and at least one sealant strip, wherein the at least one sealant strip is formed on one side of the barrier strip filling a space between the plurality of projecting extending walls thereby forming a plurality of extending rows of sealant across the transverse width of the barrier strip. Also, a respective compartmentalized sealant strip and barrier strip assembly and a pneumatic tire comprising such an assembly. This method employs a specified set of tools like an extrusion die for forming a compartmentalized sealant strip and barrier assembly which adds up to dependency and make the final product more costly.

Therefore, as we can deduce from the current state of art that, such malfunctions can hinder the proper functioning of any accommodating substance such as sealant, coolant, sensor, etc. and consequently defeat the purpose of the same. Accordingly, there is a need for a mechanism which provides a manufacturing process for integrating envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre.

OBJECT OF THE INVENTION

The main object of the invention is to provide a manufacturing process for integrating envelope(s) to accommodate sealant, coolant, sensors, etc. in a tubeless tyre.

Yet another object of the invention is to employ a high quality semi-vulcanized tubeless tyres made as per specification undergoes further manufacturing processes.

Yet another object of the invention is to introduce the incorporation of sealant, coolant, sensor etc. inside a tubeless tyre.

SUMMARY OF THE INVENTION

Accordingly, the present invention relates to a manufacturing process of envelope(s) integrated tubeless tyre. More specifically, the invention provides a manufacturing process for integrating envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre. The invention aims to provide a manufacturing process that overcomes the drawbacks and enables effective and efficient integration of envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre. The manufacturing process of envelope(s) integrated tubeless tyre is limited to high quality semi vulcanized tubeless tyres and envelope(s) made as per specification for undergoing further manufacturing processes. Though the rubber of the tyre and envelope(s) is semi- vulcanised and ready to use, still they are soft with some flowability for superior grip and further processing.

In accordance with an embodiment of the present invention, a method for integrating envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre is provided. The system comprising at least one semi-vulcanised tyre, at least one semi-vulcanised envelope like structure made of flexible material, plurality of strengthening strings/elements for envelope made up of natural/ synthetic fibers and a tyre- envelope joining machine comprising a roughening apparatus to perform mechanical abrasion of tubeless tyre internal surface and corners of envelope surface to increase surface area for bonding, a vulcanisation solution application apparatus to apply vulcanisation solution to the roughned surface of tubeless tyre and envelope(s), an adhesive solution application apparatus for applying adhesive to the roughned and vulcanised surface of tubeless tyre and envelope(s) and act as a catalyst for enhancing bonding between them, a electric heating application apparatus for applying heat to the adhesion surface of tubeless tyre and envelope(s) to improve bonding and surface finish of bonded surface and a pressure application apparatus to apply pneumatic and mechanical pressure to the adhesion and heated surface of tubeless tyre and envelope(s).

In accordance with an embodiment of the present invention, a manufacturing process for integrating envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre is provided. The manufacturing process comprises following steps of: a) receiving a semi-vulcanised tubeless tyre having an inner surface and an outer surface;

b) receiving a semi-vulcanised flexible sheet having a first surface and a second surface;

c) selecting at least one mating surface, on the inner surface of said tubeless tyre and said first surface of said flexible sheet;

d) optionally, strengthening the flexible sheet using strengthening strings/elements; e) roughening the mating surfaces on said tyre and said flexible sheet as selected in step c);

f) applying a vulcanisation solution on the roughened surfaces;

g) applying an adhesive solution on the surfaces of step f);

h) joining the surfaces of step g) with each other such that the inner surface of said tyre is in conjunction with said first surface of the rubber sheet i) applying pressure on the joined surfaces to form at least one envelope;

j) heat treating the tyre for improving bonding between the joined surfaces; k) injecting a sealant, coolant, sensor, or alike into the envelope through at least one injection hole;

1) fixing the injection hole to avoid any kind of leakage; and

m) optionally vulcanizing the fixed injection hole to obtain the tubeless tyre integrated with at least one envelope at the inner surface, containing a sealant, coolant, sensor or alike.

In another embodiment of present invention, the method can be used for integrating plurality of envelop(s) to accommodate sealant, coolant, etc. in a tubeless tyre.

BRIEF DESCRIPTION OF THE DRAWINGS

The object of the invention may be understood in more details and more particularly description of the invention briefly summarized above by reference to certain embodiments thereof which are illustrated in the appended drawings, which form a part of this specification. It is to be noted, however, that the appended drawings illustrate preferred embodiments of the invention and are therefore not to be considered limiting its scope, for the invention may admit to other equally effective equivalent embodiments.

Fig. 1 shows a flow chart of system for integrating envelope(s) to accommodate sealant, coolant, sensors, etc. in a tubeless tyre in accordance with an embodiment of the present invention. Fig. 2 shows a flow chart of manufacturing process for integrating envelope(s) to accommodate sealant, coolant, sensors, etc. in a tubeless tyre in accordance with an embodiment of the present invention.

Fig. 3 shows sectional view of a tubeless tyre with independent envelope(s) for sealant and/or coolant in accordance with an embodiment of the present invention.

Fig. 4 shows sectional view of a tubeless tyre with independent envelope(s) for sealant, coolant and balancer in accordance with an embodiment of the present invention.

Fig. 5 shows sectional view of a tubeless tyre with a single envelop in accordance with an embodiment of the present invention.

Fig. 6 shows sectional view highlighting joining of a tubeless tyre with a single envelope according to an embodiment of the present invention.

Fig. 7 shows sectional view highlighting joining of a tubeless tyre with multiple envelopes according to an embodiment of the present invention.

Fig. 8 shows sectional view of a tubeless tyre integrating with envelope(s) to accommodate sealant, coolant, sensors, etc. according to an embodiment of the present invention.

Fig. 9 shows a tubeless tyre integrating with envelope(s) to accommodate sealant, coolant, sensors, etc. according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which a preferred embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiment set forth herein. Rather, the embodiment is provided so that this disclosure will be thorough, and will fully convey the scope of the invention to those skilled in the art.

The instant invention relates to a manufacturing process of envelope(s) integrated tubeless tyre. More specifically, the invention provides a manufacturing process for integrating envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre. The manufacturing process of envelope(s) integrated tubeless tyre is limited to high quality semi vulcanized tubeless tyres and envelope(s) made as per specification for undergoing further manufacturing processes. Though the rubber of the tyre and envelope(s) is semi-vulcanised and ready to use, still they are soft with some flowability for superior grip and further processing.

The proposed manufacturing process of envelope(s) integrated tubeless tyre is limited to tyre re-treating without use of boiler at controlled temperature conditions wherein high quality semi vulcanized tubeless tyres made as per specification undergoes further manufacturing processes. Though the rubber of the tyre is semi- vulcanised and ready to use, still they are soft with some flowability for superior grip and further processing. An envelope like structure is formed in inner cavity of tubeless tyre by joining envelope forming material which is being referred to as envelope(s) hereafter. Envelope is made of flexible materials which can be formed like a sheet and can be joined with inner liner of a tubeless tyre. Said material can be either made of different kinds of rubber or polymer or plastic with or without coatings.

In one of the embodiment process of manufacturing a tubeless tyre comprising the steps of: a) receiving a semi-vulcanised tubeless tyre having an inner surface and an outer surface;

c) selecting at least one mating surface, on the inner surface of said tubeless tyre and said first surface of said flexible sheet; d) roughening the mating surfaces on said tyre and said flexible sheet as selected in step c);

e) applying a vulcanisation solution on the roughened surfaces;

f) applying an adhesive solution on the surfaces of step e);

g) joining the surfaces of step f) with each other such that the inner surface of said tyre is in conjunction with said first surface of the rubber sheet h) applying pressure on the joined surfaces to form at least one envelope;

i) heat treating the tyre for improving bonding between the joined surfaces; j) injecting a sealant, coolant, sensor, or balancer into the envelope through at least one injection hole;

k) fixing the injection hole to avoid any kind of leakage; and

1) optionally vulcanizing the fixed injection hole to obtain the tubeless tyre integrated with at least one envelope at the inner surface, containing a sealant, coolant, sensor or balancer; the tubeless tyre thus obtained has a long life and low maintenance cost and the envelope protects the sealant, coolant, sensor or alike from direct contact of air.

The flexible sheet is made of any one selected from the group of butyl rubber, halobutyl rubber, synthetic rubber, state of the art polymer, thermoelastic plastic with or without coating or alike. The pressure applied is either pneumatic or mechanical or both. The pneumatic pressure is applied by a curing bag or tube or tube like substance through compressed air. The step of applying the pneumatic pressure includes reducing moisture content using a Filter Regulator Lubricator (FRL) unit. The mechanical pressure is applied by a clamping force by disc made for this special purpose and tightening of a clamp through screws which provide requisite force, such that the pressure is selectively exerted on joined surfaces of the tubeless tyre and the flexible sheet from outside of said tubeless tyre and from the second surface of the flexible sheet. The pressure applied is in the range of 25 psi to 50 psi, wherein variation of pressure is dependent on factors such as thickness and materials of the tyre, thickness and materials of the flexible sheet and the amount of vulcanization undergone prior to the process by said tyre and said sheet. The process further includes a step of strengthening of the envelope prior to roughening of surfaces wherein the strengthening is done by using strengthening strings or elements. Said strengthening strings or elements is selected from the group of natural/ synthetic fibers such as, but not limited to like nylon, ryon, tensylon, kevlar, zylontec, or alike. Said strengthening fibers are in pieces and spreaded across in a random fashion or along the length or along the breadth or along both length and breadth or along diagonals of the flexible sheet. The area of the tubeless tyre and the flexible sheet that undergoes surface roughening treatment are of different widths based on size of tyre, usage of tyre and other joining means being used for the same. The heat treating of tyre includes applying external temperature in the range of 90OC- 160OC wherein variation of temperature is dependent on factors such as thickness and materials of the tyre, thickness and materials of the flexible sheet and the amount of vulcanization undergone prior to the process by said tyre and said sheet. The vulcanisation solution applied to the surfaces makes them sticky for carrying further process of bonding wherein a predetermined time is established depending upon the ambient temperature, moisture content in ambient environment and properties of the vulacnisation solution. The tubeless tyre obtained has plurality of envelopes to accommodate sealant, coolant, sensor. The envelope allows distribution of sealant, coolant, sensor or balancer uniformly inside the tyre across the inner surface as well as side thereof.

In one of the embodiment of said envelope(s), can be optionally provided with fibers for strengthening which are in pieces and spread across in pre-determined or random fashion. The sides of the envelope undergo surface roughening and corresponding parts of internal side of tubeless tyres side wall also undergo surface roughening in this instant manufacturing process. Surface roughening is done by a custom-built machine. Then on the roughened surface vulcanisation solution is applied and kept for a predetermined time till it becomes sticky. The predetermined time depends on the environment temperature, moisture content and properties of the vulcanisation solution. Once the solution becomes sticky bonding gum is provided between both surfaces to be joined.

In another embodiment of the invention, there is provided joining elements between the internal surface of tubeless tyre and envelopes wherein the joining elements include gum and/or other filler substances. Sometimes non sticking substance is provided in those areas where there is no need of joining based on vulcanisation level of joining elements, time and temperature of operation, pressure to be applied. Afterwards the envelop and tubeless tyre are joined with pressure.

In an alternate embodiment, for better joining and surface finish in the joining surfaces localised heating is done by means of electrical heating by tyre envelope joining machine. The pressure applied is pneumatic and in few cases the pressure will be mechanical as well. Said mechanical pressure is exerted from outside of said tubeless tyres and inside surface from envelope side. The pneumatic pressure is provided by a curing bag or tube or tube like substance through compressed air. The mechanical pressure is provided by clamping force between surfaces provided by disc made for this special purpose. Tightening of the clamp through the screws provide the requisite force. Once the envelope(s) is formed by joining only by pressure or pressure and heat then within the specified envelope(s) sealant and/or coolant and balancer is injected. The holes of injected part of the envelope are joined to avoid any kind of leakage. The product made by such process can be used in any kind of vehicles which uses or is capable of using tubeless tyres.

In another possible embodiment of the present invention, the pressure applied is pneumatic. The pneumatic pressure is provided by a curing bag or tube or tube like substance through compressed air and a Filter Regulator Lubricator (FRL) unit is utilized to reduce the moisture content that results in better quality tubeless tyre.

In another embodiment of present invention, the mechanical pressure applied on bonded surface of tubeless tyre and envelope(s) is exerted from outside of said tubeless tyres and inside surface from envelope(s) side. Further, the mechanical pressure is provided by clamping force between bonded surfaces which is provided by disc made for this special purpose and tightening of the clamp through the screws to provide the requisite force.

In another embodiment of present invention, the pressure exerted on the bonded surfaces of tubeless tyre and envelope(s) is between 25 psi to 50 psi. The variation of pressure is dependent on several factors such as thickness and materials of tubeless tyres, thickness and materials of envelope and the amount of vulcanization undergone by said tubeless tyres and said envelope.

In accordance with an embodiment of the present invention, a method for integrating envelope(s) to accommodate sealant, coolant, etc. in a tubeless tyre is provided. To manufacture a tubeless tyre having envelope(s), the requirements include at least one semi-vulcanised tyre, at least one semi-vulcanised envelope like structure made of flexible material such as, but not limited to like butyl rubber, halobutyl rubber, synthetic rubber, different kinds of polymer, thermoelastic plastic with or without coating, etc., optionally providing, plurality of strengthening strings/elements for envelope made up of natural/ synthetic fibers such as, but not limited to like nylon, ryon, tensylon, Kevlar, zylontec, etc. and a tyre-envelope joining machine comprising a roughening apparatus to perform mechanical abrasion of tubeless tyre internal surface and corners of envelope surface to increase surface area for bonding, a vulcanisation solution application apparatus to apply vulcanisation solution to the roughned surface of tubeless tyre and envelope(s), an adhesive solution application apparatus for applying adhesive to the roughned and vulcanised surface of tubeless tyre and envelope(s) and act as a catalyst for enhancing bonding between them, an electric heating application apparatus for applying heat to the adhesion surface of tubeless tyre and envelope(s) to improve bonding and surface finish of bonded surface and a pressure application apparatus to apply pneumatic and mechanical pressure to the adhesion and heated surface of tubeless tyre and envelope(s).

In one embodiment of present invention, envelope(s) are optionally provided with strengthening fibers that are in pieces and spread across in random and/or pre- determined fashion such as along the length or along the breadth or along both length and breadth or along diagonal(s).

In yet another embodiment of present invention, the area of tubeless tyre and envelope that undergoes surface roughening treatment are of different widths based on size of tyres, usage of tyres and other joining means being used for the same.

In another embodiment of present invention, the external temperature applied for joining the tubeless tyre and envelope(s) varies from 90 degree centigrade to 160 degree centigrade. The variation of temperature is dependent on several factors such as thickness and materials of tubeless tyres, thickness and materials of envelope and the amount of vulcanization undergone by said tubeless tyres and said envelope.

In another embodiment of present invention, the vulcanisation solution applied to the roughen surface of tubeless tyre and envelope(s) makes them sticky for carrying further process of bonding.

To further explain the above embodiments, Fig.l provides a simplified flow chart of system 100 for integrating envelope(s) to accommodate sealant, coolant, sensors, etc. in a tubeless tyre. The system 100 comprises tyre-envelope joining machine 101 comprising a roughening apparatus 102 to perform mechanical abrasion of tubeless tyre internal surface and corners of envelope surface to increase surface area for bonding, a vulcanisation solution application apparatus 103 to apply vulcanisation solution to the roughned surface of tubeless tyre and envelope(s), an adhesive solution application apparatus 104 for applying adhesive to the roughned and vulcanised surface of tubeless tyre and envelope(s) and act as a catalyst for enhancing bonding between them, an electric heating application apparatus 105 for applying heat to the adhesion surface of tubeless tyre and envelope(s) to improve bonding and surface finish of bonded surface and a pressure application apparatus 106 to apply pneumatic and mechanical pressure to the adhesion and heated surface of tubeless tyre and envelope(s). The area of tubeless tyre and that of the envelope that undergoes surface roughening apparatus 102 is of different widths based on size of tyres, usage of tyres and other joining means being used for the same. The vulcanisation solution applied by vulcanisation solution application apparatus 103 to the roughened surface of tubeless tyre and envelope(s) made them sticky for carrying further process of bonding. A predetermined time is established depending upon the ambient temperature, moisture content in ambient environment and properties of the vulcanisation solution. The pressure exerted by pressure application apparatus 106 on the bonded surfaces of tubeless tyre and envelope(s) is between 25 psi to 50 psi. The variation of pressure is dependent on several factors such as thickness and material of tubeless tyres, thickness and material of envelope and the amount of vulcanization undergone by said tubeless tyres and said envelope. Further, the pressure application apparatus 106 apply pneumatic pressure on bonded surface of tubeless tyre and envelope(s) by a curing bag or tube or tube like substance through compressed air. Further, the pressure application apparatus 106 applies the mechanical pressure on bonded surface of tubeless tyre and envelope(s) from outside of said tubeless tyres and inside surface from envelope(s) side. In addition, the mechanical pressure is provided by clamping force between bonded surfaces which is provided by disc made for this special purpose and tightening of the clamp through the screws provide the requisite force. The external temperature for the joining the tubeless tyre and envelope(s) varies from 90 degree centigrade to 160 degree centigrade. The variation of temperature is dependent on several factors such as thickness and materials of tubeless tyres, thickness and materials of envelope and the amount of vulcanization undergone by said tubeless tyres and said envelope. Exemplary Fig. 2 shows a flow chart of manufacturing process 200 for integrating envelope(s) to accommodate sealant, coolant, sensors, etc. in a tubeless tyre. The manufacturing process 200 comprising steps of: a) receiving a semi-vulcanised tubeless tyre having an inner surface and an outer surface; b) receiving a semi-vulcanised flexible sheet (rubber sheet) having a first surface and a second surface;

d) optionally, strengthening the flexible sheet using strengthening strings/elements;

e) roughening the mating surfaces on said tyre and said flexible sheet as selected in step c);

f) applying a vulcanisation solution on the roughened surfaces;

g) applying an adhesive solution on the surfaces of step f);

1) fixing the injection hole to avoid any kind of leakage; and

Fig. 3 shows sectional view of a tubeless tyre 300 with independent envelope(s) for sealant 301 and coolant 302. In current embodiment, there is a separate envelope 303 for accommodating sealant 301 and there is an envelope 304 for accommodating coolant 302. The present invention allows distribution of sealant 301 and coolant 302 uniformly inside the tubeless tyre 300 across the side as well as the bottom. Also, it obviates the direct contact of air with sealant 301 and coolant 302 thus improves the life of sealant 301 and coolant 302 along with life of tubeless tyre 300 and cost of ownership is also decreased.

Fig. 4 shows sectional view of a tubeless tyre 400 with independent envelope(s) for sealant 401, coolant 402 and balancer 403. The present invention allows distribution of sealant 401, coolant 402 and balancer 403 uniformly inside the tubeless tyre 400 across the side as well as the bottom. Also, it obviates the direct contact of air with sealant 401, coolant 402 and balancer 403 thus improves the life of sealant 401, coolant 402 and balancer 403 along with life of tubeless tyre 400 and cost of ownership is also decreased.

Fig. 5 shows a sectional view of a tubeless tyre 500 with a single envelope 501. Here, the envelope 501 can be used to contain any of one from sealant, coolant, balancer, etc. Integration of envelop 501 is such that, it allows uniform distribution of sealant, coolant, balancer, etc. within the tubeless tyre 500.

Fig. 6 shows sectional view highlighting joining of a tubeless tyre 600 with a single envelop 601. It is shown here that the cutting and fitting of envelop 601 is such that, the envelope's 601 roughened and vulcanised surface is aligning perfectly with the roughened and vulcanised inner side walls of tubeless tyre 600, which enables effective and efficient integration of envelope 601 with tubeless tyre 600 after application of external pressure and/or heat.

Fig. 7 shows sectional view highlighting joining of a tubeless tyre 700 with multiple envelope(s) 701 and 702. It is shown here that the cutting and fitting of envelope(s) 701 and 702 is such that, the envelopes' 701 and 702 roughened and vulcanised surface are aligning perfectly to the roughened and vulcanised inner side walls of tubeless tyre 700, which enables effective and efficient integration of envelop(s) 701 and 702 with tubeless tyre 700 after application of external pressure and/or heat.

Fig. 8 shows sectional view of a tubeless tyre 800 integrating envelope(s) 801 to accommodate sealant, coolant, sensors, balancer etc.with an embodiment of the present invention. The tubeless tyre 800 includes plurality of envelope(s) 801, sidewalls 802 and an outer circumferential tread 803. The sidewalls 802 extend radially inward from the axial outer edges of the tread portion 803. On the inner side of sidewalls 802 there are uniformly aligned strengthened and/ or non strengthened envelope(s) 801, which are stuck by applying vulcanization solution and adhesive solution on the respective roughened surface followed by external heat and pressure.

Fig. 9 shows a tubeless tyre 900 integrating envelope(s) 901 to accommodate sealant, coolant, sensors, etc. with an embodiment of the present invention. The tubeless tyre 900 includes plurality of envelope(s) 901, sidewalls 902 and an outer circumferential tread 903. The sidewalls 902 extend radially inward from the axial outer edges of the tread portion 903. On the inner side of sidewalls 902 there are uniformly aligned strengthened and/or non strengthened envelope(s) 901, which are stuck by applying vulcanization solution and adhesive solution on the respective roughened surface followed by external heat and pressure.

The foregoing description of embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principals of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.

Claims

CLAIMS I claim:

1. A process of manufacturing a tubeless tyre with envelope(s) and a product made by same process wherein said process comprises the steps of:

a) receiving a semi-vulcanised tubeless tyre having an inner surface and an outer surface;

d) roughening the mating surfaces on said tyre and said flexible sheet as selected in step c);

e) applying a vulcanisation solution on the roughened surfaces;

f) applying an adhesive solution on the surfaces of step e);

k) fixing the injection hole to avoid any kind of leakage; and

1) optionally vulcanizing the fixed injection hole to obtain the tubeless tyre integrated with at least one envelope at the inner surface, containing a sealant, coolant, sensor or balancer; the tubeless tyre thus obtained has a long life and low maintenance cost;

the envelope protects the sealant, coolant, sensor or alike from direct contact of air.

2. The process as claimed in claim 1, wherein the flexible sheet is made of any one selected from the group of butyl rubber, halobutyl rubber, synthetic rubber, state of the art polymer, thermoelastic plastic with or without coating or alike.

3. The process as claimed in claim 1, wherein the pressure applied is either pneumatic or mechanical or both.

4. The process as claimed in claim 3, wherein the pneumatic pressure is applied by a curing bag or tube or tube like substance through compressed air.

5. The process as claimed in claim 4, wherein the step of applying the pneumatic pressure includes reducing moisture content using a Filter Regulator Lubricator (FRL) unit.

6. The process as claimed in claim 1, wherein the mechanical pressure is applied by a clamping force by disc made for this special purpose and tightening of a clamp through screws which provide requisite force, such that the pressure is selectively exerted on joined surfaces of the tubeless tyre and the flexible sheet from outside of said tubeless tyre and from the second surface of the flexible sheet.

7. The process as claimed in claim 1, wherein the pressure applied is in the range of 25 psi to 50 psi, wherein variation of pressure is dependent on factors such as thickness and materials of the tyre, thickness and materials of the flexible sheet and the amount of vulcanization undergone prior to the process by said tyre and said sheet.

8. The process as claimed in claim 1, wherein the process further includes a step of strengthening of the envelope prior to roughening of surfaces wherein the strengthening is done by using strengthening strings or elements.

9. The process as claimed in claim 8, wherein said strengthening strings or elements is selected from the group of natural/synthetic fibers such as, but not limited to like nylon, ryon, tensylon, kevlar, zylontec, or alike.

10. The process as claimed in claim 9, wherein said strengthening fibers are in pieces and spreaded across in a random fashion or along the length or along the breadth or along both length and breadth or along diagonals of the flexible sheet.

11. The process as claimed in claim 1, wherein the area of the tubeless tyre and the flexible sheet that undergoes surface roughening treatment are of different widths based on size of tyre, usage of tyre and other joining means being used for the same.

12. The process as claimed in claim 1, wherein the heat treating of tyre includes applying external temperature in the range of 90°C- 160°C wherein variation of temperature is dependent on factors such as thickness and materials of the tyre, thickness and materials of the flexible sheet and the amount of vulcanization undergone prior to the process by said tyre and said sheet.

13. The process as claimed in claim 1, wherein the vulcanisation solution applied to the surfaces makes them sticky for carrying further process of bonding wherein a predetermined time is established depending upon the ambient temperature, moisture content in ambient environment and properties of the vulacnisation solution.

14. The process as claimed in claim 1, wherein the tubeless tyre obtained has plurality of envelopes to accommodate sealant, coolant, sensor.

15. The process as claimed in claim 1, wherein the envelope allows distribution of sealant, coolant, sensor or balancer uniformly inside the tyre across the inner surface as well as side thereof.