FIELD OF THE INVENTION 
       [0001]    This invention relates to a method of protecting a foam noise damper during cure of a tire, where the foam noise damper is disposed on the innerliner surface. 
       DEFINITIONS 
       [0002]    “Carcass” means the tire structure apart from the belt structure, tread, undertread, and sidewall rubber over the plies, but including the beads. 
         [0003]    “Innerliner” means the layer or layers of elastomer or other material that form the inside surface of a tire and that contain the inflating fluid within the tire. The “innerliner” of a tube-type tire is often called a “squeegee” to distinguish it from the innerliner of a tubeless tire. 
         [0004]    “Pneumatic tire” means a laminated mechanical device of generally toroidal shape (usually an open torus) having beads and a tread and made of rubber, chemicals, fabric and steel or other materials. When mounted on the wheel of a motor vehicle, the tire through its tread provides traction and contains the fluid that sustains the vehicle load. 
         [0005]    “Tread” means a molded rubber component which, when bonded to a tire casing, includes that portion of the tire that comes into contact with the road when the tire is normally inflated and under normal load, i.e., the footprint. 
         [0006]    The terms “cure” and “vulcanize” are intended to be interchangeable terms unless otherwise noted. 
         [0007]    The terms “green” and “uncured” are intended to be interchangeable unless otherwise noted. 
         [0008]    “Virgin surface” means a surface, whether cured or not, that has not been subjected to a cleaning process and that has not come in contact with a release agent. 
       BACKGROUND OF THE INVENTION 
       [0009]    Government regulations and consumer preferences continue to compel a reduction in the acceptable noise levels produced from the tires of passenger vehicles. One source of road noise is resonance within the air chamber enclosed by the innermost surface of the tire and the rim. One type of effort to reduce tire noise is damping the sound from the air vibration in the air chamber, which efforts have focused mainly on altering the innermost surface of the tire adjacent the tire carcass. In one approach, foam material is disposed as a noise damper in the inner cavity by attaching the foam to the innerliner of the tire, which is effective in reducing noise due to the tire cavity resonance at 200 to 300 Hz. However, the attachment of such a foam noise damper to a tire innerliner is problematic. 
         [0010]    Carcasses of pneumatic green tires are built as a series of layers of flexible high modulus cords encased in a low modulus rubber. An innerliner is positioned to form the innermost surface of the tire. The green tire is cured in a curing press using a curing bladder, which forces expansion of the tire. During curing, the innerliner expands with the carcass, which is forced against the indentations in the curing mold to form the tread of the tire, and all components are co-cured so as to provide a substantially cohesive bond between one and another. 
         [0011]    The innerliner for a pneumatic tubeless tire is typically formed from a compound containing a high proportion by weight of a halobutyl rubber due to its good barrier properties. Before the tire is cured, the entire inner surface of the innerliner and/or the outer surface of the curing bladder are coated with a release agent. The release agent is commonly referred to as a “lining cement” when used on the surface of the innerliner, and as a “bladder lube” or “bladder spray” when used on the curing bladder. The release agent facilitates removal of the curing bladder from the innerliner after curing so that the innerliner is not damaged. The innerliner (or squeegee) for a pneumatic tube-type tire is typically a thin layer of ply coat stock to protect the tube from direct contact with nylon. These innerliners normally do not contain halobutyl rubber since barrier properties are not required. 
         [0012]    Thus, prior to bonding a foam noise damper to the cured innerliner, in prior art methods the innerliner must be cleaned to remove contaminants present on the innerliner surface from the molding operation. In particular, the release agent must be removed from the innerliner surface. Solvents have typically been used for this cleaning operation. Solvents effective for removing the release agents contain hazardous air pollutants. These solvents are thus subject to environmental regulations, which have become more stringent in the recent past. It would thus be desirable to eliminate the need for solvent cleaning of the innerliner surface in order to comply with strict environmental regulations. In addition, solvent cleaning is labor intensive and costly due to its hazardous nature, such that significant cost savings may be realized by elimination of the solvent cleaning process. Alternatively, preparation of the innerliner for application of a foam noise damper may involve buffing the innerliner to provide a surface suitable for adhesion, see for example U.S. Pat. No. 7,669,628. 
       SUMMARY OF THE INVENTION 
       [0013]    The present invention is directed to a method for making a tire having a foam noise damper, comprising the steps of: disposing a foam noise damper onto a virgin surface of a green tire innerliner; disposing a barrier layer over the foam noise damper, the foam noise damper being located between the virgin surface of the green tire innerliner and the barrier layer; incorporating the green tire innerliner into a green tire; curing the green tire; and removing the barrier layer to reveal the foam noise damper. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention. 
           [0015]      FIG. 1  is a sectional view showing an embodiment of the present invention. 
           [0016]      FIG. 2  is a plan view, not to scale, of an assembly of a strip of a barrier layer long enough to overlie both the entire circumferential surface of a rolled sheet of innerliner and the entire circumferential surface of a foam noise damper, and to provide a pull-tab. 
           [0017]      FIG. 3  is a perspective view schematically illustrating positioning of a prepared innerliner, barrier layer and foam noise damper (as shown in  FIG. 2 ) on a tire building drum. 
           [0018]      FIG. 4  is a plan view, not to scale, of an assembly of a strip of a barrier layer peeled away from the innerliner to reveal the foam noise damper of a cured tire. 
           [0019]      FIG. 5  is a partial cross-section of a cured tire after removal of a barrier layer (as shown in  FIG. 4 ) having a foam noise damper adhered to the innerliner surface. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    In accordance with the present invention, a foam noise damper adhered to the innerliner of a green tire is protected from contamination of mold release agent and from the harsh pressure and temperature of the curing process, by overlaying a protective barrier layer over the foam noise damper and adhering the protective barrier to the green virgin innerliner surface. In one embodiment, the protective barrier layer is a thermoformable film adapted to stretch with the tire materials during the shaping and curing process. In one embodiment, the protective barrier layer is a thin rubber sheet. In one embodiment, the barrier layer is coated with a pressure-sensitive adhesive (PSA) that is pressed to the green virgin innerliner surface to reliably and releasably adhere the thermoformable film. The optional PSA is particularly effective in preventing movement of the barrier layer during high-pressure spraying of lining cement to the innerliner. The invention may be further understood by reference to the Figures. 
         [0021]    Like reference numerals are used throughout the several Figures to refer to like components, and like reference numerals are used to refer to components in both the cured and uncured (green) states. 
         [0022]      FIG. 1  depicts in cross-section an uncured, or “green,” tire assembly  10  after tire building in accordance with the present invention. Green tire assembly  10  includes a carcass  12  having a tread  13  disposed on the outermost surface, where tread  13  is the portion of the tire assembly  10  that contacts the ground during operation of the tire. As is known in the art, the carcass  12  may include one or more plies of cords and the carcass wraps the bead portions  14  of the green tire  10 . An innerliner  16  is disposed inside the carcass  12  so as to face the air chamber  24 . A compressed foam noise damper  22  is disposed on the radially inward green virgin surface  28  of the innerliner  16 . In accordance with the present invention, the foam noise damper  22  is compressed and protected with removable barrier layer  20  adhered to the green virgin surface  28  of innerliner  16 . As will be described further herein, after cure of the green tire  10 , barrier layer  20  is removed from the foam noise damper  22  and innerliner  16  to allow relaxation of the foam noise damper  22  and thereby expand to its full volume. 
         [0023]    Formation of the tire assembly  10 , involves assembling the innerliner  16  in a green state, i.e., an uncured state, adjacent the green tire carcass  12 , positioning the foam noise damper  22  on the green virgin surface  28  of innerliner  16 , and overlaying barrier layer  20  over and thereby compressing compressed foam noise damper  22  and adhering edges  27  of the barrier layer  20  to the green virgin surface  28  of green innerliner  16 . A green tread strip  13  is assembled adjacent the outermost surface of the tire carcass  12 . This green tire assembly  10  is then placed into a curing mold (not shown) such that the green tread strip  13  is positioned against the mold surface (not shown), and the barrier layer  20  is furthest from the mold surface so as to form the innermost layer, with the foam noise damper positioned between the innerliner  16  and the barrier layer  20 . 
         [0024]    Typically, before all components are in place within the mold, a release agent (not shown) is applied to the green innerliner  16  and over the barrier layer  20 . The release agent, which is also referred to as lining cement, is generally applied by a high-pressure spray. Examples of lining cement-type release agent include organopolysiloxane- or silicone-based materials, such as polydimethylsiloxane with powdered mica or crystalline silica. In one embodiment, a pressure sensitive adhesive (not shown) is applied between barrier layer  20  and the green virgin surface  28  of innerliner  16  such that the high-pressure lining cement spray does not displace the barrier layer  20  and the foam noise damper  22 . 
         [0025]    After the green assembly  10  with protected foam noise damper is placed in the mold, an expandable curing bladder (not shown) is then expanded against the innerliner  16  and barrier layer  20  to press the green tire assembly  10  into the mold surface to press the green tread strip  13  into a tread pattern formed in the mold surface. A vulcanization temperature is applied in the mold while the tire assembly  10  is subjected to the pressure from the expanded curing bladder for a time sufficient to cure the tire assembly  10 . The barrier layer  20  protects the compressed foam noise damper  22  from contamination by the mold release agent and from the harsh pressure and temperature environment of the tire mold during cure of the green tire  10 . After curing is completed, the curing bladder is deflated and stripped from the innerliner  16  and the barrier layer  20 . 
         [0026]    One embodiment of a method of the present invention may be described with further reference to  FIGS. 2-3 . As illustrated in  FIG. 2 , prior to the innerliner  16  being positioned on a building drum  32 , a foam noise damper  22  is positioned symmetrically about the longitudinal central axis of the green innerliner  16 . A barrier layer  20 , having a width greater than the width of the foam noise damper  22  but less than that of green innerliner  16 , is positioned symmetrically about the longitudinal central axis of the green innerliner  16  such that the foam noise damper  22  is between the green innerliner  16  and the barrier layer  20 . The edges  27  of barrier layer  20  are pressed to the green virgin surface  28  of the green innerliner  16  causing the barrier layer  20  to be reliably and removably adhered to the green innerliner  16 . At the same time, the foam noise damper  22  is compressed from its fully expanded state to a compressed state by the barrier layer  20 . In one embodiment, there is an overhand or “overlap”  30 , sufficient to afford a pull-tab, to facilitate easy removal of the barrier layer  20  after cure. Alternatively, no overlap is included. 
         [0027]    As shown in  FIG. 3 , from about 2 cm to 20 cm of one end of the barrier layer  20  extends beyond one end of the green innerliner  16  as it is positioned on the drum  32 , to form the overlap  30 . To facilitate visual detection after cure, the overlap  30  may be colored so as to contrast with the black of the innerliner  16 . 
         [0028]    The green tire assembly  10  is removed from the drum  32  and can be stored with the barrier layer  20  protecting the foam noise damper  22 . The innermost surface  26  is then sprayed with lining cement, which completely or partially covers the barrier layer  20 , and the green assembly  10  is placed in a curing press to be conventionally cured.  FIG. 4  shows a cured tire assembly  110  after removal from a curing press. After the cured tire assembly  110  is removed from the press, the inside of the tire may be vacuumed to remove lining cement, which is generally loosely attached to the barrier layer  20 . As seen in  FIG. 4 , the barrier layer  120  is then manually removed in one piece by pulling for example on the protruding end  130  of barrier layer  120 . The foam noise damper  122  is exposed, and is free of lining cement. After removal of the barrier layer  120 , the foam noise damper  122  relaxes and expands to its full volume. 
         [0029]    Application of the foam noise damper  22  to the drum  32  may cause the excessive stress on the foam leading to undesirable tears in the foam. To prevent tearing of the foam on the drum  32 , at least one slit or notch may be made in the cross section of the foam noise damper perpendicular to the circumferential direction of the drum. The one or more slits or notches may be made to a depth in the foam sufficient to prevent tearing upon application of the foam noise damper  22  to the drum  32 . 
         [0030]    Application of the barrier layer  20  as illustrated in  FIGS. 2 and 3  is usable in the case of a barrier layer made of a material that will stretch and survive the stress applied during the tire building process. In the case of a barrier layer made of a material that does not have sufficient stretch to survive the tire building process, rather than application of the barrier layer during the tire building process, the barrier layer  20  may instead be applied over foam noise damper  22  and to the virgin green surface of the innerliner of a completed but uncured green tire after the tire building process. The foam noise damper  22  likewise may be applied during the tire building process, or afterwards to the green tire as desired and depending on the ability of the foam to stretch and resist the stress of the tire building process. Such a green tire having the barrier layer applied after the tire building process would then be cured in a tire mold, with the inner liner surface protected as described previously herein. 
         [0031]    In one embodiment, the barrier layer is a thermoformable film. In order to expand with the innerliner during green tire building and curing, the thermoformable film should exhibit the property of necking, which refers to the ability of a material to stretch without returning back to its original shape. The film advantageously exhibits necking in at least one direction, and preferably in both directions, usually referred to as the machine direction (MD) and cross direction (CD). The necking force, in accordance with room temperature testing at a cross-head speed of 20 in./min, is advantageously below about 25 lbf, and more advantageously below about 20 lbf, in at least one direction, and preferably in both directions, for a 1 inch wide strip. Non-oriented films are desirable, though partially oriented films may also be used. Non-oriented films may be characterized by essentially equal necking forces in both the machine and cross directions. 
         [0032]    Further, the thermoformable film should exhibit a melting point greater than the curing temperature of the tire assembly, which is generally in the range of about 121° C. (250° F.) to about 200° C. (392° F.). The thermoformable film should further have sufficient strength to be removed from the innerliner in a single piece for ease of manufacture. In an exemplary embodiment, the thermoformable film may be overlapped to form a pull-tab to facilitate easy removal of the film, and the overlapped portion of the film must not fuse together. In one embodiment, the thermoformable film has a thickness less than about 5 mils (127 μm), for example less than about 3 mils (76.2 μm). In another embodiment, the thermoformable film has a thickness greater than about 0.6 mil (15 μm), for example, greater than 0.75 mil (19 μm). Nylon 6 and nylon 6,6 films on the order of 0.75 mil to 2 mils thick may serve as exemplary thermoformable films in the present invention. Exemplary films include: CAPRAN® Nylon, which is a multipurpose nylon 6 film commercially available from Honeywell, International, Pottsville, Pa.; fluorinated ethylenepropylene (FEP) films, such as TEFLON® FEP fluorocarbon film from DuPont Films or A4000 from Airtech International, Inc.; 1-phenyl-3-methyl-5-pryrazolone (PMP) films, such as PMP Release Film from Honeywell; and C917 DARTEK®, which is a nylon 6,6 film available from DuPont, Canada. Necking force, maximum tensile strength, % elongation and thickness for these exemplary films (1 inch wide) are provided below in Table 1. Exemplary thermoformable films are those that are non-oriented or only partially oriented and exhibit a necking force in both the machine direction and cross direction of less than 20 lbf. 
         [0000]    
       
         
               
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                   
                   
                 Max Tensile 
                 Necking 
                 Elonga- 
               
               
                 Sample 
                 Mil 
                 μm 
                 (MPa) 
                 (lbf) 
                 tion (%) 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 TEFLON ® FEP (MD) 
                 1 
                 25.4 
                 22 
                 2.25 
                 393 
               
               
                 TEFLON ® FEP (CD) 
                 1 
                 25.4 
                 23.5 
                 2.6 
                 272 
               
               
                 PMP (MD) 
                 1 
                 25.4 
                 28 
                 3.5 
                 107 
               
               
                 PMP (CD) 
                 1 
                 25.4 
                 28 
                 2.5 
                 90 
               
               
                 C917 DARTEK ®, (MD) 
                 2.0 
                 50.8 
                 173 
                 11.5 
                 202 
               
               
                 C917 DARTEK ®, (CD) 
                 2.0 
                 50.8 
                 118 
                 11.25 
                 128 
               
               
                 C917 DARTEK ®, (MD) 
                 0.75 
                 19 
                 48.9 
                 4.5 
                 90 
               
               
                 C917 DARTEK ®, (CD) 
                 0.75 
                 19 
                 47.7 
                 4.25 
                 59 
               
               
                 CAPRAN ® Nylon (MD) 
                 1 
                 25.4 
                 61 
                 7 
                 118 
               
               
                 CAPRAN ® Nylon (CD) 
                 1 
                 25.4 
                 63 
                 6 
                 60 
               
               
                   
               
             
          
         
       
     
         [0033]    By way of further example, nylon films are particularly useful in the method of the present invention. Examples of nylons which may be formed into film are linear polycondensates of lactams of 6 to 12 carbon atoms and conventional polycondensates of diamines and dicarboxylic acids, e.g. nylon 6,6; nylon 6,8; nylon 6,9; nylon 6,10; nylon 6,12; nylon 8,8; and nylon 12,12. Further examples to be mentioned are nylon 6, nylon 11 and nylon 12, which are manufactured from the corresponding lactams. In addition, it is possible to use polycondensates of aromatic dicarboxylic acids, e.g., isophthalic acid or terephthalic acid, with diamines, e.g., hexamethylenediamine, or octamethylenediamine, polycarbonates of aliphatic starting materials, e.g., m- and p-xylylenediamines, with adipic acid, suberic acid and sebacic acid, and polycondensates based on alicyclic starting materials, e.g., cyclohexanedicarboxylic acid, cyclohexanediacetic acid, 4,4′-diaminodicyclohexylmethane and 4,4′-diaminodicyclohexylpropane. 
         [0034]    In one embodiment, the barrier layer is an adherent, removable, inner rubber strip adhered to the innerliner of the tire. 
         [0035]    In this embodiment, the barrier layer as a removable, rubber strip is comprised of a rubber admixture of (A) about 50 to about 100, preferably about 60 to about 90, parts by weight butyl rubber and, correspondingly, (B) about 50 to about 0, preferably about 40 to about 10, parts by weight of an ethylene/propylene/nonconjugated diene terpolymer rubber. 
         [0036]    It is understood that the rubber strip can also contain conventional rubber compounding ingredients including processing oil, accelerators, conventional sulfur curing agents, pigments, carbon black, zinc oxide, stearic acid, tackifying resin, and plasticizer. 
         [0037]    In the practice of this invention, it is required that the said rubber strip is covulcanized with the tire in the sense that the uncured rubber strip is built onto the innerliner as a part of the green, or uncured, tire construction. Thus, in the molding and curing operation for producing the tire, the strip and green tire cure substantially simultaneously. 
         [0038]    In one embodiment, the occurred rubber strip barrier layer has a relatively low adhesion to the inside surface of the tire of less than about 10 lbs. per linear inch (1.8 Kg/linear cm), so that it can conveniently be pulled out by hand or by machine, and a tack value in the range of about 10 to about 30 Newtons so that it will adequately adhere, or stick, to the inside surface of the green tire. 
         [0039]    The adherent, removable, rubber strip typically has a thickness in the range of about 0.01 to about 0.1 (0.025-0.25), preferably about 0.02 to about 0.08 (0.05-0.2) inches (cm). After the tire containing the rubber strip on its innerliner has been shaped and cured, the co-cured rubber strip as the barrier layer can simply be removed by hand or by manual or automatic device. The rubber sheet can be color-coded with a pigment to contrast with the color of the tire itself so that it can be readily apparent whether it has actually been removed prior to further processing of the tire. 
         [0040]    The butyl rubber for the rubber strip is generally of the type prepared by polymerizing a mixture of isobutylene and isoprene, with the major portion being isobutylene. The butyl rubber typically has an average molecular weight in excess of 200,000, preferably in the range of about 200,000 to about 600,000 and even more preferably in the range of about 200,000 to about 400,000. 
         [0041]    The vulcanized rubber tire itself can be of various sulfur curable rubbers such as natural rubber and synthetic rubber and their mixtures or blends. For example, it can be at least one of rubbery butadiene/styrene copolymer, butadiene/acrylonitrile copolymer, cis-1,4 polyisoprene (natural or synthetic), polybutadiene, isoprene/butadiene copolymer, butyl rubber, halogenated butyl rubber, such as chloro or bromobutyl rubber, ethylene/propylene copolymer or ethylene/propylene terpolymer (EPDM). Typically the various polymers are cured or vulcanized by normal sulfur curing methods and recipes. 
         [0042]    In particular, although other portions of the tire can be of such rubbers, the innerliner virgin surface of the tire to which the rubber strip is covulcanized is typically and preferably comprised of a butyl-type rubber, natural rubber, or mixture thereof. Such butyl-type rubber can conveniently be selected from at least one of butyl rubber or a halobutyl rubber such as chlorobutyl or bromobutyl rubber. 
         [0043]    The vulcanized rubber tire itself can be of various sulfur curable rubbers such as natural rubber and synthetic rubber and their mixtures or blends. For example, it can be at least one of rubbery butadiene/styrene copolymer, butadiene/acrylonitrile copolymer, cis-1,4 polyisoprene (natural or synthetic), polybutadiene, isoprene/butadiene copolymer, butyl rubber, halogenated butyl rubber, such as chloro or bromobutyl rubber, ethylene/propylene copolymer or ethylene/propylene terpolymer (EPDM). Typically the various polymers are cured or vulcanized by normal sulfur curing methods and recipes. 
         [0044]    An exemplary recipe for the rubber strip used as a barrier layer is shown in Table 2. The rubber strip, for this example, may be prepared according to the following recipe in which the ingredients of Table 2a are mixed in a Banbury mixer and the resultant mixture mixed on a mill with the ingredients of Table 2b. 
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
                 TABLE 2a 
               
               
                   
                   
               
               
                   
                 Compound 
                 Parts 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Butyl rubber 
                 70.0 
               
               
                   
                 EPDM 1   
                 30 
               
               
                   
                 Carbon Black (FEF) 
                 50 
               
               
                   
                 Stearic Acid 
                 1.5 
               
               
                   
                 Zinc Oxide 
                 2.0 
               
               
                   
                 Tackifying Resin 2   
                 8.0 
               
               
                   
                   
               
               
                   
                   1 Ethylene/propylene/diene rubber obtained as Nordel 1320, Nordel being a trademark of the DuPont de Nemours, E.I. Co. 
               
               
                   
                   2 Hydrocarbon derived tackifying resin of the diolefin/olefin copolymer type having a softening point in the range of about 94° C. to about 98° C. 
               
             
          
         
       
     
         [0000]    
       
         
               
               
               
             
               
               
               
             
           
               
                   
                 TABLE 2b 
               
               
                   
                   
               
               
                   
                 Compound 
                 Parts 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Mercaptobenzothiazole 
                 1.0 
               
               
                   
                 Tetramethylthiuram disulfide 
                 1.25 
               
               
                   
                 Sulfur 
                 2.0 
               
               
                   
                   
               
             
          
         
       
     
         [0045]    In one embodiment, it may be desirable to include a tackifier in the recipe for the rubber composite strip as a building aid during the building of the green tire itself. In this regard, generally about 2 to about 10 parts by weight of resin tackifier for said EPDM and butyl rubbers is used. Suitable tackifiers include terpene resins and synthetic hydrocarbon-derived resins having a softening point in the range from about 50° to about 110° C. 
         [0046]    For example, such resins can be prepared by polymerizing hydrocarbon monomers in the presence of the catalyst such as aluminum chloride or boron trifluoride or boron trifluoride etherate. Such monomers, for example, can be a mixture of diolefin and monoolefin hydrocarbons containing from 4-6 carbon atoms. For example, piperylene can be copolymerized with methyl branched α-olefin containing 5-6 carbon atoms. 
         [0047]    The optional PSA (pressure sensitive adhesive) is a rubber-based adhesive that is compatible with the rubber of the innerliner. As is known in the adhesive art, PSA&#39;s typically principally comprise a polymer system, one or more tackifiers, and one or more plasticizers. In the present invention, the polymer system for the PSA is rubber-based so as to be compatible with the rubber of the innerliner. Without being bound by theory, during curing of the tire assembly, the PSA is believed to lose its status as a PSA, due to migration of the tackifier and/or other materials and/or degradation of the PSA at high temperature. When the thermoformable film is removed, all or some of the PSA, or former PSA, may be removed with the film and/or some or all may remain on or as part of the innerliner. Again, without being bound by theory, if the PSA composition is based on a rubber that is compatible with the rubber of the innerliner, then during curing, the degrading PSA may, in whole or part, migrate into the innerliner surface, thereby becoming part of the cured virgin innerliner surface. Alternatively, it may leave a cohesively-bonded surface coating, but that coating is itself an innerliner-type rubber and is free of release agent, thus being essentially the same as the cured virgin innerliner surface. Thus, in an exemplary embodiment, the PSA is curable during tire vulcanization to cohesively bond with or become a part of the tire innerliner. 
         [0048]    In one embodiment, the PSA may be a natural rubber-based, butyl rubber-based, halobutyl rubber-based or polybutadiene rubber-based adhesive, or combination thereof, since these rubbers are commonly used tire materials. By “rubber-based” is meant that the rubber is the principle component of the PSA, i.e., the component present in the greatest quantity. In a further exemplary embodiment, the PSA is a permanent grade hot-melt PSA. An exemplary PSA is commercially available from H.B. Fuller Company, Vadnais Heights, Minn., as a permanent grade, hot-melt PSA under Product Number HL2201X. Another PSA is Product Number G1110 from 3M (formerly Emtech). The PSA adheres the thermoformable film reliably to the innerliner surface, and yet allows the thermoformable film to be removed therefrom after curing the tire assembly. 
         [0049]    The PSA may be coated onto the thermoformable film by any desirable method, such as solvent coating or hot melt extrusion coating. A film could also be purchased pre-coated. The PSA-coated film may be adhered by any pressure suitable for the particular type of adhesive. For example, hand pressure may be used to adhere to the PSA to the innerliner, or a roller, such as a 1 inch roller, may be rolled along the surface of the PSA-coated film to adhere the PSA. 
         [0050]    The foam noise damper  122  is fixed to the inside of the innerliner  116  radially inward of the tread  113 , as shown in  FIG. 5 . Accordingly, to deform easily during running and not to affect the running performance such as steering stability, the material of the damper is preferably a light-weight low-density flexible material, e.g. foamed rubber, foamed synthetic resins, cellular plastics and the like. In the case of foamed materials (or sponge materials), an open-cell type and a closed-cell type can be used, but an open-cell type is preferred. For example, synthetic resin foams such as ether based polyurethane foam, ester based polyurethane foam, polyethylene foam and the like; rubber foams such as chloroprene rubber foam, ethylene-propylene rubber foam, nitrile rubber foam, silicone rubber foam and the like can be used. In particular, suitable foams must be able to resist the high temperature and pressure environment present during the tire molding process. In one embodiment, an open-cell type foam material, more specifically, polyurethane foam is used. In one embodiment, a silicone rubber foam is used. 
         [0051]    Depending on the environment where the tire is used, there is a possibility that the air which fills the tire cavity to inflate the tire is humid and the water makes condensation in the closed cavity. Accordingly, foam materials which are hard to be hydrolyzed such as ether based polyurethane are suitably used. 
         [0052]    Further, in order to prevent water from penetrating into the noise damper, a water repellent treatment can be preferably made on the foam material. Also, a mildewproof treatment can be preferably made. 
         [0053]    Furthermore, in order to avoid poison in the emission gas generated when incinerating scrap tires, it is preferred that raw materials not including halogen are used to make the foam material. 
         [0054]    By disposing a certain volume of the foam material in the tire cavity, resonances of the air in the cavity can be controlled and vibrations of the tread portion are reduced. Therefore, noise generated from the tire during running can be reduced. In particular, reduction of noise due to tire cavity resonance measured at a frequency of 200 to 300 Hz is desirable. 
         [0055]    The foam noise damper has a specific gravity and dimensions suitable to reduce noise level due to tire cavity resonance at 200 to 300 Hz. In one embodiment, the foam has a specific gravity greater in a range of 0.005 to 0.06 (5 to 60 kg/m 3 ). In one embodiment, the foam noise damper has a thickness in the tire radial direction ranging from 10 to 50 mm. In one embodiment, the foam noise damper has a width in the axial tire direction ranging from 30 to 150 mm. In one embodiment, the foam noise damper is disposed circumferentially about the tire. 
         [0056]    The foam noise damper  22  is fixed to the innerliner radially inward of the tread, and is secured adhesively to the green rubber of innerliner  16 . Upon cure of the tire, the foam noise damper  122  and cured rubber of the innerliner  16  are adhesively attached. Alternatively, the foam noise damper  122  may be fixed using an adhesive applied directly to the foam or as double-sided adhesive tape. 
         [0057]    As to the adhesive, in one embodiment an adhesive tape having a base tape with a coat or layer of an adhesive material on one side and a coat or layer of an adhesive material on the other side may be used. In one embodiment, an adhesive tape having no base tape and made up of only double layers of different adhesive materials may be used. In one embodiment, an adhesive made up of only a single layer of an adhesive material may be used. 
         [0058]    In the case of adhesive tape, the base tape may be, for example: plastic film such as polyester; sheet of plastic foam such as acrylic foam; nonwoven fabric or bonded material; a woven textile; and the like. 
         [0059]    As to the adhesive material, for example, a rubber-based adhesive comprising natural rubber and/or synthetic rubber and additives, e.g. tackifier, softener, age resistor and the like; an acrylic pressure sensitive adhesive comprising a plurality of copolymers of an acrylic ester and a polyfunctional monomer having different glass-transition temperatures (containing pressure sensitive adhesives of high heat resistant type, flame resistant type and low-temperature adhesion type); a silicone pressure sensitive adhesive comprising a silicone rubber and a resin; a polyether adhesive; a polyurethane adhesive and the like may be suitably used. 
         [0060]    The use of a thermosetting adhesive comprising a thermosetting resin, e.g. epoxy resin or the like is not preferred in view of the production efficiency because the adhesive needs to be heated up to about 130° C. for about 30 minutes. 
         [0061]    As to the adhesive materials, it is possible to use the same adhesive material, but it may be desirable to use different types of adhesive materials. For example, a rubber adhesive which adheres strongly to the tire rubber, and an acrylic pressure sensitive adhesive which adheres strongly to the noise damper are used on the respective sides of an adhesive tape or adjacently. 
         [0062]    While the present invention has been illustrated by the description of one or more embodiments thereof, and while the embodiments have been described in considerable detail, they are not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope of the general inventive concept.
The present invention is directed to a method for making a tire having a foam noise damper, comprising the steps of: disposing a foam noise damper onto a virgin surface of a green tire innerliner; disposing a barrier layer over the foam noise damper, the foam noise damper being located between the virgin surface of the green tire innerliner and the barrier layer; incorporating the green tire innerliner into a green tire; curing the green tire; and removing the barrier layer to reveal the foam noise damper.