Non-pneumatic tire with fiber metal laminate construction

Abstract

To provide a non-pneumatic tire with a fiber metal laminate construction.SOLUTION: A non-pneumatic tire includes a lower ring having a first diameter and an upper ring having a second diameter greater than the first diameter. The upper ring is substantially coaxial with the lower ring. A support structure connects the lower ring to the upper ring. At least one of the lower ring, the upper ring and the support structure includes a fiber metal laminate having at least one metal foil layer and at least one fiber and resin combination layer.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates to non-pneumatic tires, and more particularly, to non-pneumatic tires having fiber metal laminate construction. [Background technology]

[0002] Various tire designs have been developed that allow the tire to run in an uninflated or underinflated state. Non-pneumatic tires do not require inflation, while "run-flat tires" can continue to operate at relatively high speeds for extended periods of time after being partially or completely deflated. Non-pneumatic tires may include support structures, such as spokes, that connect a lower ring to an upper ring. In some non-pneumatic tires, a circumferential tread is attached to the upper ring of the tire.

[0003] It is known to provide structural reinforcement elements to the rings or spokes of non-pneumatic tires, however, non-pneumatic tires provided with known structural reinforcement elements may suffer from problems related to tire uniformity, crack propagation, fatigue resistance, or impact resistance. Summary of the Invention

[0004] In one embodiment, a non-pneumatic tire includes a lower ring having a first diameter and an upper ring having a second diameter greater than the first diameter. The upper ring is substantially coaxial with the lower ring. A support structure connects the lower ring to the upper ring. At least one of the lower ring, the upper ring, and the support structure includes a fiber metal laminate having at least one metal foil layer and at least one fiber and resin combination layer.

[0005] In another embodiment, a method of manufacturing a non-pneumatic tire includes providing a lower ring having a first diameter, an upper ring having a second diameter greater than the first diameter, and a support structure. The method further includes connecting the lower ring to the upper ring using the support structure. The steps of providing the lower ring, the upper ring, and the support structure include fabricating at least one of the lower ring, the upper ring, and the support structure with a fiber metal laminate including at least one metal foil layer and at least one fiber and resin combination layer.

[0006] In yet another embodiment, a non-pneumatic tire includes a lower ring and a circumferential tread disposed over the lower ring. The circumferential tread includes a tread layer and a tread band. A support structure interconnects the lower ring to the tread band and attaches the circumferential tread to the lower ring. At least one of the lower ring, tread band, and support structure includes a fiber metal laminate having at least one metal foil layer and at least one fiber and resin combination layer. [Brief explanation of the drawings]

[0007] 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 by multiple components, and that elements shown as multiple components may be replaced by a single component. The drawings are not to scale, and the proportions of certain elements may be exaggerated for illustrative purposes. [Figure 1] FIG. 1 is a front view of an embodiment of a non-pneumatic tire. [Figure 2] FIG. 2 is a partially enlarged front view of the non-pneumatic tire of FIG. 1. [Figure 3] 3 is a cross-sectional view of the non-pneumatic tire taken along line 3-3 of FIG. 2. [Figure 4a] 2 is a detailed cross-sectional view of one embodiment of a fiber metal laminate that may be used in various portions of the non-pneumatic tire of FIG. 1. FIG. [Figure 4b] FIG. 4b is a perspective cutaway view of FIG. 4a. [Figure 5] 1 is a cross-sectional view of another embodiment of a non-pneumatic tire. DETAILED DESCRIPTION OF THE INVENTION

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

[0009] "Axial" and "axially" refer to directions 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] "Prepreg" refers to a composite material made from pre-impregnated fibers and a partially cured polymer matrix.

[0012] "Radial" and "radially" refer to directions perpendicular to the axis of rotation of the tire.

[0013] 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.

[0014] It should be understood that while 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 one of the following terms to be simply interchangeable with another term used to describe typical tire components.

[0015] 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 "above" or "below" are used in connection with elements, an element that is "above" another element is closer to the tread than the other element.

[0016] The terms "inner" and "inwardly" refer to the general direction toward the tire's equatorial plane, and "outer" and "outwardly" refer to the general direction away from the tire's equatorial plane, toward the tire's side. 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.

[0017] 1-3 illustrate one embodiment of a non-pneumatic tire 100. The non-pneumatic tire 100 includes a lower ring 130 having a first diameter and an upper ring 140 having a second diameter larger than the first diameter. The upper ring 140 is coaxial with the lower ring 130. The lower ring 130 can engage a vehicle hub (not shown) for mounting the non-pneumatic tire 100 to a vehicle.

[0018] Spokes 200 extend between the lower ring 130 and the upper ring 140 and connect the lower ring 130 to the upper ring 140. In the illustrated embodiment, the spokes 200 are curved. In alternative embodiments, the spokes may have a more pronounced curve, such as being substantially C-shaped. In other alternative embodiments, the spokes may be any desired shape. For example, the spokes may be substantially V-shaped or serpentine-shaped. In yet other alternative embodiments, the non-pneumatic tire may include spokes of two or more different shapes. For example, the non-pneumatic tire may include C-shaped spokes alternating with V-shaped spokes around the circumference of the non-pneumatic tire. In yet another alternative embodiment, the spokes may be replaced with webbing or other support structure.

[0019] A circumferential tread 300 is attached to the top ring 140. The circumferential tread 300 includes a tread layer 302 and a tread band 304 positioned between the tread layer 302 and the top ring 140. The tread layer 302 may be made from rubber or other elastomeric material and may include tread elements (not shown), such as grooves, ribs, blocks, lugs, sipes, studs, or any other desired elements. In an alternative embodiment, the tread layer may be omitted and the tread elements may be formed directly on the top ring.

[0020] The other components of the non-pneumatic tire 100 may be made from a variety of materials. The lower ring 130 or upper ring 140 may be made from an elastomeric material or metal. The spokes 200 may also be made from an elastomeric material or metal. The tread band 304 may be made from rubber, metal (including, but not limited to, ultra-high strength steel, stainless steel, aluminum, brass, or copper), rubber, or a polymeric material (including, but not limited to, polyurethane, polyester, or polyvinyl chloride). In alternative embodiments, the lower ring, upper ring, or tread band may be made from any desired material. Specific materials can be selected for specific components to provide a non-pneumatic tire with desired performance characteristics.

[0021] Regardless of the material used to manufacture the non-pneumatic tire 100, the lower ring 130, upper ring 140, spokes 200, or tread band 304 may be reinforced with a fiber metal laminate. In alternative embodiments, a fiber metal laminate may be used to manufacture the entire lower ring, upper ring, spokes, or tread band rather than being provided as a reinforcement. Figures 4a and 4b show one exemplary embodiment of a fiber metal laminate 500 that may be used to reinforce or manufacture components of the non-pneumatic tire 100. In the illustrated embodiment, the fiber metal laminate 500 includes eleven layers 510-530 that are provided as metal foils, primers, or a combination of fibers and resins.

[0022] When the fiber metal laminate 500 is used in the lower ring 130, the upper ring 140, or the tread band 304, the layers 510-530 may be arranged such that each layer extends substantially circumferentially about the non-pneumatic tire 100, and the layers are oriented such that the layers are built on top of each other in a substantially radial direction about the non-pneumatic tire 100. Exemplary orientations of the fiber metal laminate 500 in the lower ring 130 and the upper ring 140 are shown in dashed lines in FIGS. 2 and 3. When the fiber metal laminate 500 is used in the spokes 200 or other support structures, the layers can be arranged such that each layer extends substantially radially about the non-pneumatic tire 100. An exemplary orientation of the fiber metal laminate 500 in the spokes 200 is shown in dashed lines in FIG. 2. According to this example, the layers may be oriented such that the layers are built on top of each other in a substantially circumferential direction about the non-pneumatic tire 100. In alternative embodiments, the layers may have any desired arrangement or orientation. For example, when the fiber metal laminate is used in spokes or other support structures, the layers may be arranged so that each layer extends substantially radially of the non-pneumatic tire, and the layers are oriented so that they build on top of each other substantially axially of the non-pneumatic tire.

[0023] Metal foils are provided as a first layer 510, a fifth layer 518, a seventh layer 522, and an eleventh layer 530. According to one exemplary embodiment, the metal foils are formed from stainless steel. In alternative embodiments, the metal foils may be formed from high-strength aluminum, hard-coated steel, or passivated steel (e.g., aluminum-silicon hypereutectic alloy or 4340 with a carbide / nitride coating).

[0024] The third layer 514 and the ninth layer 526 are provided as a fiber and resin combination. According to one exemplary embodiment, the fiber and resin combination is provided using a fiber prepreg, which includes fibers pre-impregnated with a resin system. In an alternative embodiment, the fiber and resin combination is provided using plain fiber (i.e., not pre-impregnated with a resin system) and a resin transfer process, whereby the plain fiber is placed in a mold and then the resin is injected into the mold. Compared to fiber prepreg, the plain fiber and resin transfer process allows for increased design flexibility. However, compared to the plain fiber and resin transfer process, the fiber prepreg offers a simpler manufacturing process and time savings. In either the fiber prepreg or the plain fiber and resin transfer process, the fiber may be polymer, glass, carbon, metal, or any other desired fiber or fiber combination. In either the fiber prepreg or the plain fiber and resin transfer process, the resin system may be a thermoset or thermoplastic type. Examples of resin systems include, but are not limited to, epoxy, polyurethane, polyacrylate, polysiloxane, vinyl ester, polyester, resins derived from dicyclopentadiene or norbornene monomers, or any other desired resin system or combination of resin systems. Specific examples of resins derived from norbornene monomers include Proxima Syntatic Thermoset Resins (STR), High Performance Resins (HPR), and Advanced Composites Resins (ACR) manufactured by MATERIA INC. Impact modifiers can optionally be added to the resin to improve the toughness of the fiber and resin combination layer. According to one exemplary embodiment, the impact modifier comprises a multilayered polymer particle design produced by KANEACE®. In alternative embodiments, any desired impact modifier can be used.

[0025] The second layer 512, the fourth layer 516, the sixth layer 520, the eighth layer 524, and the tenth layer 528 serve as primers. The primers can promote bonding between the metal foil layer and the fiber and resin combination layer. According to one exemplary embodiment, the primers can be produced from a sol-gel-style reaction on the surface of the metal foil. In alternative embodiments, the primers can be produced from a chelation process, a brass coating process, a zinc phosphate coating process, or any other desired process. In other alternative embodiments, the primers can be omitted.

[0026] According to one exemplary embodiment, the thickness of each of the metal foil layers 510, 518, 522, 530 and the fiber and resin combination layers 514, 526 may be 0.005 to 0.100 mm, and the number of interfaces between the metal foil layers and the fiber and resin combination layers may be 5 to 50. According to this exemplary embodiment, the volume fraction of metal having these properties is 15% or less of the total volume of the fiber metal laminate 500. In alternative embodiments, different layer thicknesses, number of interfaces, and metal volume fraction percentages may be provided to result in different performance characteristics that may allow for tuning of non-pneumatic tires for different applications.

[0027] The use of the fiber metal laminate 500 in the lower ring 130, upper ring 140, spokes 200, or tread band 304 can improve the performance and robustness of the non-pneumatic tire 100 while reducing the weight of the non-pneumatic tire 100. Interposing the metal foil layers 510, 518, 522, 530 between the fiber and resin combination layers 514, 526 can improve the impact and fatigue characteristics of the non-pneumatic tire 100 because the metal foil layers 510, 518, 522, 530 can arrest cracks that initiate in the fiber and resin combination layers 514, 526 and prevent the cracks from propagating throughout the non-pneumatic tire 100. Different metal foil, fiber and resin combinations, and primers can provide different performance characteristics that can allow for tailoring of the non-pneumatic tire for different applications. For example, the overall strength of a non-pneumatic tire can be improved by substituting a specific directional fiber layer within a fiber and resin combination layer that traditionally prioritizes impact performance over composite strength. Specifically, according to one example, the fiber orientation is fully circumferential (i.e., 0 degrees), which provides high strength and can benefit from an interposed metal foil layer to aid in impact performance.

[0028] In alternative embodiments, the fiber metal laminate may include fewer or more layers. Additionally, in other alternative embodiments, the different layers may be provided in any desired order. For example, in the embodiment shown in FIGS. 4a and 4b, starting with the first layer 510 and moving toward the eleventh layer 530, the following layers are provided in order: metal foil, primer, fiber and resin combination, primer, metal foil, primer, metal foil, primer, fiber and resin combination, primer, and metal foil. In another embodiment, the sequence may be metal foil, primer, metal foil, primer, fiber and resin combination, primer, fiber and resin combination, primer, metal foil, primer, and metal foil. Furthermore, in other alternative embodiments, the ratio of the different layers may be any desired ratio. For example, in the embodiment shown in FIGS. 4a and 4b, there are four layers of metal foil, five layers of primer, and two layers of fiber and resin combination. In another embodiment, the ratio may be two layers of metal foil, five layers of primer, and four layers of fiber and resin combination. Different numbers of plies, different orders of plies, and different ratios of plies can result in different performance characteristics that can allow tuning of the non-pneumatic tire for different applications.

[0029] Figure 5 illustrates another exemplary embodiment of a non-pneumatic tire 1100. The non-pneumatic tire 1100 of Figure 5 is substantially similar to the non-pneumatic tire 100 of Figures 1-3, except for the differences described herein. Accordingly, like features will be identified by like numerals increased by the value of "1000."

[0030] The non-pneumatic tire 1100 includes a lower ring 1130 and a circumferential tread 1300. The circumferential tread 1300 includes a tread layer 1302 and a tread band 1304. Unlike the non-pneumatic tire 100 of FIGS. 1-3, the non-pneumatic tire 1100 does not have an upper ring. Thus, the circumferential tread 1300 is attached to the lower ring 1130 by spokes 1200 or other support structures that interconnect the lower ring 1130 to the tread band 1304. The lower ring 1130, spokes 1200, or tread band 1304 may be manufactured from the fiber metal laminate 500 described above and shown in FIGS. 4a and 4b. According to this embodiment, an additional advantage may be realized by using a fiber metal laminate in that the spokes 1200 or other support structures and the tread band 1304 may be manufactured as an integral unit by a single winding process. Compared to known manufacturing techniques that require the support structure and tread band to be manufactured separately and then connected, the one-piece spoke 1200 and tread band 1304 unit can increase strength and reduce costs by eliminating weak points and joints between different materials and by eliminating adhesive joints.

[0031] To the extent that it is used in this specification or in the claims, the terms "includes" or "including" are intended to be inclusive, similar to the interpretation of the term "comprising" when used as a transitional phrase in a patent claim. 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." Where 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 A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms "in" or "into" are used in this specification or in the claims, they 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 connecting via another component.

[0032] 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 applicants to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and improvements 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. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants' general inventive concept.

Claims

1. A non-pneumatic tire, 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 connecting the lower ring to the upper ring; at least one of the lower ring, the upper ring, and the support structure comprises a fiber metal laminate having at least one metal foil layer and at least one fiber and resin combination layer; 10. The non-pneumatic tire further comprises a circumferential tread attached to said upper ring, said circumferential tread including a tread layer and a tread band positioned between said tread layer and said upper ring, said tread band being manufactured from said fiber metal laminate.

2. The non-pneumatic tire of claim 1 , wherein said fiber metal laminate further comprises at least one primer layer.

3. 2. The non-pneumatic tire of claim 1, wherein each of the lower ring and the upper ring comprises the fiber metal laminate, and wherein the at least one metal foil layer and the at least one fiber and resin combination layer are each disposed to extend substantially circumferentially about the tire and oriented to build on each other in a substantially radial direction about the tire.

4. 2. The non-pneumatic tire of claim 1, wherein the support structure is provided as a plurality of spokes comprising the fiber metal laminate, the at least one metal foil layer and the at least one fiber and resin combination layer each arranged to extend substantially radially of the non-pneumatic tire and oriented to build on each other substantially circumferentially of the non-pneumatic tire.

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