Abstract: A tire manufacturing method includes providing a green carcass and forming a plurality of green tread segments by a compression molding process. The method further includes assembling the plurality of green tread segments about the green carcass, thereby forming a green carcass and tread assembly, the tread having at least two bars and at least one void. The method also includes introducing the green carcass and tread assembly to a tread negative, aligning the at least two bars with corresponding mold features, and vulcanizing the green carcass and tread assembly.

Abstract: Methods of making tires with features such as ribs, lugs, or tread blocks include shaping at least one feature onto an uncured tire tread prior to vulcanization. One aspect of these methods may include shaping a feature onto the tread while the tread is associated with the tire. Shaping devices may include shaping rollers, stitching rollers, pre-molds, and annular, curved, or flat stamping plates. An additional aspect of these methods may further reduce the amount of air between a tread and carcass prior to vulcanization. These methods may be used in conjunction with manufacturing processes used on various types of tires, and are particularly suitable for use in large tire manufacturing processes.

Abstract: A green tire includes a carcass and a pre-shaped tread. The carcass includes a pair of annular beads and at least one body ply extending between the pair of annular beads. The carcass further includes a circumferential belt. The pre-shaped tread includes a plurality of tread segments, wherein each of the plurality of tread segments includes at least one bar and at least one void.