Non-pneumatic tire

Abstract

SOLUTION: To provide a non-pneumatic tire that includes rubber constituents such as a shear band, and includes at least one textile cord including yarn, where most of the yarn is fused in the cord and further the yarn is selected from one or more of aramid, polyamide, polyester, polyethylene terephthalate, polyethylene naphthalate, glass fiber and carbon fiber yarn.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a non-pneumatic tire, and more particularly to a non-pneumatic tire including a cord-reinforced rubber component such as a shear band. The non-pneumatic tire, and more particularly the cord-reinforced rubber component, includes cords including yarns fused together. [Background technology]

[0002] Non-pneumatic tires have several advantages over conventional pneumatic tires, such as increasing the tire's robustness, in particular because non-pneumatic tires do not comprise a pressurized tire cavity and therefore cannot lose air pressure. Summary of the Invention Problems to be Solved by the Invention

[0003] Although the development of non-pneumatic tires has progressed over the past few years, there remains significant room for improvement. [Means for solving the problem]

[0004] In a first aspect, the invention is directed to a non-pneumatic tire having a rubber component including at least one woven cord, the cord including yarns, a majority of the yarns being fused within the cord, the yarns being selected from one or more of aramid, polyamide, polyester, polyethylene terephthalate, polyethylene naphthalate, fiberglass, and carbon fiber yarns.

[0005] In a second aspect, the invention is directed to a non-pneumatic tire comprising a circumferential tread portion and a circumferential shear band supporting the tread portion, the shear band being comprised of a plurality of circumferential plies, at least one of the plies comprising a rubber composition reinforced with a textile cord comprising yarns at least partially fused to form a cord, the yarns being selected from one or more of aramid, polyamide, polyester, polyethylene terephthalate, polyethylene naphthalate, fiberglass and carbon fiber yarns.

[0006] In a third aspect, the present invention is directed to a non-pneumatic tire comprising a circumferential tread portion and a circumferential shear band supporting the tread portion, the shear band being comprised of a plurality of circumferential layers, at least one of said layers comprising a rubber composition reinforced by a textile cord comprising yarns at least partially fused to form a cord. Further, the yarns are selected from one or more of polyester, polyethylene terephthalate, and polyethylene naphthalate yarns. Further in accordance with the third aspect, the cords further comprise an isocyanate, and a majority of the yarns are fused by the isocyanate. The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0007] [Figure 1] 1 is a schematic side view of a non-pneumatic tire according to one embodiment of the present invention. [Diagram 2] 2 is a schematic partial cross-sectional view of the tire shown in FIG. 1 in a plane perpendicular to the circumferential direction of a shear band. [Diagram 3] FIG. 11 is a schematic partial cross-sectional view of another shear band in a plane perpendicular to the circumferential direction. [Figure 4] FIG. 13 is a schematic partial cross-sectional view of yet another shear band in a plane perpendicular to the circumferential direction. [Diagram 5] FIG. 13 is a schematic partial cross-sectional view of yet another shear band in a plane perpendicular to the circumferential direction. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] According to a first aspect, a non-pneumatic tire has a rubber component including at least one textile cord (or cords), the cord including yarns. The majority of the yarns are fused within the cord, the yarns being selected from one or more of aramid, polyamide (such as nylon), polyester, polyethylene terephthalate (PET), polyethylene naphthalate (PEN), glass fiber, and carbon fiber yarns. In particular, such fused textile cords are very robust due to the fusion of the yarns and the utilized material. Such robustness allows the provision of a non-pneumatic tire with reinforced tire components having a relatively small number of cords, especially when compared to similar components made of other types of textile cords. For example, the tire component may be a shear band, but may also be a component of the tire's support structure.

[0009] In one embodiment, the cord further comprises an isocyanate, where the majority of the yarns are fused together by the isocyanate, preferably through at least 50%, or more preferably at least 75% or 90%, of the maximum diameter of the cord (measured perpendicular to the length of the cord, where the fusion is observable in a perpendicular cross-section of the cord, e.g., by reflected light microscopy, or UV photoluminescence spectroscopy, or the like).

[0010] In another embodiment, the cord is chemically fused, such as fused with an isocyanate. For example, the cord can be immersed in an isocyanate bath.

[0011] In yet another embodiment, the isocyanate is dissolved in an organic solvent such as toluene, hexane, cyclohexane, etc.

[0012] In yet another embodiment, the isocyanate is dispersed in an aqueous dispersion. The isocyanate is exposed to the cord in a concentration sufficient to chemically fuse the individual cord yarns.

[0013] In yet another embodiment, the isocyanate is used in an organic solvent solution at a concentration of 15 to 25% by weight, based on the total weight of the solution.

[0014] In yet another embodiment, the isocyanate is used in the aqueous dispersion at a concentration in the range of 15 to 25 weight percent, based on the total weight of the dispersion. In yet another embodiment, the isocyanate is a blocked isocyanate. The blocked isocyanate may be any suitable blocked isocyanate known to be used in RFL adhesive dips, including but not limited to caprolactam blocked methylene-bis-(4-phenylisocyanate), such as Grilbond-IL6 available from EMS American Grillon, Inc., and phenol formaldehyde blocked isocyanates as disclosed in US-A-3,226,276; US-A-3,268,467; and US-A-3,298,984. The blocked isocyanate may be a reaction product of one or more isocyanates and one or more isocyanate blocking agents. Examples of the isocyanate include monoisocyanates such as phenyl isocyanate, dichlorophenyl isocyanate, and naphthalene monoisocyanate; tolylene diisocyanate, dianisidine diisocyanate, hexamethylene diisocyanate, m-phenylene diisocyanate, tetramethylene diisocyanate, alkylbenzene diisocyanate, m-xylylene diisocyanate, cyclohexylmethane diisocyanate, and 3,3-dimethoxyphenylmethane-4,4'-diisocyanate; Examples of the diisocyanates include 1-alkoxybenzene-2,4-diisocyanate, ethylene diisocyanate, propylene diisocyanate, cyclohexylene-1,2-diisocyanate, diphenylene diisocyanate, butylene-1,2-diisocyanate, diphenylmethane-4,4-diisocyanate, diphenylethane diisocyanate, and 1,5-naphthalene diisocyanate; and triisocyanates such as triphenylmethane triisocyanate and diphenylmethane triisocyanate.Examples of isocyanate blocking agents include phenols such as phenol, cresol, and resorcinol; tertiary alcohols such as t-butanol and t-pentanol; aromatic amines such as diphenylamine, diphenylnaphthylamine, and xylidine; ethyleneimines such as ethyleneimine and propyleneimine; imides such as succinimide and phthalimide; lactams such as ε-caprolactam, δ-valerolactam, and butyrolactam; ureas such as urea and diethyleneurea; and oximes such as acetoxime, cyclohexanoxime, benzophenone oxime, and α-pyrrolidone.

[0015] In yet another embodiment, the textile cord is exposed to the isocyanate by immersing the cord in a solution or dispersion of the isocyanate. In either case, the dry cord is preferably drawn into the bath of isocyanate immersion liquid at a speed sufficient to cause the isocyanate-containing liquid to essentially completely penetrate the voids between the yarns. In this manner, it is intended that the isocyanate is exposed to all of the yarn surface area and essentially complete wetting of the yarn surface is achieved. The appropriate speed at which the cord moves through the isocyanate immersion liquid to achieve such penetration and wetting can be determined by one of ordinary skill in the art without undue experimentation.

[0016] In another embodiment, after immersion in the isocyanate bath, the cord is exposed to heat and / or air to remove the solvent (or water, in the case of an aqueous dispersion of isocyanate). Sufficient heat and time are applied to cause the individual yarns to fuse under the influence of the isocyanate. Optionally, the chemically fused cord is wound on a spool for storage.

[0017] In another embodiment, the yarn is one or more of a multifilament yarn and a monofilament yarn (consisting of only a single filament). In yet another embodiment, the yarn is a multifilament yarn. In yet another embodiment, the yarn is a monofilament yarn.

[0018] In another embodiment, the cord consists essentially of isocyanate and yarn, optionally with an RFL (resorcinol-formaldehyde-latex) adhesive and / or surface coating.

[0019] In yet another embodiment, the cord further comprises an adhesive at least partially on the surface of the cord, in other words the cord may be coated, in particular dip coated, with an RFL adhesive or the like, such adhesive improving adhesion between the cord and a rubber composition that is, for example, calendered onto the fused cord to form a layer or sheet / band of cord reinforced rubber.

[0020] In yet another embodiment, each of the yarns has a linear density in the range of 800 dtex to 2200 dtex, preferably in the range of 900 dtex to 1900 dtex, or in the range of 900 dtex to 1700 dtex, or in the range of 900 dtex to 1300 dtex, or in the range of 1000 dtex to 1200 dtex. In one embodiment, the cord has a linear density in the range of 1050 dtex to 1150 dtex.

[0021] 1 dtex, or 1 decitex, as known in the art of textile cords, means the weight of 1 gram (g) per 10,000 meters (m) of yarn (untwisted / untwisted), or its equivalent.

[0022] In yet another embodiment, the cord is formed by twisting together 3 to 10, or 4 to 10, or 5 to 10, or 6 to 10, or 7 to 10, preferably 8 to 10 yarns. In other words, the cord preferably consists of 8 to 10 yarns, in particular 8, 9 or 10 yarns, with 9 yarns being particularly preferred.

[0023] In yet another embodiment, the cord has a twist factor within the range of 1 TPI (twists per inch) to 4 TPI, or 1 TPI to 3 TPI, or 1.5 TPI to 2.5 TPI.

[0024] In yet another embodiment, the cord is formed by twisting together 8-10 yarns, each yarn having a linear density in the range of 800 dtex to 2200 dtex, and the cord has a twist factor of 1 TPI to 4 TPI. The above preferred ranges are applicable here too.

[0025] In yet another embodiment, the cord has a structure selected from 1100 / 9, 1100 / 8, 1100 / 7, 940 / 2 / 3, 940 / 3 / 3, 940 / 9, 1100 / 2 / 3, 1100 / 3 / 3, 1100 / 3 / 4, 1670 / 6, 1670 / 2 / 3, 2200 / 3, and 2200 / 2 / 2.

[0026] In yet another embodiment, the cord has a (total) linear density in the range of 6000 dtex to 14000 dtex, preferably in the range of 8000 dtex to 12000 dtex, or in the range of 9000 dtex to 11000 dtex.

[0027] In yet another embodiment, the yarn is a PET yarn, which is a preferred material herein.

[0028] In yet another embodiment, the cord is composed of two of the listed yarn types to form a hybrid cord, optionally with one of the yarn types in the cord being a PET yarn.

[0029] In yet another embodiment, the cord has a stiffness in the range of 3000 mg to 15000 mg, or 5000 mg to 15000 mg, as determined according to ASTM D1388.

[0030] In yet another embodiment, the cord has a maximum diameter in the range of 1 mm to 2 mm, preferably 1 mm to 1.5 mm, or 1.1 mm to 1.4 mm.

[0031] According to a second aspect of the invention, a non-pneumatic tire comprises a circumferential tread portion and a circumferential shear band supporting the tread portion, the shear band comprising a plurality of circumferential layers, also called shear layers, at least one of said layers comprising a rubber composition reinforced by a textile cord (or cords) comprising yarns at least partially fused to form a cord. Preferably, a majority of the yarns are fused to form the cord, in other words each cord. The yarns are selected from one or more of aramid, polyamide, polyester, polyethylene terephthalate, polyethylene naphthalate, glass fiber and carbon fiber yarns.

[0032] In one embodiment, the cords are arranged essentially parallel to one another in said at least one layer, for example they may be arranged essentially parallel in a plane, for example parallel to a surface of said layer, such as a radially upper surface of said layer.

[0033] In another embodiment, the cords are provided in at least one of the layers at (cord density) 1.5 to 20 ends per inch (EPI), or 1.5 to 15 EPI, preferably 8 to 12 EPI.

[0034] In yet another embodiment, each cord has one or more of the number of twist yarns, linear yarn density, twist modulus, cord construction, and stiffness as already described herein above in the embodiments related to the first aspect of the invention.

[0035] In yet another embodiment, each layer (provided it is cord reinforced) comprises a plurality of parallel cords (e.g., laid out in a plane) that are calendered (e.g., in a rubber calender) with a rubber composition. In particular, the plurality of parallel cords are preferably calendered on two sides with rubber. Such calendering is known in the tire art.

[0036] In yet another embodiment, the rubber composition may include one or more rubbers or elastomers, such as one or more of natural rubber, synthetic polyisoprene, polybutadiene rubber, and styrene butadiene rubber. Optionally, the rubber composition further includes a filler, such as one or more of carbon black and silica. Still optionally, the rubber composition further includes one or more of oil, resin, processing aid, vulcanization accelerator, antidegradant, zinc oxide, and sulfur. The rubber composition may include additional components.

[0037] In yet another embodiment, said layer has a radial thickness in the range of 1 mm to 3 mm, preferably in the range of 1.5 mm to 2.5 mm, in other words the radial thickness of the layer, e.g. the calendered layer, comprising the rubber composition reinforced by the cords.

[0038] In yet another embodiment, the shear band comprises a woven cord or at least two layers comprising cords.

[0039] In yet another embodiment, the shear band comprises at least one radially inner belt layer comprising metal cords (optionally reinforced with a rubber composition, preferably parallel) and at least one radially outer belt layer comprising metal cords (optionally reinforced with a rubber composition, preferably parallel). Optionally, at least one of said layers comprising textile cords is arranged between the at least one radially inner belt layer and the at least one radially outer belt layer. For example, the shear band may comprise one, two, three or four of said layers comprising textile cords between said belt layers. Optionally, two radially adjacent layers comprising textile cords are spaced from each other by one or more further layers not comprising cord reinforcement.

[0040] In yet another embodiment, at least one radially outer belt layer is reinforced with metal cords which form an angle with the circumferential direction of the tire in the range of 10° to 40°, preferably in the range of 10° to 30°, more preferably in the range of 15° to 25°. Additionally or alternatively, at least one radially inner belt layer is reinforced with metal cords which form an angle with the circumferential direction of the tire of at most 5°, preferably at most 2°.

[0041] In yet another embodiment, the shear band comprises at least two (preferably two) radially outer belt layers reinforced by metal cords having opposing angles in the range of 10° to 40°, preferably in the range of 10° to 30°, and more preferably in the range of 15° to 25° with respect to the circumferential direction of the tire. Additionally or alternatively, the shear band comprises at least two radially inner belt layers reinforced by metal cords having optionally opposing angles of at most 5°, preferably at most 2° with respect to the circumferential direction of the tire.

[0042] In yet another embodiment, one or more of the belt layers has a plurality of metal cords provided in the range of 5 EPI to 40 EPI, preferably 10 EPI to 30 EPI.

[0043] In yet another embodiment, said belt layer and / or each of the layers comprising at least one cord has a radial thickness in the range of 1 mm to 3 mm, preferably in the range of 1.5 mm to 2.5 mm.

[0044] In yet another embodiment, such layers are radially spaced by one or more rubber layers, preferably free of cord reinforcement.

[0045] In yet another embodiment, the rubber layer without the cord reinforcement has a radial thickness in the range of 0.2 mm to 1.5 mm, preferably in the range of 0.3 mm to 1 mm, or in the range of 0.3 mm to 0.7 mm.

[0046] In yet another embodiment, layers including textile cords and layers without cord reinforcement are provided alternately (and / or radially) on top of each other. In particular, such an embodiment including an additional layer without cord reinforcement may help provide a lighter shear band and / or tire. The robust textile cords in the textile cord reinforced rubber layer may help provide the desired stability or stiffness to the shear band. Optionally, the layers of this embodiment, if present, are provided radially between one or more radially inner belt layers and one or more radially outer belt layers.

[0047] In yet another embodiment, the shear band comprises only layers comprising textile cords in a radial direction between at least one radially outer belt layer and at least one radially inner belt layer. Optionally, it comprises layers comprising at least 3, preferably at least 5, and / or at most 12, preferably at most 10 textile cords. In one embodiment, the shear band comprises 6 layers comprising textile cords.

[0048] In yet another embodiment, the shear band comprises a radially adjacent pair of layers comprising textile cords and rubber layers not comprising cord reinforcement. For example, the shear band is comprised of two radially adjacent layers comprising textile cords (i.e. a first pair of layers comprising textile cords) and two further radially adjacent layers comprising textile cords (i.e. a second pair of layers comprising textile cords), and optionally two radially adjacent layers without cord reinforcement (i.e. a pair of layers without cord reinforcement / pair of unreinforced rubber layers), with two radially adjacent layers without cord reinforcement (i.e. a pair of layers without cord reinforcement / unreinforced layers) radially provided between i) the two radially adjacent layers comprising textile cords and ii) the two further radially adjacent layers comprising textile cords (or radially between both pairs of layers comprising textile cords).

[0049] In yet another embodiment, a stack of at least two (preferably two) adjacent layers comprising textile cords has at least one (preferably one) rubber layer without cord reinforcement on each radial side. Optionally, further layers reinforced with textile cords are provided adjacent the radially inner belt layer and the radially outer belt layer, for example also adjacent each one of the rubber layers without cord reinforcement.

[0050] In yet another embodiment, the shear band comprises at least two layers comprising woven cords, the at least two layers being (radially) disposed between at least one radially inner belt layer and at least one radially outer belt layer.

[0051] In yet another embodiment, the layers described herein extend circumferentially and / or axially, and the thickness of such layers is measured in the radial direction of the tire.

[0052] According to a third aspect, the present invention is directed to a non-pneumatic tire comprising a circumferential tread portion and a circumferential shear band supporting the tread portion, the shear band comprising a plurality of circumferential layers, at least one of the layers (preferably at least two) comprising a rubber composition reinforced by a woven cord comprising yarns at least partially fused to form a cord. Further, the yarns are selected from one or more of polyester, polyethylene terephthalate, and polyethylene naphthalate yarns (preferably polyethylene terephthalate yarns). Still according to the third aspect, the cord further comprises an isocyanate, and a majority of the yarns (particularly of each cord) are fused by the isocyanate.

[0053] It is emphasized that all features and embodiments of the above aspects can be combined with each other.

[0054] FIG. 1 shows a non-pneumatic tire 1 according to a particular embodiment of the present invention. The tire 1 has a circumferential tread 100 circumferentially supported by a radially inner shear band 200, which is in contact with a circumferential support structure 300. The support structure 300 comprises a radially inner circumferential hub portion 330 (which can be attached to a rim, e.g. a metal rim - not shown here) and a radially outer circumferential ring / band portion 310 which is in contact with and supported by the shear band 200. Furthermore, the support structure 300 comprises a number of support elements or spokes 320 which extend from the hub portion 330 to the radially outer circumferential ring or band portion 310. For example, the support structure 300 can be made of rubber and / or thermoplastic materials. The shear band 200 preferably has a number of layers, as further shown in the example of FIG. 2 herein. The tread 100 preferably comprises one or more rubber compositions.

[0055] 2 shows a schematic cross-section of a shear band 200, which in this embodiment includes multiple layers extending substantially axially and / or circumferentially, the layers being radially stacked together.

[0056] The axial direction "a" is parallel to the axis of rotation of the tire 1. The radial direction "r" is perpendicular to the axial direction "a" and the circumferential direction "c" as shown in Fig. 2. These directions are not necessarily limited to any particular direction unless otherwise stated in this specification.

[0057] In the specific example of FIG. 2, the shear band 200 has nine layers arranged radially on top of each other. In this specific and non-limiting example, the radially outer layers of the shear band 200 are the radially outer belt layers 212, 213, each of which includes a metal reinforcement and is arranged at a low angle, for example less than 2°, relative to the circumferential direction of the tire 1. Thus, each of the radially outer belt layers 212, 213 includes a rubber composition reinforced with metal cords, preferably obtained in a calendering machine. Similarly, the radially inner belt layers 210, 211 are also reinforced with metal cords. Preferably, such metal cords are oriented parallel to each other and extend at an angle of less than 2° relative to the circumferential direction of the tire 1. The metal cords are preferably made of steel and are optionally further coated with brass. The metal cords are provided with an EPI (ends per inch) in the range of 11 to 15 EPI, preferably 13 EPI.

[0058] Furthermore, the shear band 200 includes four textile cord reinforcement layers 214, 215, 216, 217. The textile cords include PET yarns chemically fused with isocyanate. The preferred cord structure in this embodiment is 1100 / 9. The cords are furthermore dip coated with RFL adhesive to improve the cord-rubber bond. In each textile cord reinforcement layer 214, 215, 216, 217, the textile cords are essentially arranged parallel to each other with a cord density within the layer of about 10 EPI. Each layer 214, 215, 216, 217 includes or consists of a rubber composition including the textile cords (e.g., also prepared in a rubber calender). Each layer 214, 215, 216, 217 may include the same rubber composition.

[0059] In this embodiment, the radial thickness of all layers 210, 211, 212, 213, 214, 215, 216, 217, except for layer 218, is approximately 2 mm. The non-reinforced layer 218, located in the radial center of the shear band 200, comprises a rubber composition without cord reinforcement. The radial thickness of the non-reinforced rubber layer 218 is approximately 0.5 mm. Thus, preferably, the radial thickness of the entire shear band 200 is in the range of 15 mm to 18 mm, more preferably in the range of 15.5 mm to 17.5 mm.

[0060] Optionally, although not explicitly shown herein, the shear band 200 has an additional layer, for example having a radial thickness of about 1 mm, facing the support structure 300, and in particular the radially outer circumferential ring portion 310. Such an additional layer may be a layer of a rubber composition that increases the tack (or bond) to the radially outer circumferential ring portion 310, and may be referred to herein as a bond layer. Such an additional layer may also be applied to the other embodiments of the shear bands referred to herein.

[0061] FIG. 3 shows another shear band 200' for a tire according to an embodiment of the invention. In this embodiment, the shear band 200' has two radially inner belt layers 220, 221 each reinforced by parallel metal cords. In particular, these metal cords have a low angle with respect to the circumferential direction of the tire, as already described above for the shear band 200, for example. Each of the radially outer belt layers 222, 223 also consists of essentially parallel metal cords. However, contrary to the previous embodiment, the metal cords of the belt layer 222 are arranged at an angle of 23° with respect to the circumferential direction of the tire. Furthermore, the belt layer 223 consists of metal cords arranged at an angle of 23° (with respect to the circumferential direction of the tire) opposite to the angle of the metal cords of the belt layer 222.

[0062] Six radially adjacent textile cord reinforced rubber layers 224, 225, 226, 227, 228, 229 are arranged between the radially inner belt layers 220, 221 and the radially outer belt layers 222, 223. Such textile cords in this embodiment correspond to those already described in connection with the embodiment of FIG.

[0063] 3 shows six adjacent layers of textile cord reinforcement, other embodiments not shown herein can have more such layers, for example, three to nine such layers, such as three adjacent textile cord reinforcement layers, or nine adjacent textile cord reinforcement layers, etc. The belt construction can be the same as that shown in FIG.

[0064] FIG. 4 shows another shear band 200″ for a tire according to another embodiment of the invention. In this embodiment, the shear band 200″ has two radially inner belt layers 230, 231 each reinforced by parallel metal cords. Preferably, these metal cords have a low angle with respect to the circumferential direction of the tire, as already described above for example with respect to the shear bands 200 and 200′. Each of the radially outer belt layers 232, 233 also comprises essentially parallel metal cords. The metal cords of the first radially outer belt layer 232 are also arranged at an angle of 23° with respect to the circumferential direction of the tire. The second radially outer belt layer 233 also comprises metal cords, but again at an angle of 23° (with the circumferential direction of the tire) opposite to the angle of the metal cords of the first radially outer belt layer 232.

[0065] The shear band 200'' according to Fig. 4 also consists of six layers between the radially outer belt layers 232, 233 and the radially inner belt layers 230, 231, but the shear band 200'' consists of two non-(cord) reinforced rubber layers 238, 239 and four textile cord reinforced rubber layers 234, 235, 236, 237. Optionally, the two non-reinforced rubber layers 238, 239 can also be integrally formed as a single rubber layer having twice the radial thickness of each of the non-reinforced rubber layers 238, 239. The textile cords can be cords as described in other embodiments herein.

[0066] FIG. 5 shows yet another shear band 200″ for another tire according to yet another embodiment of the invention. The radially outer belt layers 242, 243 and the radially inner belt layers 240, 241 have the same structure as the corresponding layers in the embodiment of FIG. 4. FIG. 5 again has six layers arranged between the radially outer belt layers 242, 243 and the radially inner belt layers 240, 241. Furthermore, four of these layers are textile cord reinforced rubber layers 244, 246, 248, 249. Two more layers are not reinforced with cords, i.e. non-reinforced layers 245, 247. In contrast to the embodiment of FIG. 4, the two radially central layers of the shear band 200″ according to FIG. 5 are textile cord reinforced layers 248, 249, while the two radially adjacent layers 245, 247 are non-reinforced layers. The provision of non-reinforced layers can be used, for example, to adjust the stiffness of the shear band.

[0067] In a non-limiting example, the shear band and tread can be cured simultaneously. In such an example, the uncured ("green") tread is preferably placed over the green shear band, and the two are cured together in a mold. The cured shear band can be attached to a support structure with an adhesive. Alternatively, the green tread, shear band, and support structure (e.g., supporting the tread and shear band to a wheel hub) can be cured together.

[0068] The shear band (exemplified herein as a rubber member) can also be described as a cord-reinforced circumferential band that includes a plurality of (stacked) circumferential rubber layers, most of which are reinforced by cords (including, for example, metal cords and / or textile cords).

[0069] Tables 1-3 show further exemplary embodiments of layered structures of shear bands according to the present invention.

[0070] The first column indicates the radial order of the plies from the tire's supporting structure towards the tread, the second column defines the type of rubber ply, the third column gives information on the number / density of the parallel cords in each layer and the fourth column indicates the radial thickness of each layer.

[0071] [Table 1]

[0072] [Table 2] [Table 3]

[0073] As shown in the different embodiments of the shear band, including those shown in Tables 1-3 above, it is possible to provide different sequences or arrangements of layers including fused cords and non-reinforced rubber layers, preferably between metal cord reinforcement layers or belt layers, such that the overall properties of the shear band, such as stiffness and / or weight, can be tailored to desired levels to provide a non-pneumatic tire.

[0074] While Tables 1-3 above and further embodiments referred to herein include metal cord reinforcement layers, in alternative embodiments these layers are replaced with fused (woven) cord reinforcement layers.

[0075] The present invention and / or embodiments thereof are particularly useful for providing a sturdy non-pneumatic tire with a sturdy / improved shear band, for example, it is possible to provide a stiffer and / or lighter shear band, which also helps reduce rolling resistance.

[0076] The features of the above-described aspects and / or embodiments may be combined with each other.

[0077] Variations in the present invention are possible in light of the description thereof provided herein. While certain representative embodiments and details have been shown for purposes 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. It is therefore to be understood that changes can be made in the particular embodiments described that are within the full intended scope of the invention as defined by the following appended claims.

Claims

1. 1. A non-pneumatic tire comprising a rubber component including at least one woven cord, the cord comprising yarns, a majority of the yarns being fused within the cord, the yarns being selected from one or more of aramid, polyamide, polyester, polyethylene terephthalate, polyethylene naphthalate, fiberglass, and carbon fiber yarns.

2. 。 2. The non-pneumatic tire of claim 1, wherein the cord further comprises an isocyanate, and a majority of the yarns are fused by the isocyanate.

3. 。 The non-pneumatic tire of claim 1 , wherein the cord further comprises an RFL adhesive on at least a portion of a surface of the cord.

4. 。 The non-pneumatic tire of claim 1, wherein each said yarn has a linear density in the range of 800 dtex to 2200 dtex.

5. 2. The non-pneumatic tire according to claim 1, wherein the cord is formed by twisting together 8 to 10 yarns.

6. The non-pneumatic tire of claim 1, wherein the cords have a twist modulus within the range of 1 TPI to 4 TPI.

7. 2. The non-pneumatic tire of claim 1, wherein the cord is formed by twisting together 8 to 10 yarns, each yarn having a linear density in the range of 800 dtex to 2200 dtex, and the cord has a twist factor of 1 TPI to 4 TPI.

8. 2. The non-pneumatic tire of claim 1, wherein the cords have a construction selected from 1100 / 9, 1100 / 8, 1100 / 7, 940 / 2 / 3, 940 / 3 / 3, 940 / 9, 1100 / 2 / 3, 1100 / 3 / 3, 1100 / 3 / 4, 1670 / 6, 1670 / 2 / 3, 2200 / 3, and 2200 / 2 / 2.

9. 2. The non-pneumatic tire of claim 1, wherein the yarn is a polyethylene terephthalate yarn.

10. 2. The non-pneumatic tire of claim 1, wherein the cord has a stiffness in the range of 3000 mg to 15000 mg as determined according to ASTM D1388.

11. The non-pneumatic tire of claim 1, wherein the cords have a maximum diameter within the range of 1 mm to 2 mm.

12. A non-pneumatic tire having a circumferentially extending tread portion and a circumferentially extending shear band supporting the tread portion, the shear band being made of a plurality of circumferentially extending layers, at least one of the layers comprising a rubber composition reinforced with a textile cord including yarns at least partially fused to form a cord, each of the yarns being one or more selected from the group consisting of aramid, polyamide, polyester, polyethylene terephthalate, polyethylene naphthalate, glass fiber and carbon fiber yarns.

13. 。 13. Tire according to claim 12, wherein in said at least one layer having an EPI of 1.5 to 20 EPI, said textile cords are arranged essentially parallel to one another.

14. 。 13. The tire of claim 12, wherein each cord comprises one or more of the following: each yarn having a linear density in the range of 800 dtex to 2200 dtex; and an isocyanate; the yarns being at least partially fused by an isocyanate; A twist factor of 1 TPI to 4 TPI; and Stiffness in the range of 3000 mg to 15000 mg measured according to ASTM D1388.

15. The tire of claim 12, wherein at least one of said layers has a radial thickness in the range of 1 mm to 3 mm.

16. 13. The tire of claim 12, wherein the shear band comprises at least two layers comprising woven cords.

17. 。 13. The tire of claim 12, wherein the shear band comprises: at least one radially inner belt layer comprising metal cords forming an angle with the circumferential direction of the tire of less than 2°; At least one radially outer belt layer including metal cords that form an angle with the circumferential direction of the tire within the range of 10° to 40°; and At least one of the layers including textile cords is disposed between the at least one radially inner belt layer and the at least one radially outer belt layer.

18. 18. The tire of claim 17, wherein each said layer is a cord reinforced rubber layer having a thickness within the range of 1 mm to 3 mm.

19. 20. The tire of claim 17, wherein said shear band comprises at least two layers including said woven cords, said at least two layers being disposed between said at least one radially inner belt layer and said at least one radially outer belt layer.

20. A non-pneumatic tire having a circumferentially extending tread portion and a circumferentially extending shear band supporting the tread portion, The shear band includes a plurality of circumferential layers; at least one of the layers comprises a rubber composition reinforced with a textile cord comprising yarns at least partially fused to form a cord; wherein the yarn is selected from one or more of polyester, polyethylene terephthalate, and polyethylene naphthalate yarns; A non-pneumatic tire in which the cord further comprises an isocyanate, and a majority of the yarns are fused by the isocyanate.

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