Tire monitoring device

Abstract

The invention relates to a tire monitoring device comprising a sensor unit comprising a sensor assembly and an encapsulation material wherein the sensor assembly is at least predominantly surrounded by the encapsulation material. Further, the tire monitoring device includes a sensor unit holder, where the sensor unit holder includes i) a bottom portion including a bottom surface, and ii) a top portion opposite the bottom portion, and where the sensor unit is embedded in and bonded to the top portion. Furthermore, the invention relates to a tire comprising such a tire monitoring device.

Description

TECHNICAL FIELD

[0001] The present invention relates to a tire monitoring device, which particularly comprises a sensor unit and a sensor unit holder. Furthermore, the present invention relates to a tire, such as a pneumatic tire, comprising a tire monitoring device. BACKGROUND

[0002] Many contemporary tires are equipped with tire monitoring devices, such as for monitoring tire pressure. In some tires, such sensor devices are installed to the tire within the tire chamber. In one existing system, a tire pressure sensor is removably and resiliently held in a hollow rubber composition container, which is attached to the inner liner of the tire. Although such a system can be a suitable solution for many tire monitoring applications, there is room for improvement for other tire monitoring applications, particularly for ultra-high performance (UHP) or ultra-ultra-high performance (UUHP) tire applications. SUMMARY

[0003] In one aspect of the present invention, the present invention relates to a tire monitoring device comprising a sensor unit, the sensor unit comprising a sensor assembly and an encapsulation material, wherein the sensor assembly is at least predominantly surrounded by the encapsulation material. Furthermore, the tire monitoring device comprises a sensor unit holder, wherein the sensor unit holder comprises i) a bottom portion comprising a bottom surface, and ii) a top portion opposite the bottom portion, and wherein the sensor unit is embedded in and bonded to the top portion of the sensor unit holder.

[0004] The present invention provides the following technical solutions: 1. A tire monitoring device, the tire monitoring device comprising: a sensor unit, the sensor unit comprising a sensor assembly and an encapsulation material, wherein the sensor assembly is at least predominantly surrounded by the encapsulation material; and a sensor unit holder, wherein the sensor unit holder comprises i) a bottom portion comprising a bottom surface, and ii) a top portion opposite the bottom portion, and wherein the sensor unit is embedded in and bonded to the top portion.

[0005] 2. The tire monitoring device according to solution 1, wherein the sensor unit holder comprises a polymer-based material, and wherein the sensor unit is embedded in and bonded to the polymer-based material in the top portion of the sensor unit holder.

[0006] 3. The tire monitoring device according to paragraph 2, wherein the polymer-based material is one or more of a polyurethane-based material and a cast elastomer material.

[0007] 4. The tire monitoring device according to paragraph 2, wherein the sensor unit holder is made at least primarily of the polymer-based material.

[0008] 5. The tire monitoring device according to paragraph 2, wherein the polymer-based material is a cast elastomer that is cast over the sensor unit and forms the top portion that is bonded to the bottom portion of the sensor unit.

[0009] 6. The tire monitoring device according to paragraph 5, wherein the cast elastomer is a cast polyurethane elastomer.

[0010] 7. The tire monitoring device according to paragraph 5, wherein there is no adhesive between the sensor unit and the sensor unit holder.

[0011] 8. The tire monitoring device according to paragraph 2, wherein the polymer-based material comprises one or more of: an elongation at break that is 50% higher than the elongation at break of the encapsulation material as determined according to ISO 527-2; a Shore A hardness that is at least 5 Shore A greater than the Shore A hardness of the encapsulation material as determined according to ISO 7619-1; and a tensile strength that is at least 5 MPa greater than the tensile strength of the encapsulation material as determined according to ISO 527-2.

[0012] 9. The tire monitoring device according to paragraph 2, wherein the polymer-based material comprises one or more of: an elongation at break of at least 400% as determined according to ISO 527-2; a thermal conductivity of at least 0.1 W / (m-K) as determined according to ISO 22007-2:2008; a Shore A hardness in the range of 50 to 99 as determined according to ISO 7619-1; and a tensile strength of at least 12 MPa as determined according to ISO 527-2.

[0013] 10. The tire monitoring device according to paragraph 1, wherein the encapsulation material is selected from one of a polyurethane-based resin and a polyester-based resin.

[0014] 11. The tire monitoring device according to claim 1, wherein the encapsulation material comprises one or more of the following: The elongation at break in the range of 300% to 350% as determined by ISO 527-2; A thermal conductivity of at least 0.1 W / (m·K) as determined by ISO 22007-2:2008; Glass transition temperatures below -45°C as determined by ISO 11359-2:1999-10; Shore A hardness in the range of 40 to 99 as determined by ISO 7619-1; Tensile strength in the range of 0.5 MPa to 11 MPa as determined according to ISO 527-2; and According to DIN EN 62631-3-1:2016, greater than 10 9 Volume resistivity in Ohm·cm.

[0015] 12. The tire monitoring device according to claim 1, wherein the sensor assembly includes a sensor, a printed circuit board, a wireless transmitter, and a power source; and wherein the encapsulation material at least substantially surrounds each of the sensor, the printed circuit board, the wireless transmitter, and the power source.

[0016] 13. The tire monitoring device according to claim 1, wherein the sensor unit includes a cover that at least partially surrounds the sensor assembly and the encapsulation material, wherein a bottom portion of the cover is embedded in and coupled to the sensor unit retainer, and wherein a top portion of the cover extends out of the sensor unit retainer.

[0017] 14. The tire monitoring device according to claim 1, wherein the tire monitoring device includes a tire monitoring device height, the tire monitoring device height being perpendicular to the bottom surface of the sensor unit holder and measured from the bottom surface of the sensor unit holder to the outermost top surface of the sensor unit, and wherein the sensor unit holder includes one or more of the following: i) a height less than 50% of the tire monitoring device height, and ii) a height less than 50% of the total height of the sensor unit, the height being perpendicular to the bottom surface of the sensor unit holder.

[0018] 15. A tire, the tire including the tire monitoring device according to claim 1.

[0019] 16. The tire according to claim 15, wherein the tire is a pneumatic tire, the pneumatic tire includes a tread portion and an inner liner, the inner liner at least partially surrounding the tire chamber of the tire, wherein the tire monitoring device is attached to the inner liner of the tire radially below the tread portion.

[0020] 17. The tire according to claim 15, wherein the sensor unit retainer comprises a polymer-based material, and wherein the sensor unit is embedded in and bonded to the polymer-based material in the top portion of the sensor unit retainer.

[0021] 18. The tire according to claim 17, wherein the sensor unit retainer is composed of the polymer-based material, and wherein the polymer-based material is a cast polyurethane elastomer.

[0022] 19. The tire according to claim 18, further comprising one or more of a double-sided adhesive tape and a transfer tape, wherein the tire monitoring device is attached to the inner liner via the bottom surface of the sensor unit holder through one or more of the double-sided adhesive tape and the transfer tape.

[0023] 20. The tire according to claim 16, wherein the pneumatic tire is a passenger car pneumatic tire, the passenger car pneumatic tire including a speed index selected from one of ZR, W and Y. Attached Figure Description

[0024] The present invention will be described by way of example and with reference to the accompanying drawings, in which: Figure 1 This is a schematic cross-section of an inflatable tire including a tire monitoring device according to an embodiment of the present invention; Figure 2 This is a schematic cross-section of a tire monitoring device according to an embodiment of the present invention; Figure 3 yes Figure 2 The diagram shows a schematic top view of a tire monitoring device. Figure 4 This is a schematic cross-section of another tire monitoring device according to another embodiment of the present invention; Figure 5 yes Figure 4 The diagram shows a schematic top view of a tire monitoring device; and Figure 6 This is a flowchart illustrating an embodiment of a method for providing or manufacturing a tire with a sensor device according to an embodiment of the present invention. Detailed Implementation

[0025] According to a first aspect of the invention, the present invention relates to a tire monitoring device comprising a sensor unit, the sensor unit including a sensor assembly and an encapsulation material, wherein the sensor assembly is at least primarily surrounded by the encapsulation material. Furthermore, the tire monitoring device includes a sensor unit holder, wherein the sensor unit holder includes i) a bottom portion including a bottom surface, preferably for attachment to a surface of the tire; and ii) a top portion opposite the bottom portion and / or the bottom surface, and wherein the sensor unit is embedded in and attached to the top portion.

[0026] Therefore, on one hand, the present invention provides a sensor unit comprising a sensor assembly surrounded by an encapsulation material. This encapsulation material protects the sensor assembly and / or secures it in its position within the encapsulation material. In particular, the components of the sensor assembly can be held statically relative to each other. On the other hand, a tire monitoring device includes a sensor unit holder in which the sensor unit is embedded and coupled. Thus, the sensor unit holder can be attached to the tire with its bottom surface and coupled to the sensor unit with its opposing top portion. In particular, this allows the sensor unit to be manufactured using different materials, and especially with an encapsulation material different from the material forming (or primarily forming) the sensor unit holder. Furthermore, the embedding and coupling of the sensor unit to the sensor unit holder provides a fixed connection between the sensor unit holder and the sensor unit. The inventors have found that, for example, this coupling can significantly reduce hysteresis and / or heat generation, particularly when the tire is rotating at very high speeds, compared to sensors that are elastically and / or removably held in the chamber of a rubber composition container.

[0027] In one embodiment, the sensor unit holder comprises, or preferably is at least primarily composed of, and / or formed of, a polymer-based material. Optionally, the sensor unit is embedded in and bonded to the polymer-based material in the top portion of the sensor unit holder. For example, in one option, the polymer-based material may be bonded to an encapsulation material. In another option, the sensor unit may include an (outer) housing that at least partially surrounds the encapsulation material and the sensor assembly, wherein the polymer-based material of the sensor unit holder may be bonded to the housing of the sensor unit.

[0028] In another embodiment, the sensor unit includes a bottom portion and / or a bottom surface that is substantially parallel to the bottom surface of the sensor unit holder, wherein the sensor unit holder and the sensor unit comprise a height defined perpendicular to the bottom surface of the sensor unit holder. Optionally, the bottom portion of the sensor unit is coupled to the sensor unit holder at its bottom surface and / or circumferentially, or in other words, coupled along its entire circumference, preferably substantially perpendicular to its height. Thus, in other words, the bottom portion of the sensor unit may be surrounded by and coupled to the sensor unit holder, or its material, such as the polymer-based material of the sensor unit holder.

[0029] In another embodiment, the polymer-based material is selected from one or more polyurethane-based materials and cast elastomers. It should be emphasized that each of these materials is known in the art. In particular, polyurethane-based (polymer) materials and / or cast elastomers, such as cast polyurethane or cast polyurethane elastomers, are available from various manufacturers, such as BASF in Germany (e.g., Elasturan). TM Product line or Elastocast TM Product lines) are purchased, or from Huntsman in the United States (e.g., Tecnothane). TM Product line or Daltocast TM Product lines) are purchased, or from Covestro in Germany (e.g., Vulkollan). TM The materials are sourced from the product line. Optionally, one or more of the above materials may be cord and / or fiber reinforced, such as comprising one or more cords and fibers (including textile materials and / or glass fiber materials). The encapsulation materials described herein may also optionally be cord and / or fiber reinforced, such as those listed above herein. Optionally, the polymer-based materials include a glass transition temperature below -30°C (preferably below -40°C, or even below -45°C), measured by thermomechanical analysis (TMA) under ISO 11359-2:1999-10 or equivalent standards. In particular, the elastomers preferably include such a relatively low glass transition temperature, such that they are elastic above this glass transition temperature.

[0030] In another embodiment, the polymer-based material is one or more of polyurethane elastomers, cast polyurethane, and cast polyurethane elastomers. Such materials have been found to be particularly suitable for preferred embodiments of the invention. In particular, such materials can be directly bonded to the sensor unit without additional adhesive. The absence of such adhesive can be readily determined by those skilled in the art through visual inspection of the interface between the sensor unit and the sensor unit holder (e.g., cross-sectioning, and / or microscopy, and / or other analytical techniques known in the art). As mentioned above, these materials are available to those skilled in the art. A preferred (but not limiting) example of a cast polyurethane elastomer is Tecnothane from Huntsman Corporation, USA. TM MPT. Furthermore, this type of material is well-suited for bonding to the inner lining of tires, for example, via tape or suitable adhesives, such as one or more of super glue, pressure-sensitive adhesives, and cyanoacrylate-based adhesives.

[0031] In another embodiment, the sensor unit holder is formed at least primarily of and / or composed of a polymer-based material.

[0032] In another embodiment, the polymer-based material is a cast elastomer cast onto the sensor unit (preferably cast onto the bottom portion of the sensor unit) and / or formed on the top portion (of the sensor unit retainer) bonded to the bottom portion of the sensor unit. The casting onto the sensor unit can be observed, for example, on the final tire monitoring device, particularly from the perspective of a fixed bond between the sensor unit and the sensor unit retainer and / or the absence of adhesive between the sensor unit and the sensor unit retainer.

[0033] In another embodiment, there is no (additional) adhesive at the interface between the sensor unit and the sensor unit holder. In another embodiment, (additional) adhesive may be present at the interface between the sensor unit and the sensor unit holder. However, the latter is generally less preferred because it may increase manufacturing complexity.

[0034] In another embodiment, the (cast) polyurethane elastomer is based on at least one or more of the following: an isocyanate component (e.g., including one or more diisocyanates), a polyol component (e.g., including one or more polyester polyols and / or polyether polyols), and optionally one or more fillers (e.g., including one or more diamines and diols, such as butanediol and / or diethyltoluenediamine). It should be emphasized that the synthesis of such polyurethanes or polyurethane elastomers is known in the art. Furthermore, or alternatively, the polyurethane elastomer may be further described as unfoamed. In other words, as is known in the art, the cast polyurethane or cast polyurethane elastomer is not a foamed material or contains no foaming material.

[0035] In another embodiment, the polymer-based material (such as a cast elastomer or a cast polyurethane elastomer) includes one or more of the following: an elongation at break of at least 400% (preferably at least 450%, or more preferably at least 500%, and / or up to 800%) as determined according to ISO 527-2 or an equivalent standard; a thermal conductivity of at least 0.1 W / (m·K) (preferably at least 0.2 W / (m·K)) as determined according to ISO 22007-2:2008 or an equivalent standard; a Shore A hardness in the range of 50 to 99 (preferably 55 or 60, and / or up to 98) as determined according to ISO 7619-1 or an equivalent standard; and a tensile strength of at least 12 MPa (preferably at least 15 MPa, or more preferably at least 20 MPa, or even more preferably at least 25 MPa, and optionally up to 100 MPa, or up to 80 MPa) as determined according to ISO 527-2 or an equivalent standard. In particular, the tensile strength range is preferably relatively high, which allows for robust retention and stability of the retainer, making it particularly suitable for applications such as UHP, UUHP, or racing tires.

[0036] In another embodiment, the encapsulating material is a resin (or sometimes referred to as a molding resin), preferably selected from polyurethane-based resins and polyester-based resins. Polyurethane-based resins are as known to those skilled in the art and are commercially available, for example from Wevo GmbH in Germany (e.g., including Wevopur). TM The product line includes various polyurethane-based resins. Polyester-based resins are also known to those skilled in the art and are commercially available, for example from DuPont (e.g., including Rynite) in the United States. TM (Product line of polyester-based resins).

[0037] In another embodiment, the encapsulating material (and / or resin) comprises one or more of the following: elongation at break in the range of 300% to 350% (preferably to 390%, or to 360%, or to 350%) as determined according to ISO 527-2 or equivalent; thermal conductivity of at least 0.1 W / (m·K) as determined according to ISO 22007-2:2008 or equivalent; glass transition temperature below -45°C as determined by TMA or equivalent methods; Shore A hardness in the range of 40 to 99 as determined according to ISO 7619-1 or equivalent; tensile strength in the range of 0.5 MPa to 15 MPa (preferably 0.5 MPa to 11 MPa, or to 10 MPa) as determined according to ISO 527-2 or equivalent; and tensile strength greater than 10 MPa as determined according to DIN EN 62631-3-1:2016 or equivalent. 9 Ohm·cm (preferably greater than 10) 10 Ohm·cm, or more preferably greater than 10 11 Ohm·cm, or even more preferably greater than 10 12 Volume resistivity (Ohm·cm).

[0038] In another embodiment, the polymer-based material has an elongation at break that is at least 50% higher (and preferably up to 400% higher) than that of the encapsulation material. 50% higher means, for example, an absolute elongation at break value; in other words, if the elongation at break of the encapsulation material is 375% in a non-limiting example, then the elongation at break of the polymer-based material is at least 425%, i.e., 50% higher than 375%. Furthermore, or alternatively, the Shore A hardness of the polymer-based material is at least 5 Shore A values ​​greater than that of the encapsulation material (preferably at least 10 Shore A values, and at most 30 Shore A values). Furthermore, or alternatively, the tensile strength of the polymer-based material is at least 5 MPa greater than that of the encapsulation material (preferably at least 10 MPa greater) (and preferably at most 50 MPa greater). Therefore, in such preferred embodiments, one or more of the elongation at break, Shore A hardness, and tensile strength of the sensor unit retainer material are greater than one or more corresponding properties of the encapsulation material of the sensor unit. For example, this helps to provide a durable connection and / or retention of the sensor unit on the tire surface, taking into account the forces acting on the retainer during tire rotation. Furthermore, it is generally unnecessary or even undesirable to provide the same properties as the encapsulation material. For example, the preferred polymer-based material for the sensor unit retainer may be more expensive and / or may also involve a longer processing time than the encapsulation material, which becomes particularly meaningful when a large number of sensor retainers / tire monitoring devices are to be manufactured.

[0039] In another embodiment, the sensor assembly includes one or more of the following (preferably all of the following): a sensor, a printed circuit board, and a wireless transmitter (e.g., a wireless network transmitter, an RF transmitter, or a Bluetooth transmitter). TM The transceiver (or other wireless transmitter known in the art) and the power source (such as a battery). The transceiver may also be considered herein to include the transmitter. Optionally, an encapsulation material at least substantially surrounds each of the sensor, printed circuit board, wireless transmitter, and power source. For example, it is possible that the printed circuit board is completely surrounded by the encapsulation material, or in other words, encapsulated by the encapsulation material. Although openings and / or channels for air passage are provided for sensing physical properties such as pressure and / or temperature (typically located on the top surface of the sensor unit), the sensor is generally mostly surrounded. Optionally, the power source, such as a battery, does not need to be completely surrounded by the encapsulation material (but may be completely surrounded in other embodiments). For example, the side surfaces and top surface of the battery may be surrounded by the encapsulation material, and / or at least a portion of the bottom surface of the battery facing the bottom surface of the sensor unit holder may be at least partially unencapsulated or without encapsulation material. Optionally, the battery is disposed in the bottom portion of the sensor unit.

[0040] In another embodiment, the sensor assembly includes one or more of a temperature sensor, an acceleration sensor, a pressure sensor, and a strain sensor.

[0041] In another embodiment, the sensor unit includes a bottom portion and a top portion, wherein the bottom portion is embedded in the top portion of the sensor unit holder, and optionally, the bottom portion includes a bottom surface, which is preferably arranged substantially parallel to the bottom surface of the sensor unit holder. Optionally, the bottom surface of the sensor unit holder is at least as large as, or preferably at least twice the size of, the bottom surface of the sensor unit. Optionally, the bottom surface of the sensor unit holder is at least as large as, or preferably at least twice the size of, the projection of the sensor unit onto the bottom surface of the sensor unit holder in a direction perpendicular to the bottom surface of the sensor unit holder.

[0042] In another embodiment, the sensor unit includes a cover that at least partially surrounds the sensor assembly and / or encapsulation material, wherein the cover is optionally embedded in and coupled to a sensor unit holder. Furthermore, or alternatively, the top portion of the cover may extend beyond the sensor unit holder. Preferably, the cover is open at its bottom portion and / or comprises a substantially hollow cylindrical shape having a closed top and / or an opening at its bottom. The top may optionally be dome-shaped and / or curved.

[0043] In another embodiment, the cover comprises a thermoplastic polymer, such as polyethylene terephthalate (PET) or polybutylene terephthalate (PBT). Preferably, this polymer is additionally fiber-reinforced, such as with fibers as described above herein.

[0044] In another embodiment, the sensor unit is formed of an encapsulation material surrounding the sensor assembly, and / or the encapsulation material at least primarily forms the outer surface of the sensor unit.

[0045] In another embodiment, the sensor unit includes a hole, preferably having a diameter of less than 2 mm or less than 1 mm, thereby allowing air and / or gas to pass through to the sensor surrounded by encapsulation material.

[0046] In another embodiment, the sensor unit is fixedly coupled to the sensor unit holder and / or non-interchangeably coupled to or connected to the sensor unit holder.

[0047] In another embodiment, the sensor unit holder contains no rubber composition and / or one or more of the following: natural rubber (NR), synthetic polyisoprene (PI), polybutadiene (PBD) rubber, isoprene-butadiene rubber (IBR), and / or styrene-butadiene rubber (SBR). Optionally, it also contains no fillers, such as carbon black and / or silica. Optionally, the polymer-based material may also be described as non-thermoplastic.

[0048] In another embodiment, the tire monitoring device includes a height (measured from the bottom surface of the sensor unit holder (and perpendicular to the bottom surface) to the top surface or outermost top surface of the sensor unit, wherein the sensor unit holder includes one or more of the following: i) a height less than 50% (and / or optionally at least 5%) of the tire monitoring device height, and ii) a height less than 50% of the total height of the sensor unit, said height being measured perpendicular to the bottom surface of the sensor unit holder at the location where the sensor unit holder is mounted or attached to the tire, or perpendicular to the inner surface of the tire and / or the inner liner of the tire.

[0049] In another aspect, the present invention relates to tires including one or more tire monitoring devices according to the first aspect and / or embodiments thereof.

[0050] In one embodiment, the tire is a pneumatic (and optionally radial) tire comprising a circumferential tread portion and an inner liner that at least partially surrounds the tire's cavity, wherein a sensor monitoring device is attached to the tire's inner liner, preferably radially below the circumferential tread portion. The tire may optionally include a plurality of additional tire components, such as a pair of axially opposed bead portions and at least one carcass ply extending from one of the bead portions to the bead portion. The tire may also include a pair of axially opposed sidewalls and a belt layer portion disposed in the crown region of the tire between the tread portion and the carcass ply. In another option, the tire includes a cladding that covers the belt layer portion radially outward and radially below the tread portion.

[0051] In another embodiment, the tire monitoring device is mounted radially below the circumferential centerline of the tread portion and / or passes through the tire's equatorial plane. This arrangement helps to provide a well-balanced tire.

[0052] In another embodiment, the tire further includes one or more of a double-sided adhesive tape and a transfer tape, wherein the tire monitoring device is attached to the inner liner via the bottom surface of a sensor unit holder using one or more of the double-sided adhesive tape and the transfer tape. When the tire monitoring device is mounted and / or attached to the tire, the bottom portion or surface of the sensor unit or the sensor unit holder preferably corresponds to a radially outward position in the tire, and the top portion or surface of the sensor unit or the sensor unit holder preferably corresponds to a radially inward position in the tire.

[0053] In another embodiment, the tire monitoring device is attached to the inner liner via one or more of an adhesive, co-curing, rubber composition patch, transfer tape, double-sided tape, and mechanical interlocking (such as via hook and loop connection).

[0054] In another embodiment, the pneumatic tire is a pneumatic passenger car tire that includes a speed index selected from one of V, H, ZR, W, Y (preferably one of ZR, W, Y), which is provided, for example, on one or both sidewalls of the tire.

[0055] Figure 1A partial cross-section of an inflatable tire 1 having a tire monitoring device 10 according to an embodiment of the present invention is schematically illustrated. The tire 1 includes a pair of axially opposed bead portions 40, a tread portion 20, an inner liner 30 that at least partially surrounds the tire cavity of the tire 1, a pair of sidewalls 50 extending substantially radially between a respective one of the tread portion 20 and the bead portion 40, and a belt layer portion 60 radially disposed between the tread portion 20 and the inner liner 30 in the crown region of the tire 1.

[0056] The tire monitoring device 10 (which may also be referred to herein as a tire sensor device) includes a sensor unit 100 embedded in and (directly) coupled to a sensor unit holder 200. The tire monitoring device 10 and / or its sensor unit holder 200 are attached to the inner liner 30 of the tire 1 by their bottom portion and particularly by their bottom surface. This attachment is, for example, by adhesives, tape (preferably adhesive transfer tape or double-sided tape), hooks, and loops (e.g., via Velcro). TM The tire monitoring device 10 is provided by one or more of the following (connection methods), or, less preferably, by a rubber composition patch (e.g., including the provision of a vulcanizing adhesive). Preferably, the tire monitoring device 10 is applied to the tire after the tire has cured. Preferably, in order to provide a well-balanced tire, the tire monitoring device 10 is mounted to the inner liner 30 in the axial central region of the tire 1 (e.g., in the region traversed by the equatorial plane (EP) of the tire 1).

[0057] Tire monitoring device 10 typically includes at least one sensor, such as at least one tire pressure sensor for determining tire inflation pressure. Additionally, or alternatively, the tire monitoring device may include one or more of the following: a temperature sensor, a strain sensor, and one or more acceleration sensors. Such sensors can help monitor the condition and / or characteristics of the tire, such as when mounted to the rim and / or during driving. Further details regarding embodiments of the tire monitoring device are described below. Typically, the tire monitoring device is adapted to wirelessly transmit information based on measurements from said at least one sensor, for example via its transmitter, to a receiver, such as a vehicle computer, mobile device (e.g., a mobile phone, tablet, or laptop), and / or cloud services.

[0058] For better comprehensibility, Figure 1The symbols indicate the axial direction a, the circumferential direction c, and the radial direction r, as well as the equatorial plane EP. The axial direction a is parallel to the axis of rotation of the tire. The circumferential direction c is parallel to the circumference of the tire, and the radial direction r is perpendicular to both the axial direction a and the circumferential direction c. It should be emphasized that each of these directions may include different orientations, such that reference to one of these directions is not necessarily limited to a specific orientation, unless otherwise indicated herein.

[0059] Although tire 1 has been described with respect to the aforementioned tire components, it should be emphasized that tire 1 may include additional components, such as one or more carcass plies extending from one bead portion of a pair of bead portions to the other bead portion. Additionally, tire 1 may include, for example, components other than... Figure 1 In addition to those schematically indicated, there are additional belt layers. Furthermore, the tire may include one or more overlays between the tread portion and the belt layer portion. Additionally, the tread portion typically includes multiple tread grooves that are not... Figure 1 The diagram clearly illustrates this. The structural details of the pneumatic tire and its components are not the primary focus of this invention and may be chosen by those skilled in the art depending on the desired application.

[0060] Figure 2 The diagram shows... Figure 1 The diagram shows an enlarged schematic cross-section of the tire monitoring device 10. Therefore, the tire monitoring device 10 includes a sensor unit 100 embedded in and coupled to a sensor unit holder 200. In this non-limiting embodiment, the sensor unit 100 includes a sensor assembly 110, which is enclosed within a hollow container, or in other words, within a cover 130, and surrounded by an encapsulation material 120. The sensor assembly 110 includes a sensor 111, a printed circuit board (PCB) 112, and a battery 113. In this embodiment, the sensor 111 is a pressure sensor 111. The PCB 112 carries a wireless (e.g., radio frequency (RF)) transmitter chip and the sensor 111. The battery 113 powers the sensor 111 and the PCB 112, which includes the RF transmitter chip. The battery 113 is connected to the PCB 112 via an electrical connector 114.

[0061] Preferably, the sensor 111, PCB 112, electrical connector 114, and battery 113 are rigidly connected to each other. Therefore, the sensor assembly 110 is disposed within the housing 130, and the space between the housing 130 and the sensor assembly 110 is filled with an encapsulation material 120. Preferably, the encapsulation material 120 is a molding resin, or in other words, a molding resin. The encapsulation material 120 holds the sensor assembly 110 in place within the housing 130. Preferably, the housing 130 can be described as including a cup shape (e.g., an inverted cup shape) including an opening toward the bottom surface 221 of the sensor unit holder 200. Preferably, the housing 130 includes a hole 131 (specifically a top hole) to form an air passage, thereby allowing air to pass through the environment of the top portion 134 of the sensor unit 100 to reach the sensor 111. For example, if the sensor is a temperature sensor, this can improve the temperature measurement of the air surrounding the sensor unit 100 (e.g., in a tire chamber). Alternatively, if sensor 111 is a tire pressure sensor, air pressure can be determined (e.g., present in the tire chamber). The bottom portion 133 of sensor unit 100 and / or cover 130 is embedded in and coupled to the top portion 224 of sensor unit holder 200.

[0062] In this embodiment, the sensor unit holder 200 is composed of a polymer-based material 220, in this case of which is a cast polyurethane elastomer (such as Tecnothane from Huntsman, USA). TM (MPT). In particular, as in this embodiment, it is possible that this casting material is directly cast onto the bottom portion 133 of the sensor unit 100, such that it circumferentially surrounds the bottom portion 133 of the cover 130, and also contacts and / or bonds to the encapsulation material 120, for example. Optionally, the polymer base material 220 of the sensor unit holder 200 also contacts portions of the sensor assembly 110, such as the battery 113 (if the battery 113 is not completely covered by the encapsulation material 120, as in this embodiment). However, in other embodiments, the battery may be completely surrounded by the encapsulation material, such that the polymer base material of the sensor unit holder contacts the encapsulation material below the battery.

[0063] In another embodiment not depicted, the sensor unit may include a cover that closes the shroud at its bottom portion, such that the polymer-based material of the sensor unit holder is bonded to the cover (or, in other words, the bottom cover) of the shroud. For example, the material of the shroud 130 and / or the bottom cover (not shown) is a polymer-based material (preferably a thermoplastic or polymeric material), such as polybutylene terephthalate (PBT), which is preferably glass fiber reinforced (e.g., as Ultradur from BASF, Germany). TMMaterials for the product line.

[0064] Preferably, the bonding between the sensor unit holder 200 and the sensor unit 100 is done without (additional) adhesive. Typically, the top portion 224 of the sensor unit holder 200 extends only (upwards) to less than 50% of the total (maximum) height of the tire monitoring device 10. The height h is measured perpendicular to the bottom surface 221 of the sensor unit holder 200. The extension perpendicular to the height h of one or more of the sensor unit 100, the sensor unit holder 200, or the entire tire monitoring device 10 is referred to herein as the lateral extension range, and is measured only in one direction l. Figure 2 The diagram illustrates this. However, the lateral extension range can describe any direction perpendicular to the height h in this document.

[0065] Preferably, the sensor unit holder 200, and particularly its bottom portion 223, extends laterally beyond a region larger than the sensor unit 100. For example, the maximum lateral extension of the sensor unit holder 200 and / or its bottom portion 223 and / or bottom surface 221 is preferably selected to be in the range of 200% to 600%, preferably 200% to 400%, of the maximum lateral extension of the sensor unit 100. In this embodiment, the lateral circumference of the bottom portion 223 includes a circular shape, or in other words, includes a circular outline, such as... Figure 3 Further indicated. However, alternatively, such a shape can be, for example, polygonal, star-shaped, or elliptical. Optionally, the bottom surface 221 of the sensor unit holder 200 is 2 to 20 times (preferably 3 to 15 times) the area of ​​the sensor unit 100 projected vertically onto the bottom surface 221 of the sensor unit holder 200. In this example, the bottom surface 221 of the sensor unit holder 200 is approximately 9 times the area of ​​the cover 130 projected onto the bottom surface 221. This ratio improves the stability of the connection between the tire monitoring device 10 and the surface of the tire. Preferably, the bottom portion 223 includes a (preferably flat) flange and / or annular portion 222 surrounding the sensor unit 100.

[0066] Figure 3 The illustration shows a schematic top view of a tire monitoring device 10, which includes a sensor unit 100 embedded in and coupled to a sensor unit holder 200. Specifically, in this embodiment, the cover 130 of the sensor unit 100 is laterally, or in other words, circumferentially, surrounded by a polymer-based material 220 of the sensor unit holder 200. Holes 131 in the cover 130 and / or top portion 134 of the sensor unit 100 provide access to the sensor (not in...). Figure 3 The sensor is covered by a cover 130 and is clearly shown in the image.

[0067] As described above, the tire monitoring device 10 in this embodiment includes a sensor unit holder 200, which includes a substantially circular bottom portion 223 with a flange portion 222. A top portion 224 of the sensor unit holder 200 surrounds the sensor unit 100 and extends in the upward (height) direction. Although the lateral shapes of the sensor unit 100 and the sensor unit holder 200 are substantially circular in this embodiment, other shapes are possible as described herein. Furthermore, the sensor unit 100 may also include one of a polygonal, elliptical, or star shape instead of a substantially circular lateral shape. Figure 3 As can be seen, the lateral dimension of the bottom portion 223 is significantly larger than the lateral dimension of the sensor unit 100, which helps to provide the tire monitoring device 10 on the surface of the tire (e.g., on the surface of the tire). Figure 1 The lining layer (illustrated in the embodiment) is firmly held in place.

[0068] Figure 4 An alternative embodiment of the tire monitoring device 10' is schematically depicted, which includes a sensor unit 100' and a sensor unit holder 200'. The previously described embodiments and... Figure 4 The main difference between the embodiments is that the sensor unit 100' has no cover. The sensor assembly 110' is surrounded (and / or encapsulated) by an encapsulation material 120' having a substantially cylindrical shape. The sensor assembly 110' includes a sensor 111', which is connected to a printed circuit board 112', which is connected to a battery 113' via a preferably rigid electrical connector 114' (e.g., including a plug and socket).

[0069] For example, a substantially cylindrical shape of the encapsulation material surrounding the sensor assembly can be achieved using a hollow cylindrical mold, in which the sensor assembly 110' is positioned, and where the hollow space between the sensor assembly 110' and the mold is filled with a liquid polymer material (such as casting resin). In principle, this encapsulation material 120', such as casting resin, can be used with respect to… Figure 1 The embodiments described herein are the same as those described above. To provide an air passage to sensor 111', it is possible to provide holes in the encapsulation material or corresponding (or in other words, complementary) protrusions in the mold to provide an air passage or hole 121' to sensor 111' in the top portion 124' of sensor unit 100' after demolding. The encapsulation material 120', such as a casting resin, may be liquid during molding and cure at room temperature. Alternatively, such available materials may be cured by heating, for example, for several hours. The processing of such casting resins and their application to electrical components are known to those skilled in the art.

[0070] To bond the polymer-based material 220' of the sensor unit holder 200' to the (cured) encapsulation material 120', it is also possible to provide a (second) mold that includes the desired form or outer contour of the sensor holding portion 200'. Optionally, such a mold includes a container for receiving (and / or previously molded) the sensor unit 100' and a hollow space for receiving the polymer-based material of the sensor holder 200' to be manufactured. The polymer-based material, such as a cast polyurethane elastomer, can then be cast onto the bottom portion 133' of the sensor unit 100' to surround the bottom portion 133' of the sensor unit 100' and / or the encapsulation material 120', and to cover the bottom portion 133' (perpendicular to its height h). Thus, the bottom portion 133' of the sensor unit 100' is surrounded by a ring-shaped and / or upwardly projecting top portion 224' (relative to the bottom surface 221' of the sensor unit holder 200'). In this embodiment, the encapsulation material 120' defines the shape of the sensor unit 100' and is directly bonded to the polymer-based material 220' of the sensor unit holder 200'. Preferably, the sensor unit holder 200', including its top portion 224' and its bottom portion 223' having its bottom surface 221', is composed of the polymer-based material, which is preferably a cast elastomer, such as the cast polyurethane elastomer.

[0071] Figure 5 The diagram shows that it has already been shown. Figure 4 The diagram shows a schematic top view of the tire monitoring device 10', in which a sensor unit 100' is embedded in and bonded to a sensor unit holder 200'. The encapsulation material 120' of the sensor unit 100' is directly bonded to the polymer-based material 220' of the sensor unit holder 200', i.e., without adhesive. A hole 121' in the top portion 124' of the sensor unit 100', specifically in its encapsulation material 120', provides access to the sensor below. Figure 5 Air passages (not explicitly shown). Although the encapsulation material 120' has been described herein as comprising a generally cylindrical shape, this should also include cylindrical shapes with domes, such as those in... Figure 4 As shown in the diagram. Regarding... Figure 2 and Figure 3 The additional features and / or geometries described in the embodiments can also be applied. Figure 4 and Figure 5 Examples of implementations.

[0072] According to another aspect of the invention, the present invention relates to a method of manufacturing a tire monitoring device, such as one or more tire monitoring devices according to the foregoing aspects or embodiments thereof.

[0073] In one embodiment, the method includes one or more of the following steps: Provide sensor components (e.g., components having those described above in this document); The sensor assembly is placed in a mold, such as a hollow space that surrounds a generally cylindrical shape (optionally, the mold may be a polymer cover or include a polymer cover, such as a thermoplastic polymer cover as described above in this document). Resin, or in other words, molding resin, is cast into a mold to at least partially surround the sensor assembly (wherein, preferably, each component of the sensor assembly is at least primarily surrounded / encapsulated by the molding resin). Curing (preferably thermosetting) the resin to obtain a sensor unit comprising a sensor assembly that is surrounded in the resin and optionally surrounded in at least a portion (e.g., a cover) of a mold; A polymer-based material (such as the cast elastomer, for example, a (cast) polyurethane elastomer) is cast onto a portion of the sensor unit to surround and / or embed the sensor unit, preferably at less than half the height of the sensor unit; and Curing (preferably thermosetting) a polymer-based material (such as a cast elastomer, for example a cast polyurethane elastomer) to obtain a sensor unit holder that incorporates (particularly, cast into) a sensor unit and embeds the sensor unit in the sensor unit holder, and / or together form a tire monitoring device.

[0074] According to another aspect of the present invention, the present invention relates to a method for manufacturing a tire including one or more tire monitoring devices according to the foregoing aspects and / or embodiments thereof, the method comprising one or more of the following steps: A tire is provided, preferably a pneumatic tire, which includes an inner liner that at least partially surrounds the tire cavity of the tire; Provide one or more tire monitoring devices according to the foregoing aspects and / or embodiments thereof; and The tire monitoring device is attached, for example, by the bottom portion and / or bottom surface of a sensor unit holder, preferably to the inner liner of the tire. Thus, the sensor unit extends away from the inner liner and / or the sensor unit holder into the tire cavity.

[0075] In particular, the tire monitoring device may be manufactured by including the method steps described above for manufacturing the tire monitoring device.

[0076] Figure 6 A flowchart is provided for a preferred embodiment of a method of manufacturing a tire monitoring device and a tire including the tire monitoring device, such as including one or more tire monitoring devices according to the foregoing aspects and / or embodiments.

[0077] according to Figure 6 Step 10 involves providing the sensor assembly. According to... Figure 6 The second step 20 includes casting resin onto the sensor assembly to surround the sensor assembly within the resin and form a sensor unit. Optionally, in this sub-step, a hollow housing (e.g., a housing comprising a thermoplastic polymer) may be provided, and the sensor assembly provided within the housing, and resin cast onto the sensor assembly within the housing. The sensor assembly can then be bonded to the housing via resin. The housing may be part of the sensor unit. Further optional sub-steps may include curing the resin. Figure 6 Step 30 includes molding a polyurethane elastomer onto and around the bottom portion of the sensor unit to obtain a sensor unit holder bonded to the bottom portion of the sensor unit (wherein the sensor unit is embedded in the sensor unit holder). Therefore, preferably, no additional adhesive is used or required for attaching the sensor unit holder to the sensor unit.

[0078] Step 40 of the fourth method involves attaching the bottom portion of the sensor unit retainer to the inner liner of the pneumatic tire (e.g., radially below the tread portion) using an adhesive. Preferably, one or more adhesive tapes can be provided. Such tapes are preferably transfer tapes (e.g., available from 3M, USA). TM (Purchased by the company). Transfer tape typically does not have a carrier foil between the opposing adhesive surfaces of the tape. Alternatively, double-sided tape can be used, which typically includes a carrier foil between two opposing adhesive layers (such double-sided tape is also available, for example, from 3M in the United States). TM (Acquired by the company). In other words, in a preferred option, the bottom portion of the sensor unit holder is attached to the inner liner of the pneumatic tire with tape. Of course, it is possible that this method may include additional prior and / or intermediate steps not explicitly mentioned herein.

[0079] It should be emphasized that an embodiment and / or feature of one of the above aspects can also be an embodiment and / or feature of another of the above aspects. Furthermore, multiple embodiments or features of the present invention can be combined with each other.

[0080] Based on the description of the invention provided herein, variations are possible. Although specific representative embodiments and details have been illustrated for the purpose of illustrating the subject 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 subject invention. Therefore, it should be understood that changes can be made to the specific embodiments described, which will be within the full scope of the invention as defined by the following appended claims.

Claims

1. A tire monitoring device, the tire monitoring device comprising: A sensor unit, the sensor unit comprising a sensor assembly and an encapsulation material, wherein the sensor assembly is at least substantially surrounded by the encapsulation material; and A sensor unit holder, wherein the sensor unit holder includes i) a bottom portion including a bottom surface, and ii) a top portion opposite to the bottom portion, and wherein the sensor unit is embedded in and attached to the top portion.

2. The tire monitoring device according to claim 1, wherein, The sensor unit holder comprises a polymer-based material, wherein the sensor unit is embedded in and bonded to the polymer-based material in the top portion of the sensor unit holder.

3. The tire monitoring device according to claim 2, wherein, The polymer-based material is one or more of polyurethane-based materials and cast elastomer materials.

4. The tire monitoring device according to claim 2, wherein, The sensor unit holder is made primarily of the polymer-based material.

5. The tire monitoring device according to claim 2, wherein, The polymer-based material is a cast elastomer, which is cast onto the sensor unit and forms the top portion that is bonded to the bottom portion of the sensor unit.

6. The tire monitoring device according to claim 5, wherein, The cast elastomer is a cast polyurethane elastomer.

7. The tire monitoring device according to claim 5, wherein, There is no adhesive at the interface between the sensor unit and the sensor unit holder.

8. The tire monitoring device according to claim 2, wherein, The polymer-based material includes one or more of the following: According to ISO 527-2, the elongation at break is 50% higher than that of the encapsulation material. The Shore A hardness, as determined by ISO 7619-1, is at least 5 Shore A greater than that of the encapsulation material. as well as A tensile strength that is at least 5 MPa greater than the tensile strength of the encapsulation material, as determined by ISO 527-2.

9. The tire monitoring device according to claim 2, wherein, The polymer-based material includes one or more of the following: At least 400% elongation at break as determined by ISO 527-2; A thermal conductivity of at least 0.1 W / (m·K) as determined by ISO 22007-2:2008; Shore A hardness in the range of 50 to 99 as determined by ISO 7619-1; and Tensile strength of at least 12 MPa as determined by ISO 527-2.

10. The tire monitoring device according to claim 1, wherein, The encapsulation material is selected from polyurethane-based resin and polyester-based resin.

Images