Run-flat tire having partial carcass layers

An improved method for assembling components for making a run-flat tire in a nominal lapsed time, said tire including a pair of bead cores axially spaced apart associated with a rim, a tread positioned radially outside said bead cores for contacting a ground surface, a tread reinforcing package interior to said tread portion, a pair of reinforced self-supporting sidewalls each extending radially between a respective bead core and a respective axial edge of said tread reinforcing portion and an innerliner ply interior to said tire, said improved method comprising the steps of:

• a) establishing a plurality of reference planes associated with a tire building drum being normal to the axis of a green tire, said reference planes to include at least a pair of bead reference planes each associated with a respective bead core and a pair of shoulder reference planes each associated with a respective lateral edge of said tread reinforcing package, said reference planes to be used for assembling said components of said green tire on said drum;
• b) placing said innerliner ply around said building drum to extend generally from one bead reference plane to the other bead reference plane;
• c) providing a pair of first crescent-shaped reinforcing members each placed around said drum to be radially outside said innerliner ply and located in a lapping arrangement with a respective shoulder reference plane;
• d) providing an inner carcass layer with generally parallel reinforcing members to provide a radial tire carcass and placing said inner carcass layer around said drum to extend from axially outside of said one bead reference plane to a location axially outside said other bead reference plane;
• e) providing a pair of pre-assembled inner sidewall supporting complexes of said self-supporting sidewalls each formed as a unit and including a second crescent-shaped reinforcing member, a reinforced first partial carcass layer affixed to one side of said second reinforcing member, a filler rubber portion having one side affixed to an outer side of said first partial carcass layer and a reinforced second partial carcass layer affixed to an outer side of said filler rubber portion;
• f) placing each one of said supporting complexes around said drum to the outside of said inner carcass layer such that said second crescent-shaped reinforcing member contacts said first carcass layer and said first and second partial carcass layers each extend generally from a respective bead reference plane to a lapping arrangement with said respective shoulder reference plane;
• g) placing a respective bead core around said drum at each bead reference plane to be radially outside of and in contact with a respective filler rubber portion;
• h) folding both a filler end portion of each said filler rubber portion and a turned up carcass portion of each edge of said inner carcass layer around a respective bead core to encircle said respective bead core;
• i) providing a pair of pre-assembled sidewall and bead protecting complexes each formed as a unit and including a sidewall rubber, a bead support rubber affixed to an end of said sidewall rubber and a rim protector ply affixed to said bead support rubber;
• j) placing each one of said sidewall and bead protecting complexes around said drum to contact the radial outside surface of said supporting complex to extend axially outside said respective bead reference plane to an end point axially outside said respective shoulder reference plane;
• k) folding each said bead support rubber inwardly around a respective bead core to encircle said respective bead core and contact an inner surface of said innerliner ply;
• and
• l) removing the previously assembled components of the previous steps as a green tire portion from said building drum, forming said green tire portion into a toroidal shape and placing said tread reinforcing package and said tread portion in contact with the radially outside surface in a crown region of said green tire portion to generally extend between shoulder reference planes, wherein a green run-flat tire sub-assembly has been formed for curing in a tire mold to make said run-flat tire in the same lapsed time required to make an identical tire without said self-supporting sidewalls.