AIRCRAFT TIRE WITH EMBEDDED BREAKER PLIES
TECHNICAL FIELD
The present invention relates to pneumatic tires and more particularly to a novel carcass specifically for use in aircraft tires.
BACKGROUND OF THE INVENTION
An aircraft tire is subjected to extreme operating conditions which include very high internal pressure, high speeds in excess of 300 kilometers per hour (kph), and very high deflections of the section height between the wheel flange and the outside diameter of the tire. While taxiing, the deflection may be more than 30%, on takeoff 40%, and on landing 45% or more under impact conditions. These extreme pressures, loads and deflections put the sidewall between the shoulder of the tire and the bead to severe tests. The high pressure and high loads place the ply cords under severe tensile loads. The cords in the plies, particularly in the lower sidewall area, are frequently mechanically fatigued due to a high heat buildup near the beads while the aircraft is taxiing or during takeoff. In the prior art, the conventional solution to these problems was to increase the tire rigidity and to decrease tire deformation under load by increasing the number of tire plies. To further improve tire durability, the ply turnup portion of tires was typically reinforced. U.S. Patent No. 5,105,865 by Togashi et al . describes these conventional solutions and proposes that the durability of the
tire can be further improved by avoiding bending deformations of
the ply surfaces. The 5,105,865 patent describes a tire
curvature that increases the tire durability with no increase in
weight .
U.S. Patent No. 4,029,137 by Suydam teaches that an
improvement in durability can be achieved with a novel wrapping
of the ply structure about the beads. The 4,029,137 patent also
discloses a means of improving tire durability without
increasing weight .
In British Patent GB 2,087,806 by Takahaski, a biased
aircraft tire is disclosed wherein the cords of the carcass
plies are spaced further apart to achieve improved durability.
U.S. Patent No. 5,509,455 by Warchol et al . discloses an
aircraft tire with circumferentially extending reinforcement
inserts on each side of the tire. Each of the inserts has cord
reinforced members with bias angled cords that are equal but
opposite in orientation relative to the cords of the adjacent
member. The structure increases ply durability while achieving
a significant weight reduction. With increasing aircraft performance, it is apparent that
there is a continuing need to provide novel methods and tire
designs for improving aircraft tire durability.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of the present invention to provide a
pneumatic tire for an aircraft, the pneumatic tire being as defined in one or more of the appended claims and, as such,
having the capability of being constructed to accomplish one or
more of the following subsidiary objects.
It is another object of the present invention to provide a
pneumatic tire for an aircraft which meets the requirements for
double load capability required for aircraft tires.
It is a further object of the present invention to provide
a pneumatic tire for an aircraft wherein breaker plies are
embedded within a multi-layered carcass so that the ends of the
breaker plies are disposed at a location near the sidewalls of
the tire where the tread thickness is at least about 40% of the
maximum thickness of the tread.
It is a yet further object of the present invention to
provide a pneumatic tire for an aircraft wherein tread plies are
located between the multi-layered carcass and the tread
portion and extend across the carcass toward the sidewalls so
that the ends of the tread plies are disposed at a location near
the sidewalls where the tread thickness is between about 60% and
85% of the maximum tire tread thickness.
It is a yet further object of the present invention to
provide a pneumatic tire for an aircraft that improves sidewall
durability while achieving a reduction in overall tire weight.
In accordance with an embodiment of the invention, a
pneumatic tire for an aircraft is disclosed which is constructed
of a multi-layered carcass composed of a plurality of ply layers
and a pair of spaced apart bead portions having at least two
substantially inextensible bead cores disposed side by side and
spaced apart axially. The ply layers have carcass plies
extending circumferentially about the tire and between the bead
cores of opposite bead portions. A tread portion overlies the
multi-layered carcass and a pair of sidewall portions extend
from the bead portions to the tread portion. At least two
breaker plies are embedded within the multi- layered carcass
above the carcass plies. The breaker plies extend entirely
about the circumference of the tire and below the tread portion.
The first and second breaker plies are buried in the carcass so
that their first and second opposite ends are disposed at a
location where the tread portion has a thickness above about 60%
to about 85% of the maximum thickness of the tread portion
measured at the equatorial plane through the tire. The first
breaker ply is above the second breaker ply and has opposite
ends that are disposed at a location where the tread portion has
a thickness of about 20% to about 45% more than the thickness of
the tread portion at the location of the opposite ends of the
second breaker ply. Also, the second breaker ply is longer than
the first breaker ply so that the ends of the second breaker ply
are disposed closer to the pair of spaced apart bead portions
than the ends of the first breaker ply.
Also according to the invention, the tire includes tread
plies disposed in the tread portion so that the ends of the
tread plies are positioned with respect to the tread at a
location corresponding to between about 60% and 85% of the
maximum tire section thickness. Also, the tread plies are
shorter than either of the breaker plies.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a cross-sectional view illustrating the improved
aircraft tire made in accordance with the present invention;
Fig. 2 is a further enlarged cross-sectional view
illustrating one side or half of the symmetrical tire shown in
Fig. 1 and made in accordance with the present invention; and
Fig. 3 is an alternative embodiment showing two pairs of
breaker plies embedded within the carcass.
DEFINITIONS
"Apex" means a non-reinforced elastomer positioned radially
above a bead core .
"Aspect ratio" of the tire means the ratio of its section
height (SH) to its section width (SW) multiplied by 100% for
expression as a percentage.
"Axial" and "axially" means lines or directions that are
parallel to the axis of rotation of the tire.
"Bead" means that part of the tire comprising an annular
tensile member wrapped by the ply cords and shaped, with or
without other reinforcement elements such as flippers, chippers,
apexes, toe guards and chafers, to fit the design rim.
"Belt or breaker reinforcing structure" means at least two
layers of plies of parallel cords, woven or unwoven, underlying
the tread, unanchored to the bead, and having both left and
right cord angles in the range from 17 degrees to 40 degrees
with respect to the equatorial plane of the tire.
"Bias ply tire" means a tire having a carcass with
reinforcing cords in the carcass ply extending diagonally across
the tire from bead core to bead core at about 25°-50° angle with
respect to the equatorial plane of the tire. Cords run at
opposite angles in alternate layers.
"Carcass" means the tire structure apart from the belt
structure, tread, undertread, and sidewall rubber over the
plies, but including the beads.
"Circumferential" means lines or directions extending along
the perimeter of the surface of the annular tread perpendicular
to the axial direction.
"Chafers" refers to narrow strips of material placed around
the outside of the bead to protect cord plies from the rim,
distribute flexing above the rim, and to seal the tire.
"Chippers" means a reinforcement structure located in the
bead portion of the tire.
"Cord" means one of the reinforcement strands of which the
plies in the tire are comprised.
"Equatorial plane (EP) " means the plane perpendicular to
the tire's axis of rotation and passing through the center of
its tread.
"Flipper" means a reinforced fabric wrapped about the bead
core and apex.
"Footprint" means the contact patch or area of contact of
the tire tread with a flat surface at zero speed and under
normal load and pressure.
"Inner liner" means the layer or layers of elastomer or
other material that form the inside surface of a tubeless tire
and that contain the inflating gas or fluid within the tire.
"Net-to-gross ratio" means the ratio of the tire tread
rubber that makes contact with the road surface while in the
footprint, divided by the area of the tread in the footprint,
including non-contacting portions such as grooves.
"Nominal rim diameter" means the average diameter of the
rim flange at the location where the bead portion of the tire
seals .
"Normal inflation pressure" refers to the specific design
inflation pressure at a specific load assigned by the
appropriate standards organization for the service condition for
the tire.
"Normal load" refers to the specific load at a specific
design inflation pressure assigned by the appropriate standards
organization for the service condition for the tire.
"Ply" means a continuous layer of rubber-coated parallel cords .
"Radial and "radially" means directions extending radially
toward or away from the axis of rotation of the tire.
"Radial-ply tire" means a belted or circumferentially-
restricted pneumatic tire in which the ply cords which extend
from bead to bead are laid at cord angles between 65° and 90°
with respect to the equatorial plane of the tire.
"Section height (SH)" means the radial distance from the
nominal rim diameter to the outer diameter of the tire at its
equatorial plane.
DETAILED DESCRIPTION OF THE INVENTION
With reference to Fig. 1, there is illustrated a cross-
section of tire 10 which in the specific embodiment illustrated
is a size H43.5X16.0-21 tire. The tire has a 43.5 inch (110.5
cm) maximum inflated outside diameter, a 16.0 inch (40.6 cm)
maximum inflated width tire in the axial directions, and a
nominal bead diameter of 21 inches (53.3 cm) . While a specific
tire size is illustrated, it is within the terms of the
invention to incorporate the present invention in any tire
between H31X13.0-12 up through H54X21.0-24.
The tire 10 includes a ground engaging, circumferentially
extending tire tread portion 12, a pair of tire sidewalls 14,16
extending radially inwardly from the axially disposed outer
edges of the tread portion and terminating at their radial
extremities in a pair of bead portions 18,20, respectively. The
sidewalls 14,16 each have an upper portion 14a, 16a,
respectively, in the shoulder region of the tire radially
outward of the tread and radially inward of the maximum section
width of the tire, and a lower portion 14b, 16b, respectively,
adjacent the bead portions 18, 20 and radially inward of the
maximum section width of the tire 10. The tire 10 also includes
a cord reinforced carcass structure 22 that extends
circumferentially about the tire and from bead portion 18 to
bead portion 20. The cord reinforced carcass structure 22 is
constructed of a plurality of rubberized laminated ply layers of
tire cord fabric.
The cord reinforcing carcass structure 22 includes twelve
biased carcass plies of tire cord fabric 24, 25, 26, 27, 28, 29,
30, 31, 32, 33, 34, 35 (24-35). Each of the biased carcass
plies extends at a bias angle with respect to the equatorial
plane or circumferential center line of the tire, and the
adjacent biased carcass plies are disposed at the same angle but
extending in the opposite direction with respect to the
equatorial plane . The angle that the cords in the individual
carcass plies make with respect to the equatorial plane
decreases progressively from an angle of about 31° in the biased
inner ply 24 to about 28.5° in the biased outer ply 35. While
the illustrated embodiment incorporates twelve biased carcass
plies, it is within the terms of the invention to use more or
less plies depending upon the specific requirements for the
tire.
Also included in the tire tread portion 12 is a pair of
tread belts plies 40 and 42 extending circumferentially about
tire 10 and located between tread 43 and a conventional buff
line cushion gum layer 44 that generally extends from one edge
of the tread portion 12 to the axially opposite edge of the
tread portion 12. The tread plies 40, 42 reinforce and
strengthen the tread 43. The tread plies 40 and 42 have a
maximum width where their ends 40a, 40b, 42a, and 42b are
positioned with respect to the tread 43 at a location
corresponding to between about 60% and 85% and preferably about
65% to about 80% and most preferably about 65% of the maximum
tire section thickness "t" measured at the equatorial plane 60
passing through the center of tread 43. The angle of the cords
in the tread plies 40 and 42 with respect to the equatorial
plane 60 is between about 20° and 30° and preferably about 26°.
Preferably, the width of tread ply 42, is less than the width of
tread ply 40 so that ends 40a, 40b of- tread ply 40 are located
closer to sidewalls 14 and 16, respectively, as compared to ends
42a, 42b of tread ply 42. While two tread plies 40 and 42 are
illustrated, it is also within the terms of the invention to use
between one and four tread plies as required.
The material of the cords in all of the plies forming the
carcass structure 22 is nylon although any suitable material or
combination of materials can be utilized. It is believed
preferable that the cords be a textile material. Further, while
specific angles have been specified for the carcass and tread
plies, these angles can be varied within the normal range of
bias ply aircraft tires. For example, the angles of the carcass
plies can be from between about 25° to 45° for a biased ply
aircraft tire.
The bead portions 18, 20 each include three annular,
substantially inextensible bead cores 50, 52 and 54. Two
carcass plies 24 and 25 are disposed radially inwardly of the
tire 10 adjacent to the axially disposed inner sides of the
axially located inner bead core 50. The respective end portions
24a and 25a are turned axially outwardly across bead cores 52
and 54 and then turned radially outward about bead core 54.
Carcass plies 26, 27, 28 and 29 are disposed axially outward
from carcass plies 24 and 25 and radially adjacent to the inner
sides of bead core 50. Further, end portions 26a, 27a, 28a,
29a, of carcass plies 26, 27, 28 and 29, respectively, are
turned radially outwardly and then about bead core 50. Since
the carcass plies 26, 27, 28, 29 are wrapped around two sides of
bead core 50, as the progress radially outward toward sidewall
14, the tensile loading of these plies caused by inflation
pressure and loading on the tire are supported by bead core 50.
The carcass plies 30 and 31 are disposed radially inwardly
of the tire 10 adjacent to the bead core 52 and axially outward
from carcass plies 26-29. The plies 30 and 31 extend between
the bead cores 50 and 52 with their respective end portions 30a
and 30b being wrapped axially outward and about bead core 52 as
they progress radially outward toward the sidewall 14. Since
the carcass plies 30a and 31a are wrapped about two sides of the
bead core 52 as they progress radially outward, the tensile
loading of these plies caused by inflation pressure and loading
on the tire are supported by bead core 52.
The axially disposed, outer bead core 54 has two carcass
plies 32 and 33 extending radially inwardly adjacent the axially
inner sides of the bead core 54. Carcass plies 32 and 33 have
their end portions 32a and 33a, respectively, turned axially
outward adjacent the radially outward sides of the bead core 54.
The bead core 54 supports the tensile loading applied to the
plies 32, 33, by inflation pressure and loading on the tire 10.
The outer most carcass plies 34 and 35 extend radially
inward from sidewalls 14 and 16, respectively, and are
interposed between the turnup ends 24a and 25a of plies 24 and
25, respectively, and the axially outer sides of the bead core
54. The carcass ply end portions 34a and 35a turn axially
inward adjacent the bead core 54 and then extend inwardly to the
bead core 50. The end portions 34a and 35a being interposed
between the bead cores 50, 52 and 54 and the radially inner
sides of carcass plies 24 and 25, cause the bead cores 50, 52
and 54 to support the tensile loading applied to the plies 34
and 35 by inflation pressure and loading on the tire.
The carcass plies 24 and 25 extend radially outward of tire
10 and are interposed between the tread portion 12, the
sidewalls 14 and 16 and the inner liner 80. The end portions
24a and 25a terminate in the lower sidewall areas 14a, 14b,
respectively, at a point radially outwardly of the bead cores
50, 52, and 54 to support the tensile loading applied to the
plies 24 and 25.
For the purposes of this invention, an end portion shall be
that portion of a carcass ply that wraps about or extends
radially outward from a bead core. If an end portion terminates
short of the point of maximum axial width of the tire, it is not
considered a working portion of the ply since it does not exert
a significant radially outward directed pull on the bead core.
A bead core that absorbs a major radially outwardly directed
pull of a carcass ply is an active or working bead core, and for
purposes of this invention is a bead core bounded on any axial
side and a radially inner side by the working portion of a
carcass ply. The working portion of a carcass ply is that
portion of the ply extending from a bead on one side of the tire
to the opposite side's bead, and for purposes of this invention
the working portion of the carcass plies is called the ply side;
the non-working portion is the turn-up or end portion of the
ply.
Referring to Fig. 2 there is an enlarged illustration of a
group of structural components employed in the tire 10.
Radially above each bead core 50, 52, 54 is an elastomeric apex
62, 64, 66, respectively. Wrapped about each bead core 50, 52,
54 and corresponding axially adjacent apex 62, 64, 66,
respectively, is a flipper 68, 70, 72, respectively. Wrapped
about the entire bead structure is a chafer 74. The chafer 74
extends radially inwardly from an axially outer end 74a toward
the bead heel 76, turns axially inwardly extending to the bead
toe 78 where the chafer 74 turn radially outwardly to an inner
end 74b. In the embodiment as illustrated, the air chamber
formed by the tire is surrounded by a generally air impervious
innerliner 80 extending from bead portion 18 to bead portion 20.
Historically, bias ply aircraft tires have been designed
with full width carcass plies, which extend from a bead bundle
or portion on one side of the tire to the bead bundle or portion
on the other side of the tire. The breaker plies were typically
between the buff line cushion layer and the tread portion and in
spaced relationship from the carcass. In order to increase
carcass strength in any one area of the tire, it was common
practice to add full width plies to the carcass.
In accordance with the present invention, first and second
breaker plies 46 and 48 are buried in carcass structure 22 and
extend beyond the ends of the tread plies 40 and 42. While the
breaker plies 46 and 48 are illustrated as being disposed in
carcass 22 between the plies 33 and 34, it is within the terms
of the invention to locate the breaker plies at other locations
within the carcass. Further, while two breaker plies are
illustrated, it is within the terms of the invention to use two
pairs of breaker plies. The two pairs could either be disposed
adjacent one another or separated by one or more carcass plies.
The ends 46a, 46b and 48a, 48b of the breaker plies 46 and 48,
respectively, extend outward from the equatorial plane 60 to a
location where the thickness ta, tb of the tire tread portion 12
is equal to between about 60% and about 85% of the maximum tire
section thickness "t" when the tire is mounted and inflated to
its normal inflation pressure. The location of the ends of the
buried breaker plies 46 and 48 is an important aspect of the
invention. The ends 46a, 46b, 48a, 48b of breaker plies 46 and
48, respectively, extend outward towards the upper portions 14a
and 16a of sidewalls 14 and 16, respectively. The length of the
breaker plies is limited in that if they were to extend to a
location where ta or tb were equal to about 20% of the sectional
thickness t of tire tread portion 12, the effect would be that
the breaker plies would extend into the sidewalls. Further, if
the end portions 46a, 46b, 48a, 48b were to extend to a location
where ta and tb were about 35% of the maximum tire section
thickness t, the effect would be higher heat generation and
potential tire failure. On the other hand, if the tire breakers
are too narrow so that the ends are not close enough to the
sidewalls, the breaker plies do not provide the added stability
required to stiffen the tread and add strength to the casing.
The outermost breaker ply 46 has its end portions 46a and
46b disposed at a location where the thickness ta and tb of the
tread 43 is preferably between about 60% and about 85% of the
maximum tire thickness t. Correspondingly, the lower breaker
ply 48 has its ends 48a and 48b slightly longer than the plies
ends 46a and 46b of breaker ply 46. The ends 48a and 48b of
breaker ply 48 preferably extend somewhat longer than 46a and
46b of breaker ply 46 to prevent the formation of a hinge point
where the tire would naturally bend and generate additional
heat. The ends 48a and 48b of the lower breaker ply 48 extend
to a place where the thickness ta and tb is between 20% and to
about 45% less than the location of the ends 46a and 46b,
respectively, of upper breaker ply 46.
Locating the breaker plies 46 and 48 within the carcass
structure 22, shifts the deflection point of the tire 10 to a
location below the upper portions 14a, 16a, corresponding to the
shoulder portions of sidewalls 14, 16, respectively, to reduce
the heat generated. The location of the ends 46a, 46b, 48a, 48b
of the breaker plies 46, 48, respectively, result in a tire 10
where the heat buildup in the upper sidewall areas 14a, 16a does
not exceed a temperature at which the tire begins to breakdown.
Another advantage of the present design, as applied to a
H43.5X16.0-21 tire is that the number of carcass plies that
extend around the bead cores 50, 52, 54 has generally been
reduced, as compared to conventional prior art designs, to
twelve (12) plies.
An aircraft tire built in accordance with the present
invention, as illustrated in Figs. 1 and 2, was tested to meet
the standards set by the aircraft manufacturers . These are
generally known as double load requirements wherein, for
example, a tire rated for a load of 40,600 pounds can pass a
test of a double load of 81,200 pounds at 210 pounds per square
inch (psi) pressure. Also, the tire must go through a series of
tests including 50 simulated take off cycles and eight taxi
cycles at the rate of load and inflation at 40 miles (mph) for
35,000 feet. Then the tire must go through two taxi cycles of
40 mph for 35,000 feet at 1.2 times the rate of load (40,600
pounds) . Further, the tire is subjected to one cycle of
simulated take off at 1.5 times the rate of load and finally one
simulated take off at 2 times the rate of load. The placement
of the breaker plies 46, 48 within the carcass structure 22, and
the sizing of the breaker plies so that their ends 46a, 46b,
48a, 48b are positioned at a location corresponding to a
predetermined percentage of the maximum thickness of the tread
portion 12, as previously discussed resulted in a tire which was
able to pass the double load test set forth above.
A series of other tire constructions, similar in size, i.e.
H43.5X16.0-21, to the disclosed tire construction, were also
tested. Each of the other tire constructions, as described
below, experienced a heat generated failure in the shoulder
area. These tested tire constructions include:
Tire
Construction Features
1 14 plies with 29 inch building drum width
2 14 plies high angle with a 29 inch building drum width
3 16 plies with a 29 inch building drum width
4 16 plies with a 29 inch building drum width
5 14 plies plus two breakers and one tread reinforcing tread ply with a 30 inch building drum width
6 14 plies plus two breakers, one tread ply and fabric sidewall inserts with a 30 inch building drum width
7 35 degree average carcass angle with 29.5 inch building drum width
8 14 plies plus two breakers and two tread reinforcing plies with a 28.5 inch building drum width
It is apparent that there has been provided in accordance
with this invention a pneumatic tire for an aircraft that
satisfies the objects, means and advantages set forth
hereinbefore. According to the invention, the pneumatic tire
for an aircraft meets the . standards of the double load
requirement for aircraft tires and has breaker plies embedded
within a multi- layered carcass so that the ends of the breaker
plies are disposed at a location where the tread thickness is
between about 60% and 85% of the maximum thickness of the tread.
Also tread plies are incorporated in the tire and positioned so
that the ends are at a location corresponding to between about
60% and 85% of the maximum tire section thickness.
While the invention has been described in combination with
embodiments thereof, it is evident that many alternatives,
modifications, and variations will be apparent to those skilled
in the art in light of the foregoing teachings. Accordingly,
the invention is intended to embrace all such alternatives,
modifications and variations as fall within the spirit and scope
of the appended claims .