Non-pneumatic tire comprising cord reinforcement spokes

Abstract

The present invention relates to a non-pneumatic tire comprising: a radially outer circumferential band portion comprising a tread; a radially inner hub portion; and a support structure including a plurality of spokes extending between the hub portion and the circumferential belt portion. At least one spoke of the plurality of spokes includes a radially inner head portion, a radially outer foot portion, and a cord reinforcement wound between the foot portion and the head portion of the spoke. In another aspect, at least two adjacent spokes are reinforced by a common cord reinforcement extending at least from a radially outer foot portion to a radially inner head portion of the spokes, and further extends through the radially inner ring portion into the radially inner head portion of the adjacent spoke and further to the radially outer foot portion of the adjacent spoke. Another aspect provides a method for manufacturing such a tire.

Description

Technical Field

[0001] The present invention relates to a non-pneumatic tire including spokes, in particular cord-reinforced spokes. In addition, the present invention relates to a method of manufacturing a non-pneumatic tire including cord-reinforced spokes. Background Art

[0002] Some non-pneumatic tires include a support structure disposed between a tread band and a hub portion, wherein the support structure includes a plurality of spokes. In some cases, such spokes include a polymer material. To improve the durability of the spokes of a non-pneumatic tire, the spokes can be reinforced by cords or fiber materials. Although progress has been made in providing polymer spokes for non-pneumatic tires in the past few years, there is still much room for improvement. Summary of the Invention

[0003] In a first aspect, the present invention relates to a non-pneumatic tire including: a radially outer circumferential band portion including a tread; a radially inner hub portion; and a support structure including a plurality of spokes extending between the hub portion and the circumferential band portion. At least one of the plurality of spokes includes a radially inner head portion adjacent to the hub portion and a radially outer foot portion adjacent to the circumferential band portion, wherein the at least one spoke further includes a cord reinforcement wound between the foot portion and the head portion of the spoke.

[0004] In a second aspect, the present invention relates to a non-pneumatic tire including: a radially outer circumferential band portion including a tread; a radially inner hub portion; and a support structure radially disposed between the band portion and the hub portion. In addition, the support structure includes a radially outer ring portion, a radially inner ring portion, and a plurality of spokes extending from the radially outer ring portion to the radially inner ring portion. Also according to the second aspect, each spoke has a radially inner head portion and a radially outer foot portion, wherein at least two adjacent spokes of the plurality of spokes are reinforced by a common cord reinforcement, and wherein the cord reinforcement extends at least from the radially outer foot portion of one of the at least two adjacent spokes into the radially inner head portion of the one of the at least two adjacent spokes. In addition, the cord reinforcement further extends through the radially inner ring portion into the radially inner head portion of the other of the at least two adjacent spokes and further extends within the other spoke to the radially outer foot portion of the other spoke.

[0005] In a third aspect, the present invention relates to a method of manufacturing a non-pneumatic tire, wherein the tire comprises: a radially outer circumferential band portion including a tread; a radially inner hub portion; and a support structure including a plurality of cord-reinforced spokes extending between the hub portion and the circumferential band portion. Further, the spokes have a radially inner head portion and a radially outer foot portion. The method comprises the steps of: providing a mold member for molding at least a circumferential sector of the support structure, the circumferential sector including one or more of the spokes; winding a cord reinforcement between the radially outer foot portion and the radially inner head portion of one or more of the spokes in the circumferential sector of the support structure to be molded; and overmolding the cord reinforcement with a polymer composition to obtain a circumferential sector of the support structure including one or more of the spokes.

[0006] The present invention further includes at least the following technical solutions:

[0007] Solution 1. A non-pneumatic tire, the non-pneumatic tire comprising:

[0008] a radially outer circumferential band portion including a tread,

[0009] a radially inner hub portion,

[0010] a support structure including a plurality of spokes extending between the hub portion and the circumferential band portion,

[0011] wherein at least one of the plurality of spokes includes a radially inner head portion adjacent to the hub portion and a radially outer foot portion adjacent to the circumferential band portion, and

[0012] wherein the spokes include a cord reinforcement wound between the foot portion and the head portion of the spokes.

[0013] Solution 2. The tire according to Solution 1, wherein the spokes include a polymer composition, and wherein the cord reinforcement extends within the polymer composition.

[0014] Solution 3. The tire according to Solution 1, wherein the spokes include an X-shaped cross-section having pairs of radially outer legs, pairs of radially inner legs, a cross-over portion connecting the pairs of radially outer legs and the pairs of radially inner legs, a radially inner connecting portion connecting the radially inner ends of the radially inner legs, and a radially outer connecting portion connecting the radially outer ends of the radially outer legs.

[0015] Solution 4. The tire according to Solution 3, wherein the cord reinforcement at least

[0016] Extending from the radially inner end of one of the radially inner legs through said one of the radially inner legs,

[0017] further extending through the cross - over portion into one of the radially outer legs,

[0018] further extending through said one of the radially outer legs to the radially outer end portion of said one of the radially outer legs,

[0019] further extending through the radially outer connecting portion to the radially outer end portion of the other leg of the pair of radially outer legs,

[0020] further extending through said other leg of the pair of radially outer legs towards and through the cross - over portion into the other leg of the pair of radially inner legs, and

[0021] further extending to the radially inner end portion of said other leg of the pair of radially inner legs.

[0022] Aspect 5. The tire according to Aspect 3, wherein the cord reinforcement passes through the cross - over portion at least twice, and wherein the cord reinforcement extends transversely to itself in the cross - over portion.

[0023] Aspect 6. The tire according to Aspect 1, wherein the spokes comprise one or more polymer compositions selected from one or more of a thermoplastic composition and an elastomeric composition, the polymer composition being reinforced by a cord reinforcement; and wherein the cord reinforcement comprises at least one cord, the at least one cord comprising one or more of the following: textile material, glass fiber material, carbon fiber material, boron fiber material, basalt fiber material, plant - based material, and combinations of these materials.

[0024] Aspect 7. The tire according to Aspect 1, wherein the cord reinforcement is wound multiple times between the foot portion and the head portion of the spoke, and wherein the multiple passes of the cord reinforcement between the foot portion and the head portion are spatially separated from each other between the foot portion and the head portion.

[0025] Aspect 8. A non - pneumatic tire, the non - pneumatic tire comprising:

[0026] a radially outer circumferential band portion, the radially outer circumferential band portion comprising a tread;

[0027] a radially inner hub portion;

[0028] A support structure, the support structure being arranged radially between the belt portion and the hub portion and including a radially outer ring portion, a radially inner ring portion, and a plurality of spokes extending from the radially outer ring portion to the radially inner ring portion,

[0029] wherein each of the spokes has a radially inner head portion and a radially outer foot portion, and

[0030] wherein at least two adjacent spokes of the plurality of spokes are reinforced by a common cord reinforcement, wherein the cord reinforcement extends at least from the radially outer foot portion of one of the two adjacent spokes within the one of the two adjacent spokes to the radially inner head portion of the one of the two adjacent spokes, and further extends through the radially inner ring portion into the radially inner head portion of the other spoke of the two adjacent spokes and further extends within the other spoke to the radially outer foot portion of the other spoke.

[0031] Aspect 9. The tire according to Aspect 8, wherein the cord reinforcement extends through and reinforces most of the spokes of the tire.

[0032] Aspect 10. The tire according to Aspect 8, wherein the cord reinforcement extends through at least four adjacent spokes in a circumferential sector of the support structure.

[0033] Aspect 11. The tire according to Aspect 8, wherein the two adjacent spokes each have an X-shaped cross-section having a pair of radially outer legs, a pair of radially inner legs, and an intersection portion connecting the pair of radially outer legs and the pair of radially inner legs.

[0034] Aspect 12. The tire according to Aspect 11, wherein the cord reinforcement extends through a first radially outer leg of the first of the two adjacent spokes, further extends through the intersection portion of the first spoke, further extends through a first radially inner leg of the first spoke, and extends into the radially inner ring portion, and extends from the radially inner ring portion into a first radially inner leg of the second spoke of the two adjacent spokes, further extends through the intersection portion of the second spoke, and extends into a first radially outer leg of the second spoke.

[0035] Solution 13. The tire according to Solution 12, wherein the cord reinforcement extends around the tire from the radially outer leg of the second spoke through additional spokes of the tire, and wherein the cord reinforcement further extends into the second radially inner leg of the first of the two adjacent spokes, further extends through the cross - over portion of the first spoke and through the second radially outer leg of the first spoke into the radially outer ring portion, and extends from the radially outer ring portion into the second radially outer leg of the second spoke, further extends through the cross - over portion of the second spoke and into the second radially inner leg of the second spoke.

[0036] Solution 14. The tire according to Solution 11, wherein the cord reinforcement extends through the cross - over portion of each of the two adjacent spokes at least twice, and wherein the cord reinforcement extends transversely to itself through the cross - over portion.

[0037] Solution 15. The tire according to Solution 8, wherein the cord reinforcement extends around the tire at least twice so as to extend through each spoke at least twice, and wherein when passing through each spoke twice, the cord reinforcement is spatially separated from itself.

[0038] Solution 16. A method of manufacturing a non - pneumatic tire, the tire comprising:

[0039] a radially outer circumferential band portion, the radially outer circumferential band portion including a tread,

[0040] a radially inner hub portion, and

[0041] a support structure, the support structure including a plurality of cord - reinforced spokes extending between the hub portion and the circumferential band portion, wherein the spokes have a radially inner head portion and a radially outer foot portion; and

[0042] wherein the method comprises the steps of:

[0043] providing a mold member for molding at least a circumferential sector of the support structure, the circumferential sector including one or more of the spokes;

[0044] wrapping a cord reinforcement between the radially outer foot portion and the radially inner head portion of one or more of the spokes in the circumferential sector of the support structure to be molded; and

[0045] overmolding the cord reinforcement with a polymer composition to obtain the circumferential sector of the support structure including one or more of the spokes.

[0046] Solution 17. The method according to Solution 16,

[0047] wherein the step of winding the cord reinforcement includes winding the cord reinforcement at least from one of the radially outer foot portion and the radially inner head portion of the first spoke to the other of the radially outer foot portion and the radially inner head portion of the first spoke, and further winding again from the other of the radially outer foot portion and the radially inner head portion of the first spoke to the one of the radially outer foot portion and the radially inner head portion of the first spoke, and winding again from the one of the radially outer foot portion and the radially inner head portion of the first spoke to the other of the radially outer foot portion and the radially inner head portion.

[0048] Solution 18. The method according to Solution 16,

[0049] wherein winding the at least one cord reinforcement includes winding the cord reinforcement from the radially outer foot portion of the first spoke to the radially inner head portion of the first spoke, and from the radially inner head portion of the first spoke to the radially inner head portion of an adjacent second spoke, from the radially inner head portion of the second spoke to the radially outer foot portion of the second spoke, from the radially outer foot portion of the second spoke to the radially outer foot portion of a third spoke, the third spoke being adjacent to the second spoke on a side opposite the first spoke along the circumferential sector of the support structure.

[0050] Solution 19. The method according to Solution 18, wherein the method includes: winding the cord reinforcement around the tire through additional spokes of the support structure.

[0051] Solution 20. The method according to Solution 19, wherein after winding the cord reinforcement around the tire through the additional spokes of the support structure, the cord reinforcement extends back into the first spoke. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] The present invention will be described by way of example and with reference to the accompanying drawings, in which:

[0053] Figure 1 is a schematic side view of an embodiment of a non-pneumatic tire including a support structure according to an embodiment of the present invention;

[0054] Figure 2 is a schematic cross-section of a cord-reinforced spoke according to an embodiment of the present invention;

[0055] Figure 3is a schematic partial transparent cross-section of another cord-reinforced spoke according to another embodiment of the present invention;

[0056] Figure 4 is a schematic cross-section of another cord-reinforced spoke according to yet another embodiment of the present invention;

[0057] Figure 5a is a partial schematic perspective cross-section of a mold for molding a cord-reinforced spoke including an X shape according to an embodiment of the present invention;

[0058] Figure 5b is a schematic cross-section of another mold for molding a cord-reinforced spoke including an X shape according to another embodiment of the present invention;

[0059] Figure 6 is a schematic perspective view of a circumferential sector of a support structure according to yet another embodiment of the present invention, the circumferential sector including a plurality of spokes;

[0060] Figure 7 is Figure 6 a schematic cross-section of the sector of the support structure already shown in;

[0061] Figure 8 is a schematic partial transparent cross-section of a circumferential sector of a support structure according to another embodiment of the present invention, the circumferential sector including two reinforcing cords;

[0062] Figure 9 is a schematic cross-section of a circumferential sector of a support structure including a plurality of cords that connect circumferentially adjacent legs of two adjacent spokes to each other; and

[0063] Figure 10 is another schematic cross-section of a circumferential sector of a support structure including I-shaped spokes that are connected and reinforced by a common cord. Detailed Description

[0064] According to a first aspect, a non-pneumatic tire comprises: a radially outer circumferential belt portion including a (circumferential) tread or tread portion; a radially inner (circumferential) hub portion; and a (circumferential) support structure including a plurality of spokes extending between the hub portion and the circumferential belt portion, particularly along the circumferential direction. At least one of the plurality of spokes includes a radially inner head portion adjacent to the hub portion and a radially outer foot portion adjacent to the circumferential belt portion, wherein the at least one spoke further includes a cord reinforcement which preferably continuously winds (e.g., multiple times) between the foot portion and the head portion of the spoke. In particular, providing a continuously extending and / or winding cord reinforcement helps to provide an advanced support structure, its circumferential sectors, and / or spokes with improved durability. Spoke deformation, such as plastic deformation, can be reduced or avoided. In addition, such tires, support structures, their circumferential sectors, and / or spokes can be manufactured on a large scale and / or cost-effectively.

[0065] In one embodiment, the spoke comprises a polymer composition. Preferably, the cord reinforcement extends within the polymer composition. Optionally, the spoke can be described as a cord-reinforced polymer composition spoke.

[0066] In yet another embodiment, in a plane parallel to the tire equatorial plane, one or more of the spokes and / or the spokes of the support structure (such as, most or all of the spokes) include or have a cross-section of one or more of the following: X shape, V shape, C shape, I shape, H shape, O shape, S shape, Y shape, half X shape, and one or more of the curved and kinked shapes / forms of the above shapes. Preferably, the shape is an X shape, such as a straight or curved X shape. Another preferred shape is a half X shape, particularly corresponding to an X shape cut substantially along the radial direction. It is also possible to refer to such a shape as an angled bracket shape or a V-shaped shape, where the kink thereof is not necessarily at the radial center of the shape.

[0067] In another embodiment, the spoke includes or has an X-shaped cross-section (observed in a plane parallel to the tire equatorial plane or a plane parallel to the tire centerline or the like), which preferably has one or more of the following: a pair of radially outer legs, a pair of radially inner legs, and a cross portion connecting the pair of radially outer legs and the pair of radially inner legs. Preferably, the spoke further has one or more of the following: a radially inner connecting portion connecting the radially inner ends of the radially inner legs, and a radially outer connecting portion connecting the radially outer ends (such as, in the circumferential direction) of the radially outer legs. It should be emphasized that it is possible that the X shape can be bent, straight, symmetric, or asymmetric. In particular, one or more of the legs can include one or more of straight, kinked, and bent shapes, for example, in the cross-section.

[0068] In yet another embodiment, the cord reinforcement extends at least from the radially inner end of one of the radially inner legs through said one of the radially inner legs, further through the crossover portion into one of the radially outer legs, further through said one of the radially outer legs to the radially outer end portion of said one of the radially outer legs, and optionally further through the radially outer connecting portion to the radially outer end portion of the other leg of the pair of radially outer legs. And optionally, the cord reinforcement further extends through said other leg of the pair of radially outer legs towards and / or further through the crossover portion into the other leg of the pair of radially inner legs. As a further option, the cord reinforcement further extends to the radially inner end portion of said other leg of the pair of radially inner legs. Such a configuration is particularly durable.

[0069] In yet another embodiment, the cord reinforcement passes through or traverses the crossover portion at least twice. Optionally, the cord reinforcement extends through the crossover portion in a manner transverse to itself and / or spaced apart from itself (relative to the axial direction). Optionally, the cord reinforcement consists of at least one cord and / or a cord reinforcing tape. Such options may also be applicable to other embodiments herein.

[0070] In yet another embodiment, the spoke comprises a polymer composition comprising one or more of an elastomeric composition (preferably, a rubber composition) and a thermoplastic polymer, and the polymer composition is optionally reinforced by a cord reinforcement (such as at least one cord).

[0071] In yet another embodiment, the polymer may be one or more of the following: i) one or more polyamide polymers (such as, PA-12, PA-11, PA-6); ii) one or more thermoplastic polymers, such as thermoplastic polyester elastomers, thermoplastic polyurethane elastomers, polyamide thermoplastic elastomers, elastomer alloy thermoplastic vulcanizates, thermoplastic polyolefin elastomers, styrenic thermoplastic elastomers, thermoplastic resins (such as, polyester resins, polyamide resins or polyurethane resins). In particular, the term thermoplastic polymer shall also include thermoplastic resins herein.

[0072] In yet another embodiment, the thermoplastic polymer is a thermoplastic elastomer, such as a thermoplastic polyester elastomer.

[0073] In another preferred embodiment, the polymer composition is an elastomeric composition, such as a rubber composition. Optionally, the elastomeric composition (such as, a rubber composition) comprises one or more of the following: rubber (such as, comprising one or more of natural rubber, synthetic polyisoprene, butadiene rubber, styrene-butadiene rubber, and butyl rubber), filler (such as, comprising one or more of carbon black and silica), resin (such as, hydrocarbon resins selected from one or more of the following: coumarone-indene resin, petroleum hydrocarbon resin, terpene resin, styrene / α-methylstyrene resin, terpene phenol resin, rosin-derived resin, and their copolymers and / or mixtures), accelerator, anti-degradant, oil, liquid diolefin polymer, coupling agent (such as, carbon black coupling agent and / or silane), sulfur donor, and sulfur. Liquid herein means the material is in a liquid state at 23 °C. The composition can be a sulfur-curable or sulfur-cured rubber composition. Optionally, the elastomeric composition (such as, a rubber composition) can be fiber-reinforced.

[0074] In yet another embodiment, the elastomeric composition or rubber composition comprises 100 phr of rubber, which comprises one or more of natural rubber, synthetic polyisoprene, polybutadiene rubber, and styrene-butadiene rubber. Preferably, the composition comprises at least 50 phr of natural rubber (such as, from 50 phr to 100 phr of natural rubber), and optionally from 0 phr (or 5 phr) to 50 phr of polybutadiene rubber. Additionally, the elastomeric or rubber composition comprises filler, preferably comprising carbon black and / or silica. For example, such filler can be in the range of 20 phr to 150 phr, preferably in the range of 30 phr to 90 phr. Preferably, such filler mainly comprises carbon black. The elastomeric or rubber composition can further comprise from 1 phr to 40 phr of resin, preferably comprising phenolic resin. In addition, the elastomeric or rubber composition can comprise from 1 phr to 30 phr of oil, preferably from 1 phr to 20 phr of oil. Finally, the elastomeric or rubber composition can generally comprise from 1 phr to 15 phr of anti-degradants, from 0.5 phr to 10 phr of accelerators, from 0.1 phr to 10 phr of zinc oxide, and from 0.5 phr to 10 phr of sulfur. Additional components can also be present.

[0075] In yet another embodiment, the spoke can comprise a plurality of polymer compositions, such as multiple layers or portions of such compositions.

[0076] In yet another embodiment, the cord reinforcement is selected from one or more of the following: i) at least one cord, ii) at least one cord reinforcement tape, and iii) at least one fabric comprising cords. In one option, the cord reinforcement comprises or consists of at least one cord. Preferably, the cord is one of a multifilament cord and a monofilament cord. In another option, the cord reinforcement tape comprises a plurality of substantially parallel cords, which are optionally embedded in and / or joined by a polymer composition (such as a resin composition) to form a tape, and the polymer composition may comprise one or more of polyester, vinyl ester, polyurethane, and epoxy resin. In another option, the fabric may comprise a plurality of (preferably interconnected) substantially parallel cords. Optionally, these cords may form the warp cords and / or weft cords of the fabric.

[0077] In yet another embodiment, the cord reinforcement, particularly one or more cords of the cord reinforcement, comprises or consists of one or more of the following: textile material, glass fiber material, carbon fiber material, boron fiber material, basalt fiber material, plant-based material, and combinations of these materials. Optionally, the plurality of cords comprises different materials and / or is a hybrid cord of such different materials. Optionally, the plant-based material comprises one or more of cotton, hemp, flax, sisal, and bast.

[0078] In yet another embodiment, the cord reinforcement, particularly one or more cords of the cord reinforcement, comprises or consists of metal, such as steel or steel coated with brass.

[0079] In yet another embodiment, the cord reinforcement, particularly one or more cords of the cord reinforcement, comprises or consists of textile material selected from one or more of the following: polyester (preferably, PET), polyamide (preferably, PA-6, PA-6,6 (e.g., Nylon TM ), aramid), and man-made fiber. Optionally, one or more of these materials may be recycled materials. Optionally, the plurality of cords comprises different materials and / or is a hybrid cord of such different materials.

[0080] In another embodiment, one or more cords provided herein are one of a monofilament cord and a multifilament cord. For example, the cord may have a (maximum) diameter measured perpendicular to the extension of the cord in the spoke, and the (maximum) diameter is in the range of 0.01 mm to 2 mm, preferably in the range of 0.01 mm to 1 mm.

[0081] In yet another embodiment, the cord reinforcement is wound multiple times between the foot portion and the head portion, and / or multiple passes of the cord reinforcement between the foot portion and the head portion are spaced apart spatially (and / or axially) from each other between the foot portion and the head portion. It should be noted that the winding or passing of the cord reinforcement between the foot portion and the head portion does not exclude the cord reinforcement from winding around and / or passing through said portions. Optionally, the cord reinforcement passes through said portions, or multiple cord reinforcements pass through said portions.

[0082] According to a second aspect, the present invention relates to a non-pneumatic tire comprising: a radially outer circumferential belt portion including a (circumferential) tread or tread portion; a radially inner (circumferential) hub portion; and a support structure radially disposed between the belt portion and the hub portion. Further, the support structure includes a radially outer (circumferential) ring portion, a radially inner (circumferential) ring portion, and a plurality of spokes extending from the radially outer ring portion to the radially inner ring portion (preferably extending along the circumferential direction). Again according to the second aspect, each spoke has a radially inner head portion and a radially outer foot portion, wherein at least two (circumferentially) adjacent spokes of the plurality of spokes are reinforced by a common cord reinforcement, and wherein the cord reinforcement extends at least from the radially outer foot portion of one of the two adjacent spokes within the spoke to the radially inner head portion of one of the adjacent spokes. Further, the cord reinforcement further extends through the radially inner ring portion into the radially inner head portion of another of the adjacent spokes and further extends within the another spoke to the radially outer foot portion of the another spoke. Thus, such adjacent spokes and the corresponding ring portions are reinforced by a common cord reinforcement, which improves the durability of the support structure or its circumferential sector. Deformation of the support structure and / or spoke deformation (such as plastic deformation) can be reduced or avoided. Further, such tires, support structures, and / or spokes can be manufactured on a large scale.

[0083] In one embodiment, the cord reinforcement extends through and / or reinforces most of the spokes of the tire.

[0084] In another embodiment, the cord reinforcement extends through a plurality of spokes along a circumferential sector of the tire and / or the support structure or its circumferential sector.

[0085] In another embodiment, the cord reinforcement extends through at least 3, 4, 5, or 6 spokes of the tire and / or the support structure or its circumferential sector.

[0086] In yet another embodiment, the cord reinforcement extends around the tire at least twice so as to extend through each spoke at least twice. Preferably, when extending through the same spoke for the second time, the cord reinforcement is axially spaced from itself within the spoke, such as being separated by the polymer composition of the spoke. Optionally, the cord reinforcement consists of at least one cord and / or a cord reinforcing band.

[0087] In yet another embodiment, the cord reinforcement extends multiple times between two circumferential end portions of a circumferential sector of the support structure, optionally extending multiple times (e.g., twice) through each spoke within the sector.

[0088] In yet another embodiment, two adjacent spokes each include an X-shaped cross-section having one or more of the following: a pair of radially outer legs, a pair of radially inner legs, and an intersection portion connecting the pair of radially outer legs with the pair of radially inner legs.

[0089] In yet another embodiment, the cord reinforcement extends through one or more of the first radially outer legs of the first of two (circumferentially) adjacent spokes, further extends through the intersection portion of the first spoke, further extends through the first radially inner leg of the first spoke and into the radially inner ring portion, and optionally extends from the radially inner ring portion into the first radially inner leg of the second spoke of the adjacent spoke, and further extends through the intersection portion of the second spoke and into the first radially outer leg of the second spoke.

[0090] In yet another embodiment, the cord reinforcement (further) optionally extends around the tire from the radially outer leg of the second spoke through additional spokes of the tire. Preferably, the cord reinforcement extends into the second radially inner leg of the first of two adjacent spokes, further extends through the intersection portion of the first spoke and through the second radially outer leg of the first spoke into the radially outer ring portion, and extends from the radially outer ring portion into the second radially outer leg of the second spoke, further extends through the intersection portion of the second spoke and into the second radially inner leg of the second spoke.

[0091] In yet another embodiment, the cord reinforcement extends through the intersection portion of each of two adjacent spokes at least twice. Preferably, the cord reinforcement extends through the intersection portion in a manner transverse to itself and / or axially spaced from itself.

[0092] In yet another embodiment, the cord reinforcement that extends through each spoke at least twice is spatially (such as axially) separated from itself.

[0093] According to a third aspect, a method of making or manufacturing a non-pneumatic tire, where the tire includes a support structure that includes cord-reinforced spokes, includes the steps of: providing a mold member for molding at least a circumferential sector of the support structure, the circumferential sector including one or more of the spokes. Additionally, the method includes the steps of: winding a cord reinforcement between a radially outer foot portion and a radially inner head portion of one or more of the spokes in the circumferential sector of the support structure to be molded. Also according to the third aspect, the method includes the steps of: overmolding the cord reinforcement with a polymer composition to obtain a circumferential sector of the support structure that includes one or more of the spokes.

[0094] Optionally, the method is for making a tire according to the first aspect or the second aspect and optionally according to one or more corresponding embodiments.

[0095] In one embodiment of the method, the step of winding the cord reinforcement includes: winding the cord reinforcement (e.g., supported by one or more of the mold segments) at least from one of a radially outer foot portion and a radially inner head portion of a first spoke to the other of the radially outer foot portion and the radially inner head portion of the first spoke, and optionally further again from the other of the radially outer foot portion and the radially inner head portion of the first spoke to one of the radially outer foot portion and the radially inner head portion of the first spoke, and again from one of the radially outer foot portion and the radially inner head portion of the first spoke to the other of the radially outer foot portion and the radially inner head portion. For example, such steps can be performed to provide a spoke according to the first aspect or one or more of its embodiments.

[0096] In another embodiment, particularly before overmolding the cord reinforcement with the polymer composition, the cord reinforcement material is wound and / or supported on one or more mold members (such as mold inserts or mold core members). Winding the cord reinforcement directly on one or more mold members can provide an economical option for manufacturing. Optionally, the one or more cord reinforcements can be spaced from the surface of the mold member by one or more polymer layers.

[0097] In yet another embodiment, the cord reinforcement is held at a distance from one or more adjacent mold members (such as mold inserts or mold core members) by protrusions on these mold members, optionally so as to encapsulate the cord reinforcement at least mainly along its extension by overmolding the cord reinforcement with the polymer composition.

[0098] In yet another embodiment, the protrusions are provided at the edges of the one or more mold members. Optionally, the protrusions include curved surfaces. Such surfaces help avoid damaging the cord reinforcement.

[0099] In another embodiment, winding the at least one cord reinforcement includes: winding the cord reinforcement from a radially outer foot portion of a first spoke to a radially inner head portion of the first spoke, and from the radially inner head portion of the first spoke to a radially inner head portion of a (circumferentially) adjacent second spoke, from the radially inner head portion of the second spoke to a radially outer foot portion of the second spoke, from the radially outer foot portion of the second spoke to a radially outer foot portion of a third spoke, the third spoke being adjacent to the second spoke on a side opposite the first spoke (e.g., along a circumferential sector of the support structure). For example, such an embodiment can be used to manufacture a tire, a support structure, or a circumferential sector (e.g., as such), such as a tire, a support structure, or a circumferential sector according to the second aspect of the present invention or one or more of its embodiments.

[0100] In yet another embodiment, the support structure or at least a circumferential segment or sector of the support structure is manufactured (e.g., manufactured separately) by this method. For example, the support structure or its circumferential sector (preferably including a plurality of spokes) can be formed in a mold ring that defines the shape of the support structure. In the case of manufacturing a circumferential segment or sector of the support structure, such a segment or sector can be manufactured, for example, using a corresponding ring segment or ring sector-shaped mold.

[0101] In yet another embodiment, the method includes: winding the cord reinforcement around a circumferential sector of the tire and / or the support structure through additional spokes of the tire.

[0102] In yet another embodiment, after winding the cord around the tire through the additional spokes of the support structure, the cord reinforcement extends back into the first spoke.

[0103] Figure 1 A schematic side view of a tire 1 is shown, which has a circumferential belt or belt portion 110 that includes a circumferential tread or tread portion 10 carried by a circumferential shear belt 20. In addition, the tire 1 has a circumferential hub portion 160, wherein the circumferential belt portion 110 and / or its shear belt 20 is supported on the hub portion 160 by a support structure 140 that includes a plurality of spokes 130 along the circumferential direction. In the present embodiment, the spokes 130 include a curved X shape.

[0104] Figure 2One of these spokes 130 is shown in detail. The depicted spoke 130 includes paired radially outer legs 131, paired radially inner legs 132, and an intersection portion 133 connecting the two pairs of legs 131, 132 to each other. In addition, the radially outer legs 131 are connected by a radially outer connecting portion 134, and the radially inner legs 132 are connected by a radially inner connecting portion 135. The spoke 130 is reinforced by at least one cord 150, which is wound between a radially inner head portion 137 and a radially outer foot portion 136, here substantially in a Z-shaped winding pattern. In particular, in the present embodiment, the cord 150 is wound through the connecting portion 135 and through one of the radially inner legs 132 from this connecting portion, further through the intersection portion 133, further through one of the radially outer legs 131 and further into and through the connecting portion 134.

[0105] In a number of embodiments and / or figures herein, a circumferential direction c, an axial direction a, and a radial direction r are indicated for better orientation. The circumferential direction c is perpendicular to the axial direction a. The same applies to the radial direction r. The axial direction a is parallel to the axis of rotation of the tire. Unless otherwise described herein, such directions mentioned herein are not necessarily limited to a specific orientation of a given direction.

[0106] In Figure 3 a schematic cross-section of, another spoke 230 of a support structure according to an embodiment of the present invention is shown. The spoke 230 includes a straight X-shape. In other words, the radially inner legs 232 of the paired radially inner legs 232 and the radially outer legs 231 of the paired radially outer legs 231 extend straight. The two pairs of legs 231, 232 are radially connected to each other by an intersection portion 233. In addition, the paired radially inner legs 232 are connected by a radially inner connecting portion 235 at their radially inner portions. Similarly, the paired radially outer legs 231 are connected by a radially outer connecting portion 234 in their radially outer portions. The spoke 230 is cord-reinforced by a cord 250 that winds from the radially outer connecting portion 234 through one of the radially outer legs 231, through the intersection portion 233, and further through one of the radially inner legs 232 into the radially inner connecting portion 235, further into the second leg of the radially inner legs 232, again into the intersection portion 233, from there into the second leg of the radially outer legs 231 and into the radially outer connecting portion 234. In addition, in the present embodiment, the cord 250 crosses itself transversely in the intersection portion 233. Preferably, the cord 250 crosses itself at a distance from itself (in particular separated along the axial direction) in the intersection portion 233. Although in Figure 3is not shown in the embodiments, but it is possible that the cord is wound multiple times between the foot portion 236 and the head portion 237 of the spoke 230. A similar option is shown in Figure 5a below.

[0107] Figure 4 Another embodiment is shown that includes a portion or circumferential segment of a support structure of a spoke 330 according to another embodiment of the present invention. The spoke 330 has a radially inner head portion 337 and a radially outer foot portion 336, and the two portions are connected by a rib portion 333. In this embodiment, the rib portion 333 is curved or bent in the circumferential direction. However, in a similar embodiment, it is also possible that the cross-section of the rib portion 333 is straight or kinked (not shown in this embodiment). In the cross-section shown in Figure 4 , the cord 350 is wound between the radially inner head portion 337 and the radially outer foot portion 336. Thus, in this embodiment, the cord passes through the radial height of the rib portion 333 twice and / or extends twice within the radial height of the rib portion. Similarly, in other embodiments disclosed herein (such as those including an X-shaped cross-sectional shape), it may be mentioned that the cord reinforcement extends at least twice within the radial height of the spoke and / or passes through the radial height of the spoke at least twice. In the embodiment of Figure 4 , the cord 350 passes substantially along and through the rib portion 333. Alternatively, it may also cross itself (transversely) within the rib portion 333. Preferably, when extending through the rib portion 333 at least twice, the cord is spaced apart from itself (such as in one or more of the axial direction and the circumferential direction).

[0108] Figure 5a An embodiment is shown of manufacturing a circumferential sector of a support structure including an X-shaped spoke using a mold 400, where the cord 450 is wound multiple times between the head portion and the foot portion of the spoke to be manufactured. In particular, Figure 5a the embodiment shown in includes two mold inserts 410 and 420 around which the cord 450 is wound. These mold inserts 410 and 420 can be axially inserted into the mold cavity 470 of the mold 400 to define the outer shape of the spoke to be molded. As shown in Figure 5aAlso visible is that the cord 450 crosses itself multiple times in the crossing portion of the spokes and / or between the two die inserts 410, 420. Preferably, the cord 450 crosses itself through the spokes and / or at a distance (e.g., an axial distance) from itself. In other words, preferably, the cord 450 is spaced apart from itself along most of its length or extension. When the cord 450 and the die inserts 410, 420 are inserted into the die cavity 470, the cord 450 can be overmolded in the die cavity 470 with a polymer composition (such as, a rubber composition) or other compositions disclosed herein. In particular, it is possible that the die 400 includes one or more channels or passages (not explicitly shown) for injecting the polymer composition into the die cavity 470 or in other words into one or more gaps that are formed between the die inserts 410, 420 and the outer die member 490 that defines the die cavity 470 of the die 400.

[0109] Figure 5b Another schematically depicted embodiment of a method for manufacturing a support structure and / or a spoke including a circumferential sector with an X-shaped cross-section using a die 400' is disclosed. As Figure 5b shown in the cross-section of, the die 400' includes two die inserts 410', 420' that are inserted into the die cavity 470' of the outer die member 490' to at least partially define the outer shape of the spoke to be molded. The cord 450' is wound between two radial end portions (such as, the head portion and the base portion of the spoke to be molded) on the die inserts 410' and 420'. Additionally, for the previous Figure 5aIn the design shown, the die inserts 410', 420' include protrusions, spacers or, in other words, bulges 480' at their (axially extending) edges, which are adapted to space the cord 450' wound around the die inserts 410', 420' from the side surfaces of the die inserts 410', 420'. Preferably, the cord 450' is positioned substantially centrally between the adjacent surfaces of the respective die inserts 410', 420' and the adjacent surface of the outer die member 490' (the adjacent surface facing the respective die inserts 410', 420'). Thus, areas where the cord 450' may appear at the surface of the spokes can be reduced and / or avoided. Once the cord 450' has been positioned in the die cavity 470' and optionally tensioned on the die inserts 410', 420', the remaining space or (multiple) gaps of the die cavity 470' can be filled with one or more polymer compositions in order to overmold the cord 450' and form the spokes. For overmolding, the die 400' is preferably closed at one or both of its axial side and / or face side. Additionally, as another option, the die 400' may have one or more inlets and / or channels for injecting one or more polymer compositions into the die cavity 470'. It is also possible to inject different polymer compositions in order to provide a spoke having more than just one polymer composition in one or more of the width, height and length of the spoke. The above also applies to the previous embodiments.

[0110] Figure 6 A schematic perspective view shows a circumferential sector of the support structure 540, which includes six spokes 530 extending radially between a radially inner ring portion 545 and a radially outer ring portion 544. In the present embodiment, each spoke includes an X-shaped cross-section in a plane parallel to the tire equatorial plane or the circumferential centerline of the tire, respectively. For example, a plurality of such circumferential sectors 540 of the support structure may be manufactured. Such sectors 540 can be assembled later to form a complete circumferential support structure. In particular, it is possible that such sectors 540 can be molded, for example, with an uncured rubber composition and later cured or co-cured together with additional sectors to form a (complete) annular support structure. It is also possible that other uncured components of the non-pneumatic tire are assembled with the support structure or its sectors and later co-cured together. Additionally, or alternatively, adhesives may be used to attach and / or connect the various parts and / or components of the tire, as is known per se to those skilled in the art. Figure 6 The sector 540 shown in is reinforced with one or more cords (extending inside the spokes 530 and not visible in the Figure 6 perspective view).

[0111] In this context, Figure 7 showsFigure 6 Schematic cross-section of a sector, wherein the cord 550 extends from one circumferential end of the sector 540 through a plurality (in this case all) of the spokes 530 to the second circumferential end of the sector 540. In particular, the cord 550 extends from the left hand side or, in other words, from the first circumferential end of the radially outer ring portion 544 through the first leg 531 of the spoke 530, further through its crossing portion into its radially inner leg 532 and further into the radially inner ring portion 545. From there, the cord extends into the radially inner leg 532' of the second adjacent or neighboring spoke, further into its crossing portion, and into one of its radially outer legs 531' and then continuously into the radially outer ring portion 544. As Figure 7 can be seen, such a cord trajectory through the spoke 530 continues along the circumferential sector 540. Thus, adjacent spokes 530 are interconnected by the same cord 550, which can significantly improve the durability of the support structure and / or its spokes 530. It also improves the connection between the two ring portions 545, 544 and the adjacent spokes 530 connecting these ring portions 545, 544.

[0112] Figure 8 shows an alternative embodiment of a segment similar to the segment already shown in Figure 7 . According to Figure 8 , the support structure segment or sector 640 includes two cords 650, 650'. The depicted sector 640 includes a plurality of spokes 630 that connect the radially inner ring portion 645 and the radially outer ring portion 644. The cord 650 extends through the sector 640 in a manner similar to the cord 550 in the Figure 7 previous embodiment. However, additionally, Figure 7 the cord 650' also extends through the sector 640. In this non-limiting embodiment, the cord 650' extends from the radially inner ring portion 645 through the radially inner leg 632 of the first spoke 630, through its crossing portion 633 into its radially outer leg portion 631, further into the radially outer ring portion 644, from this ring portion 644 into the radially outer leg of an adjacent additional spoke 630, from this adjacent radially outer leg through the crossing portion of the adjacent spoke 630, and from this crossing portion and through the radially inner leg towards the radially inner ring portion 645 of the sector 640. It should be noted that the cords 650 and 650' cross each other in each of the spokes 630 (especially in the crossing portions), preferably with an axial distance between them. Such an arrangement of the cords 650, 650' helps to significantly improve the durability of the sector 640 of the support structure. Optionally, but not shown herein, it may be possible to use only a single cord to achieve a similar effect. In particular, such a cord may travel or extend back within the same sector, or may extend multiple times within the sector of the support structure.

[0113] Figure 9 Another embodiment of the support structure or only its circumferential segment or sector 740 is shown. The geometry of the sector 740 is similar to the geometry of the sectors already shown in Figure 7 and Figure 8 However, in contrast to these previous embodiments, the sector 740 according to Figure 9 includes a plurality of cords, namely cords 750, 751, 752, 753, 754, 755 and 756. In particular, such cords substantially form an annular cord reinforcement that connects and / or reinforces the circumferentially adjacent legs of adjacent spokes 730. In the embodiment depicted in Figure 9 two separate cords pass through each intersection of the respective spokes. In particular, these two cords are circumferentially separated from each other. However, it is also possible that these two cords are axially separated and overlap or cross in the circumferential direction. Considering one of the cords (such as cord 751), cord 751 extends from the radially outer ring portion 744 into the radially outer leg of an adjacent spoke, further extends through the adjacent intersection, and further extends towards the radially inner ring portion 745 by passing through the radially inner leg, and extends from the radially inner ring portion 745 through the radially inner leg of an adjacent spoke, further extends into the intersection of the same spoke, further extends into the radially outer leg of the same spoke, and extends back towards its opposite end portion into the radially outer ring portion 744.

[0114] Figure 10 Yet another embodiment of the circumferential sector 840 of the support structure is shown, where the sector 840 includes I-shaped spokes 830. These spokes 830 extend between a radially inner ring portion 845 and a radially outer ring portion 844 so as to support the radially outer ring portion 844 on the radially inner ring portion 845. According to this embodiment, a cord 850 extends through a plurality (such as all) of the spokes 830, for example, as shown in a undulating path between the two ring portions 845, 844. Thus, each of the spokes 830 is reinforced by the same cord 850, which supports the overall stability and durability of the sector 840 of the support structure.

[0115] Although not shown in the embodiments above, another embodiment consists in that a plurality of circumferential rows of spokes are arranged axially beside each other, such as two, three or four such rows. The circumferential position of such spokes may be the same or circumferentially shifted for different rows.

[0116] The mold, mold insert and / or mold member are preferably provided with one or more temperature-resistant materials, the melting point of the temperature-resistant materials being, for example, higher than 200 °C, preferably higher than 300 °C. Plastic, ceramic or metallic materials are non-limiting examples of such mold materials.

[0117] Broadly speaking, the present invention and its embodiments provide durable spokes, durable sectors of the support structure, and / or a durable support structure. Potential plastic deformation of the spokes can be avoided or at least reduced. The cord reinforcement can be placed in a defined manner and / or allows for mass production, particularly in a cost-effective manner.

[0118] It should be emphasized that the aspects, embodiments, and features disclosed herein can be combined with one another.

[0119] Based on the description of the present invention provided herein, variations within the present invention are possible. Although certain representative embodiments and details have been shown for the purpose of illustrating the present invention, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the scope of the present invention. Accordingly, it will be understood that changes can be made in the specific embodiments described, which will fall within the full intended scope of the present invention as defined by the following appended claims.

Claims

1. A non-pneumatic tire, comprising: a radially outer circumferential belt portion comprising the tread, The radially inner hub portion, a support structure comprising a plurality of spokes extending between the hub portion and the circumferential band portion, wherein at least one spoke of the plurality of spokes includes a radially inner head portion adjacent to the hub portion and a radially outer foot portion adjacent to the circumferential band portion, and wherein the spoke includes a cord reinforcement wound between the foot portion and the head portion of the spoke.

2. The tire according to claim 1, wherein: The spoke comprises a polymer composition, and wherein the cord reinforcement extends within the polymer composition.

3. The tire according to claim 1, wherein: The spoke includes an X-shaped cross-section having a pair of radially outer legs, a pair of radially inner legs, a cross portion connecting the pair of radially outer legs with the pair of radially inner legs, a radially inner connecting portion connecting the radially inner ends of the radially inner legs, and a radially outer connecting portion connecting the radially outer ends of the radially outer legs.

4. The tire according to claim 3, wherein: The cord reinforcement is at least extending from a radially inner end of one of the radially inner legs through the one of the radially inner legs, further extending through the intersection portion into one of the radially outer legs, further extending through said one of said radially outer legs to a radially outer end portion of said one of said radially outer legs, further extending through the radially outer connecting portion to the radially outer end portion of the other leg of the pair of radially outer legs, further extending through the other leg of the pair of radially outer legs toward and through the intersection into the other leg of the pair of radially inner legs, and Further extending to the radially inner end portion of the other leg of the pair of radially inner legs.

5. The tire according to claim 3, wherein: The cord reinforcement passes through the intersection portion at least twice, and wherein the cord reinforcement extends transversely to itself in the intersection portion.

6. The tire according to claim 1, wherein: The spokes include one or more polymer compositions selected from one or more of a thermoplastic composition and an elastomeric composition, the polymer composition being reinforced by a cord reinforcement; and wherein the cord reinforcement includes at least one cord, the at least one cord including one or more of the following: a textile material, a glass fiber material, a carbon fiber material, a boron fiber material, a basalt fiber material, a plant-based material, and a combination of these materials.

7. The tire according to claim 1, wherein: The cord reinforcement is wrapped multiple times between the foot portion and the head portion of the spoke, and wherein the multiple passes of the cord reinforcement between the foot portion and the head portion are spatially separated from each other between the foot portion and the head portion.

8. A non-pneumatic tire, comprising: a radially outer circumferential band portion, the radially outer circumferential band portion comprising a tread; a radially inner hub portion; a support structure disposed radially between the band portion and the hub portion and comprising a radially outer ring portion, a radially inner ring portion, and a plurality of spokes extending from the radially outer ring portion to the radially inner ring portion, wherein each of the spokes has a radially inner head portion and a radially outer foot portion, and wherein at least two adjacent spokes among the plurality of spokes are reinforced by a common cord reinforcement, wherein the cord reinforcement extends at least from the radially outer foot portion of one of the two adjacent spokes within the one of the two adjacent spokes to the radially inner head portion of the one of the adjacent spokes, and further extends through the radially inner ring portion into the radially inner head portion of the other of the adjacent spokes and further within the other spoke to the radially outer foot portion of the other spoke.

9. The tire according to claim 8, wherein: The cord reinforcement extends through and reinforces a majority of the spokes of the tire.

10. The tire according to claim 8, wherein: The cord reinforcement extends through at least four adjacent spokes in a circumferential sector of the support structure.

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