Non-pneumatic tire including cord reinforcement spoke

Abstract

To provide a manufacturing method of a non-pneumatic tire which includes a cord reinforcement spoke.SOLUTION: At least one spoke of a plurality of spokes 130 includes a head part 137 on a radially inner side, a foot part 136 on a radially outer side, and a cord-reinforcement material 150 wound between the foot part and the head part of the spoke. In another aspect, at least two adjacent spokes are reinforced by a common cord-reinforcement material that enters from the foot part on the radially outer side into the head part on the radially inner side of one spoke, further passes through a radially inner ring part, enters the head part on the radially inner side of an adjacent spoke, and further extends to the foot part on the radially outer side of the adjacent spoke. In another aspect, a method manufactures such a tire is disclosed.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a non-pneumatic tire having spokes, particularly cord-reinforced spokes. Further, the present invention relates to a method for manufacturing a non-pneumatic tire having cord-reinforced spokes.

Background Art

[0002] Some non-pneumatic tires have a support structure disposed between a tread band and a hub portion and including a plurality of spokes. In some cases, such spokes include a polymeric material. To improve the durability of the spokes of a non-pneumatic tire, the spokes may be reinforced with cords or fiber materials. Progress has been made over the past several years in providing polymeric spokes for non-pneumatic tires, but there is still much room for improvement.

Summary of the Invention

Means for Solving the Problems

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

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

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

Brief Description of the Drawings

[0006]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5a

Figure 5b

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Figure 9

Figure 10

MODE FOR CARRYING OUT THE INVENTION

[0007] According to a first aspect, a non-pneumatic tire has a radially outer circumferential band portion having a (circumferential) tread or tread portion, a radially inner (circumferential) hub portion, and a (circumferential) support structure having a plurality of spokes extending particularly along the circumferential direction between the hub portion and the circumferential band portion. At least one spoke of the plurality of spokes has a radially inner head adjacent to the hub portion and a radially outer foot adjacent to the circumferential band portion, and at least one spoke preferably further has a cord reinforcing material wound continuously, for example a plurality of times, between the foot and the head of the spoke. In particular, providing a continuously extending and / or wound cord reinforcing material serves to provide an advanced support structure, its circumferential sector, and / or spokes with improved durability. Deformation of the spokes such as plastic deformation can be reduced or prevented. Furthermore, such tires, support structures, their circumferential sectors, and / or spokes can be manufactured on a large scale and / or cost-effectively.

[0008] In one embodiment, the spoke includes a polymer composition. Preferably, the cord reinforcing material extends within the polymer composition. Optionally, the spoke can be referred to as a cord-reinforced polymer composition spoke.

[0009] In yet another embodiment, one or more spokes of the spoke and / or the support structure, for example, most or all of the plurality of spokes, include or have one or more cross-sections of an X-shape, V-shape, C-shape, I-shape, H-shape, O-shape, S-shape, Y-shape, semi-X shape, and one or more of the bent and folded shapes / morphologies of the aforementioned shapes in a plane parallel to the equatorial plane of the tire. Preferably, the shape is an X-shape such as a straight or curved X-shape. Another preferred shape is, in particular, a semi-X shape corresponding essentially to an X-shape cut radially. Shapes such as an arcuate or chevron shape can also be mentioned, and the bend thereof is not necessarily at the radial center of the shape.

[0010] In another embodiment, the spoke includes or has an X-shaped cross-section (when viewed in a plane parallel to the equatorial plane of the tire, or a plane parallel to the center line of the tire, or an equivalent plane), and the X-shaped cross-section preferably has one or more of a pair of radially outer legs, a pair of radially inner legs, and an intersection connecting the pair of radially outer legs and the pair of radially inner legs. Preferably, the spoke has, for example in the circumferential direction, one or more of a radially inner connecting portion connecting the radially inner ends of one of the radially inner legs and a radially outer connecting portion connecting the radially outer ends of one of the radially outer legs. It should be noted that the X-shape may be curved, straight, symmetric, or asymmetric. In particular, one or more of the said legs may have, for example in the said cross-section, one or more of a straight, bent, and curved shape.

[0011] In yet another embodiment, the cord reinforcement at least passes through one of the radially inner legs from the radially inner end of one of the radially inner legs, further through the intersection, enters one of the radially outer legs, and further passes through one of the radially outer legs to reach the radially outer end of one of the radially outer legs, and optionally further extends through the radially outer connecting portion to the radially outer end of the other leg of the pair of radially outer legs. Also optionally, the cord reinforcement passes through the other leg of the pair of radially outer legs, towards the intersection, and / or further through the intersection and further extends to the other leg of the pair of radially inner legs. As a further option, the cord reinforcement further extends to the radially inner end of the other leg of the pair of radially inner legs. Such a configuration is particularly excellent in durability.

[0012] In yet another embodiment, the cord reinforcement passes through or traverses the intersection at least twice. Optionally, the cord reinforcement extends laterally relative to itself through the intersection and / or extends spaced (axially) from itself. Optionally, the cord reinforcement consists of at least one cord and / or consists of a cord reinforcement tape. Such options can also be applied to other embodiments of this specification.

[0013] In yet another embodiment, the spoke is a polymer composition comprising one or more of an elastomer composition (preferably a rubber composition) and a thermoplastic polymer, optionally reinforced by a cord reinforcement such as at least one cord.

[0014] In yet another embodiment, the polymer may be one or more of i) one or more polyamide polymers (such as PA-12, PA-11, PA-6, etc.), and ii) one or more thermoplastic polymers, for example, thermoplastic polyester elastomers, thermoplastic polyurethane elastomers, polyamide thermoplastic elastomers, elastomer alloy thermoplastic vulcanizates, thermoplastic polyolefin elastomers, styrenic thermoplastic elastomers, thermoplastic resins (such as polyester resins, polyamide resins, polyurethane resins, etc.). In particular, for the purposes of this specification, the thermoplastic polymer shall also include thermoplastic resins.

[0015] In yet another embodiment, the thermoplastic polymer is a thermoplastic elastomer such as a thermoplastic polyester elastomer.

[0016] In another preferred embodiment, the polymer composition is an elastomeric composition such as a rubber composition. Optionally, the elastomeric composition (such as a rubber composition) includes one or more of rubber (such as those containing one or more of natural rubber, synthetic polyisoprene, butadiene rubber, styrene-butadiene rubber, and butyl rubber), filler (such as those containing one or more of carbon black and silica), resin (such as hydrocarbon resins selected from one or more of coumarone-indene resin, petroleum hydrocarbon resin, terpene resin, styrene / alpha-methylstyrene resin, terpene phenol resin, rosin-derived resin, and their copolymers and / or mixtures), accelerator, antioxidant, oil, liquid diene polymer, coupling agent (such as carbon black coupling agent and silane), sulfur donor, and sulfur. Here, the term "liquid" means that the material is in a liquid state at 23 °C. The composition may be a sulfur-curable or sulfur-cured rubber composition. Optionally, an elastomeric composition such as a rubber composition may be fiber-reinforced.

[0017] In yet another embodiment, the elastomeric composition or rubber composition comprises 100 phr of rubber, including one or more of natural rubber, synthetic polyisoprene, polybutadiene rubber, and styrene butadiene rubber. Preferably, the composition comprises at least 50 phr of natural rubber (such as 50 - 100 phr of natural rubber), and optionally 0 - 50 phr (or 5 - 50 phr) of polybutadiene rubber. Further, the elastomeric or rubber composition preferably comprises a filler, including carbon black and / or silica. For example, such a filler may be in the range of 20 - 150 phr, preferably 30 - 90 phr. Preferably, such a filler mainly comprises carbon black. The elastomeric or rubber composition may further comprise 1 - 40 phr of a resin, preferably including a phenolic resin. Further, the elastomeric or rubber composition may comprise 1 - 30 phr, preferably 1 - 20 phr of an oil. Finally, the elastomeric or rubber composition may typically comprise 1 - 15 phr of an anti-degradant, 0.5 - 10 phr of an accelerator, 0.1 - 10 phr of zinc oxide, and 0.5 - 10 phr of sulfur. Also, other components may be included.

[0018] In yet another embodiment, the spoke may comprise a plurality of polymer compositions, such as a plurality of layers or portions of such a composition.

[0019] In yet another embodiment, the cord reinforcement is selected from one or more of i) at least one cord, ii) at least one cord reinforcement tape, and iii) at least one fabric comprising cords. In one option, the cord reinforcement has or consists of at least one cord. Preferably, the cord is either a multifilament cord or a monofilament cord. In another option, the cord reinforcement tape comprises a plurality of essentially parallel cords optionally embedded in and / or connected by a polymer composition such as a resin composition to form the tape, and the polymer composition may comprise one or more of polyester, vinyl ester, polyurethane, and epoxy. In another option, the fabric may preferably comprise a plurality of essentially parallel cords that are interconnected. Optionally, these cords may form the warp cords and / or the weft cords of the fabric.

[0020] In yet another embodiment, the cord reinforcement, particularly one or more cords of the cord reinforcement, comprises or consists of one or more of a fiber material, a glass fiber material, a carbon fiber material, a boron fiber material, a basalt fiber material, a plant-derived material, and combinations of these materials. Optionally, the plurality of cords comprises different materials and / or is a hybrid cord of such different materials. Optionally, the plant-derived material comprises one or more of cotton, hemp, flax, sisal, and bast.

[0021] In yet another embodiment, the cord reinforcement, particularly one or more cords of the cord reinforcement, comprises or consists of a metal such as steel or brass-coated steel.

[0022] In yet another embodiment, the cord reinforcement, in particular one or more cords of the cord reinforcement, comprises or consists of a fiber material selected from one or more of polyester (preferably PET), polyamide (preferably PA-6, PA-6,6, such as nylon®, and aromatic polyamide / aramid), and rayon. Optionally, one or more of these materials may be recycled materials. Optionally, the plurality of cords comprises different materials and / or is a hybrid cord of such different materials.

[0023] In another embodiment, one or more cords provided herein are either single-filament cords or multifilament cords. For example, the cord may have a (maximum) diameter in the range of 0.01 - 2 mm, preferably 0.01 - 1 mm, measured perpendicular to the extension of the cord in the spoke.

[0024] In yet another embodiment, the cord reinforcement is wound multiple times between the foot and the head, and / or the multiple passes of the cord reinforcement between the foot and the head are spatially (and / or axially) separated from each other between the foot and the head. It should be noted that the winding or passing of the cord reinforcement between the foot and the head does not exclude the winding and / or passing of the cord reinforcement through said portion. Optionally, the cord reinforcement passes through said portion or a plurality of cord reinforcements pass through said portion.

[0025] According to a second aspect, the present invention relates to a non-pneumatic tire having a radially outer circumferential band portion having a (circumferential) tread or tread portion, a radially inner (circumferential) hub portion, and a support structure disposed radially between the band portion and the hub portion. Further, the support structure has a (circumferential) radially outer ring portion, a (circumferential) radially inner ring portion, and a plurality of spokes extending from the radially outer ring portion to the radially inner ring portion, preferably along the circumferential direction. According to a further second aspect, each spoke has a radially inner head and a radially outer foot, and at least two (circumferentially) adjacent spokes of the plurality of spokes are reinforced by a common cord reinforcement, and the cord reinforcement extends at least from the radially outer foot of one of the two adjacent spokes through the spoke to the radially inner head of the adjacent spoke. Further, the cord reinforcement enters the radially inner head of the other spoke of the adjacent spoke through the radially inner ring portion and further extends through the other spoke to the radially outer foot of the other spoke. Thus, such adjacent spokes and their respective ring portions are reinforced by a common cord reinforcement, thereby improving the durability of the support structure or its circumferential sector. Deformation of the spokes, such as deformation and / or plastic deformation of the support structure, can be reduced or prevented. Further, such tires, support structures, and / or spokes can be manufactured on a large scale.

[0026] In one embodiment, the cord reinforcement extends through and / or reinforces most of the spokes of the tire.

[0027] In another embodiment, the cord reinforcement extends through a plurality of spokes along the circumferential sector of the tire and / or of the support structure or its circumferential sector.

[0028] In another embodiment, the cord reinforcement extends through at least 3, 4, 5, or 6 spokes of the tire and / or of the support structure or its circumferential sector.

[0029] In yet another embodiment, the cord reinforcement extends around the tire at least twice such that it extends through each spoke at least twice. Preferably, when extending through the same spoke a second time, the cord reinforcement is axially spaced from itself within this spoke, such as being separated by the polymeric composition of the spoke. Optionally, the cord reinforcement consists of at least one cord and / or consists of a cord reinforcement tape.

[0030] In yet another embodiment, the cord reinforcement extends multiple times between two circumferential ends of a circumferential sector of the support structure and optionally extends multiple times (e.g., twice) through each spoke within the sector.

[0031] In yet another embodiment, two adjacent spokes each have an X-shaped cross-section, and the X-shaped cross-section has one or more of a pair of radially outer legs, a pair of radially inner legs, and an intersection connecting the pair of radially outer legs and the pair of radially inner legs.

[0032] In yet another embodiment, the cord reinforcement passes through one or more of the first radially outer legs of the first spoke of two (circumferentially) adjacent spokes, then through the intersection of the first spoke, then through the first radially inner leg of the first spoke, and extends into the radially inner ring portion and optionally enters from the radially inner ring portion into the first radially inner leg of the second spoke of the adjacent spoke, then passes through the intersection of the second spoke, and extends into the first radially outer leg of the second spoke.

[0033] In yet another embodiment, the cord reinforcement extends from the radially outer leg of the second spoke, through yet another spoke of the tire, and optionally (further) around the circumference of the tire. Preferably, the cord reinforcement enters the second radially inner leg of the first spoke of two adjacent spokes, further passes through the intersection of the first spoke, passes through the second radially outer leg of the first spoke and enters the radially outer ring portion, enters the second radially outer leg of the second spoke from the radially outer ring portion, further passes through the intersection of the second spoke, and extends into the second radially inner leg of the second spoke.

[0034] In yet another embodiment, the cord reinforcement extends through the intersection of each of two adjacent spokes at least twice. Preferably, the cord reinforcement extends laterally with respect to itself through the intersection and / or extends axially spaced from itself.

[0035] In yet another embodiment, the cord reinforcement extending through each spoke at least twice is spatially separated from itself, for example axially.

[0036] According to a third aspect, a method of manufacturing or fabricating a non-pneumatic tire comprising a support structure with cord-reinforced spokes includes providing a mold member for forming at least a circumferential sector of a support structure having one or more spokes. Further, the method includes winding a cord reinforcement between the radially outer feet and the radially inner heads of one or more spokes in the circumferential sector of the support structure to be formed. According to a third aspect further, the method includes overmolding the cord reinforcement with a polymer composition to obtain a circumferential sector of a support structure having one or more spokes.

[0037] Optionally, the method is used to manufacture a tire according to the first aspect or the second aspect, and optionally to manufacture a tire according to one or more respective embodiments.

[0038] In one embodiment of the method, the step of winding the cord reinforcement comprises winding the cord reinforcement (supported, for example, by one or more mold segments) from at least one of the radially outer foot and the radially inner head of the first spoke to the other of the radially outer foot and the radially inner head of the first spoke, optionally further winding from the other of the radially outer foot and the radially inner head of the first spoke back to the one of the radially outer foot and the radially inner head of the first spoke, and again winding from the one of the radially outer foot and the radially inner head of the first spoke to the other of the radially outer foot and the radially inner head. For example, such a step may be performed to provide a spoke according to the first aspect, or one or more of its embodiments.

[0039] In another embodiment, the cord reinforcement is wrapped around and / or supported by one or more mold members (such as a mold insert or a mold core member), particularly before overmolding the cord reinforcement with a polymer composition. Wrapping the cord reinforcement directly around one or more mold members can provide an economical option for manufacturing. Optionally, one or more cord reinforcements may be spaced from the surface of the mold member by one or more polymer layers.

[0040] In yet another embodiment, the cord reinforcement is held at a distance from one or more adjacent mold members, such as a mold insert or a mold core member, by protrusions on those mold members, whereby, optionally, by overmolding the cord reinforcement with a polymer composition, the cord reinforcement can be at least primarily sealed along its extension.

[0041] In yet another embodiment, the protrusions are provided at the edges of one or more mold members. Optionally, the protrusions have a curved surface. Such a surface helps prevent damage to the cord reinforcement.

[0042] In another embodiment, winding at least one cord reinforcement comprises winding the cord reinforcement from the radially outer foot of the first spoke to the radially inner head of the first spoke, from the radially inner head of the first spoke to the radially inner head of the (circumferentially) adjacent second spoke, from the radially inner head of the second spoke to the radially outer foot of the second spoke, and from the radially outer foot of the second spoke to the radially outer foot of the third spoke adjacent to the second spoke on the side opposite the first spoke, for example along a circumferential sector of the support structure. For example, such an embodiment may be used to manufacture a tire, a support structure, or a circumferential sector (e.g., per se) as according to or related to one or more of the embodiments of the second aspect of the present invention.

[0043] In yet another embodiment, the support structure, or at least a circumferential segment or sector of the support structure, is manufactured by the method, for example separately manufactured. For example, a support structure or a circumferential sector thereof, preferably having a plurality of spokes, can be formed within a mold ring defining the shape of the support structure. When manufacturing a circumferential segment or sector of the support structure, such a segment or sector can be manufactured, for example, using a mold in the form of a corresponding ring segment or ring sector.

[0044] In yet another embodiment, the method comprises winding the cord reinforcement through yet another spoke of the tire around the tire and / or around a circumferential sector of the support structure.

[0045] In yet another embodiment, the cord reinforcement extends back into the first spoke after being wound around the tire through the yet another spoke of the support structure.

[0046] FIG. 1 shows a schematic side view of a tire 1 having a circumferential band or band portion 110 including a circumferential tread or tread portion 10 supported by a circumferential shear band 20. Further, the tire 1 has a circumferential hub portion 160, and the circumferential band portion 110 and / or its shear band 20 is supported on the hub portion 160 by a support structure 140 having a plurality of spokes 130 along the circumferential direction. In this embodiment, the spokes 130 are in a bent X shape.

[0047] One of those spokes 130 is shown in detail in FIG. 2. The illustrated spoke 130 has a pair of radially outer legs 131, a pair of radially inner legs 132, and an intersection 133 connecting the legs 131, 132. Further, the radially outer legs 131 are connected by a radially outer connection 134, and the radially inner legs 132 are connected by a radially inner connection 135. The spoke 130 is reinforced by at least one cord 150 wound between a radially inner head 137 and a radially outer foot 136, here by a cord 150 wound essentially in a Z pattern. In particular, in this embodiment, the cord 150 passes through the connection 135, then through one of the radially inner legs 132 therefrom, further through the intersection 133, further through one of the radially outer legs 131, and further into and through the connection 134 and is wound.

[0048] In a plurality of embodiments and / or drawings herein, for better orientation, a circumferential direction c, an axial direction a, and a radial direction r are shown. The circumferential direction c is perpendicular to the axial direction a. The same applies to the radial direction r. The axial direction a is parallel to the rotation axis of the tire. Such directions referred to in this specification are not necessarily limited to a particular orientation of a given direction unless otherwise specifically stated in this specification.

[0049] A schematic cross-section of FIG. 3 shows another spoke 230 of a support structure according to an embodiment of the present invention. The spoke 230 is in a straight X-shape. That is, a pair of radially inner legs 232 and a pair of radially outer legs 231 extend linearly. Both legs 231, 232 are connected to each other radially by an intersection 233. Further, the pair of radially inner legs 232 are connected at their inner radial portions by a radially inner connection 235. Similarly, the pair of radially outer legs 231 are connected at their outer radial portions by a radially outer connection 234. The spoke 230 is cord-reinforced by a cord 250, which winds from the radially outer connection 234 through one of the radially outer legs 231, through the intersection 233, further through one of the radially inner legs 232 into the radially inner connection 235, then into the other of the radially inner legs 232, again into the intersection 233, from there into the other of the radially outer legs 231, and into the radially outer connection 234. Further, in this embodiment, the cord 250 intersects horizontally at the intersection 233. Preferably, the cord 250 intersects at the intersection 233 at a distance from itself, particularly axially. Although not shown in the embodiment of FIG. 3, it is also possible for the cord to be wound multiple times between the foot 236 and the head 237 of the spoke 230. Similar options are shown in FIG. 5a described later in this specification.

[0050] Figure 4 shows yet another embodiment of a partial or circumferential segment of a support structure having a spoke 330 according to another embodiment of the present invention. This spoke 330 has a radially inner head 337 and a radially outer foot 336 connected by a rib portion 333. In this embodiment, the rib portion 333 is bent or curved circumferentially. However, in similar embodiments, it is also possible for the cross-section of the rib portion 333 to be linear or bent (not shown in this embodiment). In the cross-section shown in Figure 4, a cord 350 is wound between the radially inner head 337 and the radially outer foot 336. Thus, in this embodiment, the cord passes twice through the radial height of the rib portion 333 and / or extends over twice the radial height. Similarly, in other embodiments disclosed herein having an X-shaped cross-sectional shape, it can also be said that the cord reinforcement extends over at least twice the radial height of the spoke and / or passes through at least twice the radial height. In the embodiment of Figure 4, the cord 350 is essentially along and through the rib portion 333. Alternatively, it can also cross (laterally) at the rib portion 333. Preferably, the cord is spaced from itself when extending through the rib portion 333 at least twice (e.g., in one or both of the axial and circumferential directions).

[0051] FIG. 5a shows one embodiment of manufacturing a circumferential sector of a support structure having an X-shaped spoke using a mold 400, in which a cord 450 is wound multiple times between the head and the foot of the spoke to be manufactured. In particular, the embodiment shown in FIG. 5a has two mold inserts 410, 420 around which the cord 450 is wound. These mold inserts 410, 420 can be inserted axially into the mold cavity 470 of the mold 400 so as to define the outer shape of the spoke to be formed. As can also be seen in FIG. 5a, the cord 450 crosses multiple times at the intersection of the spokes and / or between both mold inserts 410, 420. Preferably, the cord 450 crosses through the spoke and / or at a distance from itself, for example, axially at a distance. In other words, preferably, the cord 450 is arranged at a distance from itself over most of its length or extension. When the cord 450 and the mold inserts 410, 420 are inserted into the mold cavity 470, the cord 450 can be overmolded in the mold cavity 470 using a polymer composition such as a rubber composition or other compositions disclosed herein. In particular, the mold 400 can have one or more flow paths or passages (not explicitly shown) for injecting the polymer composition into the mold cavity 470, that is, into one or more gaps formed between the mold inserts 410, 420 and the outer mold member 490 that defines the mold cavity 470 of the mold 400.

[0052] FIG. 5b discloses another embodiment schematically showing a method of manufacturing a support structure and / or a circumferential sector of a spoke having an X-shaped cross-section using a mold 400'. As shown in the cross-section of FIG. 5b, the mold 400' has two mold inserts 410', 420' that are inserted into a mold cavity 470' of an outer mold member 490' to at least partially define the outer shape of the spoke to be formed. A cord 450' is wound between both radial ends (e.g., the head and base of the spoke to be formed) on the mold inserts 410', 420'. The mold inserts 410', 420' have, in addition to the design shown in FIG. 5a described above, projections, spacers, or in other words, bulges 480' at their (axially extending) edges, which are adapted to space the cord 450' wound around the mold inserts 410', 420' from the sides of the mold inserts 410', 420'. Preferably, the cord 450' is essentially centered between the adjacent surfaces of each mold insert 410', 420' and the adjacent surfaces of the outer mold member 490' facing each mold insert 410', 420'. Thus, the region where the cord 450' may appear on the surface of the spoke can be reduced and / or prevented. Once the cord 450' is placed on the mold inserts 410', 420' within the mold cavity 470' and optionally tensioned, the remaining space or gap in the mold cavity 470' may be filled with one or more polymer compositions to overmold the cord 450' to form the spoke. For overmolding, the mold 400' is preferably closed on one or both of its axial and / or planar sides. Additionally, as another option, the mold 400' may have one or more inlets and / or flow paths for injecting one or more polymer compositions into the mold cavity 470'. It is also possible to inject different polymer compositions to compose the spoke of multiple polymer compositions over one or more of its width, height, and length. The same also applies to the embodiments described above.

[0053] FIG. 6 shows a schematic perspective view of a circumferential sector of a support structure 540 having six spokes 530 extending radially between a radially inner ring portion 545 and a radially outer ring portion 544. In this embodiment, each spoke has an X-shaped cross section in a plane parallel to the equatorial plane of the tire or the circumferential center line of the tire. For example, it is possible to manufacture a plurality of such circumferential sectors 540 of the support structure. Such sectors 540 can later be assembled to form a complete circumferential support structure. In particular, such sectors 540 can be molded, for example, from an unvulcanized rubber composition and later cured or co-cured together with another sector to form a (complete) annular support structure. Also, other unvulcanized components of the non-pneumatic tire can be assembled with the support structure or a sector thereof and later co-cured together. Additionally, or alternatively, as is known to those skilled in the art, adhesives can be used to attach and / or connect the plurality of parts and / or components of the tire. The sector 540 shown in FIG. 6 is reinforced with one or more cords (extending inside the spoke 530 and not visible in the perspective view of FIG. 6).

[0054] In this context, FIG. 7 shows a schematic cross-section of the sector of FIG. 6, in which the code 550 extends through all of the plurality of spokes 530 from one circumferential end of the sector 540 to the other circumferential end of the sector 540. In particular, the code 550 enters from the left, i.e., from the first circumferential end of the radially outer ring portion 544, passes through the first leg portion 531 of the spoke 530, further passes through its intersection, enters the radially inner leg portion 532, and further extends into the radially inner ring portion 545. From there, it extends to the radially inner leg portion 532' of the adjacent second spoke, enters its intersection, enters one of its radially outer leg portions 531', and then continues to extend into the radially outer ring portion 544. As can be seen in FIG. 7, such a trajectory of the code through the spokes 530 continues along the circumferential sector 540. Thereby, since the adjacent spokes 530 are interconnected by the same code 550, the durability of the support structure and / or its spokes 530 can be significantly improved. Also, the connection between both ring portions 545, 544 and the adjacent spokes 530 connecting these ring portions 545, 544 is improved.

[0055] Figure 8 shows an alternative embodiment of a segment similar to that already shown in Figure 7. According to Figure 8, a segment or sector 640 of the support structure has two cords 650, 650'. The illustrated sector 640 has a plurality of spokes 630 connecting a radially inner ring portion 645 and a radially outer ring portion 644. Cord 650 extends through sector 640, similar to cord 550 of the previously described embodiment of Figure 7. However, cord 650' of Figure 7 also extends through sector 640. In this non-limiting embodiment, cord 650' extends from the radially inner ring portion 645, through the radially inner leg 632 of the first spoke 630, through its intersection 633 into the radially outer leg 631, and further into the radially outer ring portion 644. From this ring portion 644, it enters the radially outer leg of another adjacent spoke 630, passes through the intersection of the adjacent spoke 630 from this adjacent radially outer leg, passes through the radially inner leg from this intersection, and extends towards the radially inner ring portion 645 of sector 640. It should be noted that cords 650 and 650' preferably intersect axially spaced apart from each other at each spoke 630 (especially at its intersection). Such an arrangement of cords 650, 650' helps to significantly improve the durability of sector 640 of the support structure. Although not shown herein, optionally, a similar effect can be obtained using only a single cord. In particular, such a cord can loop or reciprocate within the same sector, or extend multiple times within a sector of the support structure.

[0056] Figure 9 shows another embodiment of the support structure, namely another embodiment of only its circumferential segment or sector 740. The shape of sector 740 is similar to the shape of the sectors already shown in FIGS. 7 and 8. However, unlike these previously described embodiments, sector 740 of FIG. 9 has a plurality of cords, namely cords 750, 751, 752, 753, 754, 755, 756. In particular, such cords form an essentially ring-shaped cord reinforcement that connects and / or reinforces the legs adjacent in the circumferential direction of adjacent spokes 730. In the embodiment shown in FIG. 9, two separate cords pass through the intersection of each spoke. In particular, these two cords are circumferentially spaced from each other. However, it is also possible for these two cords to be axially spaced from each other and overlap or intersect circumferentially. Looking at one of the plurality of cords, such as cord 751, cord 751 enters from the radially outer ring portion 744 into the radially outer leg of the adjacent spoke, passes through the adjacent intersection, further passes through the radially outer leg, and extends towards the radially inner ring portion 745. It passes through the radially inner leg of the adjacent spoke from the radially inner ring portion 745, further enters the intersection of the same spoke, further enters the radially outer leg of the same spoke, and returns to the radially outer ring portion 744 and extends towards the opposite end thereof.

[0057] FIG. 10 shows yet another embodiment of the circumferential sector 840 of the support structure, in which the sector 840 has I-shaped spokes 830. These spokes 830 extend between the radially inner ring portion 845 and the radially outer ring portion 844 such that the radially outer ring portion 844 is supported on the radially inner ring portion 845. According to this embodiment, cord 850 extends through a plurality (for example, all) of the spokes 830, for example as shown here, tracing a wavy path between both ring portions 845, 844. Thus, each spoke 830 is reinforced by the same cord 850 that supports the overall stability and durability of sector 840 of the support structure.

[0058] Although not shown in the above-described embodiments, in another embodiment, a plurality of circumferential spoke rows, such as two rows, three rows, or four rows, are provided side by side in the axial direction. For each row, the circumferential positions of such spokes may be the same or may be offset in the circumferential direction.

[0059] The mold, mold insert, and / or mold member are preferably composed of one or more heat-resistant materials having a melting point higher than 200°C, preferably higher than 300°C. Plastic, ceramic, or metal materials are non-limiting examples of such mold materials.

[0060] In summary, the present invention and its embodiments provide durable spokes, sectors of a durable support structure, and / or a durable support structure. Potential plastic deformation of the spokes can be prevented or at least reduced. The cord reinforcements can be arranged in a defined manner and / or mass-produced in a particularly cost-effective manner.

[0061] Note that the aspects, embodiments, and features disclosed in this specification can be combined with each other.

[0062] In light of the description provided herein, variations within the present invention are possible. Specific representative embodiments and details have been shown for the purpose of explaining the present invention, but it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the scope of the present invention. Therefore, it should be understood that changes can be made to the specific embodiments described within the full intended scope of the present invention as defined by the following appended claims.

Claims

Claim 1 A non-pneumatic tire, comprising a circumferential band portion on the radially outer side having a tread, a hub portion on the radially inner side, and a support structure having a plurality of spokes extending between the hub portion and the circumferential band portion, wherein at least one of the plurality of spokes has a radially inner head adjacent to the hub portion and a radially outer foot adjacent to the circumferential band portion, and the spoke has a cord reinforcing material wound between the foot and the head of the spoke. Claim 2 The tire according to claim 1, wherein the spoke contains a polymer composition, and the cord reinforcing material extends within the polymer composition. Claim 3 The tire according to claim 1, wherein the spoke has an X-shaped cross-section, and the X-shaped cross-section has a pair of radially outer legs, a pair of radially inner legs, an intersection connecting the pair of radially outer legs and the pair of radially inner legs, a radially inner connecting portion connecting the radially inner ends of the radially inner legs, and a radially outer connecting portion connecting the radially outer ends of the radially outer legs. Claim 4 The cord reinforcing material at least extends from a radially inner end of one of the radially inner legs through the one of the radially inner legs, further passes through the intersection and enters one of the radially outer legs, further passes through the one of the radially outer legs and reaches a radially outer end of the one of the radially outer legs, further passes through the radially outer connecting portion and reaches a radially outer end of the other leg of the pair of radially outer legs, further passes through the other leg of the pair of radially outer legs, heads towards the intersection, passes through it and enters the other leg of the pair of radially inner legs, and further extends to a radially inner end of the other leg of the pair of radially inner legs. The tire according to claim 3. Claim 5 The tire according to claim 3, wherein the cord reinforcing material passes through the intersection at least twice and extends transversely to itself at the intersection. Claim 6 The spoke includes one or more polymer compositions selected from one or more of a thermoplastic composition and an elastomer composition reinforced by the cord reinforcing material, and the cord reinforcing material has at least one cord including one or more of a fiber material, a glass fiber material, a carbon fiber material, a boron fiber material, a basalt fiber material, a plant-derived material, and a combination of these materials. The tire according to claim 1.

7. The cord reinforcing material is wound a plurality of times between the foot portion and the head portion of the spoke, and the plurality of passes of the cord reinforcing material between the foot portion and the head portion are spatially separated from each other between the foot portion and the head portion. The tire according to claim 1.

8. A non-pneumatic tire, A circumferential band portion on the radially outer side having a tread, A hub portion on the radially inner side, A support structure disposed radially between the band portion and the hub portion, having a radially outer ring portion, a radially inner ring portion, and a plurality of spokes extending from the radially outer ring portion to the radially inner ring portion, Each spoke has a radially inner head portion and a radially outer foot portion, At least two adjacent spokes of the plurality of spokes are reinforced by a common cord reinforcing material, and the cord reinforcing material reaches at least from the radially outer foot portion of one of the two adjacent spokes through the inside of the one of the two adjacent spokes to the radially inner head portion of the one of the adjacent spokes, and further passes through the radially inner ring portion and enters the radially inner head portion of the other spoke of the adjacent spoke, and further extends through the other spoke to the radially outer foot portion of the other spoke. A non-pneumatic tire.

9. The cord reinforcing material extends through and reinforces most of the spoke of the tire. The tire according to claim 8.

10. The cord reinforcing material extends through at least four adjacent spokes in the circumferential sector of the support structure. The tire according to claim 8.

11. The two adjacent spokes each have an X-shaped cross section, and the X-shaped cross section has a pair of radially outer leg portions, a pair of radially inner leg portions, and an intersection portion connecting the pair of radially outer leg portions and the pair of radially inner leg portions. The tire according to claim 8.

12. The cord reinforcing material passes through a first radially outer leg portion of a first spoke of the two adjacent spokes, further passes through the intersection portion of the first spoke, further passes through a first radially inner leg portion of the first spoke, enters the radially inner ring portion, enters a first radially inner leg portion of a second spoke of the adjacent spoke from the radially inner ring portion, further passes through the intersection portion of the second spoke, and extends into a first radially outer leg portion of the second spoke. The tire according to claim 11.

13. The cord reinforcing material extends around the tire through yet another spoke of the tire from the radially outer leg portion of the second spoke. The cord reinforcing material enters a second radially inner leg portion of the first spoke of the two adjacent spokes, further passes through the intersection portion of the first spoke, enters the radially outer ring portion through a second radially outer leg portion of the first spoke, enters a second radially outer leg portion of the second spoke from the radially outer ring portion, further passes through the intersection portion of the second spoke, and further extends into a second radially inner leg portion of the second spoke. The tire according to claim 12.

14. The cord reinforcing material extends through at least two passes through each of the intersection portions of the two adjacent spokes and extends laterally with respect to itself through the intersection portions. The tire according to claim 11.

15. The cord reinforcing material extends around the tire at least twice so as to extend through each spoke at least twice and is spatially separated from itself when passing through each spoke twice. The tire according to claim 8.

16. A method of manufacturing a non-pneumatic tire, wherein the tire has a circumferential band portion on the radially outer side including a tread, a hub portion on the radially inner side, and a support structure having a plurality of cord reinforcing spokes extending between the hub portion and the circumferential band portion, the spokes having a radially inner head and a radially outer foot, and the method includes providing a mold member for forming at least a circumferential sector of the support structure having one or more of the spokes; winding a cord reinforcing material between a radially outer foot and a radially inner head of the one or more spokes in the circumferential sector of the support structure to be formed. Overmolding the code reinforcement with a polymer composition to obtain the circumferential sector of the support structure having the one or more spokes, a method comprising.

17. The step of winding the code reinforcement includes winding the code reinforcement from one of at least a radially outer foot and a radially inner head of the first spoke to the other of the radially outer foot and the radially inner head of the first spoke, and further from the other of the radially outer foot and the radially inner head of the first spoke to the one of the radially outer foot and the radially inner head of the first spoke again, and winding from the one of the radially outer foot and the radially inner head of the first spoke to the other of the radially outer foot and the radially inner head again. The method according to claim 16.

18. Winding the at least one code reinforcement includes winding the code reinforcement from a radially outer foot of a first spoke to a radially inner head of the first spoke, winding from the radially inner head of the first spoke to a radially inner head of an adjacent second spoke, winding from the radially inner head of the second spoke to a radially outer foot of the second spoke, and winding from the radially outer foot of the second spoke along the circumferential sector of the support structure to a radially outer foot of a third spoke adjacent to the second spoke on the side opposite the first spoke. The method according to claim 16.

19. The method according to claim 18, including passing the code reinforcement through yet another spoke of the support structure and winding it around the tire.

20. The method according to claim 19, wherein the code reinforcement extends back into the first spoke after passing the code reinforcement through yet another spoke of the support structure and winding it around the tire.

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