Process for the manufacture of two-wheeled-vehicle tires

A process for manufacturing a radial tire for two-wheeled vehicles, said tire comprising a toroidal carcass of rubberized fabric plies with the plies lying in a toric final configuration and the ends of the cords of the plies folded back around metal bead cores, a tread band having a tread pattern on its surface comprising hollows or grooves, and a belt structure between the carcass and the tread band which includes substantially circumferentially oriented cords, said cords being high-elongation lang-lay type, rubberized metal cords having an ultimate elongation between 4% and 8%, with a load-elongation diagram having a curvilinear portion whose center line ranges between an elongation value of 1.5% to 3% and which mutually connects two substantially rectilinear lengths of different inclinations relative to the axes of said diagram, such that the cord is initially more elongated at low loads, said tire having a ratio of tread radial height to tread maximum width between 0.15 and 0:45, said process comprising the steps of:

• manufacturing a tire carcass in the form of a cylindrical sleeve of rubberized fabric reinforced with cords substantially parallel to the axis of said sleeve and folding back the ends of said sleeve each about at least one annular, circumferentially inextensible, metal bead core, said bead cores lying in planes perpendicular to the sleeve axis;
• toroidally shaping said sleeve, by radially expanding the sleeve wall and moving said bead cores towards each other in the axial direction to an intermediate toric configuration of lesser diameter than that of said final configuration, the difference between said diameters being not less than the depth of said grooves, and greater than 1.5% of the value of the lesser diameter elevating the diameter value of said intermediate configuration, depending upon the position of said center-line in the load-elongation diagram so that the subsequent expansion of said carcass in said mold to the final toroidal configuration places said belt cords in a tensile condition corresponding to a point on said diagram located within said curvilinear portion, by selecting a corresponding value for the moving of said beads,
• assembling said belt structure to said toroidally shaped sleeve,
• superimposing the tread band on said belt structure at a radially outer portion thereof,
• introducing the thus assembled tire into a vulcanizing mold and closing said mold,
• expanding the tire radially outwardly against the mold surface, whereby the carcass plies reach said final toric configuration, the tread band is molded with said tread pattern and said belt reinforcing cords are put in a tensile pre-loaded condition corresponding to a point of their load-elongation diagram within said curvilinear portion;
• and
• vulcanizing said tire assembly.