Systems and methods for building non-pneumatic tires

Abstract

The system for a non-pneumatic tire structure includes a curing envelope sized and configured to receive the top ring and circumferential tread of the non-pneumatic tire structure. The system further includes a tensioning system having a first seal ring, a second seal ring, and a tensioner. The tensioner connects the first seal ring and the second seal ring to each other. Each tensioner includes a first head and a second head configured to be attached to the first seal ring and the second seal ring, respectively. A connector member connects the first head and the second head to each other. The tensioner further includes an adjustment mechanism. The adjustment mechanism allows adjustment of the distance between the first head and the second head. The adjustment is used to cause the tensioning system to press the curing envelope against the non-pneumatic tire structure to create a substantially airtight seal between the curing envelope and the non-pneumatic tire structure.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates to systems and methods for making non-pneumatic tires, and more particularly, to systems and methods for applying a tread to a non-pneumatic tire structure. [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 a puncture that completely or partially loses pressurized air. Non-pneumatic tires may include multiple spokes, webbing, or other support structures connecting a lower ring to an upper ring. It is known to use adhesives or cements to adhere a pre-cured tread to the upper ring of a non-pneumatic tire. Summary of the Invention

[0003] In one embodiment, a system for a non-pneumatic tire structure includes a curing envelope sized and configured to receive an upper ring and a circumferential tread of the non-pneumatic tire structure. The system further includes a tensioning system having a first seal ring, a second seal ring, and a plurality of tensioners. The plurality of tensioners connect the first seal ring and the second seal ring to each other. Each of the plurality of tensioners includes a first head configured to attach to the first seal ring and a second head configured to attach to the second seal ring. A connector member connects the first head and the second head to each other. Each of the plurality of tensioners further includes an adjustment mechanism. The adjustment mechanism is configured to allow adjustment of the distance between the first head and the second head. The adjustment is used to cause the tensioning system to press the cure envelope against the non-pneumatic tire structure to create a substantially airtight seal between the cure envelope and the non-pneumatic tire structure.

[0004] In another embodiment, a method of making a non-pneumatic tire includes providing a tire structure. The tire structure includes a lower ring having a first diameter, an upper ring having a second diameter larger than the first diameter, the upper ring being substantially coaxial with the lower ring, and a support structure extending between the lower ring and the upper ring. The method further includes providing an elastomeric tread circumferentially around a top of the upper ring. The tire structure and the elastomeric tread are received within a curing envelope. A tensioning system is disposed around the curing envelope. The tensioning system includes a first seal ring, a second seal ring, and a plurality of tensioners connecting the first seal ring and the second seal ring to each other. Each of the plurality of tensioners includes an adjustment mechanism. The method further includes adjusting each member of the adjustment mechanism to cause the first seal ring and the second seal ring to press the curing envelope against the tire structure to create a substantially airtight seal between the curing envelope and the tire structure, thereby creating a substantially airtight environment defined by the curing envelope and the tire structure. Heat is introduced into the substantially airtight environment.

[0005] In yet another embodiment, a system for assembling a non-pneumatic tire structure includes a curing envelope sized and configured to receive an upper ring and a circumferential tread of the non-pneumatic tire structure. The system further includes a tensioning system having a first seal ring, a second seal ring, and a plurality of tensioners. The plurality of tensioners connect the first seal ring and the second seal ring to each other. Each of the plurality of tensioners includes a first anchor including a first adjustment mechanism that attaches a first head to a first body, a second anchor including a second adjustment mechanism that attaches a second head to a second body, and a connector member that connects the first anchor and the second anchor to each other. The first adjustment mechanism and the second adjustment mechanism are each configured to allow adjustment of the distance between the first head and the second head. The first and second adjustment mechanisms are used to decrease the distance between the first and second heads, causing the tensioning system to press the cure envelope against the non-pneumatic tire structure to create a substantially airtight seal between the cure envelope and the non-pneumatic tire structure. [Brief explanation of the drawings]

[0006] The accompanying drawings, together with the detailed description provided below, illustrate structures that describe exemplary embodiments of the claimed invention. Similar elements are identified with the same reference numerals. It should be understood that elements shown as a single component may be replaced 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 perspective view of one embodiment of a non-pneumatic tire. [Figure 2] FIG. 2 is an enlarged partial perspective view of the non-pneumatic tire of FIG. [Figure 3] FIG. 3 is a schematic diagram illustrating a cross section of one embodiment of a non-pneumatic tire. [Figure 4]FIG. 4 is a schematic diagram illustrating a cross section of an alternative embodiment of a non-pneumatic tire. [Figure 5] FIG. 5 is a schematic diagram illustrating a cross section of another alternative embodiment of a non-pneumatic tire. [Figure 6] FIG. 6 is a schematic diagram illustrating a perspective view of one embodiment of a curing envelope for a non-pneumatic tire. [Figure 7] FIG. 7 is a perspective view of one embodiment of a sealing system for manufacturing a non-pneumatic tire. [Figure 8] FIG. 8 is a cross-sectional view taken along a portion of FIG. [Figure 9] FIG. 9 is a side view of one embodiment of a tensioner that can be used with the sealing system of FIG. [Figure 10] FIG. 10 is a flow chart illustrating an exemplary method for manufacturing a non-pneumatic tire. [Figure 11] FIG. 11 is a side view of an alternative embodiment of a tensioner that can be used with the sealing system of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0007] The following contains definitions of selected terms used herein. These definitions include various examples and / 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 singular and plural forms of a term may be within the scope of the definition.

[0008] "Axial" and "axially" refer to directions parallel to the axis of rotation of the tire.

[0009] "Circumferential" and "circumferentially" refer to a direction extending along the perimeter of the surface of the tread perpendicular to the axial direction.

[0010] "Radial" and "radially" refer to directions perpendicular to the axis of rotation of the tire.

[0011] 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.

[0012] 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 of the following terms to be purely interchangeable with another term used to describe a typical tire component.

[0013] 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.

[0014] The terms "inward" and "inwardly" refer to the general direction toward the tire's equatorial plane, and "outward" and "outwardly" refer to the general direction away from the tire's equatorial plane, toward the tire's sidewall. Thus, when relative directional terms such as "inner" and "outer" are used in connection with elements, the "inner" elements are spaced closer to the tire's equatorial plane than the "outer" elements.

[0015] FIG. 1 is a perspective view of one embodiment of a non-pneumatic tire 100. The non-pneumatic tire 100 includes a lower ring 110 having a first diameter and an upper ring 120 having a second diameter larger than the first diameter. The upper ring 120 is substantially coaxial with the lower ring 110. A plurality of spokes 130 extend between the lower ring 110 and the upper ring 120. In alternative embodiments, webbing or other support structure may be employed in place of the spokes. It should be understood that the term "support structure" can refer to either the webbing or the spokes.

[0016] In one embodiment, the lower ring 110, the upper ring 120, and the spokes 130 are each constructed from the same material. In one particular embodiment, the lower ring 110, the upper ring 120, and the spokes 130 are each constructed from steel. In alternative embodiments, the lower ring 110, the upper ring 120, and the spokes 130 are each constructed from other metals, carbon fiber, resins, or polymeric materials such as polyurethane, polyester, nylon, or polyvinyl chloride (PVC). However, it should be understood that other materials may be used, and the rings and spokes are not limited to the listed materials.

[0017] In alternative embodiments, one or more of the lower ring 110, upper ring 120, and spokes 130 are constructed from different materials. For example, the upper ring 120 may be a steel band, while the lower ring 120 and spokes 130 are constructed from other metals, carbon fiber, resin, or polymeric materials such as polyurethane, polyester, nylon, or polyvinyl chloride (PVC).

[0018] In the illustrated embodiment, the lower ring 110 is shown as being attached to a hub 140. It should be understood that the illustrated hub is merely exemplary and that the lower ring 110 may be attached to any hub or wheel structure.

[0019] In the illustrated embodiment, a circumferential tread 150 is disposed about the top ring 120. The circumferential tread 150 may be constructed of an elastomeric material, such as natural or synthetic rubber. The tread 150 is shown as having a plurality of circumferential grooves that define a plurality of ribs. It should be understood that the tread may include tread elements such as grooves, ribs, blocks, lugs, sipes, studs, and other elements. Shear bands or other shear elements or reinforcing structures (not shown) may be disposed between the top ring 120 and the tread 140. Alternatively, the shear bands or other shear elements may be disposed within the tread.

[0020] In one embodiment, the circumferential tread 150 is affixed to the top of the upper ring 120, with no pressure-sensitive adhesive disposed between the upper ring 120 and the circumferential tread 150. In one such embodiment, the circumferential tread 150 is bonded directly to the top of the upper ring 120. In another such embodiment, a strip of cured rubber (not shown) or a heat-sensitive adhesive is disposed between the circumferential tread 150 and the upper ring 120.

[0021] 2 is an enlarged, partial perspective view of the non-pneumatic tire of FIG. 1. As can be seen in this view, spokes 130 are a plurality of curved, or arcuate, spokes that intersect with one another. However, it should be understood that the illustrated spokes are merely exemplary. In other embodiments, the spokes may be straight or segmented. Additionally, non-intersecting spokes may be used.

[0022] As can be seen in this figure, the top ring 120 in this embodiment has a width greater than the spokes 130, and the top ring 120 extends outward from the spokes 130, thereby defining a ledge 170. The ledge 170 may also be referred to as a ceiling. In one embodiment, the ledge 170 has a width between 0.375 inches (0.95 cm) and 1 inch (2.54 cm). In alternative embodiments, the ledge may have a width between 0.25 inches (0.64 cm) and 1.5 inches (3.8 cm).

[0023] From this view, the ledge 170 is shown on only one side of the tire. However, it should be understood that the spokes 130 are attached to the top ring 120 such that a first side of the top ring 120 extends outward from the first side of the spokes 130 to define the first ledge 170, and a second side of the top ring 120 extends outward from the second side of the spokes 130 to define a second ledge (not shown). In one embodiment, the first ledge has a width equal to the width of the second ledge. In an alternative embodiment, the first ledge is wider than the second ledge. In another alternative embodiment, the ledge is omitted from one or both sides.

[0024] The relative dimensions of a non-pneumatic tire structure can vary. For example, Figures 3-5 are schematic diagrams illustrating cross sections of three different embodiments of a non-pneumatic tire. In Figure 3, non-pneumatic tire 200 includes a lower ring 210, an upper ring 220, and a support structure 230 extending between lower ring 210 and upper ring 220. A circumferential tread 250 is disposed on an upper surface of upper ring 220. Support structure 230 may be spokes, webbing, or other support structure. While support structure 230 is shown as axially continuous, in other embodiments, the support structure is axially discontinuous.

[0025] In this embodiment, the lower ring 210, the upper ring 220, and the circumferential tread 250 each have substantially the same first axial width W1. The support structure 230 has a second axial width W2 that is less than the first axial width W1. Thus, the upper ring 220 extends outward from the support structure 230 on either side of the non-pneumatic tire 200 to define a first ledge 270a on the first side of the tire 200 and a second ledge 270b on the second side of the tire 200.

[0026] Additionally, in this embodiment, the lower ring 210 also extends outward from the support structure 230, forming a ledge on each side of the tire 200. In alternative embodiments (not shown), the tread may be wider or narrower than the upper ring.

[0027] 4, non-pneumatic tire 300 includes a lower ring 310, an upper ring 320, and a support structure 330 extending between lower ring 310 and upper ring 320. A circumferential tread 350 is attached to the upper surface of upper ring 320. Support structure 330 may be spokes, webbing, or other support structure. While support structure 330 is shown as axially continuous, in other embodiments, the support structure is axially discontinuous.

[0028] In this embodiment, the upper ring 320 and the circumferential tread 350 each have substantially the same first axial width W1. The lower ring 310 and the support structure 230 each have substantially the same second axial width W2 that is less than the first axial width W1. Thus, the upper ring 320 extends outward from the support structure 330 on either side of the non-pneumatic tire 300, thereby defining a first ledge 370a on a first side of the tire 300 and a second ledge 370b on a second side of the tire 300. In this embodiment, the lower ring 310 is flush with the support structure 330. In an alternative embodiment (not shown), the tread may be wider or narrower than the upper ring.

[0029] 5, non-pneumatic tire 400 includes a lower ring 410, an upper ring 420, and a support structure 430 extending between lower ring 410 and upper ring 420. A circumferential tread 450 is disposed on an upper surface of upper ring 420. Support structure 430 may be spokes, webbing, or other support structure. Although support structure 430 is shown as axially continuous, in other embodiments, the support structure is axially discontinuous.

[0030] In this embodiment, the upper ring 420, circumferential tread 450, lower ring 410, and support structure 430 all have substantially the same axial width W. Thus, in this embodiment, the upper ring 420, support structure 430, and lower ring 410 are substantially flush with one another and do not have ledges on either side. In alternative embodiments (not shown), the tread may be wider or narrower than the upper ring.

[0031] It should be understood that Figures 3-5 are merely exemplary and that the relative widths of the components of a non-pneumatic tire may vary.

[0032] As previously mentioned, a process for manufacturing a non-pneumatic tire can include bonding a pre-cured tread to an upper ring of the non-pneumatic tire. FIGS. 6-9 illustrate a sealing system 500 that can be used during this bonding process. The sealing system 500 includes a curing envelope 505 and a tensioning system 600. The tensioning system 600 is configured to press the curing envelope 505 against a portion of the non-pneumatic tire to create a substantially airtight seal between the curing envelope 505 and the non-pneumatic tire. The seal results in the portion of the non-pneumatic tire, including the pre-cured tread and the upper ring, being enclosed within a substantially airtight environment defined by the curing envelope 505 and the portion of the non-pneumatic tire against which the curing envelope 505 is pressed. Heat and pressure can be introduced into the airtight environment to bond the pre-cured tread to the upper ring. According to one embodiment, a seal is formed between the curing envelope 505 and the upper ring of the non-pneumatic tire.

[0033] Referring to FIG. 6 , the curing envelope 505 is sized and configured to receive the upper ring and circumferential tread of a non-pneumatic tire structure. The curing envelope 505 has a pair of sides 510 terminating in a first end 520 and a second end 530. While the sides 510 are shown as flat, it should be understood that they may be curved or contoured as desired. The first end 520 and the second end 530 each define an inner diameter ID of the curing envelope 505. The curing envelope 505 also has an apex 540 that defines an outer diameter OD. While the apex 540 is shown as flat, it should be understood that the apex 540 may be curved or contoured as desired.

[0034] The curing envelope 505 is sized and configured for use with a specific size non-pneumatic tire. However, it should be understood that the curing envelope 505 may be sized and configured to accommodate a range of tire sizes, rather than just one specific tire size. According to one example, the inner diameter ID may be 22 inches (56 cm) to 58 inches (147 cm). According to this example, the outer diameter OD may be 28 inches (71 cm) to 60 inches (152 cm). In one embodiment, the side 510 of the curing envelope 505 has a length of 2 to 6 inches (5 to 15 cm). In other words, the outer diameter OD is 2 to 6 inches larger than the inner diameter ID.

[0035] The curing envelope 505 may be a sheet of butyl rubber, other rubber compounds, neoprene, polythread, latex, or other flexible material. The sheet of material may have a thickness of 0.008 inches (0.02 cm) to 0.12 inches (0.3 cm). The sheet may be damaged or torn by any sharp edges on the spokes or support structure of a non-pneumatic tire. Therefore, it is advantageous for the first end 510 and second end 520 to engage the surface of the upper ring of the non-pneumatic tire rather than extending to the spokes or support structure. Therefore, the side 510 of the curing envelope 505 is sized and configured so that it does not extend to the spokes or support structure. In other words, the inner diameter ID and outer diameter OD are preferably selected so that the side 510 does not extend to the spokes or support structure.

[0036] 7-9, tensioning system 600 includes a first seal ring 605, a second seal ring 610, and a plurality of tensioners 615. Tensioners 615 connect first seal ring 605 and second seal ring 610 to one another. In the illustrated embodiment, each of first seal ring 605 and second seal ring 610 is substantially annular in shape and extends between a first edge 620 and a second edge 625. First edge 620 is located within an inner diameter ID of seal rings 605, 610. sr The second edge 625 defines an outer diameter OD of the sealing ring 605, 610. sr In other alternative embodiments, the seal ring may be of any desired shape.

[0037] The first seal ring 605 and the second seal ring 610 are preferably constructed from a material that is lightweight and rigid, yet does not flex or bend under heat. In one embodiment, the first seal ring 605 and the second seal ring 610 are constructed from aluminum.

[0038] First seal ring 605 and second seal ring 610 each include a plurality of slots 630. Slots 630 extend radially inward from second edge 625 toward first edge 620. In the illustrated embodiment, each slot 630 is substantially linear and has semicircular-shaped ends. Moreover, in the illustrated embodiment, first seal ring 605 and second seal ring 610 each include eight slots 630. In alternative embodiments, seal rings may include more or fewer slots. In other alternative embodiments, seal rings may include non-linear slots or slots with end shapes other than semicircular.

[0039] The first seal ring 605 and the second seal ring 610 are sized and configured for use with a particular size non-pneumatic tire. However, it should be understood that the first seal ring 605 and the second seal ring 610 may be sized and configured to accommodate a range of non-pneumatic tire sizes, rather than just one particular tire size. According to one embodiment, the inner diameter ID sr is smaller than the inner diameter of the upper ring of a non-pneumatic tire and the outer diameter OD sr is greater than the outer diameter of the upper ring of the non-pneumatic tire. According to this embodiment, the inner diameter ID sr may be 0 to 20 inches (0 to 51 centimeters), and the outer diameter OD sr Furthermore, according to this embodiment, the length L of each slot 630 of the sealing rings 605, 610 may be 24 to 50 inches (61 to 127 centimeters). s is 2 to 8 inches (5 to 20 centimeters).

[0040] Each member of the plurality of tensioners 615 includes a first anchor 640, a second anchor 645, and a connector member 650 interconnecting the first anchor 640 and the second anchor 645. In the illustrated embodiment, the connector member 650 is a flexible member in the form of a chain. In alternative embodiments, the connector member may be any desired flexible member, such as a cable or rope. In other alternative embodiments, the connector member may be a rigid member, such as a rod.

[0041] First anchor 640 and second anchor 645 each include a body 655 and a head 660. Body 655 extends between a first end 665 and a second end 670. Head 660 extends between a first end 675 and a second end 680. An adjustment mechanism 685 attaches first end 665 of body 655 to first end 675 of head 660. A retainer 690 is provided at second end 670 of body 655. Retainer 690 attaches body 655 to connector member 650. In the illustrated embodiment, retainer 690 is a loop. In other alternative embodiments, the retainer can be in any desired configuration. In other alternative embodiments, the retainer may be omitted, and the connector member may be attached directly to the body.

[0042] A fastening portion 695 is provided toward the second end 680 of the head 660. The fastening portion 695 is configured to attach the head 660 to one of the seal rings, thereby attaching the first anchor 640 and the second anchor 645 to the first seal ring 605 and the second seal ring 610, respectively. In the illustrated embodiment, the fastening portion 695 is a reduced diameter portion formed in the head 660. The reduced diameter portions and slots 630 of the first seal ring 605 and the second seal ring 610 are sized and configured to allow the slots to receive the reduced diameter portions and provide the desired attachment of the first anchor 640 and the second anchor 645 to the first seal ring 605 and the second seal ring 610, respectively.

[0043] In an alternative embodiment (not shown), the fastening portion may be two diametrically opposed notched portions that extend only partially around the circumference of the head. In another alternative embodiment (not shown), the fastening portion may be a flanged end of the head. In yet another alternative embodiment (not shown), the fastening portion may be one or more pins that extend radially from the head. Such pins may be removable or may be permanent structures.

[0044] The adjustment mechanism 685 adjusts the distance D between the head 660 of the first anchor 640 and the head 660 of the second anchor 645. t According to one example embodiment, the distance D t is adjustable over a range of 0.5 to 4 inches (1 to 10 centimeters). In alternative embodiments, the tensioner may allow adjustability over any desired range of distances. In other alternative embodiments, only one of the first anchor or the second anchor may include an adjustment mechanism.

[0045] When the tensioning system 600, including the sealing rings 605, 610 and tensioner 615, is placed around the cure envelope 505, which in turn is placed around both the top ring and the circumferential tread of the non-pneumatic tire, the adjustment mechanism 685 is used to adjust the distance D t , thereby effectively moving the first sealing ring 605 and the second sealing ring 610 toward each other, forcing the cured envelope 505 into engagement with the upper ring of the non-pneumatic tire to create the substantially airtight seal described above.

[0046] In the illustrated embodiment, the adjustment mechanism 685 includes a threaded rod 700 extending from the body 655 that is received by a threaded passage 705 on the head 660. In an alternative embodiment, the adjustment mechanism may adjust the distance D t For example, the locations of the threaded passage and threaded rod may be reversed so that the head contains the threaded rod and the body contains the threaded passage.

[0047] Figure 10 shows an exemplary method 800 for using the sealing system 500 of Figures 6-9 to manufacture a non-pneumatic tire. At 805, a tire structure is provided. The tire structure has a lower ring, an upper ring, and a support structure, such as any of the tire structures described above with respect to Figures 1-5.

[0048] At 810, an elastomeric tread is provided circumferentially around the top of the top ring. The elastomeric tread may be a pre-cured or partially cured tread with any desired tread elements pre-formed before the tread is provided around the top ring. In one embodiment, a strip of raw rubber (cushion gum) or heat-sensitive adhesive is first applied to either the elastomeric tread or the top ring. In an alternative embodiment, the elastomeric tread is placed directly on the top ring.

[0049] At 815, a curing envelope is placed around the elastomeric tread. The curing envelope may have the structure described above with respect to FIG.

[0050] At 820, a tensioning system is positioned around the curing envelope. The tensioning system may have the structure described above with respect to Figures 7-9 and may include a first sealing ring, a second sealing ring, and multiple tensioners, each having an adjustment mechanism. At 825, the tensioning system is used to create a substantially airtight seal between the curing envelope and the tire structure. The seal may be created by using the adjustment mechanism of the tensioning member to move the first ring and the second ring toward each other and press the curing envelope into engagement with a portion of the tire structure.

[0051] Optionally, a wicking material may be placed between the tread and the curing envelope. One example of a wicking material is a loosely woven nylon cloth. The wicking material may be wrapped around the entire tread or placed where the tensioner is located. The wicking material prevents the tensioning system from sealing the curing envelope against the tread, thus creating an isolated pocket. The wicking material therefore helps to evacuate air from the curing envelope.

[0052] At 830, after the seal is created, heat and pressure are introduced to the curing envelope. In one embodiment, heat is introduced at a temperature of 200°F to 300°F (90°C to 150°C) and pressure is applied at 40 to 100 psi (276 to 689 kPa). Because the elastomeric tread is pre-cured, the tread is only heated to a temperature sufficient to bond the tread to the top ring.

[0053] When the elastomeric tread is a partially cured rubber, the curing system may cure the elastomeric tread so that it bonds to the top ring. Alternatively, a layer of green cushion stock (not shown) or heat-sensitive adhesive is placed between the tread and the top ring. During curing, the cushion stock or heat-sensitive adhesive bonds the elastomeric tread to the top ring. In all cases, when cushion stock or heat-sensitive adhesive is placed between the top ring and the tread, the cushion stock or heat-sensitive adhesive bonds to both the top ring and the tread during the curing process.

[0054] Although the method of making a tire has been described with reference to a particular cure envelope and tensioning system to provide the desired seal, it should be understood that these examples are not intended to be limiting, and the method may be practiced using any other mechanism to provide the desired seal.

[0055] Figure 11 shows an alternative embodiment of a tensioner 915. This tensioner embodiment may be used with the sealing system described above with reference to Figures 6-9. The tensioner 915 includes a body 920, a first head 925, and a second head 930.

[0056] A first connector member 935 connects the first head 925 to a first end 940 of the body 920. A second connector member 945 connects the second head 930 to a second end 950 of the body 920. In the illustrated embodiment, the first connector member 935 and the second connector member 945 are each flexible members in the form of cables. In alternative embodiments, the connector members may be any desired flexible members, such as, for example, a chain or rope. In other alternative embodiments, the connector members may be rigid members, such as a rod.

[0057] The first head 925 and the second head 930 each extend between a first end 955 and a second end 960. The first end 955 of the head 925 is connected to a respective one of the first connector member 935 and the second connector member 945. A fastening portion 965 is provided toward the second end 960 of the heads 925, 930. In the illustrated embodiment, the fastening portion 965 is a reduced diameter portion formed within the heads 925, 930. In alternative embodiments, other fastening portions, such as those described above with respect to the head 660 of the tensioner 615, may be employed.

[0058] The fastening portions 965 of the heads 925, 930 and the slots on the seal rings used with the tensioners are sized and configured to allow the slots to receive the reduced diameter portions, thereby attaching the first and second heads to the first and second seal rings, respectively.

[0059] The body 920 includes a first portion 970 and a second portion 975. The adjustment mechanism 980 connects the first portion 970 and the second portion 975 to each other. The adjustment mechanism adjusts the distance D between the fastening portion 965 of the first head 925 and the fastening portion 965 of the second head 930. t According to one example embodiment, the distance D t is adjustable over a range of 0.5 to 4 inches (1 to 10 centimeters). In alternative embodiments, the tensioner may allow adjustability over any desired range of distances.

[0060] According to one exemplary embodiment, the adjustment mechanism 980 includes a threaded passage 985 on the first portion 970 of the body 920 that receives a threaded rod 990 extending from the second portion 975 of the body 920. In an alternative embodiment, the adjustment mechanism may adjust the distance D t For example, the locations of the threaded passage and the threaded rod may be reversed such that a first portion of the body includes the threaded rod and a second portion of the body includes the threaded passage.

[0061] To the extent that the terms "includes" or "including," as used herein or in the claims, are intended to be inclusive, similar to the term "comprising," as interpreted when used as a transitional word in a 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 Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms "in" or "into" are used herein 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 by connecting through one or more other components.

[0062] While the present application has been illustrated by the description of its embodiments, and those embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will be readily apparent to those skilled in the art. Therefore, the present application in its broader aspects is not limited to the specific details, representative apparatus and methods, and examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.

Claims

1. 1. A system for assembling a non-pneumatic tire structure, said system comprising: a curing envelope sized and configured to receive an upper ring and a circumferential tread of said non-pneumatic tire structure; 1. A tensioning system comprising: a first seal ring; a second seal ring; and a tensioning system comprising a plurality of tensioners, the plurality of tensioners connecting the first seal ring and the second seal ring to one another, each tensioner comprising: a first head, the first head configured to be attached to the first seal ring; a second head, the second head configured to be attached to the second seal ring; a connector member that connects the first head and the second head to each other; an adjustment mechanism configured to allow adjustment of the distance between the first head and the second head; wherein the adjustment mechanism causes the tensioning system to press the curing envelope against the non-pneumatic tire structure to create a substantially airtight seal between the curing envelope and the non-pneumatic tire structure.

2. 2. The system of claim 1, wherein each of the plurality of tensioners includes a first body and a second body, the connector member connects the first body and the second body to one another, the adjustment mechanism includes a first adjustment mechanism and a second adjustment mechanism, the first adjustment mechanism attaches the first head to the first body, and the second adjustment mechanism attaches the second head to the second body.

3. 2. The system of claim 1, wherein each individual one of the plurality of tensioners includes a body having a first portion and a second portion, the adjustment mechanism connects the first portion and the second portion to one another, the connector member includes a first connector member and a second connector member, the first connector member connects the first head to the first portion of the body, and the second connector member connects the second head to the second portion of the body.

4. The system of claim 1 , wherein the adjustment mechanism includes a threaded passage that receives a threaded rod.

5. 2. The system of claim 1, wherein the first seal ring and the second seal ring each include a plurality of slots, the first head and the second head each include reduced diameter portions, the slots receiving the reduced diameter portions and attaching the first head and the second head to the first seal ring and the second seal ring, respectively.

6. 6. The system of claim 5, wherein the first seal ring and the second seal ring include a first edge and a second edge, and each of the plurality of slots extends radially inward from the second edge toward the first edge.

7. The system of claim 1 , wherein the connector member is a flexible member.

8. 2. The system of claim 1, wherein the curing envelope includes a top and first and second sides extending from the top, and the first and second sealing rings press the first and second sides, respectively, against opposite sides of the non-pneumatic tire structure to create the substantially airtight seal.

9. The system of claim 1 , wherein the first seal ring and the second seal ring press a first side and a second side, respectively, against the top ring of the non-pneumatic tire structure.

10. 10. The system of claim 9, wherein the first side and the second side are dimensioned such that when the curing envelope receives the top ring and the circumferential tread of the non-pneumatic tire structure, the first side and the second side do not extend to the support structure.

11. 1. A method of making a non-pneumatic tire, comprising: providing a tire structure, the tire structure including: a lower ring having a first diameter; an upper ring having a second diameter greater than the first diameter, the upper ring being substantially coaxial with the lower ring; and a support structure extending between the lower ring and the upper ring; providing an elastomeric tread circumferentially around the top of said upper ring; receiving the tire structure and the elastomeric tread within a curing envelope; disposing a tensioning system around the curing envelope, the tensioning system including a first seal ring, a second seal ring, and a plurality of tensioners connecting the first seal ring and the second seal ring, each tensioner including an adjustment mechanism; adjusting each of the adjusting mechanisms to cause the first and second sealing rings to press the curing envelope against the tire structure to create a substantially airtight seal between the curing envelope and the tire structure, thereby creating a substantially airtight environment defined by the curing envelope and the tire structure; and introducing heat into the substantially airtight environment.

12. The method of claim 11 , further comprising introducing pressure into the substantially airtight environment.

13. 12. The method of claim 11, wherein each individual one of the plurality of tensioners includes a first body and a second body, the connector member connects the first body and the second body to one another, the adjustment mechanism includes a first adjustment mechanism and a second adjustment mechanism, the first adjustment mechanism attaches a first head to the first body and the second adjustment mechanism attaches a second head to the second body, and the step of creating a substantially airtight environment includes adjusting at least one of the first adjustment mechanism and the second adjustment mechanism to decrease a distance between the first head and the second head.

14. 12. The method of claim 11, wherein each individual one of the plurality of tensioners includes a body having a first portion and a second portion, the adjustment mechanism connects the first portion and the second portion to one another, the connector member includes a first connector member and a second connector member, the first connector member connects a first head to the first portion of the body, and the second connector member connects a second head to the second portion of the body, and wherein the step of creating a substantially airtight environment includes adjusting the adjustment mechanism to decrease a distance between the first head and the second head.

15. The method of claim 11 further comprising placing a wicking material between the elastomeric tread and the curing envelope.

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