Non-pneumatic tire with web structure

Abstract

The present disclosure provides a non-pneumatic tire including a lower ring having a first diameter, an upper ring having a second diameter greater than the first diameter, and a plurality of closed geometries connected to the lower ring. The non-pneumatic tire also includes a plurality of spokes extending from each closed geometry to the upper ring. Each spoke of the plurality of spokes includes a first linear portion connected to one of the plurality of closed geometries and extending in a first direction, and a second linear portion connected to the upper ring and extending in a second direction different from the first direction.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a non-pneumatic tire having a web structure and a method of manufacturing the same. More particularly, the present disclosure relates to a non-pneumatic tire having a web formed of a plurality of closed geometries and a plurality of spokes and a method of manufacturing the same. BACKGROUND

[0002] Various tire constructions have been developed that enable the tire to travel in an uninflated or underinflated state. Non-pneumatic tires do not require inflation, while "run-flat" tires can continue to travel at relatively high speeds for extended periods of time after being punctured and losing all or part of the pressurized air. Non-pneumatic tires can include a plurality of spokes, a web, or other support structure connecting an inner ring to an outer ring. SUMMARY

[0003] In one embodiment, a non-pneumatic tire has a plurality of hoops including at least a first hoop and a second hoop. Each hoop of the plurality of hoops has opposing faces that lie in opposing planes that are substantially perpendicular to an axis of rotation of the non-pneumatic tire. Each hoop of the plurality of hoops includes a lower ring having a first diameter and an upper ring having a second diameter that is greater than the first diameter. The upper ring is substantially coaxial with the lower ring. Each hoop of the plurality of hoops also has a support structure extending between the lower ring and the upper ring. The support structure includes a plurality of closed geometries connected to the lower ring and a plurality of spokes extending from each closed geometry to the upper ring. Each spoke of the plurality of spokes includes a first linear portion connected to one of the plurality of closed geometries and extending in a first direction and a second linear portion connected to the upper ring and extending in a second direction that is different than the first direction.

[0004] In another embodiment, a method of manufacturing a non-pneumatic tire includes providing a first bead having a first face and a second face. The first bead includes a first lower ring extending laterally from the first face to the second face and a first upper ring extending laterally from the first face to the second face. The first upper ring is substantially coaxial with the first lower ring. The first bead also includes a first plurality of closed geometries connected to the first lower ring and extending laterally from the first face to the second face, and a first plurality of spokes extending from the first plurality of closed geometries to the first upper ring. Each of the first plurality of spokes includes a first linear portion connected to one of the first plurality of closed geometries and extending in a first direction, and a second linear portion connected to the upper ring and extending in a second direction different from the first direction. The method also includes providing a second bead having a first face and a second face. The second bead includes a second lower ring extending laterally from the first face to the second face, and a second upper ring extending laterally from the first face to the second face. The second upper ring is substantially coaxial with the second lower ring. The second bead also includes a second plurality of closed geometries connected to the second lower ring and extending laterally from the first face to the second face, and a second plurality of spokes extending from the second plurality of closed geometries to the second upper ring. The second plurality of spokes has substantially the same geometry as the first plurality of spokes. The method also includes aligning the first face of the first bead with the first face of the second bead such that the first plurality of spokes extends in an opposite direction from the second plurality of spokes.

[0005] In yet another embodiment, a non-pneumatic tire includes a lower ring having a first diameter, an upper ring having a second diameter greater than the first diameter, and a plurality of closed geometries connected to the lower ring. The non-pneumatic tire also includes a plurality of spokes extending from each of the closed geometries to the upper ring. Each of the plurality of spokes includes a first linear portion connected to one of the plurality of closed geometries and extending in a first direction, and a second linear portion connected to the upper ring and extending in a second direction different from the first direction. BRIEF DESCRIPTION OF DRAWINGS

[0006] In the drawings, which are not intended to be to scale, like reference numerals designate like structures where possible. The detailed description incorporates functional and structural

[0007] Figure 1 is a front view of one embodiment of a bead 100 of a non-pneumatic tire;

[0008] Figure 2is a partial elevational view of an enlarged portion of the ring 100;

[0009] Figure 3 is a partial elevational view of an enlarged portion of a first linear portion of a pair of spokes in the ring 100;

[0010] Figure 4 is a partial elevational view of an enlarged portion of a second linear portion of a pair of spokes in the ring 100;

[0011] Figure 5 is a partial elevational view of an enlarged portion of a joint between the second linear portion of the spokes and the upper ring of the ring 100;

[0012] Figure 6 is an elevational view of one embodiment of a plurality of rings assembled to form a non-pneumatic tire;

[0013] Figure 7 is a partial elevational view of one embodiment of a partially assembled non-pneumatic tire having a first ring and a second ring;

[0014] Figure 8 is a partial elevational view of an alternative embodiment of a partially assembled non-pneumatic tire having a first ring and a second ring;

[0015] Figure 9 is a partial elevational view of a simplified embodiment of a non-pneumatic tire 400 having a first ring and a second ring in an unloaded state; and

[0016] Figure 10 is a partial elevational view of a non-pneumatic tire 400 in a loaded state. DETAILED DESCRIPTION

[0017] The following includes definitions of selected terms employed herein. The definitions include various examples or forms of components that fall within the scope of a term and that can be used in implementations. Not all of the examples are intended to be limiting in nature. Both the singular and the plural form of terms can be within the definitions.

[0018] “Axial” and “axially” refer to a direction parallel to the axis of rotation of the tire.

[0019] “Circumferential” and “circumferentially” refer to a direction along the circumference of the surface of the tread perpendicular to the axial direction.

[0020] “Radial” and “radially” refer to a direction perpendicular to the axis of rotation of the tire.

[0021] “Tread” as used herein refers to the portion of the tire that contacts the road or ground under normal inflation and normal load conditions.

[0022] While like terms are used to describe common tire components for the following description, it should be understood that any one of the following terms is not fully interchangeable with another term used to describe a common tire component as the terms carry slightly different meanings to one of ordinary skill in the art.

[0023] Direction is elucidated herein with reference to the axis of rotation of the tire. The terms "upwardly" and "upwardly" refer to the general direction toward the tread of the tire, while "downwardly" and "downwardly" refer to the general direction toward the axis of rotation of the tire. Thus, when relative directional terms such as "upper" and "lower" or "top" and "bottom" are used in connection with an element, the "upper" or "top" element is spatially closer to the tread than the "lower" or "bottom" element. Further, when relative directional terms such as "above" or "below" are used in connection with an element, if a certain element is "above" another element, it means that the element is closer to the tread than the other element.

[0024] The terms "inwardly" and "inwardly" refer to the general direction toward the equatorial plane of the tire, while "outwardly" and "outwardly" refer to the general direction away from the equatorial plane of the tire and toward the side of the tire. Thus, when relative directional terms such as "inner" and "outer" are used in connection with an element, the "inner" element is spatially closer to the equatorial plane of the tire than the "outer" element.

[0025] Figure 1 A front view of one embodiment of a hoop 100 of a non-pneumatic tire is shown. The hoop 100 includes a lower ring 105 having a first diameter and an upper ring 110 having a second diameter greater than the first diameter. The lower ring 105 is coaxial with the upper ring 110. The hoop 100 also includes a web or web structure formed by a plurality of closed geometric shapes 115 connected to the lower ring 105 and a plurality of spokes 120 extending from each closed geometric shape 115 to the upper ring 110.

[0026] Each of the plurality of closed geometric shapes 115 defines an opening extending from a first side of the hoop 100 to a second side of the hoop 100. Thus, the opening is visible from both the first side and the second side of the hoop 100. In the illustrated embodiment, each of the closed geometric shapes 115 is a substantially identically sized hexagonal shape. In alternative embodiments, one or more of the closed geometric shapes can have different sizes. It should also be understood that the closed geometric shapes are not limited to hexagonal shapes. In other alternative embodiments, the closed geometric shapes can be triangular, square, rectangular, pentagonal, heptagonal, octagonal, circular, oval, elliptical, or any other geometric shape. The closed geometric shapes can have straight sides, curved sides, or both straight and curved sides.

[0027] In the illustrated embodiment, a pair of spokes 120a, 120b extends from each closed geometry 115. In an alternative embodiment, a single spoke extends from each closed geometry. In another alternative embodiment, three or more spokes extend from each closed geometry. In yet another alternative embodiment, the number of spokes extending from each closed geometry can vary.

[0028] Figure 2 A partial elevation view of a magnified portion of the hoop 100 is shown, and a single geometry 115a is shown along with its associated pair of spokes, including a first spoke 120a and a second spoke 120b. As can be seen in this view, the first spoke 120a includes a first linear portion 125 that connects to the closed geometry 115a and extends in a first direction. The first spoke 120a also includes a second linear portion 130 that connects to the first linear portion 125 and extends in a second direction, different from the first direction, to the upper ring 110, and forms an acute angle with the upper ring 110.

[0029] Similarly, the second spoke 120b also includes a first linear portion 135 that connects to the closed geometry 115a and extends in the first direction. The second spoke 120b also includes a second linear portion 140 that connects to the first linear portion 135 and extends in the second direction to the upper ring 110, thus also forming an acute angle with the upper ring 110.

[0030] • The spokes 120 have directional geometry such that they are pre-set to bend in a particular direction when the spokes 120 are deflected, to avoid collision with adjacent spokes. In the illustrated embodiment, the first linear portion 125 of the first spoke 120a is substantially parallel to the first linear portion 135 of the second spoke 120b. In an alternative direction, the first linear portion of the first spoke can extend at an angle from the closed geometry that is different from the first linear portion of the second spoke.

[0031] Additionally, the second linear portion 130 of the first spoke 120a is substantially parallel to the second linear portion 140 of the second spoke 120b. In an alternative direction, the second linear portion of the first spoke can extend at an angle from the upper ring that is different from the second linear portion of the second spoke. In another alternative embodiment, the second linear portion of at least one spoke forms a right angle with the upper ring.

[0032] Figure 3A partial elevational view of an enlarged portion of the first linear portion 125, 135 of a pair of spokes 120a, 120b connected to the closed geometric shape 115a is shown. As can be seen in this view, the first linear portion 125, 135 of each spoke 120a, 120b has a variable thickness. For example, the first linear portion 125 of the first spoke 120a has a first end portion having a first thickness Tl, a second end portion having a second thickness T2, and an intermediate portion having a third thickness T3. In the illustrated embodiment, the first thickness Tl is approximately equal to the second thickness T2, and the third thickness T3 is less than the first thickness Tl and less than the second thickness T2.

[0033] In an alternative embodiment (not shown), the first thickness is greater than the second thickness, and the second thickness is greater than the third thickness. In another alternative embodiment (not shown), the second thickness is greater than the first thickness, and the first thickness is greater than the third thickness. In yet another alternative embodiment (not shown), the first thickness is approximately equal to the second thickness, and the third thickness is greater than both the first thickness and the second thickness. In still another embodiment (not shown), the first thickness is less than the second thickness, and the second thickness is less than the third thickness. In yet another alternative embodiment (not shown), the second thickness is less than the first thickness, and the first thickness is less than the third thickness.

[0034] Figure 4 A partial elevational view of an enlarged portion of the second linear portion 130, 140 of a pair of spokes 120a, 120b connected to the upper ring 110 is shown. As can be seen in this view, the second linear portion 130, 140 of each spoke 120a, 120b has a variable thickness. For example, the second linear portion 130 of the first spoke 120a has a first end portion having a fourth thickness T4, a second end portion having a fifth thickness T5, and an intermediate portion having a sixth thickness T6. In the illustrated embodiment, the fourth thickness T4 is approximately equal to the fifth thickness T5, and the sixth thickness T6 is less than the fourth thickness T4 and less than the fifth thickness T5.

[0035] In an alternative embodiment (not shown), the fourth thickness is greater than the fifth thickness, and the fifth thickness is greater than the sixth thickness. In another alternative embodiment (not shown), the fifth thickness is greater than the fourth thickness, and the fourth thickness is greater than the sixth thickness. In yet another alternative embodiment (not shown), the fourth thickness is approximately equal to the fifth thickness, and the sixth thickness is greater than both the fourth thickness and the fifth thickness. In still another embodiment (not shown), the fourth thickness is less than the fifth thickness, and the fifth thickness is less than the sixth thickness. In yet another alternative embodiment (not shown), the fifth thickness is less than the fourth thickness, and the fourth thickness is less than the sixth thickness.

[0036] In the illustrated embodiment, the first, second, fourth and fifth thicknesses (T1, T2, T4, T5) are all approximately equal to one another. Similarly, the third thickness T3 is approximately equal to the sixth thickness T6. However, it will be appreciated that the relative thicknesses of these portions can vary. Altering the thickness of each spoke in one of the above-described manners along its length can reduce or even minimise surface strain when the spoke is deflected.

[0037] As can be seen in Figures 2 to 4 each spoke 120a, 120b, the first linear portion 125, 135 is connected to the respective second linear portion 130, 140 by an elliptical transition 145. The use of an elliptical transition, rather than a rounded corner, can reduce or even minimise surface strain when the spoke is deflected. However, for ease of manufacture, it can be desirable to employ a different transition. Thus, in alternative embodiments, the first linear portion of each spoke is connected to the respective second linear portion by a rounded (i.e. defined by a circular arc) or other curved transition. The curved transition can be defined by a plurality of radii. In yet further alternative embodiments, the first linear portion and the second linear portion form an acute angle. In still further alternative embodiments, one or more additional linear portions are provided between the first linear portion and the second linear portion.

[0038] Additionally, as best shown in Figure 3 each spoke 120a, 120b, the first linear portion 125, 135 is connected to the respective second linear portion 130, 140 by an elliptical transition 145. The use of an elliptical transition, rather than a rounded corner, can reduce or even minimise surface strain when the spoke is deflected. However, for ease of manufacture, it can be desirable to employ a different transition. Thus, in alternative embodiments, the first linear portion of each spoke is connected to the respective second linear portion by a rounded (i.e. defined by a circular arc) or other curved transition. The curved transition can be defined by a plurality of radii. In yet further alternative embodiments, the first linear portion and the second linear portion form an acute angle. In still further alternative embodiments, one or more additional linear portions are provided between the first linear portion and the second linear portion.

[0039] Figure 5 A partial elevational view showing an enlarged portion of the junction between the second linear portion 130 of the spoke 120 and the upper ring 110 of the hoop 100 is shown. In the illustrated embodiment, the second linear portion 130 of each spoke 120 is connected to the upper ring 110 by a pair of elliptical transitions 160, 165. In alternative embodiments, the second linear portion of each spoke is connected to the upper ring by a rounded or other curved transition. In yet further alternative embodiments, the second linear portion forms an acute angle with the upper ring.

[0040] Because the second linear portion 130 extends in a non-radial direction, it does not form a right angle with the upper ring 110. Instead, the second linear portion forms an acute angle with the upper ring 110 at the first elliptical transition 160 and a obtuse angle with the upper ring 110 at the second elliptical transition 165. In alternative embodiments, the second linear portion of each spoke is connected to the upper ring by a rounded transition. In yet another alternative embodiment, the second linear portion forms an acute angle with the upper ring.

[0041] The angle and thickness of each linear portion can be selected to control the deflection of each spoke. Similarly, the shape of the connection or transition between the two linear portions, between the linear portion and the upper ring, or between the linear portion and the closed geometry can also be selected to control the deflection of each spoke. Such variables can be varied to control the direction and magnitude of deflection and to reduce stress concentrations in the spokes, ring, and closed geometry.

[0042] The hoop 100 can be composed of a polymeric material, such as a natural or synthetic rubber, other elastomeric materials. Alternatively, the hoop 100 can be composed of a stiffer polymeric material, such as polyurethane, polyester, nylon, and polyvinyl chloride (PVC). In all cases, the hoop 100 can optionally include a reinforcement layer, such as a reinforcement cord or web, embedded in or disposed about certain components. The reinforcement can be formed of a cord composed of nylon, polyester, fiberglass, carbon fiber, aramid, glass, polyethylene (polyethylene terephthalate), steel, other metals, or other reinforcing materials. In another alternative embodiment, the hoop 100 can be composed of a metal, such as steel, aluminum, or a metal alloy.

[0043] In one embodiment, a non-pneumatic tire can be formed using a single hoop, such as the hoop 100. In such embodiments, a tread layer (not shown) can be disposed circumferentially about the hoop. The tread layer can be composed of rubber or another elastomeric material. The tread layer can include a shear element, such as a shear band. The shear element can include one or more layers of substantially inelastic material. Such layers can be formed of a metal, such as steel. Such layers can be formed of a sheet or cord of material. The shear element can optionally include a layer of ductile material, such as an elastomer. For example, the shear element can include a pair of inelastic layers separated by a layer of ductile material.

[0044] The tread layer can also include a plurality of tread elements, such as grooves, ribs, blocks, lugs, sipes, and other known tread elements. In alternative embodiments (not shown), a separate tread layer can be omitted. In such cases, the tread elements can be formed directly on the upper ring of the hoop.

[0045] Alternatively, a plurality of hoops can be assembled to form a non-pneumatic tire. For example, Figure 6A front view of one embodiment of a plurality of hoops 100 assembled to form a non-pneumatic tire 200 having a tread 205 is shown. In this embodiment, each of the hoops 100 is substantially identical to the hoop 100 shown in FIGS. 1-4 and discussed above. Like numbers are used for like components. However, it should be understood that any of the alternative embodiments of the hoop discussed above can similarly apply to the multi-hoop embodiment. Additionally, in alternative embodiments, hoops having different features can be used in the multi-hoop tire. Figures 1 to 5 The hoop 100 shown in FIGS. 1-4 and discussed above. Like numbers are used for like components. However, it should be understood that any of the alternative embodiments of the hoop discussed above can similarly apply to the multi-hoop embodiment. Additionally, in alternative embodiments, hoops having different features can be used in the multi-hoop tire.

[0046] In the illustrated embodiment, the plurality of hoops 100 of the non-pneumatic tire 200 includes a first hoop 100a, a second hoop 100b, and a series of additional hoops. Each hoop 100 has opposing faces that lie in opposing planes that are substantially perpendicular to an axis of rotation of the non-pneumatic tire 200. In one embodiment, each hoop 100 is 1 inch (2.54 cm) wide, and the non-pneumatic tire 200 includes 12 hoops and is therefore 12 inches (30.48 cm) wide. In alternative embodiments, each hoop can have a width of 0.5 inches to 6 inches (1.27 cm to 15.24 cm), and the non-pneumatic tire can be formed from 1 to 120 hoops such that the non-pneumatic tire has a width of 5 inches to 12 inches (12.7 cm to 30.48 cm).

[0047] In the illustrated embodiment, the hoops 100 are arranged such that the opening of each of the plurality of closed geometric shapes 115 of the first hoop 100a is aligned with the opening of a corresponding one of the plurality of closed geometric shapes 115 of the second hoop 100b and subsequent hoops. The first hoop 100a is arranged in a first orientation, and the second hoop is arranged in an opposite orientation, and the subsequent hoops are arranged in alternating orientations.

[0048] Accordingly, the first linear portion 125a of the first spoke connected to the first closed geometric shape 115 on the first hoop 100a extends in a different direction than the first linear portion 125b of the first spoke connected to the first closed geometric shape 115 on the second hoop 100b. Similarly, the second linear portion 130a of the first spoke extending from the first closed geometric shape 115 on the first hoop 100a extends in a different direction than the second linear portion 130b of the first spoke extending from the first closed geometric shape 115 on the second hoop 100b.

[0049] Here, the first hoop 100a and the second hoop 100b are sized such that the first linear portion 125a of the first spoke extending from the first closed geometry 115 on the first hoop 100a is substantially parallel to the second linear portion 130b of the first spoke extending from the first closed geometry 115 on the second hoop 100b. Additionally, the second linear portion 130a of the first spoke extending from the first closed geometry 115 on the first hoop 100a is substantially parallel to the first linear portion 125b of the first spoke connected to the first closed geometry 115 on the second hoop 100b.

[0050] Similarly, the first linear portion 135a of the second spoke extending from the first closed geometry 115 on the first hoop 100a is substantially parallel to the second linear portion 140b of the second spoke extending from the first closed geometry 115 on the second hoop 100b. Additionally, the second linear portion 140a of the second spoke extending from the first closed geometry 115 on the first hoop 100a is substantially parallel to the first linear portion 135b of the second spoke connected to the first closed geometry 115 on the second hoop 100b. In alternative embodiments, however, portions of different spokes are not parallel to one another.

[0051] In one embodiment, adjacent hoops in the tire are axially spaced apart from one another. In alternative embodiments, adjacent hoops are in contact with one another. In all embodiments, however, the hoops 100 are assembled such that adjacent hoops are not directly adhered or otherwise directly secured to one another. As such, deflection of a given spoke is not constrained by spokes or webs of adjacent hoops.

[0052] The stiffness of a hoop can be adjusted by varying the number of pitches around the hoop’s circumference. For example, Figure 1 The illustrated hoop 100 has 30 pitches. That is, the hoop 100 includes 30 closed geometries 115 and 30 associated pairs of spokes 120 (for a total of 60 spokes 120). This 30-pitch arrangement is also shown in FIG. 2, which illustrates a partial elevation view of one embodiment of a partially assembled non-pneumatic tire having a first hoop 100a and a second hoop 100b. Figure 7 By contrast, FIG. 3 illustrates a partial elevation view of one embodiment of a partially assembled non-pneumatic tire having a first hoop 100a and a second hoop 100b. In this embodiment, the first hoop 100a has 30 pitches and the second hoop 100b has 20 pitches. Figure 8A partial front view of an alternative embodiment of a partially assembled non-pneumatic tire having first and second hoops 300a, 300b is shown. In this embodiment, each hoop 300a, 300b has 45 pitches. That is, each hoop 300a, 300b includes 45 closed geometric shapes 315 and 45 associated pairs of spokes 320 (for a total of 90 spokes 320). The pitches in hoops 300a, 300b are spaced relatively closer together compared to the pitches in hoops 100a, 100b. Thus, when these hoops are made of similar materials and are similar in size, hoops 300a, 300b are stiffer than hoops 100a, 100b.

[0053] To manufacture one of the non-pneumatic tires described above, a manufacturer provides a first hoop having a first face and a second face. The first hoop includes a first lower ring extending laterally from the first face to the second face and a first upper ring extending laterally from the first face to the second face. The first upper ring is substantially coaxial with the first lower ring. The first hoop further includes a first plurality of closed geometric shapes connected to the first lower ring and extending laterally from the first face to the second face, and a first plurality of spokes extending from the first plurality of closed geometric shapes to the first upper ring. Each spoke of the plurality of spokes includes a first linear portion connected to one of the first plurality of closed geometric shapes and extending in a first direction, and a second linear portion connected to the upper ring and extending in a second direction different from the first direction.

[0054] The manufacturer also provides a second hoop having a first face and a second face. The second hoop includes a second lower ring extending laterally from the first face to the second face, and a second upper ring extending laterally from the first face to the second face. The second upper ring is substantially coaxial with the second lower ring. The second hoop further includes a second plurality of closed geometric shapes connected to the second lower ring and extending laterally from the first face to the second face, and a second plurality of spokes extending from the second plurality of closed geometric shapes to the second upper ring, the second plurality of spokes having substantially the same geometry as the first plurality of spokes.

[0055] The manufacturer then aligns the first face of the first hoop with the first face of the second hoop such that the first plurality of spokes extends in an opposite direction from the second plurality of spokes. The alignment of the first face of the first hoop with the first face of the second hoop can include placing the first hoop adjacent to the second hoop without adhering the first plurality of spokes to the second plurality of spokes. The first hoop can contact the second hoop, or the first hoop can be axially spaced apart from the second hoop.

[0056] In some embodiments, the manufacturer may also provide a third ring hoop having a first face and a second face. The third ring hoop includes a third lower ring extending laterally from the first face to the second face, and a third upper ring extending laterally from the first face to the second face, the third upper ring being substantially coaxial with the third lower ring. The third ring hoop also includes a third plurality of closed geometries connected to the third lower ring and extending laterally from the first face to the second face, and a third plurality of spokes extending from the third plurality of closed geometries to the third upper ring. The third plurality of spokes may have substantially the same geometry as the first plurality of spokes. The manufacturer then aligns the second face of the third ring hoop with the second face of the second ring hoop such that the third plurality of spokes extend in the opposite direction to the second plurality of spokes. The manufacturer may repeat this process until the desired number of ring hoops has been assembled.

[0057] In one embodiment, the manufacturer also circumferentially wraps the tread around the first upper ring and the second upper ring. In another embodiment, the manufacturer may form tread elements in the upper ring of the assembled ring clamps.

[0058] The spokes of an assembled tire can be designed to deflect a desired amount in a desired direction under a given load. Figure 9 and Figure 10 The image shows an example of spoke deflection in a non-pneumatic tire. Figure 9 A partial front view of a simplified embodiment of a non-pneumatic tire 400 with a first hoop 405 and a second hoop 410 in an unloaded state is shown. The first hoop 405 and the second hoop 410 each include a plurality of closed geometries 415 and a plurality of spokes 420, similar to the closed geometries and spokes described above in other embodiments.

[0059] Figure 10 A partial front view of a non-pneumatic tire 400 under load is shown. When the non-pneumatic tire 400 is placed under a load exceeding a predetermined threshold, the spokes 420 below the axis of rotation deflect accordingly. The spokes have an oriented geometry such that they are pre-configured to bend in a specific direction when deflected to avoid collision with adjacent spokes. In the illustrated embodiment, the spokes 420 in the first ring 405 deflect along a first direction, and the spokes 420 in the second ring 410 deflect along a second direction different from the first direction.

[0060] In one embodiment, the non-pneumatic tire can be designed to carry a load of 5000 pounds of force or greater while maximizing fatigue resistance. In other words, the designer of the non-pneumatic tire can select the angle and thickness of each linear portion to control the deflection of each spoke under such a load. Similarly, the designer of the non-pneumatic tire can select the shape of the connection or transition between two linear portions, between a linear portion and an upper ring, or between a linear portion and a closed geometric shape to control the deflection of each spoke under such a load.

[0061] To the extent that the term "includes" or "including" is used in the specification or claims, it is intended to be inclusive in a manner similar to "comprising" as equivalent terminology is perceived to be as set forth at the same page number columns 3 and 4 of Bryan A. Garner, A Dictionary of Modern Legal Usage 2d Ed. 1995. Additionally, to the extent that the term "or" is used in the detailed description or claims, it is intended to mean "either A or B or both A and B." When the applicant intends to indicate "only A or B but not both" then the term "only A or B but not both" will be used. Thus, use of the term "or" in the present document is the inclusive, and not the exclusive use. See, Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d Ed. 1995). Additionally, to the extent that the term "in" is used in the specification or claims, it is intended to further mean "onto" or "onto to." Furthermore, to the extent that the term "connected" is used in the detailed description or claims, it is intended to be inclusive of the direct connected and the indirectly connected such as connected through another one or more components.

[0062] While this application has been illustrated by the description of the embodiments thereof, and while the same has been described in considerable detail, it is not the intention that the application be limited thereto. Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the application in its broader aspects is not limited to the specific details, representative apparatus, and methods, and illustrative examples shown and described. Accordingly, departures can be made from such details without departing from the spirit or scope of applicant's general inventive concept.

Claims

1. A non-pneumatic tire comprising: a plurality of hoops including at least a first hoop and a second hoop, each of the plurality of hoops having opposing faces in opposing planes substantially perpendicular to an axis of rotation of the non-pneumatic tire, wherein each of the plurality of hoops comprises: a lower hoop having a first diameter; an upper hoop having a second diameter greater than the first diameter, the upper hoop substantially coaxial with the lower hoop; a support structure extending between the lower hoop and the upper hoop, wherein the support structure comprises: a plurality of closed geometries connected to the lower hoop; and a plurality of spokes extending from each closed geometry to the upper hoop, each of the plurality of spokes comprising a first linear portion connected to one of the plurality of closed geometries and extending in a first direction and a second linear portion connected to the upper hoop and extending in a second direction different from the first direction, wherein the plurality of spokes extending from each closed geometry comprises a first spoke and a second spoke, and wherein the first linear portion of the first spoke is substantially parallel to the first linear portion of the second spoke.

2. The non-pneumatic tire of claim 1, wherein each of the plurality of closed geometries defines an opening visible from a first side of the non-pneumatic tire.

3. The non-pneumatic tire of claim 2, wherein each opening of the plurality of closed geometries of the first hoop is aligned with a corresponding opening of the plurality of closed geometries of the second hoop.

4. The non-pneumatic tire of claim 1, wherein the second linear portion of the first spoke is substantially parallel to the second linear portion of the second spoke.

5. The non-pneumatic tire of claim 1, wherein a first closed geometry on the first hoop is aligned with a first closed geometry on the second hoop, wherein the first linear portion of the first spoke connected to the first closed geometry on the first hoop extends in a different direction than a first linear portion of a first spoke connected to the first closed geometry on the second hoop, and wherein the second linear portion of the first spoke extending from the first closed geometry on the first hoop extends in a different direction than a second linear portion of the first spoke extending from the first closed geometry on the second hoop.

6. The non-pneumatic tire of claim 1, wherein the plurality of spokes of the first hoop are configured to deflect in a first deflection direction when a load is applied to the non-pneumatic tire.

7. The non-pneumatic tire of claim 6, wherein the plurality of spokes of the second hoop are configured to deflect in a second deflection direction opposite the first deflection direction when a load is applied to the non-pneumatic tire.

8. The non-pneumatic tire of claim 1, wherein the first linear portion of each spoke is connected to the second linear portion by an elliptical transition.

9. A method of manufacturing a non-pneumatic tire, the method comprising: providing a first collar having a first face and a second face, the first collar comprising: a first lower ring extending laterally from the first face to the second face; a first upper ring extending laterally from the first face to the second face, the first upper ring being substantially coaxial with the first lower ring; a first plurality of closed geometric shapes connected to the first lower ring and extending laterally from the first face to the second face; and a first plurality of spokes extending from the first plurality of closed geometric shapes to the first upper ring, each of the first plurality of spokes comprising a first linear portion connected to one of the first plurality of closed geometric shapes and extending in a first direction, and a second linear portion connected to the upper ring and extending in a second direction different from the first direction, wherein the first plurality of spokes extending from each of the first plurality of closed geometric shapes comprises a first spoke and a second spoke, and wherein the first linear portion of the first spoke of the first plurality of spokes is substantially parallel to the first linear portion of the second spoke of the first plurality of spokes; providing a second collar having a first face and a second face, the second collar comprising: a second lower ring extending laterally from the first face to the second face; a second upper ring extending laterally from the first face to the second face, the second upper ring being substantially coaxial with the second lower ring; a second plurality of closed geometric shapes connected to the second lower ring and extending laterally from the first face to the second face; and a second plurality of spokes extending from the second plurality of closed geometric shapes to the second upper ring, the second plurality of spokes having substantially the same geometry as the first plurality of spokes, wherein the second plurality of spokes extending from each of the second plurality of closed geometric shapes comprises a first spoke and a second spoke, and wherein the first linear portion of the first spoke of the second plurality of spokes is substantially parallel to the first linear portion of the second spoke of the second plurality of spokes; and aligning the first face of the first collar with the first face of the second collar such that the first plurality of spokes extends in an opposite direction from the second plurality of spokes.

10. The method of claim 9, further comprising wrapping a tread circumferentially around the first upper ring and the second upper ring.

11. The method of claim 9, wherein the aligning of the first face of the first collar with the first face of the second collar comprises placing the first collar adjacent to the second collar without adhering the first plurality of spokes to the second plurality of spokes.

12. The method of claim 9, further comprising applying an elliptical transition between the first linear portion and the second linear portion of each spoke.

13. The method of claim 9, further comprising: providing a third collar having a first face and a second face, the third collar comprising: a third lower ring extending laterally from the first face to the second face; a third upper ring extending laterally from the first face to the second face, the third upper ring being substantially coaxial with the third lower ring; a third plurality of closed geometric shapes connected to the third lower ring and extending laterally from the first face to the second face; and a third plurality of spokes extending from the third plurality of closed geometric shapes to the third upper ring, the third plurality of spokes having substantially the same geometric shape as the first plurality of spokes; and aligning the second face of the third collar with the second face of the second collar such that the third plurality of spokes extend in an opposite direction from the second plurality of spokes.

14. The method of claim 9, wherein each of the first plurality of closed geometric shapes has a hexagonal shape, and wherein each of the second plurality of closed geometric shapes has a hexagonal shape.

Images