Methods of manufacturing and installing elastomeric fills for use in pneumatic tire casings

A method of forming a fill to be inserted in casings for pneumatic tires, comprising the steps of:

• a) obtaining at least a first profile of the interior of a predetermined size casing for pneumatic tires;
• b) determining at least one angle of contact between at least one strip of a fill and a sidewall of the casing from the profile;
• c) forming the at least one strip of fill from an elastomeric material, the at least one strip of fill having first and second sides;
• d) orienting at least one of the first and second sides at an angle corresponding to the at least one angle of contact;
• e) inserting a first time a flexible member into the casing of a tire;
• f) deforming the flexible member to conform to the interior of the casing to obtain the first profile thereof;
• g) performing said first insertion step when the tire casing is in a relaxed state;
• h) spreading the tire casing;
• i) inserting a second time the flexible member in the tire casing subsequent to said spreading step;
• and,
• j) deforming the flexible member to conform to the interior of the casing to obtain a second profile.

A method of forming a fill to be inserted in casings for pneumatic tires, comprising the steps of:

• a) determining dimensions of interior cavity of a predetermined size tire casing;
• b) providing the a plurality of elongated strips of high density foam rubber, the elongated strips having a length and transverse cross-sectional contour corresponding to an interior surface of an associated tire casing;
• c) determining percentage of air cells in at least one of the plurality of elongated strips;
• d) forming at least one of the elongated strips to be oversized with respect to the corresponding portion of the tire casing in the relaxed state by a predetermined percentage such that when the elongated strips are inserted into the tire casing and subsequently mounted on a wheel-rim the at least one elongated strip is compressed a percentage less than the percentage of air cells therein;
• e) determining a profile of the interior of the tire casing when in a spread state;
• and,
• f) forming the at least one of the elongated strips to be oversized with respect to the corresponding portion of the tire casing in the relaxed state by the predetermined percentage based in part on the profile.