Self-supporting spoke structure for non-pneumatic tire

Abstract

A non-pneumatic tire includes a lower ring having a first diameter and an upper ring having a second diameter. The upper ring is substantially coaxial with the lower ring. A support structure connects the lower ring to the upper ring. The supporting structure is composed of a plurality of spokes. The support structure is arranged and configured such that adjacent spokes of the plurality of spokes contact each other upon occurrence of a high impact event.

Description

Technical Field

[0001] The present disclosure relates to a non-pneumatic tire. More specifically, the present disclosure relates to a non-pneumatic tire having a support structure with spokes designed to contact each other during a high impact event. Background Art

[0002] Various tire constructions have been developed that enable the tire to be driven in an uninflated or underinflated state. Non-pneumatic tires do not require inflation, while "run-flat tires" can continue to be driven at relatively high speeds for extended periods of time after being punctured and partially or completely decompressed. Non-pneumatic tires may include support structure, such as spokes or webs, connecting a lower ring to an upper ring. In some non-pneumatic tires, a circumferential tread may be attached to the upper ring of the tire.

[0003] The circumferential tread may include a tread band. The tread band may be a single layer of material or a multi-layer band. Such a tread band may also be referred to as a shear band, a shear element, or a thin, annular high-strength band element. When used in a non-pneumatic tire or in a pneumatic tire in a partially pressurized or unpressurized state, the shear element acts as a structural compression member. When used in a fully pressurized pneumatic tire, the shear element acts as a tension member.

[0004] Tire design for both pneumatic and non-pneumatic tires involves a balance of many factors, including but not limited to load capacity, handling, and ride quality. Regardless of the balance chosen between these factors, non-pneumatic tires must be durable and able to withstand high impact events, such as hitting curbs, potholes or other obstacles or road imperfections. Summary of the invention

[0005] In one embodiment, a non-pneumatic tire includes a lower ring having a first diameter and an upper ring having a second diameter. The upper ring is substantially coaxial with the lower ring. A support structure connects the lower ring to the upper ring. The support structure is composed of a plurality of spokes. The plurality of spokes are arranged into at least a first spoke group and a second spoke group axially spaced apart from the first spoke group. Each of the plurality of spokes includes a first end connected to the lower ring and a second end connected to the upper ring. A toggle portion is located between the first end and the second end. The toggle portion is concavely bent relative to the lower ring.

[0006] In another embodiment, a method of manufacturing a non-pneumatic tire includes providing a lower ring having a first diameter and an upper ring having a second diameter greater than the first diameter. A plurality of spokes are formed. Each spoke extends between a first end and a second end. Each spoke has a toggle portion located between the first end and the second end. The plurality of spokes are arranged into a first spoke group and a second spoke group axially spaced from the first spoke group. The lower ring is connected to the upper ring via the first spoke group and the second spoke group.

[0007] In yet another embodiment, a non-pneumatic tire includes a lower ring having a first diameter and an upper ring having a second diameter. The upper ring is substantially coaxial with the lower ring. A support structure connects the lower ring to the upper ring. The support structure is composed of a plurality of spokes. The support structure is arranged and configured so that adjacent spokes of the plurality of spokes do not contact each other when the non-pneumatic tire is in a first condition, and so that adjacent spokes of the plurality of spokes contact each other when the non-pneumatic tire is in a second condition. The first condition is when the tire is rolling on a flat surface. The second condition is different from the first condition. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] In the accompanying drawings, structures are shown which, together with the detailed description provided below, describe exemplary embodiments of the invention protected by the claims. Similar elements are indicated by the same reference numerals. It should be understood that elements shown as a single component may be replaced with multiple components, and elements shown as multiple components may be replaced with a single component. The drawings are not drawn to scale, and for illustrative purposes, the proportions of certain elements may be exaggerated.

[0009] Figure 1 is a side view of one embodiment of a non-pneumatic tire,

[0010] Figure 2 yes Figure 1 Another side view of a non-pneumatic tire,

[0011] Figure 3 yes Figure 1 The cross-sectional view along 3-3,

[0012] Figure 4 yes Figure 1 A detailed view of area A,

[0013] Figure 5 yes Figure 1 Detail of region A of FIG. 1 with some features removed for clarity.

[0014] Figure 6 yes Figure 1 Detail of a single spoke used in a non-pneumatic tire.

[0015] Figure 7 When the tire is on a flat surface and carrying a normal load Figure 1 a side view of a portion of a non-pneumatic tire,

[0016] Figure 8 When the tire is on a flat surface and carrying a normal load Figure 1 A side view of a portion of a non-pneumatic tire with some features removed for clarity.

[0017] Fig. 9When the tire is on an uneven surface Figure 1 a side view of a portion of a non-pneumatic tire,

[0018] Fig.10 When the tire is on an uneven surface Figure 1 A side view of a portion of a non-pneumatic tire with some features removed for clarity.

[0019] Fig.11 It shows the manufacturing Figure 1 A flowchart of a method for a non-pneumatic tire,

[0020] Fig.12 is another embodiment of a spoke for a non-pneumatic tire,

[0021] Fig.12a yes Fig.12 An end view of the spokes along II, and

[0022] Fig.13 Another embodiment of a spoke for a non-pneumatic tire. DETAILED DESCRIPTION

[0023] The following includes definitions of selected terms used herein. These definitions include various examples or forms of components that fall within the scope of the term and can be used for implementation. The examples are not intended to be limiting. Both singular and plural forms of the terms may be within the definitions.

[0024] "Axial" and "axially" refer to directions parallel to the tire's axis of rotation.

[0025] “Circumferential” and “circumferentially” refer to directions perpendicular to the axial direction extending along the circumference of the surface of the tread.

[0026] "Radial" and "radially" refer to directions perpendicular to the tire's axis of rotation.

[0027] As used herein, "tread" means that portion of the tire that comes into contact with the road or ground under normally inflated and normally loaded conditions.

[0028] Although similar terms are used in the following description to describe common tire components, it should be understood that because these terms carry slightly different meanings, one of ordinary skill in the art would not consider any of the following terms to be completely interchangeable with another term used to describe common tire components.

[0029] Directions are set forth herein with reference to the axis of rotation of the tire. The terms "upwardly" and "upwardly" refer to a general direction toward the tread of the tire, while "downwardly" and "downwardly" refer to a 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 conjunction with an element, the "upper" or "top" element is spatially closer to the tread than the "lower" or "bottom" element. Additionally, when relative directional terms such as "above" or "below" are used in conjunction with an element, if an element is "above" another element, it means that the element is closer to the tread than the other element.

[0030] The terms "inwardly" and "inwardly" refer to general directions toward the equatorial plane of the tire, while "outwardly" and "outwardly" refer to general directions away from the equatorial plane of the tire and toward the sides of the tire. Thus, when relative directional terms such as "inner" and "outer" are used in conjunction with an element, the "inner" element is spatially closer to the equatorial plane of the tire than the "outer" element.

[0031] Figures 1 to 5 One embodiment of a non-pneumatic tire 10 is shown. The non-pneumatic tire 10 is shown for exemplary purposes only and is not intended to be limiting. In the illustrated embodiment, the non-pneumatic tire 10 includes a generally annular lower ring 20. The lower ring 20 can engage a vehicle wheel hub (not shown) to attach the tire 10 to the vehicle. The lower ring 20 has an inner surface 23 and an outer surface 24, and can be made of a polymeric material, an elastomeric material, a metal, a composite composed of a polymer reinforced with glass or carbon fiber, or any other desired material or combination of materials.

[0032] The non-pneumatic tire 10 also includes a generally annular upper ring 30. The upper ring 30 has a diameter greater than the diameter of the lower ring 20 and is substantially coaxial with the lower ring 20. The upper ring 30 has an inner surface 33 and an outer surface 34, and may be made of a polymeric material, an elastomeric material, a metal, a composite composed of a polymer reinforced with glass or carbon fiber, or any other desired material or combination of materials. A circumferential tread 70 is attached to the outer surface 34 of the upper ring 30. The circumferential tread 70 may be attached to the upper ring 30 adhesively, mechanically, or by any other desired arrangement.

[0033] like Figure 3 As shown, the circumferential tread 70 includes a tread band 72 and a tread layer 74. The tread band 72 and the tread layer 74 may be made of the same material or different materials. The tread layer 74 may be made of rubber and may include tread elements (not shown), such as grooves, ribs, blocks, lugs, sipes, posts, or any other desired tread elements. The tread band may include a filament assembly.

[0034] In the illustrated embodiment, the tread band 72 is shown as a single layer. In an alternative embodiment, the tread band can be a multi-layer band. Such a multi-layer tread band may include one or more layers of substantially inextensible material. The layer may be formed by a sheet of material, a rope of material, a thread of material, or any other desired arrangement. In other alternative embodiments, the multi-layer tread band may include a layer of extensible material, such as an elastomer. According to an example embodiment, the tread band may include a pair of inextensible layers separated by a layer of extensible material. In other alternative embodiments, the tread band may include a band known as a shear band, a shear element, or a thin annular high-strength belt element.

[0035] The support structure 100 connects the lower ring 20 to the upper ring 30. The support structure 100 extends from the outer surface 24 of the lower ring 20 and the inner surface 33 of the upper ring 30. The support structure 100 is composed of a plurality of spokes 200. In the illustrated embodiment, the plurality of spokes 200 are arranged into two axially spaced spoke sets, including a first spoke set 202 and a second spoke set 204 axially spaced from the first spoke set 202. In alternative embodiments, the support structure may include more than two axially spaced spoke sets.

[0036] like Figure 3 As shown, the first spoke group 202 and the second spoke group 204 are spaced apart from each other in the axial direction. In alternative embodiments, the space between the first spoke group and the second spoke group can be larger or smaller, or the first spoke group and the second spoke group can be arranged with no space between them. Figure 1 Each spoke 200 of the first spoke set 202 is substantially convex relative to the clockwise circumferential direction of the non-pneumatic tire 10 and each spoke of the second spoke set 204 is substantially concave relative to the clockwise circumferential direction of the non-pneumatic tire 10 when viewed at the angle shown.

[0037] All spokes 200 of the first spoke group 202 and the second spoke group 204 have the same configuration. Therefore, the description of the spokes 200 will refer to Figure 6 The spoke 200 is made of a single spoke 200 shown in FIG. The spoke 200 may be made of a metal such as steel or aluminum, a polymer such as polyester or nylon, a composite such as a glass fiber or carbon fiber reinforced polymer, or any other desired material or material combination. The spoke 200 may be provided with reinforcements (not shown).

[0038] The spoke 200 extends between a first end 206 and a second end 208 and has a generally rectangular cross-section including a first surface 210 and a second surface 212 facing opposite the first surface 210. The spoke thickness t refers to the distance between the first surface 210 and the second surface 212. In the illustrated embodiment, the spoke 200 has a constant thickness between the first end 206 and the second end 208. In alternative embodiments, the thickness of the spoke may vary between the first end and the second end. For example, the spoke may have a relatively thick portion at the first end and the second end, and a relatively thin portion between the ends. In other alternative embodiments, the spoke may have any desired cross-sectional shape (e.g., circular, diamond, hexagonal, etc.) or may have a combination of different cross-sectional shapes.

[0039] An integral foot 214 is provided toward the first end 206 of the spoke 200. The first surface 210 of the spoke 200 is attached to the outer surface 24 of the lower ring 20 at the foot 214 to connect the first end 206 of the spoke 200 to the lower ring 20. The foot 214 can be attached to the outer surface 24 of the lower ring 20 using welding, brazing, soldering, adhesives, mechanical fasteners (e.g., bolts, rivets), keys / keyways, or any other desired arrangement. In the illustrated embodiment, the foot 214 is substantially straight and the entire length (the dimension of the foot extending in the circumferential direction of the tire) and the entire width (the dimension of the foot extending in the axial direction of the tire) are fixed to the outer surface 24 of the lower ring 20. In alternative embodiments, the foot can be a separate component attached to the spoke. In other alternative embodiments, the foot can be curved to match the radius of curvature of the outer surface of the lower ring or have any other desired curvature. In further alternative embodiments, only a portion or multiple discrete portions of the foot can be attached to the outer surface of the lower ring. In other alternative embodiments, the feet may be attached below the outer surface of the lower ring, or the spokes may extend through the lower ring so that the feet may be attached to the inner surface of the lower ring.

[0040] The flex member 216 is disposed at the second end 208 of the spoke 200. The flex member 216 has a width extending in the axial direction of the tire. The flex member 216 may be made of a polymer (e.g., polyurethane or rubber), a thin curved metal piece, or any other desired material or material combination. In the illustrated embodiment, the flex member 216 is configured as a cuboid and is arranged so that the end of the flex member 216 is aligned with the second end 208 of the spoke 200. In other alternative embodiments, the flex member may be arranged so that the end of the flex member is retracted relative to the second end of the spoke, or may be arranged so that the end of the flex member extends beyond the second end of the spoke. In other alternative embodiments, the flex member may be replaced by a mechanical pin joint (i.e., a hinge).

[0041] The flex member 216 includes a spoke-facing surface 218 and a ring-facing surface 220. The spoke-facing surface 218 of the flex member 216 is attached to the second surface 212 of the spoke 200, and the ring-facing surface 220 is attached to the inner surface 33 of the upper ring 30 to connect the second end 208 of the spoke 200 to the upper ring 30. The attachment between the flex member 216 and the spoke 200 or between the flex member 216 and the upper ring 30 can be achieved using welding, brazing, soldering, adhesives, mechanical fasteners (e.g., bolts, rivets), keys / keyways, or any other desired arrangement. For example, the attachment can be provided by pouring polyurethane directly onto the spoke, with or without first coating the spoke with a primer.

[0042] The flex members 216 provide flexibility to the connection between the second ends 208 of the spokes 200 and the upper ring 30. This flexibility reduces the likelihood of high stresses being generated within the spokes 200, thereby increasing the robustness of the non-pneumatic tire 10. The connection provided by the feet 214 at the first ends 206 of the spokes 200 is more rigid than the flexible connection provided by the flex members 216.

[0043] In alternative embodiments, the flexure members may have shapes or configurations that are different than those specifically shown and described. In other alternative embodiments, additional structures or mechanisms may supplement the flexure members to attach the second ends of the spokes to the upper ring. In further alternative embodiments, the flexure members may be omitted and the second ends of the spokes may be directly attached to the upper ring. In these alternative embodiments, the second ends of the spokes may be directly attached to the inner surface of the upper ring, above the inner surface of the upper ring, or the spokes may extend through the upper ring so that the second ends may be attached to the outer surface of the upper ring.

[0044] The spoke 200 includes a toggle portion 222 located between the first end 206 and the second end 208. The toggle portion 222 has a first radius of curvature r1. According to an exemplary embodiment, the first radius of curvature r1 is 2 inches to 6 inches (5 cm to 15 cm). When attached to the upper ring 20 and the lower ring 30, the toggle portion 222 is concavely curved relative to the lower ring 20.

[0045] The transition portion 224 is disposed between the toggle portion 222 and the first end 206. The transition portion 224 has a second radius of curvature r2. According to an exemplary embodiment, the second radius of curvature r2 is 0 inches to 2 inches (0 cm to 5 cm). When attached to the upper ring 20 and the lower ring 30, the transition portion 224 is convexly curved relative to the lower ring 20. Therefore, relative to the single spoke 200, the toggle portion 222 and the transition portion 224 are concavely curved in opposite facing directions. In an alternative embodiment, the toggle portion and the transition portion are concavely (or convexly) curved in the same direction.

[0046] The foot 214 extends from the transition portion 224 to the first end 206 of the spoke 200. The first connecting portion 226 connects the transition portion 224 to the toggle portion 222, and the second connecting portion 228 connects the toggle portion 222 to the second end 208 of the spoke 200. In the illustrated embodiment, the first connecting portion 226 and the second connecting portion 228 are both linear. In alternative embodiments, the first connecting portion or the second connecting portion may be curved or have any other desired configuration. In other alternative embodiments, the transition portion and the foot may be omitted. In such alternative embodiments, the first end of the spoke will be located at the end of the first connecting portion.

[0047] The base plane p1 intersects the transition portion 224 and the second end 208 of the spoke 200 and serves as a reference for various dimensional aspects of the spoke 200. The angle between the base plane p1 and the second plane p2 extending tangentially to the outer surface 24 of the lower ring 20 at the transition portion 224 is α. According to an exemplary embodiment, the angle α is +0 degrees to 20 degrees. The distance between the transition portion 224 and the second end 208 of the spoke 200 along a direction parallel to the base plane p1 is d1. According to an exemplary embodiment, the distance d1 is 10 inches to 25 inches (25 cm to 63.5 cm). Along the direction parallel to the base plane p1, the distance between the center of the transition portion 224 and the center of the first radius of curvature r1 of the elbow portion 222 is d2. According to an exemplary embodiment, the value of the distance d2 is 20% to 70% of the distance d1. The maximum distance between the elbow portion 222 and the base plane p1 along a direction perpendicular to the base plane p1 is d3. According to one example embodiment, distance d3 is 2 inches to 4 inches (5 cm to 10 cm).

[0048] Reference Fig.10 , the transition portion 224 of one spoke 200 is separated from the first end 206 of the adjacent spoke 200 by a first spacing distance s1. The second ends 208 of the adjacent spokes 200 are separated from each other by a second spacing distance s2 (see also Figure 5 ).

[0049] A non-pneumatic tire constructed according to the above-described design parameters may provide a more robust assembly, particularly in terms of impact performance. Figure 7 and Figure 8 A tire is shown in an exemplary first condition. Figure 7 and Figure 8 As shown, according to a non-limiting example, in a first condition, the tire 10 is rolling on a flat surface while bearing a load (i.e., normal operation), the non-pneumatic tire 10 is deformed, but adjacent spokes 200 do not contact each other. The lack of contact between adjacent spokes 200 during normal operation is desirable to avoid generating unnecessary stress in the structure of the non-pneumatic tire 10.

[0050] It is expected that the non-pneumatic tire 10 will be exposed to high impact events during its life, such as striking a curb, a pothole, or other obstacle or road defect. During a high impact event, the non-pneumatic tire 10 may deform at a significantly higher level than the deformation that occurs during normal operation. An example of a high impact event is a non-pneumatic tire 10 striking a curb at a low speed (e.g., striking a 6-inch (15-cm) curb at 5 mph (8 km / h)). Another example of a high impact event is a non-pneumatic tire 10 striking a jump road defect at a high speed (e.g., striking a 1-inch (2.5-cm) jump at 70 mph (113 km / h). These are merely examples and are not meant to limit the definition of a "high impact event."

[0051] Fig. 9 and Fig.10 1 shows a tire in an exemplary second condition, the second condition being different from the first condition. Fig. 9 and Fig.10 As shown, according to a non-limiting example, in a second condition, the non-pneumatic tire 10 experiences a high impact event in which the tire rolls on an uneven surface. According to one non-limiting example, the uneven surface is a road defect that protrudes above the ground or is pressed into the ground by a distance of 3 inches (8 cm). According to another non-limiting example, the uneven surface is a road defect that protrudes above the ground or is pressed into the ground by a distance of 4.5 inches (11 cm). According to yet another non-limiting example, the uneven surface is a road defect that protrudes above the ground or is pressed into the ground by a distance of 6 inches (15 cm).

[0052] The non-pneumatic tire 10 responds to a high impact event by deforming so that adjacent spokes 200 contact one another. It has been surprisingly discovered that the contact between adjacent spokes 200 during a high impact event significantly reduces the stress experienced by each spoke 200, as compared to a non-pneumatic tire where the spokes do not contact one another during the high impact event. The reduction in stress in each spoke 200 is a result of the contact between adjacent spokes 200 because the contact distributes the load among the plurality of spokes 200. In other words, rather than a single spoke 200 absorbing the load generated by a high impact event, the plurality of spokes 200 share the same load, thereby reducing the peak load of any one single spoke 200.

[0053] In the illustrated embodiment, the non-pneumatic tire 10 is arranged and configured so that at least three adjacent spokes 200 are in contact with each other simultaneously during a high impact event, and the spokes 200 in contact with each other are located adjacent to the obstacle or road defect that caused the high impact event. In alternative embodiments, the non-pneumatic tire may be arranged and configured to have a lesser or greater number of adjacent spokes in contact with each other simultaneously during a high impact event. In other alternative embodiments, the adjacent spokes in contact with each other simultaneously may be located at any position along the circumferential direction of the tire (i.e., spaced apart from the obstacle or road defect that caused the high impact event).

[0054] Design parameters of the spokes 200 and other components of the non-pneumatic tire 10 may be varied to provide desired performance characteristics to the non-pneumatic tire 10. Preferably, these design parameters are selected so that contact between adjacent spokes 200 occurs before the spokes 200 begin to yield or experience any other form of damage.

[0055] The maximum distance d3 between the toggle portion 222 and the base plane p1 in a direction perpendicular to the base plane p1 affects the spoke stiffness and when contact between adjacent spokes 200 will occur. Increasing the distance d3 will physically move each spoke 200 closer to the adjacent spoke 200, thus causing contact between adjacent spokes 200 to occur relatively sooner. In addition, increasing the distance d3 will reduce the stiffness of the spokes 200, thereby increasing the amount of deflection for a given load, which increases the likelihood of contact between adjacent spokes 200. Reducing the distance d3 will have the opposite effect and will physically move each spoke 200 away from the adjacent spoke 200, thus causing contact between adjacent spokes 200 to occur relatively later. In addition, reducing the distance d3 will increase the stiffness of the spokes 200, thus reducing the amount of deflection for a given load, which reduces the likelihood of contact between adjacent spokes 200.

[0056] The distance d2 between the transition portion 224 and the center of the first radius of curvature r1 of the toggle portion 222 in a direction parallel to the base plane p1 affects when contact will occur with the adjacent spokes 200. When the distance d2 is a larger percentage of d1, this will cause contact between adjacent spokes 200 to occur relatively quickly. When the distance d2 is a smaller percentage of d1, this will cause contact between adjacent spokes 200 to occur relatively late.

[0057] The radius of curvature r1 of the toggle portion 222 affects when contact with adjacent spokes 200 will occur. Reducing the radius of curvature r1 will cause contact between adjacent spokes 200 to occur relatively late, while increasing the radius of curvature r1 will cause contact between adjacent spokes 200 to occur relatively soon. The spoke thickness t affects the stiffness of the spoke 200. Increasing the spoke thickness t will increase the stiffness of the spoke 200, while reducing the spoke thickness will reduce the stiffness of the spoke 200.

[0058] In addition, it has been found that the vertical stiffness of the tire is affected by the combination of the spoke thickness t and the distance d3. Increasing the distance d3 reduces the tire stiffness, while reducing the distance d3 increases the tire stiffness. Therefore, it has been found that in order to meet the target value of tire stiffness, spokes with a larger thickness t should be combined with a larger distance d3, while spokes with a smaller thickness t should be combined with a smaller distance d3.

[0059] Fig.11 10 is a flow chart showing an exemplary method for manufacturing a non-pneumatic tire. At 1010, a lower ring and an upper ring are provided. The lower ring has a first diameter, and the upper ring has a second diameter greater than the first diameter. At 1020, a plurality of spokes are formed. The spokes may be formed using hot stamping, cold forming, extrusion, rolling, bending, or any other desired method. In addition, the spokes may be formed using a variety of composite manufacturing techniques (e.g., resin transfer molding and high pressure resin transfer molding). Other examples of methods for forming spokes include wet layup, prepreg lamination. Each spoke extends between a first end and a second end. A toggle portion is located between the first end and the second end, and a transition portion is located between the first end and the toggle portion. The toggle portion and the transition portion are concavely curved in opposite facing directions. A foot extends from the transition portion.

[0060] At 1030, a flex member is attached to the spokes. At 1040, the spokes are arranged into a first spoke set and a second spoke set axially spaced from the first spoke set. Additionally, a plurality of spokes of the first spoke set are arranged to be concavely curved relative to a first circumferential direction of the tire, and a plurality of spokes of the second spoke set are arranged to be convexly curved relative to the first circumferential direction of the tire.

[0061] At 1050, the lower ring is connected to the upper ring using the first spoke group and the second spoke group. The foot of each spoke is attached to the lower ring to connect the first end of each spoke to the lower ring. The flex member is attached to the upper ring to connect the second end of each spoke to the upper ring.

[0062] In alternative embodiments, the aforementioned steps may occur in an order different from that specifically described. In other alternative embodiments, the method may include a greater or lesser number of steps.

[0063] Fig.12 and Fig.12a Another embodiment of a spoke 1200 is shown. Fig.12 and Fig.12a The spokes of 1200 with Figures 1 to 10 The spokes 200 in FIG. 1 are substantially identical except for the differences described herein. Therefore, similar features will be identified by similar numbers increased by a factor of "1000". Figures 1 to 10 In the illustrated spoke 200, the second connecting portion 228 is linear. In contrast, Fig.12 and Fig.12a The spoke 1200 has a curved second connecting portion 1228 with a radius of curvature r3. Compared with the linear second connecting portion, Fig.12 and Fig.12a The curved second connecting portion 1228 in the spoke 1200 significantly enhances the self-supporting behavior. According to an exemplary embodiment, the radius of curvature r3 is 10 inches to 50 inches (25 cm to 127 cm).

[0064] In addition to the above Figures 1 to 10 In addition to the design parameters and resulting changes in performance characteristics discussed in the illustrated spoke 200, Fig.12 and Fig.12a The radius of curvature r3 of the curved second connection portion 1228 in the spoke 1200 can be varied to affect performance. The radius of curvature r3 of the curved second connection portion 1228 and the length l of the flexure member 1216 挠曲 The second connection portion 1228 is a curved second connection portion 1228 that is formed by a plurality of curved surfaces 1224 and 1225. The curved ... curved second connection portion 1228. The curved second connection portion 1228 is a curved second connection portion 1228 that is curved second connection portion 1228. The curved second connection portion 1228 is a curved second connection portion 1228 that is curved second connection portion 1228. The curved second connection portion 1228 is a curved second connection portion 1228 that is curved second connection portion 1228. The curved second connection portion 1228 is a curved second connection portion 1228 that is curved second connection portion 1228. The curved second connection portion 1228 is a curved second connection portion 1228 that is curved second connection portion 1228. The curved second connection portion 1228 is a curved second connection portion 1228 that is curved second connection portion 1228. The curved second connection portion 1228 is a curved second connection portion 1228 that is curved second connection portion 1

[0065] The length l of the flexure member 1216 挠曲 This affects its ability to apply torque at the ends of the spokes 1200. This torque acts to straighten the curved second connecting portion 1228 when the tire is rolling under normal load or subjected to a high impact event. Therefore, it has been found that a curved second connecting portion 1228 having a smaller radius of curvature r3 is more effective than a curved second connecting portion 1228 having a longer length l 挠曲 The flexure member 1216 is optimally matched, and the curved second connecting portion 1228 having a larger radius of curvature r3 is optimally matched with the curved second connecting portion 1228 having a shorter length l 挠曲 The flexure member 1216 is optimally matched. In addition to the length l of the flexure member 1216 挠曲 In addition, the ability of the flexure members 1216 to apply torque on the spokes 1200 is also affected by the stiffness of the material used to make the flexure members 1216. Therefore, when using a softer material, it is desirable to provide a flexure member having a longer length l. 挠曲 flexure member 1216, and when using a harder material, it is desirable to provide a flexure member 1216 having a shorter length l 挠曲 Flexure member 1216.

[0066] Fig.13 Another embodiment of a spoke 2200 is shown. Fig.13 The spokes of 2200 with Figures 1 to 10 The spokes 200 in FIG. 1 are substantially identical except for the differences described herein. Therefore, similar features will be identified by similar numbers increased by a factor of "2000".

[0067] The spoke 2200 extends between a first end 2206 and a second end 2208. A foot 2214 is provided toward the first end 2206 of the spoke 2200. The foot 2214 is attached to the lower ring 20 to connect the first end 2206 of the spoke 2200 to the lower ring 20. A flex member 2216 is provided at the second end 2208 of the spoke 2200. The flex member 2216 is used to connect the second end 2208 of the spoke 2200 to the upper ring 30.

[0068] The spoke 2200 includes a toggle portion 2222 located between the first end 2206 and the second end 2208. The transition portion 2224 is disposed between the toggle portion 2222 and the first end 2206. The foot 2214 extends from the transition portion 2224 to the first end 2206 of the spoke 2200. The first connecting portion 2226 connects the transition portion 2224 to the toggle portion 2222. The second connecting portion 2228 connects the toggle portion 2222 to the second end 2208 of the spoke 2200. The base plane p1 intersects the transition portion 2224 and the second end 2208 of the spoke 2200, and the second plane p2 extends tangentially to the lower ring 20 at the transition portion 2224. The angle between the base plane p1 and the second plane p2 is α.

[0069] and Figures 1 to 10 Compared to the spoke 200 in FIG. 1 (where the angle α has a positive value), Fig.13 In the embodiment of the spoke 2200 shown, the angle α has a negative value. As used herein, a positive value of angle α means that, moving clockwise around the intersection point between the base plane p1 and the second plane p2 as the center point, the base plane p1 is located in front of the second plane p2. Using this same reference system, a negative value of angle α means that the base plane p1 is located behind the second plane p2. According to an example embodiment, in Fig.13 In the illustrated spoke 2200, the angle α is between -30 degrees and 0 degrees. Negative values ​​of angle α can reduce spoke stress compared to spokes having positive values ​​of angle α.

[0070] The non-pneumatic tire described herein improves the robustness of the non-pneumatic tire by providing an arrangement in which adjacent spokes contact each other during a high impact event. The contact between adjacent spokes results in multiple spokes sharing the load, thereby significantly reducing the stress experienced by any single spoke in the non-pneumatic tire. Thus, the durability of the non-pneumatic tire is improved.

[0071] To the extent that the terms "including" or "having" are used in the specification or claims, they are intended to be inclusive in a manner similar to how the term "comprising" is understood when used as a transitional word in a claim. Furthermore, to the extent that the term "or" is employed (e.g., A or B), the term is intended to mean "A or B or both." When applicants intend to indicate "only A or B but not both," then the term "only A or B but not both" will be employed. Thus, the use of the term "or" herein is inclusive and does not have an exclusive use. See Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). In addition, to the extent the terms "in" or "into" are used in the specification and claims, the terms are intended to additionally mean "on" or "onto." Furthermore, to the extent the term "connected" is used in the specification or claims, the term is intended to mean not only "directly connected to," but also "indirectly connected to," such as connected through another component or components.

[0072] Although the present application has been illustrated by descriptions of its embodiments, and although the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will be apparent to those skilled in the art. Therefore, in its broader aspects, the present application is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. For example, each spoke may be provided with a rubber coating to cushion the impact when contact occurs between adjacent spokes, or to reduce friction or wear during such contact. Therefore, departures from such details may be made without departing from the spirit or scope of the applicant's overall inventive concept.

Claims

1. A non-pneumatic tire, comprising: a lower ring having a first diameter, an upper ring having a second diameter, the upper ring being substantially coaxial with the lower ring; as well as a support structure connecting the lower ring to the upper ring, the support structure being comprised of a plurality of spokes arranged into at least a first spoke set and a second spoke set axially spaced from the first spoke set, each of the plurality of spokes comprising: connected to a first end of the lower ring; A second end connected to the upper ring; and A toggle portion is located between the first end and the second end, the toggle portion being concavely curved relative to the lower ring.

2. The non-pneumatic tire of claim 1, wherein the spokes of the first spoke set are concavely curved relative to a first circumferential direction of the tire, and the spokes of the second spoke set are convexly curved relative to the first circumferential direction of the tire.

3. The non-pneumatic tire of claim 1, wherein each of the plurality of spokes further comprises a flex member attached to the spoke and the upper ring to connect the second end of the spoke to the upper ring. 4 . The non-pneumatic tire according to claim 1 , wherein each of the plurality of spokes further comprises a connecting portion connecting the toggle portion to the second end, the connecting portion being bent.

5. The non-pneumatic tire of claim 1, wherein each of the plurality of spokes further comprises a transition portion between the first end and the toggle portion, the transition portion being convexly curved relative to the lower ring.

6. The non-pneumatic tire of claim 5, wherein each of the plurality of spokes further comprises a foot extending from the transition portion, the foot attached to the lower ring to connect the first end of the spoke to the lower ring, the foot being substantially linear.

7. The non-pneumatic tire of claim 5, wherein each of the plurality of spokes further comprises a foot extending from the transition portion, the foot being attached to the lower ring to connect the first end of the spoke to the lower ring, the foot being substantially curved and having a first radius of curvature substantially equal to a second radius of curvature of the lower ring.

8. The non-pneumatic tire of claim 5, wherein a base plane intersects the transition portion and the second end of the spoke, and a first angle is defined as the angle between the base plane and a plane extending tangentially to the lower ring at the transition portion, the first angle having a value between -30 degrees and +20 degrees.

9. The non-pneumatic tire of claim 8, wherein a first distance is defined as a distance between the transition portion and the second end of the spoke in a direction parallel to the base plane, the first distance having a value between 10 inches and 25 inches (25 cm to 63.5 cm), a second distance is defined as a distance between the transition portion and the center of a radius of curvature of the toggle portion in a direction parallel to the base plane, the second distance having a value between 20% and 70% of the value of the first distance, and a third distance is defined as a maximum distance between the base plane and the toggle portion in a direction perpendicular to the base plane, the third distance having a value between 2 inches and 4 inches (5 cm to 10 cm).

10. The non-pneumatic tire of claim 1, wherein the non-pneumatic tire is arranged and configured such that at least three adjacent spokes of the plurality of spokes contact each other upon a high impact event.

11. A method of manufacturing a non-pneumatic tire, the method comprising the steps of: providing a lower ring having a first diameter and an upper ring having a second diameter greater than the first diameter; forming a plurality of spokes, each spoke extending between a first end and a second end, each spoke including a toggle portion located between the first end and the second end; arranging the plurality of spokes into a first spoke group and a second spoke group axially spaced from the first spoke group; as well as The lower ring is connected to the upper ring using the first and second spoke sets.

12. The method of manufacturing a non-pneumatic tire according to claim 11, wherein arranging the plurality of spokes into the first spoke group and the second spoke group comprises: The spokes of the first spoke set are arranged to be concavely curved relative to a first circumferential direction of the tire, and the spokes of the second spoke set are arranged to be convexly curved relative to the first circumferential direction of the tire.

13. The method for manufacturing a non-pneumatic tire according to claim 11, further comprising the steps of: Attaching a flex member to each spoke and attaching the flex member to the upper ring, wherein attaching the flex member to the upper ring connects the second ends of the spokes to the upper ring during connection of the lower ring to the upper ring.

14. The method of manufacturing a non-pneumatic tire according to claim 11, wherein each spoke further comprises a transition portion between the first end and the toggle portion, the toggle portion and the transition portion being concavely curved in opposite facing directions.

15. The method of manufacturing a non-pneumatic tire according to claim 15, wherein forming the plurality of spokes further comprises: A foot is formed extending from the transition portion and the foot is attached to the lower ring, wherein attaching the foot to the lower ring connects the first end of the spoke to the lower ring during connection of the lower ring to the upper ring.

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