Field of invention

This invention relates to a device for supporting a tyre during a water jet milling process, such as an ultra-high pressure water (UHPW) jet milling process. This invention also relates to a water jet milling apparatus, such as an ultra-high pressure water jet milling apparatus. This invention also relates to a system for recovering rubber from a product. This invention also relates to associated methods of supporting a tyre during a water jet milling process, such as an ultra-high pressure water jet milling process; and associated methods of processing tyres by water jet milling, such as by ultra-high pressure water jet milling.

Background

Rubber containing products, such as vehicle tyres, should be disposed of in an economical and environmentally friendly way. Additionally, legislation prevents certain waste rubber, such as whole and shredded tyres, from being disposed of in landfill. Therefore, the recovery and recycling of rubber from rubber-containing products, such as vehicle tyres, has important commercial application.

The recycling of rubber-containing products, such as vehicle tyres, is typically performed as a multi-step process. Rubber products are typically deconstructed into materials or particles which can be recycled or otherwise safely disposed of. A particularly commercially valuable output product is crumb rubber. In one processing step, it is known to use ultra-high pressure water (UHPW) jet milling to break up the surface of the input waste rubber. UHPW jet milling typically comprises generating an ultra-high pressure water jet that impinges on the rubber surface to cut and fragment the rubber into small particles. During UHPW jet milling the rubber item being processed must be properly secured and supported to ensure safe and controlled processing. The ultra-high pressure water jet should preferably be presented to the product in a consistent manner to aid processing uniformity and control. Additionally, it is desirable for the UHPW jet apparatus to be adaptable to process rubberised products, such as tyres, having a variety of different diameters and widths.

The present invention, in at least some of its embodiments, seeks to address at least some of the above described problems, desires and needs. The present invention, in at least some of its embodiments, provides a device that can at least adequately support and stabilise products, such as tyres, of various widths to enable controlled pressure water jet milling, such as ultra-high pressure water jet milling.

Summary of invention

According to a first aspect of the invention there is provided a device for supporting a tyre during a water jet milling process, the device comprising: a carrier assembly having an axis, the carrier assembly carrying a first stabilising member and a second stabilising member for inserting into a cavity defined by an inner liner of a tyre, the carrier assembly further carrying at least one support structure disposed axially between the first and second stabilising members, the at least one support structure comprising a support surface; wherein the first and second stabilising members are relatively moveable along the longitudinal axis so as to vary an axial distance between the first and second stabilising members; and wherein the at least one support structure is moveable to a support position in which the support surface is substantially aligned with or positioned radially outward from a radially outer edge of the first and/or second stabilising member so as to form at least a part of a support region for supporting the tyre.

The water jet milling process can be an ultra-high pressure water (UHPW) jet milling process. The term “ultra-high pressure water jet” refers to a water jet having a water pressure of at least 1500 bar, optionally at least 2000 bar. The axial distance can be a width, for example, the axial distance can substantially correspond to the width of the tyre being supported. Varying the axial distance between the first and second stabilising members allows products of various widths to be processed on the same machine without the need to change component parts. Positioning the support structure in the support position provides a reinforcing support to the product being processed by water jet milling, such as ultra-high pressure water (UHPW) jet milling. This can improve the stability and control achieved during water jet milling.

An actuator for controlling the movement of the support structure to the support position is coupled between the carrier assembly and the support structure. The actuator can be a pneumatic actuator. The actuator can be an electrical actuator. The actuator can maintain pressure against an end stop thereby locking the actuator in position. The actuator can comprise a screw thread with a non-reversing drive. The actuator can be controlled by a controller. The actuator can comprise concentric actuator rods.

The support structure can be moveable to a storage position in which the support surface is radially inward of the radially outer edge of the first and/or second stabilising member.

The support structure can be moveable so that the support structure is fully contained within a cross-section of the first and/or second stabilising member. The support structure can be fully contained with the cross-section of the first and/or second stabilising member when in the storage position.

The support structure can be pivotally coupled to the carrier assembly. Pivotally coupling the support structure to the carrier assembly can assist in storing the support structure within the cross-section of the first and/or second stabilising members.

The at least one support structure can be moveable along the axis. The at least one support structure can have a width of more than 20 mm, more than 40 mm, or more than 50 mm. The at least one support structure can have a width of less than 200 mm, less than 150 mm, less than 100 mm, or less than about 80 mm. The at least one support structure can have a width of about 50 mm. The at least one support structure can be made from a metallic material, such as stainless steel, plated mild steel or the like. The at least one support structure can be a plurality of support structures. The at least one support structure can be two or three support structures.

The support region can comprise one or more grooves. The or each support surface or auxiliary support surface can comprise one or more grooves. Grooves help to reduce friction between the support region and the product being processed. This can assist in moving the product being processed across the support region during processing; thereby helping to ensure the entire area of the product is exposed to the UHPW jet. During UHPW processing, a jet of water can be provided to the support region, for example, to the grooves. This can help to lubricate and reduce friction between the support region (e.g. grooves) and the tyre being processed. Providing a jet of water to the support region (e.g. grooves) can also help to remove residual rubber particles and other debris from support region.

The one or more grooves can be orientated substantially orthogonal to the axis. The one or more grooves can be orientated to form at least a portion of a circumference around the axis. The one or more grooves can be orientated to form an arc around the axis.

The one or more grooves can have a width of 3 mm or more, or about 5 mm. The one or more grooves can have a width of 10 mm of less, 8 mm or less, or about 5 mm. The one or more grooves can have a rounded or bevelled profile.

The first and/or second stabilising member can be a stabilising plate.

The first and/or second stabilising member can support a sidewall of a tyre being processed. The first and/or second stabilising member can comprise one or more grooves. Grooves can help to reduce friction between the first and/or second stabilising member and the product being processed. For example, grooves can help to reduce friction between the first and/or second stabilising member and the sidewall of the tyre. During UHPW processing, a jet of water can be supplied to the first and/or second stabilising members (e.g. to the grooves of the stabilising members). This can help to lubricate and reduce friction between the tyre being processed (e.g. the sidewall of the tyre) and the first and second stabilising members. Providing a jet of water to the first and/or second stabilising members (e.g. to the grooves) can also help to remove residual rubber particles and other debris from the stabilising members.

The first stabilising member can have a cross-section that substantially corresponds to a cross-section of the second stabilising member. The cross- sections of the first and second stabilising members can be substantially aligned. The first and/or second stabilising members can have rounded corners.

Rounded corners can help to avoid the product being processed being pierced, cut or otherwise damaged by the stabilising members.

The device can further comprise a first roller coupled to the first stabilising member. The device can further comprise a second roller coupled to the second stabilising member. The first and second rollers can form a part of the support region. Each support structure can also comprise a roller that can be aligned with the first and/or second rollers.

The device can further comprise an auxiliary support structure coupled to the first or second stabilising member, the auxiliary support structure comprising an auxiliary support surface, and wherein the support region comprises the auxiliary support surface. The device can comprise two auxiliary support structures, one of the auxiliary support structures coupled to the first stabilising member and the other auxiliary support structure coupled to the second stabilising member. Each of the two auxiliary support structures can have an auxiliary support surface, wherein the support region comprises the auxiliary support surfaces of each of the two auxiliary support structures. When in the storage position, the support structure can be substantially aligned with the auxiliary support structure transverse to the axis. The carrier assembly can comprise a plurality of carrier arms. Each carrier arm can carry one of the first stabilising member, the second stabilising member, and the at least one support structure.

The at least one support structure can be carried by two or more carrier arms. At least two of the carrier arms are arranged as a concentric shaft. The concentric shaft can extend through the first and/or the second stabilising member parallel to the axis.

The concentric shaft can comprises an inner shaft for carrying a first support structure of the at least one support structure, and an outer shaft for carrying a second support structure of the at least one support structure.

Each of the first stabilising member, the second stabilising member, and the at least one support structure are independently moveable along the axis. The movement of at least one of the first stabilising member, the second stabilising member, and the at least one support structure can be controlled by a controller. The controller can include a positional feedback mechanism for determining the position of at least one of the first stabilising member, the second stabilising member, and the at least one support structure.

The support region can extend across more than 50 %, optionally more than 60 %, optionally more than 70 %, optionally more than 80 %, or optionally more than 90 % of the axial distance between the first and second stabilising members. The support region corresponds to the region that would be in contact with the backside of the product being processed. The support region typically provides reinforcing support to the product being processed. According to a second aspect of the invention there is a method of supporting a tyre using the device according to the first aspect, the method comprising the steps of: a. inserting the first and second stabilising members into a cavity defined by an inner liner of the tyre to be supported; b. increasing the axial distance between the first and second stabilising members; and c. moving the support structure to the support position so that the support surface of the support structure is substantially aligned with or positioned radially outward from the radially outer edge of the first and/or second stabilising member so as to form at least a part of the support region for supporting the tyre.

The tyre can be a vehicle tyre, such as a car tyre, a van tyre, a lorry tyre; a tyre for agricultural vehicles, such as tractors; a tyre for heavy industrial plant equipment and machinery; or an aeroplane tyre. The tyre can be a rubber tyre. The tyre can have a size in the range from 145/80-R12 to 355/25-R21. That is, the tyre can have a width in the range of about 145 mm to 355 mm. The tyre can be suitable for use with a rim size of between 12 inches (305 mm) to 21 inches (533 mm). The rim size typically corresponds to the inner diameter of the tyre.

Step b) can comprise increasing the axial distance between the first and second stabilising members so as to tension the inner liner of the tyre being supported.

According to a third aspect of the invention there is provided a water jet milling apparatus comprising the device according to the first aspect of the invention. The water jet milling apparatus can be an ultra-high pressure water (UHPW) jet milling apparatus,

The water jet milling apparatus can comprise a first water jet assembly for processing (e.g. milling) a front side of a product to be processed, such as a tread region of a tyre. The water jet milling apparatus can comprise a second water jet assembly for processing (e.g. milling) a side region of the product, such as a sidewall of a tyre. The second water jet assembly can be substantially orthogonal to the first water jet assembly. The water jet milling apparatus can further comprise a third water jet assembly configured to process a backside of the product being processed, such as an inner liner of a tyre. The water jet milling apparatus can be used to process multiple sides of a product in the same apparatus. The apparatus can be used to process multiple sides of a product simultaneously. The water jet milling apparatus can comprise a drive roller for moving the position of the product being processed. For example, the drive roller can rotate a tyre during UHPW jet milling so that the full circumference of the tyre can be exposed to the UHPW jet. The drive roller can comprise a plurality of grips for gripping the product being processed. The water jet milling apparatus can further comprising a shear cutting device. According to a fourth aspect of the invention there is provided a method of water jet milling a tyre comprising the steps of: a. supporting the tyre using the device of the first aspect of the invention; b. impacting a tread region of the tyre with an ultra-high pressure water (UHPW) jet to at least partially remove particles from the tread region; and c. collecting the particles that are removed.

The water jet milling process can be an ultra-high pressure water (UHPW) jet milling process. The term “ultra-high pressure water jet” refers to a water jet having a water pressure of at least 1500 bar, optionally at least 2000 bar. The particles removed can be rubber particles of the tread region. The method can further comprise the step of impacting at least one sidewall region of the tyre with a second ultra-high pressure water jet to at least partially remove particles from the sidewall region. Each sidewall region of the tyre (e.g. on either side of the tyre) can be impacted with an ultra-high pressure water jet to at least partially remove particles from each sidewall region.

The step of impacting the sidewall region can occur simultaneously with the step of impacting the tread region. The particles removed from the tread region can be collected separately to the particles removed from the sidewall region.

According to a fifth aspect there is a rubber recycling system comprising the water jet milling apparatus of the third aspect. The rubber recycling system can further comprise one or more of a sidewall processing apparatus (e.g. a sidewall milling machine), a filtration apparatus, an auxiliary filtration apparatus, a drying apparatus, and/or a separation apparatus.

Whilst the invention has been described above, it extends to any combination of the features set out above, or in the following description, drawings and claims. For example, any features disclosed in relation to one aspect of the invention may be combined with any features of any of the other aspects of the invention.

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a cross-sectional view of a tyre;

Figure 2 is a schematic of a rubber recycling system;

Figure 3 is a flow chart showing steps in a rubber recycling process using ultra-high pressure water jet milling;

Figures 4 and 5 are views of an ultra-high pressure water jet milling apparatus;

Figure 6 is a view of a shear cutting apparatus;

Figure 7 is a view of an UFIPW jet milling apparatus comprising a shear cutter and secondary UFIPW jet assembly;

Figure 8 is a schematic view of an electrostatic separation apparatus; Figure 9 is a view of an UHPW jet milling apparatus comprising an auxiliary jet assembly configured to process a sidewall of a tyre;

Figures 10 to 12 are views of a tyre mount device in a narrow configuration; Figure 13 is a cross-sectional view of a tyre mount device with the support structure in a storage position;

Figure 14 is a cross-sectional view of a tyre mount device with the support structure in a support position;

Figure 15 is a cross-sectional view of a tyre; Figure 16 is a cross-sectional view of a tyre under tension;

Figures 17 to 19 are views of a tyre mount device in an first expanded configuration;

Figures 20 to 22 are views of a tyre mount device in a second expanded configuration; Figures 23 to 25 are views of a tyre mount device in a third expanded configuration;

Figures 26 to 28 are schematic views of a tyre being processed in an UFIPW jet apparatus;

Processes to recover and recycle rubber from rubber-containing products, such as vehicle tyres, are typically multi-step processes. Figure 1 shows a schematic cross-section of a typical vehicle tyre 10. The tyre 10 has a width, denoted by the letter w. The tyre 10 comprises an outer tread region 12 on which the tyre 10 can roll; a sidewall 14; and an inner liner 16. The inner liner 16 defines a cavity 17. The region of the inner liner 16 that is radially inwardly adjacent to the outer tread region 12 can be referred to as the inner tread region 18. Tread reinforcement layers (not shown), such as a zero-degree belt, bracing plies, and radial casing plies, may be included between the outer and inner tread regions to improve the structural integrity and performance of the tyre 10. The bracing plies can be made from polyester cords reinforced with metal, such as steel. The radial casing plies can be made from textile fibre cords. The inner liner can be made from a synthetic rubber. The sidewall rubber can be made from an abrasion resistant compound. The tyre 10 further comprises a bead 19 around the inner rim of the tyre 10. The bead 19 can comprise a bead wire. The bead wire can be made from a metal, such as steel.

System

Figure 2 shows an exemplary system 20 for removing and collecting rubber, and optionally metal, from a tyre 10. Whilst the system 20 shown in Figure 2 is configured to process a tyre, the system could also be used to process other rubber-containing products. In particular, the system 20 can be used to recycle rubber from at least the outer tread region 12, the sidewall 14, and the inner liner 16 (including the inner tread region 18) of a vehicle tyre 10. Optionally, the system can be used to recover metal from the tread reinforcement layers disposed between the outer and inner tread regions, and also from the bead wire 19. The system 20 comprises an ultra-high pressure water (UFIPW) jet milling apparatus 22, a filtration apparatus 24, at least one auxiliary filtration apparatus 26, and a drying apparatus 28. The system 20 can further comprise separation apparatus, such as a vibrating sieve or an electrostatic separation apparatus, for separating crumb rubber, rubber fibre, and any non-rubber materials. The system 20 can further comprise an adapted carding machine (not shown) for combing recovered fibre-reinforcement so as to remove crumb and to align fibre-reinforcement. The system 20 can also be used to process rubber products other than vehicle tyres. Process

Figure 3 shows a typical process for processing a tyre using the system 20. The process is a multi-step process, however, some steps can be performed in the same apparatus.

Initially, a rubber product, such as a tyre 10, is loaded into the system 20 and introduced into a water jet milling apparatus, such as a UHPW jet milling apparatus 22 (step 130). A UHPW jet milling process (step 132) is performed on the outer tread region 12 (and optionally sidewall 14) of the tyre 10 by the UHPW apparatus 22. Figures 4 and 5 show a UHPW jet milling apparatus 22. The UHPW jet milling apparatus 22 is described in detail below. The UHPW jet milling process (step 132) causes rubber in the tyre 10 to be dislodged from the main carcass of the tyre 10 (e.g. from the outer tread region 12). The dislodged rubber particles, for example in the form of crumb rubber or reinforcement fibre, are washed down to the sump of the UHPW apparatus 22 and collected for further processing. Magnetic particles can be removed using one or more magnets, such as a permanent magnet or an electromagnet. Typically, the rubber dislodged from the outer tread region 12 is in the form of crumb rubber; and the rubber dislodged from the sidewall 14 is in the form of crumb rubber and reinforcement fibre. Optionally, one or both of the sidewalls 14 of the tyre 10 can be processed at the same time as processing the outer tread region 12.

The UHPW jet milling process (step 132) typically separates the outer tread region 12 from the sidewall 14 of the tyre 10. Once the sidewall 14 is detached from the main carcass of the tyre 10, the sidewall can be processed separately in a sidewall milling machine (not shown).

Once the tread region is detached from the sidewall, the tread reinforcement (i.e. the reinforcing layers between the outer and inner tread regions) can be cut (step 134) to form a tyre band. The tread reinforcement is typically comprised of steel. Optionally, the tread reinforcement is cut into multiple strands. Figure 6 shows a schematic of a tread reinforcement cutting apparatus 700. The shear cutting apparatus 700 comprises a cutter 702. The cutter 702 is clamped against a support bar 704 and is rolled across the tread reinforcement to provide a cutting action. Cutting the tread reinforcement using the shear cutting apparatus 700 can help to avoid partial metal contamination. The shear cutting apparatus 700 can be incorporated into the UHPW jet milling apparatus 22 to avoid handling the tread region separately. Cutting the tread reinforcement can allow the inner liner 16, including the inner tread region 18, to be subsequently processed, for example by UHPW jet milling. For example, the inner liner 16 can be removed from the metal tread reinforcement by UHPW processing. The metal tread reinforcement can be subsequently collected and recycled. The metal reinforcement typically has a high scrap value. Figure 7 shows a UHPW jet milling apparatus 822 comprising a secondary UHPW jet assembly 832 for processing the inner liner of a tyre band 810 after the tread reinforcement has been cut. The secondary UHPW jet assembly 832 can be housed in a band processing box 840. The tyre band 810 is supported by rollers 850. Preferably, the tyre band 810 being processed is supported on the backside surface (i.e. the side of the tyre band 810 away from the UHPW jet) to provide a more stable and controlled UHPW cutting process.

As rubber particles are dislodged (or sputtered) from the tyre 10, the reinforcing structures within the tyre (e.g. tread reinforcement layers and bead wire) become exposed. The metallic material of these reinforcing structures does not readily erode during the UHPW jet milling process (although some erosion may occur). These reinforcing structures can optionally be recovered and recycled after the rubber has been removed. Any residual rubber attached to the reinforcing structures can be removed by further UHPW jet milling (or by other means). For example, if the tyre comprises a steel bead wire, the steel bead wire can be recycled. The crumb rubber and rubber fibre dislodged from the rubber product during the UHPW jet milling step can accumulate on the walls of the UHPW apparatus 22. The dislodged material is typically washed down to the sump of the UHPW apparatus 22 using water where it forms a slurry. The slurry can be collected for further processing (step 136). The slurry is transferred to a filtration apparatus 24, for example using a vacuum lift mechanism or other means, where the larger rubber particles can be separated from the slurry (step 138). A vacuum lift mechanism helps to prevent the pumps from becoming clogged or blocked with particles from the slurry. Magnets (not shown) can also be used to remove magnetic metal particles from the slurry. The filtration apparatus 24 can comprise a plurality of filters, such as wire cloth filters, each having different pore sizes so that rubber particles of different diameters can be separated into different fractions. Typically, the pore size becomes progressively finer. For example, the filtration apparatus 24 can comprise a series of vibrating sieves to separate larger rubber particles from the water in the slurry. A mechanical arm can spread the rubber particles across the filter mesh. This can help to prevent the filter from becoming clogged or blocked. Additional water jets can be supplied to the filters to help spread the particles and to help wash through the smaller particles to the lower (finer) filters. The different fractions can remain separate or can be recombined during the subsequent processing steps. The rubber particles collected by the filters can undergo further processing.

The water that passes through the filters typically comprises very fine rubber particles (e.g. with a diameter of less than about 5 pm), and is collected at the sump of the filtration apparatus 24. This water can undergo further filtering steps using the auxiliary filtration apparatus 26 to remove the finer grade (i.e. smaller size) rubber particles from the water. The auxiliary filtration apparatus 26 can comprise at least one filter cartridges. For example, the auxiliary filtration apparatus comprise a first filter cartridge 27a to filter particles having a diameter of 5 pm or greater. The auxiliary filtration apparatus can comprise a second filter cartridge 27b to filter particles having a diameter of 1 pm of greater. After the water has passed through the filtration apparatus 24 and 26, the water is substantially free from rubber particles. The filtered water can be disposed of, or recycled back into the UFIPW pump. The rubber particles that are collected by the primary filtration apparatus 24 are subsequently transferred to the drying apparatus 28 for drying (step 140). The drying apparatus removes residual water from the rubber particles. The drying apparatus can be a batch dryer or a continuous flow dryer. After drying, the rubber particles can optionally undergo further processing steps to separate the crumb rubber from the reinforcement fibre (step 142). The separation can be achieved using electrostatics or mechanics (e.g. vibration). Figure 8 shows an apparatus 900 for separating crumb rubber from reinforcement fibre. The apparatus 900 is also suitable for separating the rubber particles from other contaminants, such as metal particles, nails, stones, and the like. The dried rubber particles from the drying apparatus are introduced into the separation apparatus 900 via an inlet 902, such as a funnel. The rubber particles are transported along a conveyor belt 904. A first electrostatically charged plate 906 is positioned so that rubber crumb travelling on the conveyor belt 904 is electrostatically attracted to the electrostatically charged plate 906. A flow of air can assist the attraction of electrostatically charger rubber particles to the electrostatically charged plate 906. The material that is not attracted to the electrostatically charged plate (typically including reinforcement fibre) is collected at the end of the conveyor belt 904 and diverted into a reinforcement fibre collection bin 908. An air blowing system, such as a low velocity exhaust fan 910, can assist the collection of the reinforcement fibre into the reinforcement fibre collection bin 908. The material that is attracted to the electrostatically charged plate 906 (typically including rubber crumb) is transferred to a rubber crumb collection bin 912, optionally via a second electrostatically charged plate 914. A carding machine (not shown) can be used to align the reinforcement fibre and to help separate crumb rubber from the mixture. The filtration, drying and separation steps 138, 140, 142 can be repeated as many times as desired. The carding machine can help to further clean reinforcement fibre.

After separation, the different grades of crumb rubber (and reinforcement fibre) can be packaged, disposed of, or processed further as desired. For example, the reinforcement fibre can be further processed into a matting material for use as an insulation material. UHPW jet milling apparatus

The UHPW jet milling apparatus will now be described in further detail. Figures 4 and 5 show a water jet milling apparatus 22 used for ultra-high pressure water (UHPW) jet milling a rubber-containing product. The product being processed in Figures 4 and 5 is a tyre 10. The vehicle tyre is typically an end-of-life vehicle tyre, where the rubber components of the tyre 10 are desired to be recovered, recycled and/or re-used. The UHPW jet milling apparatus 22 can remove rubber particles (e.g. crumb rubber) from the tread of the tyre. The UHPW jet milling apparatus 22 can also remove rubber particles (e.g. rubber fibre) from the sidewalls, bead and/or inner liner of the tyre 10. The UHPW apparatus 22 comprises a tyre mount device 30 for supporting the rubber product being milled, a jet assembly 32, and a drive roller 34. These components are typically housed within walls, so as to contain the UHPW jets and any material removed from the product being processed. However, the UHPW apparatus typically also comprises a vent (not shown) to regulate the internal pressure of the apparatus 22, and prevent the internal pressure becoming too high. The jet assembly 32 comprises at least one nozzle 36 for jetting a flow of liquid towards the product being milled. Typically, the flow is jetted at an ultra high pressure, for example, at a pressure of 1500 to 3000 bar. The nozzle aperture can have a diameter from about 0.002 inches (50 pm) to about 0.052 inches (1.3 mm). The carcass of the tyre 10 is preferably still in tact prior to being subjected to UHPW jet milling, which allows the drive roller 34 to rotate the tyre 10 during the UHPW processing. The drive roller 34 comprises grips 35, such as spikes, to grip the tyre so that when the drive roller 34 rotates, the tyre is caused to rotate. Rotating the tyre allows all external surfaces of the tyre to be exposed to the water jets expelled from the nozzle 36.

The UHPW apparatus 22 can also comprise an auxiliary jet assembly 38 (Figure 5) to UHPW jet mill the sidewall 14 of the tyre 10. This allows the outer tread region 12 and the sidewall 14 to be processed simultaneously and/or in the same UHPW apparatus 22. This can reduce processing time.

Tyre mounting device

During a UHPW jet milling process, the product being processed must be adequately supported. In an embodiment where a tyre 10 is being processed, the support should provide a stable platform upon which the tyre 10 can be rotated during UHPW jet milling process.

Figures 10 to 14 show a device 30 for supporting a rubber product, such as a tyre 10, during an UHPW jet milling process. The device 30 has an adjustable dimension, such as an adjustable width, so that the device 30 can adequately support products of different widths during a UHPW jet milling process. The device 30 is particularly well suited for supporting vehicle tyres because the device 30 can be inserted into the cavity 17 that is defined by the inner liner 16 of a tyre. The device 30 can also be referred to as a tyre mount. The device 30 can be used to support tyres from personal transport vehicles, and light commercial vehicles (e.g. vans). For example, the device 30 can be used to support tyres in the range of sizes from 145/80-R12 to 355/25-R21. That is, the device 30 can support tyres with a width in the range about 145 mm to 355 mm. The device 30 can support tyres suitable for use with a rim size of between 12 inches (305 mm) to 21 inches (533 mm). The rim size substantially corresponds to the inner diameter of the tyre 10 (i.e. the diameter of the bead rim). The device can be adapted for use to support larger tyres, for example, tyres from lorries, trucks, agricultural vehicles such as tractors, and heavy industrial plant equipment and machinery. The device can also be adapted for use to support smaller vehicle tyres. The device 30 comprises a carrier assembly 42. The carrier assembly comprises a series of carrier arms. The first carrier arm 44 carries a first stabilising member 46. The second carrier arm 48 carries a second stabilising member 50. The second carrier arm 48 can be a support slide. The carrier arms 52a and 52b carry a first support structure 54. The carrier arms 56a and 56b carry a second support structure 58. In the embodiment shown in Figure 10, each of the first stabilising member 46, the second stabilising member 50, the first and second support structures 54, 58 are carried by different carrier arms. The carrier arms 52a and 56a are arranged as concentric shafts. The carrier arm 56a is an inner shaft, and the carrier arm 52a is an outer shaft. The carrier arms 52b and 56b are arranged as concentric shafts. The carrier arm 56b is an inner shaft, and the carrier arm 52b is an outer shaft.

The first carrier arm 44 is moveable relative to the second carrier arm 48 along a longitudinal axis 60. For example, the second carrier arm 48 can be moved by a linear actuator along the axis 60 relative to the first carrier arm 44. Accordingly, the axial distance between the first and second stabilising members 46, 50 can be varied. The axial distance between the first and second stabilising members can be a width. The axial distance between the first and second stabilising members can substantially correspond to the width of a tyre. The distance between the first and second stabilising members 46, 50 is typically suitable to allow the stabilising members 46, 40 to be inserted into a cavity 17 defined by an inner liner of tyres with a size ranging between 145/80/R12 to 310/25/R21. Lower profile tyres can also be accommodated. The distance between the first and second stabilising members 46, 50 can be >50 mm, >100 mm, about >120 mm, >140 mm, or >150 mm. The distance between the first and second stabilising members 46, 50 can be < 350 mm, < 310 mm, < 275 mm or < 255 mm. A stop 61 can limit the maximum distance between the first and second stabilising members 46, 50. A cross-section of the second carrier arm 48 is an inverted T-shape. The second carrier arm 48 can slide through a complementary cut-out portion in the first carrier arm 44. Using a non circular (e.g. T-shaped) cross-section for second carrier arm 48 and a complementary non-circular cut out portion in the first carrier arm 44 can prevent the second carrier arm 48 rotating about the longitudinal axis with respect to the first carrier arm 44. The first and second carrier arms 44, 48 can move independently from the other carrier arms. The carrier arms 52a and 52b move in unison. The carrier arms 56a and 56bmove in unison. The carrier arms 52a and 52b can move independently from the carrier arms 56a and 56b. Therefore, the position of each of the first stabilising member 46, the second stabilising member 50, the first support structure 54, and the second support structure 58 can be independently controlled and positioned along the longitudinal axis. Typically, a controller (not shown) controls the movement and position of each of these components. The first stabilising member 46 is typically substantially orthogonal to the longitudinal axis 60. The first stabilising member is typically a plate, such as a metallic plate. The first stabilising member can, for example, be made from stainless steel, plated mild steel or the like. A radial outer edge of the first stabilising member 46 is curved so as to complement the shape of a tyre. The radial outer edge of the first stabilising member can be an arc. The radial outer edge of the first stabilising member 46 can therefore provide a smooth profile to allow the product to move on. The corners of the first stabilising member 46 can be rounded. Removing sharp or angled corners can help to prevent damaging the product being processed. The second stabilising member 50 is typically a mirror image of the first stabilising member 46. However, the cross-sectional shapes of the first and second stabilising members 46, 50 do not have to correspond exactly. The second stabilising member 50 is typically a plate, such as a metallic plate. Typically, the radial outer edge of the first stabilising member 46 is radially aligned with the radial outer edge of the second stabilising member 50. The term “radially” used here means radial with respect to the axis 60.

The device 30 further comprises optional first and second auxiliary support structures 62, 64. The first auxiliary support structure 62 is rigidly coupled to the first stabilising member 46. The first auxiliary support structure 62 has a first auxiliary support surface 66 which can provide support to the inner tread region 18 of a tyre 10 being supported. The first auxiliary support surface 66 is substantially aligned with a part of the radially outer edge of the first stabilising member 46. The second auxiliary support structure 64 is rigidly coupled to the second stabilising member 50. The second auxiliary support structure 64 has a second auxiliary support surface 68 which can provide support to the inner tread region 18 of a tyre 10 being supported. The second auxiliary support surface 68 is substantially aligned with a part of the radially outer edge of the second stabilising member 50. The first and second auxiliary support surfaces 66, 68 can provide permanent support surfaces to a tyre 10 being supported. The first and second auxiliary support surfaces 66, 68 typically form a part of a support region 70. The support region is the region of the device 30 that provides reinforcing support to a product being supported. For example, the support region can provide reinforcing support to the underside (or backside) of a product during UHPW jet milling. In the case of a tyre, the support region can provide reinforcing support to the inner liner immediately behind the tread area of the tyre (i.e. the support region can provide reinforcing support to the inner tread region 18). The device 30 further comprises optional first and second rollers 72, 74 coupled to the first and second stabilising members 46, 50 respectively. The first and second rollers 72, 74 can form a part of the support region. The first and second rollers 72, 74 can help to assist in the movement of the product during processing. For example, the rollers 72, 74 can assist in a tyre rotating on the support region during UHPW jet milling.

Figures 10 to 12 show the device 30 in a narrow configuration, i.e. where the distance between the first and second stabilising members is small. For example, in the narrow configuration, the axial distance between the first and second stabilising members can be about 124 mm. In this configuration the first and second support structures 54, 58 are disposed radially inward of the first and second auxiliary support structures 62, 64 respectively.

Figure 13 shows a cross-section of the device 30 with the first support structure 54 in a radially inward (or lowered) position. The first support structure 54 is substantially contained within the cross-sectional area of the first stabilising member 46. Containing the first and second support structures 54, 58 substantially within the cross-sectional area of the first and/or second stabilising members 46, 50 can make the device 30 more compact. The first support structure 54 is moveable to a support position. That is, the first support structure 54 is moveable so that the first support surface 76 can be moved radially outward so that it aligns with or is positioned radially outward from the radially outer edge of the first stabilising member. Figure 14 shows the first support structure 54 in the support position (i.e. a radially outward position where the support surface 76 of the first support structure is substantially aligned with the radially outer edge of the first stabilising member 46).

The carrier arms 52a and 52b form a part of a carrier body 52. The first support structure 54 is pivotally coupled to the carrier body 52 at a pivot 78. The first support structure 54 is shaped so that rotation about the pivot will permit the radial movement of the first support surface 76 whilst avoiding the roller 72. The movement of the first support structure 54 is controlled by an actuator 80. The actuator 80 is coupled between the first support structure 54 and the carrier body 52. The actuator 80 can be a pneumatic actuator. The actuator 80 can be electronically controlled. In some embodiments, the first support structure 54 is moved by use of a lever.

The second support structure 58 is typically shaped, configured, and operated in the same way as the first support structure 54.

The support surfaces of each of the first, second and auxiliary support structures 54, 58, 62, 64 comprise a plurality of grooves 82. The grooves 82 are typically aligned in the direction that the tyre 10 will rotate during the UHPW jet milling process. The grooves typically form an arc about the axis 60. The grooves 82 can reduce friction between the support region 70 and the product being processed. A flow of water can also be supplied to the grooves 82 of the support region 70 during UHPW processing to further reduce friction. Each groove can have a rounded or bevelled edge to help avoid piercing or cutting the product being processed. Each groove typically has a width of about 3 mm or more, or about 5 mm. Each groove typically has a width of about 10 mm or less, 8 mm or less, or about 5 mm. The support structure can comprise a stack of metal sheets, wherein the position or height of each adjacent metal sheet alternates to provide a support surface comprising a plurality of grooves. The support structures and/or auxiliary support structures can be manufactured, for example, by machined casting or by metal printing. The support structures can, for example, be made from stainless steel, plated mild steel, or other suitable materials.

Operation of tyre mounting device

In operation, the device 30 is initially in a narrow configuration (as shown in Figures 10 to 12). For example, the axial distance between the first and second stabilising members can be about 124 mm. In this configuration, the axial distance between the first and second stabilising members 46, 50 (i.e. the width) is less than the width of a tyre 10 to be processed. The tyre 10 is hung over the first and second stabilising members 46, 50 so that the first and second stabilising members 46, 50 are inserted into the cavity 17 defined by the inner liner 16 of the tyre 10. Figure 15 shows a schematic of the first and second stabilising members being inserted into the cavity 17 of the tyre 10.

The axial distance between the stabilising members (d) is increased so that the inner liner 16 is under tension (as shown in Figure 16). This helps to secure the tyre 10 on the tyre mount device 30. The change in axial distance d is dependent upon the width of the tyre being processed. Typically, the axial distance is increased to substantially match the internal width of the tyre being processed. This first and second stabilising members 46, 50 thereby provide a support surface, guide surface and/or stabilising surface to the sidewalls and bead area of the tyre being processed. During UHPW jet milling, the tread region is subject to a very high pressure. To ensure the tread region is suitably supported, the first and/or second support structures 54, 58 can be positioned against the inner tread region 18 to provide structural reinforcement. The tyre mount device 30 of the present invention can therefore be used to support tyres of different widths whilst still providing adequate support to the region being processed.

Figures 17 to 19 show the device in a first expanded configuration, suitable to tyres having an intermediate width. For example, in the first expanded configuration, the device 30 is configured to support a tyre 10 having an internal width of about 176 mm (i.e. the axial distance between the first and second stabilising members is about 176 mm). In this configuration, the second support structure 58 is positioned between the first and second auxiliary support structures 66, 68. In this configuration, the support surface of the second support structure 58 is aligned with the radially outer edge of the first and second stabilising members 46, 50. In this configuration the support region 70 comprises the radially outer edges of the first and second stabilising members 46,50; and the support surfaces of the first and second auxiliary support structures 64, 66, and the support surface of the second support structure 58. Consequently, the support region extends across substantially all of the axial distance between the first and second stabilising members 46, 50. During UFIPW jet milling, the support region 70 typically contacts the inner tread region of the tyre 10 being supported. The support region 70 provides reinforcing support to the inner tread region, which can help to avoid undesirable and uncontrolled damage to the tyre during processing. The first support structure is retained below the first auxiliary support structure 62.

Figures 20 to 22 show the tyre mount device 30 in a second expanded configuration, wherein the axial distance d is larger than in the first expanded configuration. The second expanded configuration is suitable for tyres with a larger width. For example, in the second expanded configuration, the device 30 is configured to support a tyre 10 having an internal width of 228 mm (i.e. the axial distance between the first and second stabilising members is about 228 mm). The first support structure 54 can be positioned between the first auxiliary support structure 62 and the second support structure 58 so that the support surface 70 is aligned with the support surfaces of the first and second auxiliary support structures 62, 64 and the support surface of the second support structure 58. These aligned support surfaces form the support region 70. Despite the axial distance being increased, the support region 70 continues to provide reinforcing support to substantially the full width of the inner tread region 18 of the tyre 10 being processed.

Figures 23 to 25 show the tyre mount device 30 in a third expanded configuration, where the axial distance d is larger than in the second expanded configuration. The third expanded configuration is suitable for tyres 10 with an even larger width. For example, in the third expanded configuration, the device 30 is configured to support a tyre 10 having an internal width of up to 312 mm (i.e. the axial distance between the first and second stabilising members is about 312 mm). In the third expanded configuration, each of the support structures 54, 58, 62, 64 are spaced apart. The spacing between the adjacent support structures is typically not more than the width of each support structure. Therefore, the support structures can still provide a support region that provides reinforcing support to the product being processed across more than 50 %, optionally more than 60 %, optionally more than 70 %, optionally more than 80 % or optionally more than 90 % of the axial distance between the first and second stabilising members 46, 50. Preferably, gaps between the adjacent support structures are minimised.

It will be appreciated that the tyre mount device 30 can be used to provide support to tyre 10 of a range of different widths, and that the tyre mount device 30 can provide reinforcing support across substantially the full width of the inner tread region 18. The device 30 can further comprise additional moveable support structures (not shown) to supplement the first and second support structures 54, 58.

UHPW iet milling process After mounting the tyre onto the device 30, the tyre is rolled (or driven) into a processing position underneath the jet assembly 32. Figure 26 shows a schematic representation of a tyre 10 being loaded into a processing position. The movement of the tyre 10 underneath the jet assembly 32 is represented by the arrow 90. The inset is a cross-section through the width of the tyre 10. After positioning the tyre 10 in the processing position, the jet assembly 32 and the drive roller 34 are lowered (Figure 27). The driver roller 34 is lowered so that the grips 35 contact the outer tread region 12 of the tyre 10. The pressure applied by the drive roller 34 to the tyre 10 is adjustable to ensure the tyre 10 is sufficiently secured to the support region 70 so that the drive roller 34 can drive the movement of the tyre 10 irrespective of the amount of rubber removed from either the tread region or the sidewall region. The jet assembly 32 is lowered so that the nozzles 36 are a pre-determined distance away from the product being processed. The distance between the nozzle and the product being processed can influence the intensity and rate of the UHPW jet milling process.

During UHPW processing, the jet assembly 32 can be controlled to traverse the full width of the product being processed (see insert of Figure 28). For example, the jet assembly 32 can be moved in a reciprocating manner across the width of the product being processed. This helps to ensure the full width of the tyre is processed during UHPW processing. Additionally, the jet head of the jet assembly 32 can be rotated during UHPW processing. This can help to ensure the tyre is processed uniformly. The jet head can rotate at a high speed, for example, 1000 rpm to 3000 rpm so that each stream of water from each nozzle cuts a narrow swath of rubber from the product being processed. The distance between the jet head and the product being processed, the speed at which the jet head rotates, and the pressure of the water jet can be varied to control the size (e.g. diameter) of the particles removed from the product. The current method enables the size of the particles collected to be controlled. Different sized particles can have different applications and value. The driver roller 35 rotates to cause the tyre 10 to also rotate (Figure

28). The arrows represent the rotation of the drive roller 34, and tyre 10. This helps to ensure the full circumference of the tyre is processed during UHPW processing. The first and second stabilising members 46, 50 provide a surface to stabilise and guide the rotation of the tyre. During UHPW processing, a jet of water is typically provided to the grooves 82 in order to lubricate and reduce friction between the tyre mount 30 and the tyre being processed. A jet of water can also be provided to the first and second stabilising member to lubricate and reduce friction between the sidewall of the tyre and the first and second stabilising members. Providing a jet of water can also help to remove residual rubber particles and other debris from the device 30.

The tyre mount device 30 supports the tyre from within the cavity 17 defined by the inner liner. This permits both the outer tread region 12 and the sidewall 14 of the tyre 10 to be processed simultaneously and/or within the same apparatus. Optionally, a shield (not shown) can be provided so that water jets directed towards the outer tread region are kept isolated from the sidewall of the tyre 10.