System and method for protecting a support structure of a non-pneumatic tire

Abstract

A method of making a non-pneumatic tire includes providing a non-pneumatic tire structure and providing a first disk and a second disk. The method further includes bonding the first disk to a first side of the non-pneumatic tire structure and bonding the second disk to a second side of the non-pneumatic tire structure. The method also includes providing an elastomeric tread around an upper portion of the non-pneumatic tire structure in a circumferential direction and bonding a curing envelope around the elastomeric tread. Bonding the curing envelope around the elastomeric tread includes bonding a first end of the curing envelope to the first side of the non-pneumatic tire structure and bonding a second end of the curing envelope to the second side of the non-pneumatic tire structure. The method further includes applying heat within the curing envelope.

Description

[Technical field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates to non-pneumatic tires and systems and methods for making the same. More specifically, this disclosure relates to systems and methods for applying a tread to a non-pneumatic tire structure. [Background technology]

[0002] Various tire constructions have been developed that allow the tire to run in an uninflated or underinflated state. Non-pneumatic tires do not require inflation, but "run-flat tires" may continue to operate for extended periods of time and at relatively high speeds after a puncture and complete or partial loss of pressurized air. Non-pneumatic tires may include multiple spokes, webbing, or other support structures connecting a lower ring to an upper ring. It is known to use adhesives or cements to bond a pre-cured tread to the upper ring of a non-pneumatic tire. Summary of the Invention [Problem to be solved by the invention]

[0003] In one embodiment, a method of making a non-pneumatic tire includes providing a tire structure having a lower ring having a first diameter, an upper ring having a second diameter greater than the first diameter, the upper ring being substantially coaxial with the lower ring, and a support structure extending between the lower ring and the upper ring. The method further includes providing a first disk and a second disk. Each of the first and second disks has an upper diameter and a central opening defining a lower diameter. The method also includes affixing the first disk to a first side of the tire structure and affixing the second disk to a second side of the tire structure. The method further includes providing an elastomeric tread circumferentially around an upper portion of the upper ring and affixing a curing envelope around the elastomeric tread. Affixing the curing envelope around the elastomeric tread includes the steps of: adhering a first end of the curing envelope to a first side of the tire structure at a location below the support structure; and adhering a second end of the curing envelope to a second side of the tire structure at a location below the support structure. The method also includes applying heat within the curing envelope.

[0004] In another embodiment, a system for assembling a circumferential tread and a non-pneumatic tire structure is provided, the non-pneumatic tire structure having an upper ring, a lower ring, and a support structure extending between the upper ring and the lower ring. The system includes a curing envelope sized to receive the non-pneumatic tire structure and the circumferential tread, a first disk configured to be secured to a first side of the non-pneumatic tire structure, and a second disk configured to be secured to a second side of the non-pneumatic tire structure. The system also includes a first fastener configured to secure the first side of the curing envelope to the non-pneumatic tire structure and a second fastener configured to secure the second side of the curing envelope to the non-pneumatic tire structure.

[0005] In yet another embodiment, a method of making a non-pneumatic tire includes providing a non-pneumatic tire structure and providing a first disk and a second disk. The method further includes bonding the first disk to a first side of the non-pneumatic tire structure and bonding the second disk to a second side of the non-pneumatic tire structure. The method also includes providing an elastomeric tread around an upper portion of the non-pneumatic tire structure in a circumferential direction and bonding a curing envelope around the elastomeric tread. Bonding the curing envelope around the elastomeric tread includes bonding a first end of the curing envelope to the first side of the non-pneumatic tire structure and bonding a second end of the curing envelope to the second side of the non-pneumatic tire structure. The method further includes applying heat within the curing envelope. [Brief description of the drawings]

[0006] The accompanying drawings, together with the detailed description provided below, illustrate structures that describe exemplary embodiments of the claimed invention. Similar elements are identified with the same reference numerals. It should be understood that elements shown as a single component may be replaced with multiple components, and that elements shown as multiple components may be replaced with a single component. The drawings are not to scale, and the proportions of certain elements may be exaggerated for illustrative purposes.

[0007] [Figure 1] FIG. 1 is a front view of one embodiment of a non-pneumatic tire. [Diagram 2] FIG. 2 is a front view of an alternative embodiment of a non-pneumatic tire. [Diagram 3] FIG. 3 is a schematic diagram illustrating a perspective view of one embodiment of a curing envelope for a non-pneumatic tire. [Figure 4] FIG. 4 is a schematic diagram illustrating a front view of one embodiment of a protective disk. [Diagram 5] FIG. 5 is a schematic diagram illustrating a front view of one embodiment of a protective disk secured to a non-pneumatic tire. [Figure 6] FIG. 6 is a schematic diagram illustrating a front view of one embodiment of a protective disk secured to a non-pneumatic tire and hub assembly. [Figure 7] FIG. 7 is a front view of one embodiment of the arc band and ratchet assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] The following includes definitions of select terms used herein. These definitions include various examples and / or forms of components that fall within the scope of the term and may be used for implementation. The examples are not intended to be limiting. Both the singular and plural forms of a term may be within the scope of the definition.

[0009] "Axial" and "axially" refer to the direction parallel to the axis of rotation of the tire.

[0010] "Circumferential" and "circumferentially" refer to a direction extending along the perimeter of the surface of the tread perpendicular to the axial direction.

[0011] "Radial" and "radially" refer to directions perpendicular to the axis of rotation of the tire.

[0012] As used herein, "tread" refers to that portion of the tire that comes into contact with the road or ground under normal inflation and normal load.

[0013] It should be understood that, although similar terms are used in the following description to describe typical tire components, the terms, of course, have slightly different connotations and one of ordinary skill in the art would not consider any of the following terms to be purely interchangeable with another term used to describe typical tire components.

[0014] As used herein, directions are stated with reference to the tire's axis of rotation. The terms "upward" and "upwardly" refer to the general direction toward the tire's tread, and "downward" and "downwardly" refer to the general direction toward the tire's axis of rotation. Thus, when relative directional terms such as "upper" and "lower" or "top" and "bottom" are used in connection with elements, the "upper" or "top" element is spaced closer to the tread than the "lower" or "bottom" element. Additionally, when relative directional terms such as "up" or "down" are used in connection with elements, an element that is "up" another element is closer to the tread than the other element.

[0015] The terms "inward" and "inwardly" refer to the general direction toward the tire's equatorial plane, and "outward" and "outwardly" refer to the general direction away from the tire's equatorial plane, toward the tire's sidewall. Thus, when relative directional terms such as "inner" and "outer" are used in connection with elements, the "inner" elements are spaced closer to the tire's equatorial plane than the "outer" elements.

[0016] 1 illustrates one embodiment of a non-pneumatic tire 10. The non-pneumatic tire 10 is merely illustrative and is not intended to be limiting. In the illustrated embodiment, the non-pneumatic tire 10 includes a generally annular lower ring 20 that engages a rim (not shown) on which the tire 10 is mounted. The generally annular lower ring 20 has an inner surface 23 and an outer surface 24, and may be made from an elastomeric material or metal.

[0017] The non-pneumatic tire 10 further includes a generally annular upper ring 30 surrounding an interconnected web 40, which is a support structure connected to the generally annular lower ring 20. In an alternative embodiment, a plurality of spokes or other support structures connect the lower ring to the upper ring. The upper ring 30 can be configured to deform in an area 48 around and including the contact patch region 32, which reduces vibrations and improves ride comfort.

[0018] In one embodiment, the generally annular lower ring 20 and the generally annular upper ring 30 are made from the same material as the interconnected webs 40. In one particular embodiment, the lower ring 20, the upper ring 30, and the webs 40 are each constructed from steel. In alternative embodiments, the lower ring 20, the upper ring 30, and the webs 40 are each constructed from other metals, carbon fiber, resins, or polymeric materials such as polyurethane, polyester, nylon, or polyvinyl chloride (PVC). However, it should be understood that other materials may be used and that the rings and spokes are not limited to the listed materials.

[0019] In an alternative embodiment, at least one of the generally annular lower ring, the generally annular upper ring, and the interconnected webs are made from different materials. For example, the upper ring 30 can be a steel band, while the lower ring 20 and webs 40 are constructed from other metals, carbon fiber, resins, or polymeric materials such as polyurethane, polyester, nylon, or polyvinyl chloride (PVC).

[0020] In the illustrated embodiment, the interconnected webs 40 have at least two radially adjacent layers 56, 58 of web elements 42 that define a plurality of generally polygonal openings 50. In other embodiments (not shown), other web configurations may be used.

[0021] As shown in FIG. 1, the generally annular top ring 30 may have a radially outer surface 34 to which a circumferential tread 70 is attached. The circumferential tread 70 may be constructed of an elastomeric material, such as natural or synthetic rubber, or other elastomeric material. The tread 70 may have a number of circumferential grooves that define a number of ribs. It should be understood that the tread may include tread elements such as grooves, ribs, blocks, lugs, sipes, studs, and other elements. A shear band or other shear element or reinforcing structure (not shown) may be disposed between the top ring 30 and the tread 70. Alternatively, the shear band or other shear element may be disposed within the tread.

[0022] In one embodiment, the circumferential tread 70 is secured to the top of the upper ring 30, with no pressure sensitive adhesive disposed between the upper ring 30 and the circumferential tread 70. In one such embodiment, the circumferential tread 70 is bonded directly to the top of the upper ring 30. In another such embodiment, a strip of cured rubber (not shown) or a temperature sensitive adhesive is disposed between the circumferential tread 70 and the upper ring 30.

[0023] 2 is a front view of an alternative embodiment of a non-pneumatic tire 100. The non-pneumatic tire 100 includes an inner ring 110 having a first diameter and an outer ring 120 having a second diameter larger than the first diameter. The outer ring 120 is substantially coaxial with the lower ring 110. In the illustrated embodiment, the inner ring 110 is shown as being attached to a hub H. A plurality of spokes 130 extend between the inner ring 110 and the outer ring 120. It should be understood that the term "support structure" can refer to either the webbing (such as 40 in FIG. 1) or the spokes (such as spokes 130 in FIG. 2).

[0024] In one embodiment, each of the lower ring 110, upper ring 120, and spokes 130 are constructed from the same material. In one particular embodiment, each of the lower ring 110, upper ring 120, and spokes 130 are constructed from steel. In alternative embodiments, each of the lower ring 110, upper ring 120, and spokes 130 are constructed from other metals, carbon fiber, resins, or polymeric materials such as polyurethane, polyester, nylon, or polyvinyl chloride (PVC). However, it should be understood that other materials may be used and that the rings and spokes are not limited to the listed materials.

[0025] In alternative embodiments, one or more of the lower ring 110, upper ring 120, and spokes 130 are constructed from different materials. For example, the upper ring 120 can be a steel band, while the lower ring 120 and spokes 130 are constructed from other metals, carbon fiber, resins, or polymeric materials such as polyurethane, polyester, nylon, or polyvinyl chloride (PVC).

[0026] In the illustrated embodiment, a circumferential tread 140 is disposed about the top ring 120. The circumferential tread 140 may be constructed of an elastomeric material, such as natural or synthetic rubber, or other elastomeric material. The circumferential tread 140 may have a number of circumferential grooves that define a number of ribs. It should be understood that the circumferential tread may include tread elements, such as grooves, ribs, blocks, lugs, sipes, studs, and other elements. A shear band or other shear element or reinforcing structure (not shown) may be disposed between the top ring 120 and the tread 140. Alternatively, the shear band or other shear element may be disposed within the tread.

[0027] In one embodiment, the circumferential tread 140 is secured to the top of the top ring 120, with no pressure sensitive adhesive disposed between the top ring 120 and the circumferential tread 140. In one such embodiment, the circumferential tread 140 is bonded directly to the top of the top ring 120. In another such embodiment, a strip of cured rubber (not shown) or a temperature sensitive adhesive is disposed between the circumferential tread 140 and the top ring 120.

[0028] To make a non-pneumatic tire such as tire 10 or tire 100, a manufacturer provides a tire structure including a lower ring (such as lower ring 20 or lower ring 110) having a first diameter, an upper ring (such as upper ring 30 or upper ring 120) having a second diameter larger than the first diameter, and a support structure (such as webs 40 or spokes 130) extending between the lower ring and the upper ring. The manufacturer also provides an elastomeric tread (such as tread 70 or tread 140) and wraps the tread around the upper ring. The manufacturer secures a cure envelope, such as cure envelope 200 shown in FIG. 3, around the tire structure and the circumferential tread.

[0029] 3, the curing envelope 200 is sized to receive a circumferential tread and a non-pneumatic tire structure, including an upper ring, a lower ring, and a support structure. The curing envelope 200 has a pair of sides 210 terminating in a first end 220 and a second end 230. The first and second ends 220, 230 each define an inside diameter ID of the curing envelope 200. The inside diameter ID may be between 9 inches (23 cm) and 24 inches (61 cm). While the sides 210 are shown as flat, it should be understood that they may be curved or contoured as desired.

[0030] The curing envelope also has a top 240 that defines an outer diameter OD. The outer diameter OD can be between 28 inches (71 cm) and 60 inches (152 cm). While the top 240 is shown as being flat, it should be understood that it can be curved or contoured as desired. In one embodiment, the side 210 of the curing envelope 200 has a length between 4 and 51 inches (10 and 130 cm). In other words, the outer diameter OD is between 4 and 51 inches larger than the inner diameter ID.

[0031] The curing envelope 200 may be a sheet of butyl rubber, other rubber compounds, neoprene, polyyarn, latex, or other flexible material. The sheet of material may have a thickness of 0.008 inches (0.02 cm) to 0.12 inches (0.3 cm). The sheet of material may be damaged or torn by any sharp edges on the supporting structure of the non-pneumatic tire. Additionally, the sheet of material may damage the supporting structure of the non-pneumatic tire. Therefore, it is advantageous to use a protection device for the supporting structure.

[0032] One example of a protective device is a protective disk. Figure 4 is a schematic diagram illustrating a front view of one embodiment of a protective disk 300. The protective disk 300 has an upper diameter 310 and a central opening 320 that defines a lower diameter 330. The protective disk may be constructed from aluminum, carbon fiber, or polymeric materials. Alternatively, the protective disk may be constructed from any material that is sufficiently rigid and capable of withstanding the heat and pressure applied within the curing envelope.

[0033] In one embodiment, the top diameter 310 of the disk 300 is equal to a first diameter of the top ring of the non-pneumatic tire structure and the bottom diameter 330 of the disk 300 is equal to a second diameter of the bottom ring of the non-pneumatic tire structure. In alternative embodiments, the top diameter 310 of the disk 300 can be larger or smaller than the first diameter of the top ring of the non-pneumatic tire structure. Similarly, the bottom diameter 330 of the disk 300 can be larger or smaller than the second diameter of the bottom ring of the non-pneumatic tire structure.

[0034] A pair of protective disks may be used, including a first disk and a second disk. The first disk may be secured to a first side of the tire structure, and the second disk may be secured to a second side of the tire structure. The first and second disks may be secured to the tire structure before the curing envelope is secured to the tire structure. In one embodiment, the upper diameter of the first disk is equal to the upper diameter of the second disk, and the lower diameter of the first disk is equal to the lower diameter of the second disk. In an alternative embodiment, the first and second disks may have different dimensions.

[0035] Figure 5 is a schematic diagram illustrating a front view of a protective disk 300 secured to the tire structure of the non-pneumatic tire 100 of Figure 2. However, it should be understood that the non-pneumatic tire 100 is merely exemplary and that the protective disk 300 may be secured to any non-pneumatic tire structure. Although only one side is shown in Figure 5, a similar arrangement may be employed on the other side of the tire.

[0036] In this example, the protective disk 300 is secured to the side of the tire structure such that the upper diameter 310 of the protective disk 300 abuts the upper ring 120 of the tire structure and the lower diameter 330 of the protective disk 300 abuts the lower ring 110 of the tire structure. Thus, the support structure is not visible. However, it should be understood that the upper diameter 310 of the protective disk 300 may extend above or below the upper ring of the tire structure. Similarly, the lower diameter 330 of the protective disk 300 may extend above or below the lower ring of the tire structure.

[0037] After the protective disk 300 is secured to the tire structure and the tread 140 is extended around the upper ring 120 of the tire structure, the first end 220 of the curing envelope 200 can be secured to a first side of the tire structure at a position below the support structure, and the second end 230 of the curing envelope 200 can be secured to a second side of the tire structure at a position below the support structure.

[0038] In one embodiment, securing the cure envelope 200 around the elastomeric tread and tire structure includes securing each end of the cure envelope with an arc band, such as the arc band 600 shown in FIG. 7. In the illustrated embodiment, the arc band 600 has a first end 610 and a second end 620. The ratchet assembly 700 includes a body 710 with a handle 720 pivotally connected to the body 710 at a pivot point 730. The body 710 is connected to the arc band 600 at a first location spaced apart from the first end 610 and at a second location near the second end 620. The handle 720 can be pivoted between a first orientation and a second orientation to change the size of the arc band from a first diameter to a second diameter.

[0039] In one embodiment, affixing the curing envelope 200 about the elastomeric tread and tire structure includes affixing a first end of the curing envelope to a lower surface of the inner ring and affixing a second end of the curing envelope to a lower surface of the inner ring. In an alternative embodiment, affixing the curing envelope 200 about the elastomeric tread and tire structure includes affixing a first end of the curing envelope to a first disk and affixing a second end of the curing envelope to a second disk.

[0040] In another alternative embodiment, the tire structure may be attached to the rim before the protective disk is secured to the tire structure. For example, FIG. 6 is a schematic diagram illustrating a front view of one embodiment of a protective disk 300 secured to a non-pneumatic tire and hub assembly. In this example, the lower ring 110 of the tire structure is attached to the hub (or rim) H. After the tire structure is attached to the hub, the protective disk 300 is secured to the side of the tire structure such that the upper diameter 310 of the protective disk 300 abuts the upper ring 120 of the tire structure and the lower diameter 330 of the protective disk 300 abuts the lower ring 110 of the tire structure. Thus, the support structure is not visible. However, it should be understood that the upper diameter 310 of the protective disk 300 may extend above or below the upper ring of the tire structure. Similarly, the lower diameter 330 of the protective disk 300 may extend above or below the lower ring of the tire structure.

[0041] After the protective disk 300 is secured to the tire structure and the tread 140 is extended around the upper ring 120 of the tire structure, a first end of the curing envelope is secured to the hub (or rim) H and a second end of the curing envelope is secured to the hub (or rim) H.

[0042] In either embodiment, heat and pressure are applied within the cure envelope after the cure envelope is secured to the tire structure. In one embodiment, heat is applied at a temperature of 200°F to 300°F (90°C to 150°C). The elastomeric tread can be a pre-cured or partially cured tread with any desired tread elements pre-formed before the tread is provided around the top ring. Because the elastomeric tread is pre-cured or partially cured, it is only heated to a temperature sufficient to bond the elastomeric tread to the top ring.

[0043] In one embodiment, a strip of green rubber or temperature sensitive adhesive is first applied to either the elastomeric tread or the top ring, In such an embodiment, applied heat causes the green rubber or adhesive to bond the elastomeric tread to the top ring.

[0044] The terms "includes" or "including", to the extent that they are used in this specification or in the claims, are intended to be inclusive, similar to the term "comprising", as interpreted when used as a transitional term in the claims. Furthermore, to the extent that the term "or" is used (e.g., A or B), it is intended to mean "A or B, or both". When applicants intend to indicate "only A or B but not both", the term "only A or B but not both" is used. Thus, the use of the term "or" herein is inclusive, not exclusive. See Bryan Garner, A Dictionary of Modern Legal Usage 624 (2d.Ed.1995). Also, the terms "in" or "into", to the extent that they are used in this specification or in the claims, are intended to additionally mean "on" or "onto". Furthermore, to the extent the term "connect" is used in this specification or the claims, it is intended to mean not only "directly connected to," but also "indirectly connected to," such as connected via one or more other components.

[0045] While the present application has been illustrated by the description of its embodiments, and those embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any manner limit the scope of the appended claims to such details. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, the present application in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Thus, departures may be made from such details without departing from the spirit or scope of the applicants' general inventive concept.

Claims

1. 1. A method of making a non-pneumatic tire, comprising: A tire structure is provided, the tire structure comprising: a lower ring having a first diameter; an upper ring having a second diameter greater than the first diameter and substantially coaxial with the lower ring; a support structure extending between the lower ring and the upper ring; providing a first disk and a second disk, each of the first and second disks having a central opening defining an upper diameter and a lower diameter; securing the first disc to a first side of the tire structure; securing the second disk to a second side of the tire structure; providing an elastomeric tread circumferentially about a top portion of the top ring; securing a curing envelope about the elastomeric tread, the curing envelope comprising: a first end of the curing envelope secured to the first side of the tire structure at a location below the support structure; and a second end of the curing envelope secured to the second side of the tire structure at a location below the support structure; and applying heat within the curing envelope.

2. The method of claim 1 , wherein the bonding of the cure envelope around the elastomeric tread comprises bonding each end of the cure envelope with an arc band.

3. 2. The method of claim 1, wherein the bonding of the curing envelope around the elastomeric tread comprises bonding the first end of the curing envelope to the lower surface of the lower ring and bonding the second end of the curing envelope to the lower surface of the lower ring.

4. The method of claim 1 further comprising mounting the tire structure on a rim.

5. 5. The method of claim 4, wherein the bonding of the cured envelope around the elastomeric tread comprises bonding the first end of the cured envelope to the rim and bonding the second end of the cured envelope to the rim.

6. 2. The method of claim 1, wherein the bonding of the curing envelope around the elastomeric tread comprises bonding the first end of the curing envelope to the first disk and bonding the second end of the curing envelope to the second disk.

7. 2. The method of claim 1, wherein the upper diameter of the first disk is equal to the upper diameter of the second disk and the lower diameter of the first disk is equal to the lower diameter of the second disk.

8. 2. The method of claim 1, wherein the upper diameter of the first disk is equal to the second diameter of the upper ring and the lower diameter of the first disk is equal to the first diameter of the lower ring.

9. 1. A system for assembling a circumferential tread and non-pneumatic tire structure, the non-pneumatic tire structure having an upper ring, a lower ring, and a support structure extending between the upper ring and the lower ring, comprising: a cured envelope sized to receive the non-pneumatic tire structure and a circumferential tread; a first disc configured to be secured to a first side of the non-pneumatic tire structure; a second disc configured to be secured to a second side of the non-pneumatic tire structure; a first fastener configured to secure a first side of the cured envelope to the non-pneumatic tire structure; a second fastener configured to secure a second side of the cured envelope to the non-pneumatic tire structure.

10. 10. The system of claim 9, wherein the first disk has a first upper diameter and a first central opening defining a first lower diameter, and the second disk has a second upper diameter and a second central opening defining a second lower diameter.

11. The system of claim 10 , wherein the first upper diameter is equal to the second upper diameter and the first lower diameter is equal to the second lower diameter.

12. 10. The system of claim 9, wherein each of the first disk and the second disk is constructed from a material selected from the group consisting of aluminum, carbon fiber, and polymeric materials.

13. 10. The system of claim 9, wherein the first fastener is an arc band and the second fastener is an arc band.

14. 10. The system of claim 9, wherein the first fastener is configured to secure the first side of the curing envelope directly to the non-pneumatic tire structure and the second fastener is configured to secure the second side of the curing envelope directly to the non-pneumatic tire structure.

15. 10. The system of claim 9, wherein the first fastener is configured to secure the first side of the cured envelope to a rim and the second fastener is configured to secure the second side of the cured envelope to the rim.

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