Apparatus and process for making a tape useful as a tire cap ply

Abstract

An apparatus and process are used to make tape which can be used as cap plies, breakers and reinforcement in the carcass of tires. The tape is made by dipping a plurality of single end cords in a solvent-based cement. The cords are converged before entering the dip pan so that they are fixed in a single plane when they are dipped. The cement, which comprises solvent and an elastomeric composition, is dried so that the majority of the solvent evaporates. The elastomeric composition remains, encapsulating the cords, thereby forming the tape.

1 . An apparatus for producing a tape suitable for use as a cap ply from a plurality of single end cords, comprising: 
 a) a dip pan for applying a cement to the single end cords; and    b) means for converging the cords before they travel to the dip pan, so that the cords converge and are fixed in a single plane as they are dipped in the dip pan.    
   
   
       2 . The apparatus of  claim 1 , wherein the converging means includes: 
 (i) a first comb for converging the cords before they travel to the dip pan; and    (ii) a second comb disposed between the first comb and the dip pan for further converging the cords after they leave the first comb and before they travel to the dip pan.    
   
   
       3 . The apparatus of  claim 2 , wherein the first comb has a plurality of first grooves, each first groove having a plurality of teeth with first spaces therebetween, wherein the cords travel through the first spaces to the second comb, and the second comb has a plurality of second grooves, each second groove having a plurality of teeth with second spaces therebetween, wherein the cords travel through the second spaces to the dip pan, wherein the width of each of the second grooves is less than the width of each of the first grooves, so that the cords converge as they travel from the first grooves to the second grooves.  
   
   
       4 . The apparatus of  claim 1 , further including an oven for drying the cement.  
   
   
       5 . The apparatus of  claim 1 , further including a dip pan roll disposed in the dip pan and having a plurality of teeth and valleys, and a press roll disposed above the dip pan roll, having a plurality of teeth and valleys, wherein the teeth of the press roll mesh with the valleys of the dip pan roll to compress the cement into the spaces between the single end cords.  
   
   
       6 . The apparatus of  claim 1 , further including at least one guide roll adapted to guide the tape after the tape exits the dip pan, wherein the first guide roll has a plurality of grooves formed in the outer periphery thereof, and the second guide roll has a plurality of grooves formed in the outer periphery thereof, and wherein the grooves in the second guide roll are spaced apart by a greater distance than the grooves in the first guide roll.  
   
   
       7 . The apparatus of  claim 1 , further including a winder for winding the tape after it exits the oven, wherein the winder comprises a shaft having a valley of a width sufficient for accommodating the tape after it exits the dip pan.  
   
   
       8 . The apparatus of  claim 2 , further including a third comb disposed between the dip pan and the winder, the third comb having a plurality of teeth, wherein the teeth are spaced apart by a distance sufficient for accommodating the tape as it is presented to the winder.  
   
   
       9 . A process for producing a tape suitable for use as a cap ply from a plurality of single end cords, comprising: 
 a) converging the plurality of single end cords so that the cords are fixed in a single plane as they travel through the dip pan;    b) applying a dip in the dip pan to the cords so that the cords are encapsulated in the dip; and    c) drying the dip to form a tape.    
   
   
       10 . The process of  claim 9 , further including pressing the dip into the spaces between the cords.  
   
   
       11 . The process of  claim 9 , wherein the dip is a cement comprising an elastomeric composition dissolved in a solvent, and further including the step of drying the cement so that the majority of the solvent evaporates, and the elastomeric composition remains, thereby forming the tape.  
   
   
       12 . A process for making a tape suitable for use as a cap ply, comprising: 
 a) dipping a plurality of single end cords in a solvent-based cement comprising a solvent and an elastomeric composition; and    b) drying the cement so that the majority of the solvent evaporates, and the elastomeric composition remains, encapsulating the cords, thereby forming the tape.    
   
   
       13 . A tape made by the process of  claim 12 .  
   
   
       14 . The tape of  claim 13 , wherein the solvent comprises 0.0009-5% by weight of the tape.  
   
   
       15 . A tape suitable for use as a cap ply, comprising a plurality of single end cords encapsulated in an elastomeric composition, and trace amounts of a solvent.  
   
   
       16 . The tape of  claim 15 , wherein the solvent comprises 0.0009-5% of the weight of the tape.  
   
   
       17 . The tape of  claim 15 , wherein the solvent is toluene.  
   
   
       18 . The tape of  claim 15 , wherein the elastomeric composition is selected from the group consisting of a natural rubber, a natural rubber with styrene butadiene or styrene butadiene with polybutadiene.