Method for Producing Tire-Curing Bladder
[0001] FIELD
[0002] A method of manufacturing tire forming bladders is disclosed herein.
[0003] BACKGROUND OF THE ART
[0004] Tire curing apparatuses, such as tire presses, typically cure or vulcanize a tire by
applying both internal and external heat and pressure. A tire press uses a heated outer metal
mold that serves to shape and vulcanize the outside of the tire. This is used in conjunction with
a rubber curing bladder that is inflated in the inside of a tire carcass and heated to vulcanize the
interior of the tire.
[0005] Due to the mechanical strain that tire-curing bladders are subjected to and the special
function they are called upon to perform, tire-curing bladders are typically required to be of a
custom size and dimension to meet the requirements of each different tire design. Forming a
tire-curing bladder may require a custom-made mold that is expensive and time-consuming to
produce. Alternatively, tire-curing bladders can also be hand-made and cured in an autoclave
using a relatively time-consuming, high-cost manufacturing process.
[0006] SUMMARY
[0007] A method for forming and curing an uncured tire-curing bladder with a bladder-curing
bladder includes providing an uncured tire-curing bladder having an inner and outer surface on
or in a recess of an outer-surface curing mold; inflating the bladder-curing bladder into the
recess and exerting pressure on the inner surface of the uncured tire-curing bladder; and curing
the uncured tire-curing bladder by providing heat, pressure, or both to the inner surface and the
outer surface of the tire-curing bladder to form a cured tire-curing bladder.
[0008] A thin tire-curing bladder includes an organic rubber layer and excludes a silicone rubber
layer. In an embodiment a tire-curing bladder has a thickness of about 1 mm to less than 2.5
mm.
[0009] A curing apparatus includes a press operable to heat an outer surface mold; an outer
surface mold coupled to the press comprising a plurality of rings defining a recess; a first foot
area recess defined in one or more rings configured to receive a foot area of a tire-curing
bladder; and a second foot area recess defined in one or more rings configured to receive a foot
area of a bladder-curing bladder.
[0010] As used herein the terms "a" and "the" mean one or more, unless the context clearly
indicates to the contrary.
[0011] The terms "cure" and "vulcanize" are used interchangeably herein. While the disclosure
is focused on sulfur curing (vulcanization) where sulfidic bridges crosslink polymer chains, the
technology disclosed herein is also applicable to other types of curing.
[0012] The term "tire" or "tires," as used herein, includes, for example, both pneumatic radial
tires as well as pneumatic bias ply tires.
[0013] BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0014] Figure 1 is a partial cross-section of a prior art transfer molding apparatus for forming a
tire-curing bladder.
[0015] Figure 2 is diagram of an embodiment of processes for making and curing a tire-curing
bladder 132 and tire.
[0016] Figure 3 is a diagram of an embodiment of a process for assembling a tire-curing bladder
132 on a drum.
[0017] Figure 4A is a partial cross-sectional view of an embodiment of the tire-curing bladder
132 of Figure 3.
[0018] Figure 4B is a partial cross-section of an embodiment of the tire-curing bladder 132 of
Figure 3 and a process for curing a the tire-curing bladder 132 with a bladder-curing bladder
136.
[0019] Figure 5 is a partial cross-sectional view of a tire-curing mold apparatus 402 where an
embodiment of a tire-curing bladder 406 is placed inside a green tire 404 and set in a recess of
the tire-curing mold 409.
[0020] Figure 6 is a partial cross-sectional view of a modified tire-curing mold apparatus 403
with an embodiment of a bladder-curing bladder 136 set within a tire-curing bladder 132 that is
inside a recess 409 of the tire-curing mold.
[0021] Figure 7A is a cross-sectional view of a bladder curing mold 702 with an embodiment of
a bladder-curing bladder 136 set within a tire-curing bladder 132.
[0022] Figure 7B is a cross-sectional view of a pre-assembled bladder curing mold 702 with an
embodiment of a bladder-curing bladder 136 set within a tire-curing bladder 132.
[0023] DETAILED DESCRIPTION
[0024] Surprisingly, in contrast to the prior art methods of transfer or injection molding that
required custom molds, a suitably customized tire-curing bladder can be cured in a tire-building
mold itself or a mold that is configured to fit in a tire press, thereby achieving both tire build
time reduction and cost reduction. For example, an outer-surface curing mold for a tire-curing
bladder may be configured for compatibility with a tire-curing press. The outer-surface curing
mold may be coupled to a container that is itself dimensioned to fit into a tire-curing press.
[0025] The tire press for which the customized tire-curing bladder is designed for use may be
used to cure the outside of the tire-curing bladder, while the inside of the tire-curing bladder is
cured with a separate bladder-curing bladder. The outer-surface curing mold for forming the
tire-curing bladder may be of dimensions similar to what the dimensions are for a tire curing
mold it is designed for use in. Time and costs may be reduced by using a generically-sized,
bladder-curing bladder to cure a tire-curing bladder and provide the tire-curing bladder with
customized dimensions that are adapted to the same or similar sized tire for which the tire-curing
bladder is to be used to cure.
[0026] In an embodiment, a blank tire mold that corresponds to the dimensions of a tire mold,
except it is smaller in the axial and bead-to-bead dimensions, may be used as the outer-surface
curing mold for the tire-curing bladder.
[0027] In an embodiment, the method of curing the tire-curing bladder with a bladder-curing
bladder is complementary to building the pre-cured tire-curing bladder on a drum. This allows
for versatility in adding reinforcing layers and changing thicknesses.
[0028] Figure 1 depicts a prior art transfer mold for making a tire-curing bladder. This prior art
method of making a curing bladder requires a three -part metal mold that includes a first-half
outer mold 10, a second-half outer mold 12, and a rigid inside mold 14. A rubber blank 18 is
forced out of the compartment 16 and disposed in the interface between the first- and secondhalf
outer molds 10, 12. In operation, a rubber blank 18 is placed in the compartment 16 and
heat and pressure is applied to force the rubber to melt and flow into the mold area 20 which is
defined by the surfaces of the first-half outer mold 10, second-half outer mold 12, and the rigid
inside mold 14.
[0029] Injection and transfer molds are expensive and time-consuming to produce. The metal
mold pieces must be specially made for each different curing bladder size and shape required by
the tire maker. Conventionally, it was also expected that each tire with different shape and/or
dimensions required a custom-built tire-curing bladder to meet those dimensions. Furthermore,
due to the high rubber flow required by the transfer mold method to flow the rubber into the foot
area 22 of the tire-curing bladder there was a lower limit on the gauge of the bladder that could
be formed. Bladders formed by this conventional method could effectively only reach a
minimum thickness of about 4.5 mm. A bladder of such thickness has limited heat transfer
capabilities, which in turn limits its efficiency in curing the inner portion of a tire. In addition,
the high rubber flow also produces large deformations, which reduces the quality and durability
of the bladder.
[0030] Figure 2 depicts an overview of the processes disclosed herein wherein a tire-curing
bladder 132 is cured by a bladder-curing bladder 136.
[0031] A step of manufacturing the bladder-curing bladder 110 is depicted in Figure 2. In the
example step 110, a bladder-curing bladder 136 as disclosed herein may be manufactured
quickly and inexpensively without the need for a precise size and shape. A general-sized
bladder-curing bladder 136 can be formed by conventional techniques and be useful for curing
numerous sizes and shapes of tire-curing bladders. Contrary to the prior art techniques of
bladder curing of tires, a one-size-fits-many approach may be effectively used to bladder cure a
tire-curing bladder.
[0032] The bladder-curing bladder 136 may be manufactured by cost-efficient techniques, such
as extruding or calendaring a rubber sheet 112 or by injection or transfer molding 114. A
conventional curing process may be used 116. Because a single-sized and dimensioned bladdercuring
bladder 136 can be used for curing many different dimensioned tire-curing bladders, time
and cost efficiencies are gained by this method. Other processes to cure the bladder-curing
bladder 136 may be used as well, including curing the bladder-curing bladder 136 in a tire mold,
such as the same tire mold used in the tire-curing bladder cure process 130.
[0033] A bladder-curing bladder 136 may have a geometry and composition similar to that of a
conventional tire-curing bladder. A foot area of the bladder-curing bladder 136 may be provided
with additional thickness in comparison to the center portion of the bladder-curing bladder 136.
In an embodiment, the bladder-curing bladder 136 comprises a single or double-foot shape in the
foot area according to the configuration of the mold it is designed to be used with.
[0034] Figure 2 also depicts a step of building the uncured tire-curing bladder 120. In an
embodiment, various methods may be used to form the uncured tire-curing bladder 120,
including, for example, rubber sheet extrusion or calendaring 122, transfer or injection molding
124, and hand-assembly 126. In an embodiment, drum building techniques 128 are used to build
a tire-curing bladder.
[0035] For further information on the drum building technique 128, reference is made to Figure
3. In an embodiment, a hollow cylindrical drum 202 is provided, upon which an uncured rubber
sheet 204 is wrapped. In other embodiments the drum is not required to be hollow or
cylindrical. In an embodiment, the ends of the rubber sheet 204 may extend to reach around the
cylindrical drum 202 to overlap or abut. The drum 202 functions to provide a basic ring or
partial toroidal shape to the uncured tire-curing bladder 132. The uncured rubber sheet 204 may,
for example, be extruded or calendered.
[0036] In an embodiment, a reinforced sheet 206 that includes woven fiber or other reinforcing
materials is applied onto the rubber sheet 204 on the cylindrical drum 202. These
reinforcements include corded sheets or strips of material. The cords are embedded in the
reinforced sheet 206. The reinforcement material may be selected from materials used for body
ply or belt materials of a tire. Reinforcements are added to control the inflated shape of the tirecuring
bladder when it is used to cure a tire.
[0037] In an embodiment, an additional layer or layers 208 may also be applied for shaping or
reinforcing the 132 tire-curing bladder. In an embodiment, additional layer sheets, may be used
to urge the tire-curing bladder into a partial toroidal shape with sides, rather than just a flattened
ring. The foot area 222 of the tire-curing bladder 132 may be provided with additional thickness
in comparison to the center portion of the tire-curing bladder 132. In an embodiment, the tirecuring
bladder 132 comprises a single or double-foot shape in the foot area 222 according to the
configuration of the tire-curing mold it is designed to be used with.
[0038] The additional layer 208 in this embodiment is comprised of a calendered or extruded
rubber shape. In an embodiment, the rubber sheet 204 is a flat component with a single
thickness. The additional layer 208 has a shape, meaning that the thickness of this component
varies along the width.
[0039] The drum building process 128 allows the creation of a tire-curing bladder 132 that is
very thin, and not subject to the limitations of injection and transfer molding processes 124. Use
of the drum building process 128 in conjunction with the gentle bladder curing process allows
for exceptionally thin bladders having a gauge of less than 2.5 mm, including, for example, from
about 2 mm to about 1 mm, about 1.75 mm to about 0.75 mm, or about 1.25 mm to about 1.1
mm. These thicknesses may be measured at the center of the tire-curing bladder. This
disclosure should not be construed to limit the method for making the bladder at higher
thicknesses, such as up to 4.5 mm or 8 mm.
[0040] In an embodiment, the thickness of the tire-curing bladder 132 is thinnest at the center
and thickest at the foot area 222. In an embodiment, the tire-curing bladder 132 is of
approximately uniform thickness from shoulder- to-shoulder or from foot-to-foot. The drum
building process 128 also allows for a customized inflated shape, customized reinforcement, and
variable stiffness.
[0041] Referring again to Figure 2, a bladder curing process 130 is depicted for curing the
uncured tire-curing bladder 132 that is manufactured in the previously discussed tire-curing
bladder building step 120. In the bladder curing process 130, the uncured tire-curing bladder
132, is cured by an outer surface mold 134 and a bladder-curing bladder 136 manufactured in the
previously discussed bladder-curing bladder manufacturing step 110.
[0042] Reference is made to Figure 4A and 4B for further details of the bladder curing process
130. Figure 4A shows a partial cross-sectional view of the embodiment of the uncured tirecuring
bladder 132 originally shown in Figure 3. Figure 4A shows a partial cross-sectional view
of the uncured tire-curing bladder 132 removed from the hollow cylinder 202. This uncured
tire-curing bladder 132 has an inner surface 302 and an outer surface 304.
[0043] As shown in Figure 4B the uncured tire-curing bladder 132 is provided on or in a recess
308 of an outer-surface curing mold 134. In an embodiment, a foot area of the tire-curing
bladder 132 may be secured at an edge of the recess of the outer-surface curing mold 134. Once
properly positioned, the bladder-curing bladder 136 is inflated into the recess 308 thereby
exerting pressure on the inner surface 302 of the uncured tire-curing bladder 132. The source of
inflation may be, for example, a conventional tire press apparatus. The pressure exerted by the
inflation of the bladder-curing bladder 136 causes the tire-curing bladder 132 to move into the
recess 308, and into contact with the curing surface 310 of the outer-surface curing mold 134.
[0044] Heat is applied to the outer-surface curing mold 134 and the inflated bladder-curing
bladder 132. This heat, for example, may be applied by a conventional tire press apparatus. The
uncured tire-curing bladder 132 is thus cured by receiving the heat transferred from the outersurface
curing mold 134 and the inflated bladder-curing bladder 136, as well as the pressure
caused from the inflation of the bladder-curing bladder 136.
[0045] The bladder-curing bladder 136 may be inflated and heated by a heated fluid, such as, for
example, by a mixture of water, steam, and/or nitrogen gas heated to a temperature of, for
example, about 160°C to about 210°C, or through other means known by those of skill in the art
of tire vulcanization. The outer-surface curing mold 134 may also be heated by means known to
those of skill in the art of tire vulcanization.
[0046] In an embodiment, the tire-curing bladder cure process 130 incorporates an outer-surface
curing mold 134 that is used for vulcanizing a green tire, which may be a blank unpatterned
mold, such as those used for racing slicks or a patterned mold for producing passenger tires with
tread patterns.
[0047] Figure 5 shows a partial cross-section of an example tire-curing mold 402. The tirecuring
mold 402 includes several ring-shaped plates that are combined to hold the green tire 404
in place. Rings 410, 420, 430, 440, and 450 function to grip the enlarged foot area 405 (in this
case a double-sided foot) of the tire-curing bladder 406 in a foot area recess 417 of the tirecuring
mold 402. The top side plate 460 and bottom side plate 465 function to enclose and
support the sidewall 407 and shoulder portions 408, 409 of the green tire 404. The tread ring
470 mounts along the outer circumference of the tire curing mold 402 and has an inner surface
475 with protrusions and/or grooves. The tread ring 470 functions to impart a tread pattern in
the outer circumference of the green tire 404. The rings and plates described above define the
recess 409 of the tire curing mold 402.
[0048] In an embodiment, as shown in Figure 6, a modified tire-curing mold 403 can be used to
cure the tire-curing bladder 132 instead of a green tire. The modified tire curing mold 403 has
been modified to replace tread pattern geometry on the inner surface 475 of the tread ring 470,
sidewall stamping, and traditional bead ring contour with a smooth or textured surface and a
single sided foot recess 418 formed by modified rings 440A, 450A for attaching the tire-curing
bladder 132.
[0049] In Figure 6 an embodiment of a bladder-curing bladder 136 is provided in the recess 409
of the modified tire-curing mold 403, and the tire-curing bladder 132 is provided between the
bladder-curing bladder 136 and the inner surface of the modified tire-curing mold 403.
[0050] In the embodiment of Figure 6, the tire-curing bladder 132 has a single-sided foot 405A
that is held in the foot recess area 418 of rings 440A and 450A. A double-sided foot 405B of the
bladder-curing bladder 136 is held in the foot area recess 417 of the modified tire-curing mold
403.
[0051] In an alternative embodiment, the bladder-curing bladder 136 and the tire-curing bladder
132 are both secured in the foot area recess 417 of the unmodified tire mold 402 of Figure 5. In
another embodiment, the bladder-curing bladder 136 may be secured by other means, while the
tire-curing bladder has a double foot that is held in the foot area recess 417.
[0052] In each of these embodiments, the tire-curing mold 402 or modified tire-curing mold 403
used for curing the tire-curing bladder 132 may be of the same or similar dimensions as a tirecuring
mold 402 that is used for vulcanizing a green tire 404 with the cured tire-curing bladder
142, except it is smaller in one or more of the axial and bead-to-bead dimensions.
[0053] In an embodiment, the outer-surface curing mold 134 is a mold used for curing blank
tires. A blank tire, as referred to herein, is a tire without any tread pattern. A blank tire mold,
for example, may be used for vulcanization of racing slicks. In this embodiment, the tire curing
mold is the same or substantially the same as depicted in Figure 5 and 6, except the tread ring
470 has a smooth inner-surface 475 with no tread pattern. However in this embodiment, and
even in tire blanks, the inner surface 475 of the tread ring 470 may be imparted with small
grooves for circulating air to aid in removal of the cured tire-curing bladder 142 from the blank
tire curing mold. In addition, a mold-release coating composition may be present on the uncured
tire-curing bladder 132, the bladder-curing bladder 136, or both.
[0054] Just as in the tire vulcanization process, the tire-curing bladder 132 is cured by heat being
transferred from a tire press to each of the plates and rings of the tire-curing mold 402 to
vulcanize from the outer surface of the tire-curing bladder 132, and the bladder-curing bladder
136 is inflated with a heated fluid, such as water, steam and/or nitrogen gas to vulcanize from
the inner surface of the tire-curing bladder 132.
[0055] Alternatively, as shown in Figures 7A and 7B, in another embodiment, a dedicated
bladder-curing tailored mold 702 may be used for curing the tire-curing bladder 132. Figure 7A
shows the tailored mold 702 assembled with the tire-curing bladder 132 and bladder-curing
bladder 136 in place, while Figure 7B shows the pre-assembled view.
[0056] In the embodiment of Figures 7A and 7B, an additional foot area recess 737 is provided
to anchor the tire-curing bladder 132, while the bladder-curing bladder 136 is gripped by a foot
area recess 717 that is substantially the same as the embodiment of Figure 6. In addition, the
tailored mold 702 includes stackable ring segments 790 that allow the tailored mold 702 to be
adjusted to accommodate a range of axial (bead-to-bead) widths. The tailored mold 702 may
have the same dimensions or approximately the same dimensions of a tire-curing mold that is
used for vulcanizing a green tire with the cured tire-curing bladder 142. In an embodiment, the
tailored mold 702 is smaller in one or more of the axial and bead-to-bead dimensions than a tirecuring
mold that tire-curing bladder 132 is to be used with.
[0057] Like the tire-curing mold 402 of Figures 5 and 6, the tailored mold 702 includes several
ring-shaped plates that are combined to hold the bladders 132, 136 in place. Rings 710, 720,
730, 740, function to grip the foot area 705 (in this case a double-sided foot) of the bladdercuring
bladder 136 in a foot area recess 717 of the tailored mold 702. Rings 740 and 750
include a recess 737 that functions to anchor the foot area 715 (in this case a single-sided foot)
of the tire-curing bladder 132. In this example, the inflated bladder-curing bladder 136 will
contact the inner side of the foot area 715 of the tire-curing bladder 132. The tailored mold 702
allows for rings 710, 720, 730, 740, and 750 to be adjusted to accommodate a range of recessed
foot diameters.
[0058] Shoulder rings 765, 760 function to enclose and support shoulder portions 760, 761 of
the tire-curing bladder 132 in the tailored mold 702. The stackable ring segment(s) 790 mount
along the outer circumference of the tailored mold 702 and have an inner surface 775 that is
predominantly smooth, but in an embodiment may be provided with air circulation channels.
The rings described above define the recess 709 of the tailored mold 702.
[0059] As shown by comparing Figures 7A and 7B the bladder-curing bladder 136 and tirecuring
bladder 132 may be loaded into the tailored mold 702 and then enclosed in the tailored
mold 702 by moving the rings on the right side of Figures 7A and 7B 710, 750, together in the
axial direction along with the right shoulder ring 765. Stackable rings 790 can also be moved
axially.
[0060] One or more bladder-curing bladders 136 of the same size can be used to create various
different sized tire-curing bladders 132. The dimensions of the bladder-curing bladder 136 and
the tire-curing bladder 132 that it (the bladder-curing bladder 136) is utilized to cure may vary
up to 40% in the axial (bead-to-bead) dimension or radial dimension, or both, such as, for
example, about 0.5% to about 40%, about 1% to about 15%, or about 5% to about 10%.
However, the bladder-curing bladder 136 is smaller than the tire-curing bladder 132. This
feature allows for versatility and alleviates the need for a specialized bladder for each tire size.
In an embodiment the bladder-curing bladder 136 stretches 5-40% to cure the tire-curing bladder
132.
[0061] Returning to Figure 2, once the tire-curing bladder 132 is cured, and a green tire 144 is
manufactured 140 (Pneumatic tires can, for example, be made according to the constructions
disclosed in U.S. Pat. Nos. 5,866,171; 5,876,527; 5,931,211; and 5,971,046, the disclosures of
which are incorporated herein by reference), the cured tire-curing bladder 142 is placed on or
inside the green tire 144, which is set in a tire curing mold 146, such as the one depicted in
Figure 5. The green tire 144 is cured by imparting a fluid at high temperature and pressure to
the inside of the cured tire-curing bladder 142 and heat to the metal plates of the tire-curing mold
146. The cured tire-curing bladder 142 thereby expands to press the green tire 144 against the
inner surface of the tire-curing mold 146. With a non-blank tire mold a tread pattern is
impressed in the outer circumferential surface of the green tire 144 and the green tire 144 is
vulcanized. In an embodiment, the heat and pressure may be supplied as a mixture of water,
steam, and/or nitrogen gas heated to a temperature of, for example, about 160°C to about 210°C.
[0062] In an embodiment of the above-described process, a custom-sized tire can be created
more quickly and cheaply because a relatively custom-sized bladder to match it can be quickly
created without the need for an expensive custom-made transfer or injection bladder mold. The
tailored mold 702 can be used to create a cured tire-curing bladder 142 quickly using a general
sized bladder-curing bladder, without the need to create a custom injection or transfer mold with
rigid inner and outer surfaces for curing the tire-curing bladder shape.
[0063] In either of the above embodiments, the tire-curing bladder 132 need not be exactly
dimensioned to match the interior of the green tire 144 to be effective, and may vary up to 40%
in either the axial (bead-to-bead) dimension or the radial dimension, or both, such as, for
example, about 0.5% to about 30%, about 1% to about 15%, or about 5% to about 10%, so long
as the dimensions of the tire-curing bladder 132 is smaller than the interior of the green tire 144.
[0064] In an embodiment, a green tire 144 is cured with the cured tire-curing bladder 132 and a
tire-curing mold 146. The tire-curing mold 146 has cross-sectional axial and radial dimensions
of X and Y. The outer surface mold 134 that was used to cure the tire-curing bladder 132 has
cross-sectional axial and radial dimensions of 0.6X to X and 0.6Y to Y.
[0065] In an embodiment, the bladder-curing bladder 136 has a cross-sectional axial and radial
dimensions of 0.6X to X and 0.6Y to Y, wherein X and Y are the cross-sectional axial and radial
dimensions of the interior of the outer surface mold 134 used to cure the tire-curing bladder 132.
[0066] In an embodiment, a first uncured tire-curing bladder 132 may be cured with a bladdercuring
bladder 136. A subsequent uncured tire-curing bladder with at least one different
dimension that varies from about 0.5% to about 40% of the first uncured tire-curing 132 bladder
may also be cured with the same bladder-curing bladder 136, so long as it is smaller in its
dimensions than the subsequent uncured tire-curing bladder.
[0067] In an embodiment, the outer mold used in making the tire-curing bladder and the green
tire may be a low-profile tire, such as a tire with a section height less than 100 mm.
Conventional curing of low profile tires presents a special challenge due to their acutely angled
dimensions in the shoulder area of the tire. By using a bladder-curing bladder 136 to cure the
tire-curing bladder 132 in the same mold as the low profile tire or a mold of similar dimensions
but smaller in the bead-to-bead and/or axial dimension, the tire-curing bladder 132 can acquire a
customized dimension that will enhance its ability to inflate into acute angles and cure the low
profile tire.
[0068] In an embodiment, one or more rubber elastomers are used for the tire-curing bladder
132 and bladder-curing bladder 136. In an embodiment, the bladders 132, 136 comprise one or
more organic elastomers, such as carbon-backbone -based elastomers, rather than silicone-based
elastomers. For example, the organic elastomer may be selected from the following,
individually as well as in combination, according to the desired final properties of the rubber
compound: a butyl rubber, a halobutyl rubber, a modified butyl rubber, an ethylene propylene
rubber, an ethylene propylene diene rubber (EPDM), a nitrile butadiene rubber, a hydrogenated
nitrile butadiene rubber, a styrene butadiene rubber, a chloroprene rubber, an isoprene rubber, an
epichlorohydrin rubber, an acrylic rubber, a chlorosulfonated polyethylene, and a fluorocarbon
rubber. In an embodiment, the composition is exclusive of ethylene -propylene-dieneterpolymer,
silicone rubber, or both. In another embodiment, silicone rubber may be present.
The elastomers may contain a variety of functional groups, including but not limited to tin,
silicon, and amine containing functional groups. The rubber polymers may be prepared by
emulsion, solution, or bulk polymerization according to known suitable methods.
[0069] In an embodiment containing a blend of more than one polymer, the ratios (expressed in
terms parts per hundred rubber (phr)) of such polymer blends can be adjusted according to the
desired final viscoelastic properties desired for the polymerized rubber compound. For example,
in an embodiment natural rubber or polyisoprene may comprise about 5 to about 80 phr, such as
about 20 phr to about 60 phr, or about 35 phr to about 55 phr; and butyl or halobutyl rubber may
comprise about 60 phr to about 5 phr, such as about 50 phr to about 10 phr, or about 25 phr to
about 15 phr. In an embodiment, one of the rubbers above is selected and comprises the entire
rubber component.
[0070] In an embodiment, the bladders may comprise one or more fillers to provide
reinforcement and/or improved air permeability. The filler may be selected from the group
consisting of carbon black, silica, various types of clay or mineral fillers. For example, clay and
mineral fillers include aluminum silicate, calcium silicate, magnesium silicate, clay (hydrous
aluminum silicate), talc (hydrous magnesium silicate), and mica.
[0071] The total amount of filler may be from about 1 to about 100 phr, such as from about 30
to about 80 phr, from about 40 to about 70 phr, or from about 50 to about 100 phr of filler.
[0072] Additional rubber compounding ingredients may include curing packages, processing
aids, coupling agents, and the like. For example, without limitation, the bladders 132, 136
disclosed herein may also contain such additional ingredients in the following amounts:
processing oils/aids: from about 0 to about 75 phr, such as from about 5 to about 40 phr;
stearic acid: from about 0 to about 5 phr, such as from about 0.1 to about 3phr;
zinc oxide: from about 0 to about 10 phr, such as from about 0.1 to about 5 phr;
sulfur: from about 0 to about 10 phr, such as from about 0.1 to about 4 phr; and
accelerators: from about 0 to about 10 phr, such as from about 0.1 to about 5 phr.
[0073] The invention is not limited to only the above embodiments. The claims follow.

What is claimed is:
1. A method for forming and curing an uncured tire-curing bladder with a bladder-curing
bladder, comprising:
providing an uncured tire-curing bladder having an inner and outer surface on or
in a recess of an outer-surface curing mold;
inflating the bladder-curing bladder into the recess and exerting pressure on the
inner surface of the uncured tire-curing bladder; and
curing the uncured tire-curing bladder by providing heat, pressure, or both to the
inner surface and the outer surface of the tire-curing bladder to form a cured tire-curing
bladder.
2. The method of claim 1, further comprising securing a foot area of the tire-curing bladder
at an edge of the recess of the outer-surface curing mold.
3. The method of claim 1, wherein the steps of claim 1 are repeated with a subsequent
uncured tire-curing bladder with at least one different dimension that varies from about
0.5% to about 40% of said uncured tire-curing bladder, wherein the dimensions of the
uncured tire-curing bladder are smaller than the subsequent uncured tire-curing bladder.
4. The method of claim 1, wherein the outer-surface curing mold is configured for
compatibility with a tire-curing press.
5. The method of claim 4, wherein the cured tire-curing bladder is used to cure a tire in a
tire curing mold that fits in a tire curing press.
6. The method of claim 4, wherein the cured tire-curing bladder is used to cure a tire in a
tire-curing mold that corresponds to the dimensions of the outer-surface curing mold.
7. The method of claim 1, further comprising curing a green tire with the cured tire-curing
bladder and a tire-curing mold, the tire-curing mold having cross-sectional axial and
radial dimensions of X and Y, and the outer surface curing mold having cross-sectional
axial and radial dimensions of 0.6X to X and 0.6Y to Y.
8. The method of claim 1, wherein the outer-surface curing mold is a mold corresponding
to the dimensions of a low-profile tire.
9. The method of claim 1, wherein the bladder-curing bladder, upon inflation, forces the
outer surface of the uncured tire-curing bladder into contact with the outer-surface curing
mold.
10. The method of claim 1, wherein the tire-curing bladder has a thickness of less than 4.5
mm.
11. A tire-curing bladder comprising an organic rubber layer, and excluding a silicone rubber
layer, the tire-curing bladder having a thickness of about 1 to less than 2.5 mm.
12. The tire-curing bladder of claim 11 comprising a reinforcing layer.
13. The tire-curing bladder of claim 11, wherein the thickness of about 1 to less than about
2.5 mm is at the center of the tire-curing bladder.
14. The tire-curing bladder of claim 11, the organic rubber layer comprising: butyl rubber, a
halobutyl rubber, a modified butyl rubber, an ethylene propylene rubber, an ethylene
propylene diene rubber (EPDM), a nitrile butadiene rubber, a hydrogenated nitrile
butadiene rubber, a styrene butadiene rubber, a chloroprene rubber, an isoprene rubber,
an epichlorohydrin rubber, an acrylic rubber, a chlorosulfonated polyethylene, or a
fluorocarbon rubber.
15. A curing apparatus, comprising:
a press operable to heat an outer surface mold;
an outer surface mold coupled to the press comprising a plurality of rings
defining a recess;
a first foot area recess defined in one or more rings configured to receive a foot
area of a tire-curing bladder;
a second foot area recess defined in one or more rings configured to receive a foot
area of a bladder-curing bladder.