Non-pneumatic tire and manufacturing system and method thereof

Abstract

The system for assembling a tread and non-pneumatic tire structure includes a curing envelope sized to receive a top ring and a circumferential tread of the non-pneumatic tire structure. The curing envelope includes a first side configured to be secured to a bottom of a first ledge of the top ring. The curing envelope also includes a second side configured to be secured to a bottom of a second ledge of the top ring. The system further includes a first fastener configured to secure the first side of the curing envelope to the bottom of the first ledge of the top ring. The system also includes a second fastener configured to secure the second side of the curing envelope to the bottom of the second ledge of the top ring.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE This disclosure relates to non-pneumatic tires and systems and methods for manufacturing the same, 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 a non-pneumatic upper ring. Summary of the Invention [Problem to be solved by the invention]

[0003] In one embodiment, a method for manufacturing a non-pneumatic tire includes providing a tire structure having a lower ring having a first diameter and a first width and an upper ring having a second diameter and a second width greater than the first diameter, the upper ring being substantially coaxial with the lower ring. The tire structure further includes a support structure extending between the lower ring and the upper ring. The support structure has a third width less than the second width such that a first side of the upper ring extends outward from the first side of the support structure to define a first ledge. Additionally, a second side of the upper ring extends outward from the second side of the support structure to define a second ledge. The method further includes providing an elastomeric tread circumferentially around a top of the upper ring and securing a curing envelope around the elastomeric tread. Securing the curing envelope includes securing a first side of the curing envelope to a bottom of a first ledge of the upper ring and securing a second side of the curing envelope to a bottom of a second ledge of the upper ring. The method also includes applying heat within the curing envelope.

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

[0005] In yet another embodiment, a non-pneumatic tire includes a lower ring having a first diameter and a first width and an upper ring having a second diameter and a second width greater than the first diameter. The upper ring is substantially coaxial with the lower ring. The non-pneumatic tire further includes a support structure extending between the lower ring and the upper ring. The support structure has a third width less than the second width. The support structure is attached to the upper ring such that a first side of the upper ring extends outward from the first side of the support structure to define a first ledge. The support structure is attached to the upper ring such that a second side of the upper ring extends outward from the second side of the support structure to define a second ledge. The non-pneumatic tire further includes an elastomeric tread circumferentially attached to a top of the upper ring. No pressure-sensitive adhesive is disposed between the upper ring and the elastomeric tread. [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 an enlarged partial perspective view 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 front view of one embodiment of an arc adjustable band and ratchet assembly. [Figure 8] 8 is an enlarged front view of one embodiment of the ratchet assembly of FIG. [Figure 9] 9 is a perspective view of the arc adjustable band and ratchet assembly of FIG. 7. FIG. [Figure 10] FIG. 10 is a schematic top view of one embodiment of an inverted hose clamp. [Figure 11] FIG. 11 is a front view of the inverted hose clamp of FIG. 10 having a helical screw assembly. [Figure 12] FIG. 12 is a front view of one embodiment of a helical screw. [Figure 13] FIG. 13 is a front view of one embodiment of a sealing ring. [Figure 14] 14 is a partial cross-sectional view of the sealing ring of FIG. [Figure 15] FIG. 15 is a front view of one embodiment of a snap ring. [Figure 16A] 16A and 16B are front views of an expansion ring in a closed and open position, respectively. [Figure 16B] 16B is a front view of the expansion ring in the closed and open positions, respectively. [Figure 17] FIG. 17 is a front view of the arc adjustable band of FIGS. 7-9 having a flat elastomeric belt disposed around the circumference of the band. [Figure 18] FIG. 18 is a front view of one embodiment of a hanger for a non-pneumatic tire. 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 the 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 of the same material. In one particular embodiment, the lower ring 110, the upper ring 120, and the spokes 130 are each constructed of steel. In alternative embodiments, the lower ring 110, the upper ring 120, and the spokes 130 are each constructed of other metals, carbon fiber, resin, 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 of different materials. For example, the upper ring 120 may be a steel band, while the lower ring 120 and spokes 130 may be constructed of other metals, carbon fiber, resins, 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 hub shown 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 also 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 attached to the top of the upper ring 120, and no pressure-sensitive adhesive is 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 temperature-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 view, the top ring 120 has a greater width than the spokes 130, and the top ring 120 extends outward from the spokes 130 to define 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 ledges 170 on only one side of the tire are shown. 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.

[0024] The relative dimensions of a non-pneumatic tire structure can vary. For example, Figures 3 and 4 are schematic diagrams illustrating cross sections of two 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 both sides 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. Additionally, in this embodiment, the lower ring 210 also extends outward from the support structure 230 to form a ledge on each side of the tire 200 .

[0026] In an alternative embodiment (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 both sides of the non-pneumatic tire 300 to define a first ledge 370a on the first side of the tire 300 and a second ledge 370b on the second side of the tire 300.

[0029] In this embodiment, the lower ring 310 is flush with the support structure 330 .

[0030] In an alternative embodiment (not shown), the tread may be wider or narrower than the upper ring.

[0031] It should be understood that Figures 3 and 4 are merely exemplary and that the relative widths of the components of a non-pneumatic tire may vary.

[0032] 5 is an enlarged, partial perspective view of another alternative embodiment of a non-pneumatic tire 400. The non-pneumatic tire 400 includes a lower ring 410 having a first diameter and an upper ring 420 having a second diameter larger than the first diameter. The upper ring 420 is substantially coaxial with the lower ring 410. A plurality of spokes 430 extend between the lower ring 410 and the upper ring 420. The lower ring 410 is attached to a hub 440. A circumferential tread 450 is disposed around the upper ring 420.

[0033] Both sides of the top ring 420 extend outward beyond the spokes 430 to define a ledge on each side of the tire. During manufacturing of the non-pneumatic tire 400, each ledge may receive a securing element or fastener, such as the band 460 shown here, for securing a curing envelope, such as the curing envelope 500 shown in FIG. 6, around the circumferential tread 450.

[0034] Continuing with reference to FIG. 6 , the curing envelope 500 is sized to receive the upper ring and circumferential tread of a non-pneumatic tire structure without extending to the spokes or support structures. The curing envelope 500 has a pair of opposite sides 510 terminating in a first end 520 and a second end 530. The first end 520 and the second end 530 each define an inner diameter ID of the curing envelope 500. The inner diameter ID may be between 22 inches (56 cm) and 58 inches (147 cm). While the opposite sides 510 are shown as flat, it should be understood that they may be curved or contoured as desired.

[0035] The curing envelope also has a top 540 that defines an outer diameter OD. The outer diameter OD may be between 28 inches (71 cm) and 60 inches (152 cm). While the top 540 is shown as flat, it should be understood that it may be curved or contoured as desired. In one embodiment, each side 510 of the curing envelope 500 has a length of between 2 and 6 inches (5 and 15 cm). In other words, the outer diameter OD is between 2 and 6 inches larger than the inner diameter ID.

[0036] The curing envelope 500 may be a sheet of butyl rubber, other rubber compound, 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 the non-pneumatic tire. Therefore, it is advantageous for the first end 510 and second end 520 to be secured to the top ring of the non-pneumatic tire rather than extending to the spokes or support structure.

[0037] The curing envelope 500 and band 460, or other such fasteners, may be used in a method of manufacturing a non-pneumatic tire. Such a method includes providing a tire structure having a bottom ring, a top ring, and a support structure, such as any of the tire structures described above with respect to Figures 1-5.

[0038] In other words, the support structure has a width that is less than a width of the upper ring, such that a first side of the upper ring extends outward from the first side of the support structure to define a first ledge, and a second side of the upper ring extends outward from the second side of the support structure to define a second ledge. The method further includes providing an elastomeric tread circumferentially around a top of the upper ring and securing a curing envelope around the elastomeric tread. The step of securing the curing envelope includes securing a first side of the curing envelope to a bottom of the first ledge of the upper ring and securing a second side of the curing envelope to a bottom of the second ledge of the upper ring.

[0039] The method further includes applying heat and pressure within the curing envelope. In one embodiment, the heat is applied at a temperature of 200°F to 300°F (90°C to 150°C). The elastomeric tread may be a pre-cured or partially cured tread, with any desired tread elements pre-formed before the tread is placed around the top ring. Because the elastomeric tread is pre-cured or partially cured, the tread is heated only to a temperature sufficient to bond the tread to the top ring.

[0040] In one embodiment, a strip of raw rubber or heat sensitive adhesive is first applied to either the tread or the upper ring, and in such an embodiment, applied heat causes the raw rubber or adhesive to bond the tread to the upper ring.

[0041] Although the tire manufacturing method has been described using simple bands 460 as fasteners, other types of fasteners may be used. Exemplary fasteners are shown in Figures 7-17. It should be understood that these examples are not intended to be limiting and that other fasteners may be used.

[0042] Figure 7 is a front view of one embodiment of the arc adjustable band 600 and ratchet assembly 700. Figures 8 and 9 show additional views of the arc adjustable band 600 and ratchet assembly 700. The arc adjustable band 600 and ratchet assembly 700 are described herein with reference to each of Figures 7-9.

[0043] Arc adjustable band 600 has a first end 610 and a second end 620. First end 610 has a plurality of openings 630 along its length, and second end 620 has a ratchet assembly 700 secured thereto. In the illustrated embodiment, the ratchet assembly is configured to engage at least one of the openings 630 to maintain adjustable band 600 in a substantially circular configuration. Arc adjustable band 600 may be made of steel or other metallic or rigid material.

[0044] Ratchet assembly 700 includes a body 710 and a handle 720. Handle 720 is pivotally connected to body 710 at pivot point 730. A spring mechanism 740 is connected between body 710 and handle 720 and biases ratchet assembly 700 toward an open or closed position.

[0045] The body 710 of the ratchet assembly 700 has a curved or arcuate shape that corresponds to the rounded shape of the arc-adjustable band 600. The body 710 is fixedly attached to the second end 620 of the arc-adjustable band 600. As shown in FIG. 9 , in this embodiment, the body 710 is attached to the second end 620 with a rivet 750. In an alternative embodiment (not shown), the body may be attached to the second end by welding or brazing, or with adhesives, bolts, or other known fasteners. In another alternative embodiment, the body may be removably attached to the second end of the arc-adjustable band.

[0046] The handle 720 of the ratchet assembly 700 is removably attached to the first end 610 of the arc adjustable band 600. As shown in FIG. 9 , the handle 720 is attached by a pair of bolts 760 that extend through two selected openings 630 in the first end 610 of the arc adjustable band 600.

[0047] During operation, the handle 720 of the ratchet assembly 700 can be moved to a first position where the bolted end of the handle 720 is proximate the riveted portion of the body 710. In this first position, the arc-adjustable band 600 has a smallest diameter and can be inserted into or removed from a sealing position relative to the cure envelope and non-pneumatic tire. When the arc-adjustable band 600 is in the sealing position, the handle 720 can then be moved to a second position where the bolted end of the handle 720 is distal from the riveted portion of the body 710. In this second position, the arc-adjustable band 600 has a largest diameter and abuts the end of the cure envelope and the ledge of the outer ring of the non-pneumatic tire. In this manner, the arc-adjustable band 600 seals the cure envelope against the non-pneumatic tire.

[0048] In one embodiment, the width of the arc-adjustable band 600 is equal to the width of the ledge of the outer ring of the non-pneumatic tire. In an alternative embodiment, the arc-adjustable band is narrower than the ledge of the outer ring of the non-pneumatic tire. In another alternative embodiment, the arc-adjustable band is wider than the ledge of the outer ring of the non-pneumatic tire.

[0049] In the illustrated embodiment, the bolts 760 may be removed from the arc adjustable band 600 to allow a user to attach the handle 720 to different points on the arc adjustable band 600 through a different selected pair of openings 630 as desired. Thus, the diameter of the arc adjustable band 600 may be adjusted to seal the cure envelope for different sized non-pneumatic tires.

[0050] In another embodiment, an inverted hose clamp may be employed as the fastener instead of the arc-adjustable band. Figures 10 and 11 are schematic diagrams of a top and side view, respectively, of one embodiment of an inverted hose clamp 800. The inverted hose clamp 800 includes a band 810 having a plurality of slots 820, each spaced apart by the same distance d. The band 810 may be made of steel or another metal or rigid material.

[0051] As seen in FIG. 11 , a helical thread (or worm gear) 830 is attached to the inner surface of the band 810. The helical thread 830 is similar to that used in a conventional hose clamp that fits around the outer surface of a hose. However, a conventional hose clamp has a helical thread or worm gear on the outer surface of the band. Herein, the term "reverse hose clamp" refers to the reverse orientation of the helical thread 830. A "reverse hose clamp" is not limited to clamps used with hoses.

[0052] An example of a helical screw 830 is shown in FIG. 12. The helical screw 830 includes a threaded rod 840 and a head 850. The threads of the threaded rod 840 have a pitch p that corresponds to the distance d between the slots 820 of the band 810. Thus, the threads engage with the slots 820. When the head 850 of the helical screw 830 is rotated in a first direction, the rotation of the threaded rod 840 engages with the slots 820 and moves the band 810 toward a smaller diameter position so that the band can be inserted into or removed from a sealing position relative to the curing envelope and non-pneumatic tire. When the reverse hose clamp 800 is in the sealing position, the head 850 of the helical screw 830 can then be rotated in a second direction. As a result, rotation of threaded rod 840 likewise engages slot 820, moving band 810 toward a larger diameter position until band 810 abuts the end of the cure envelope and the ledge of the outer ring of the non-pneumatic tire. In this manner, reverse hose clamp 800 seals the cure envelope against the non-pneumatic tire.

[0053] The helical thread 830 may be rotated by hand. Alternatively, the helical thread 830 may be rotated manually using a tool such as a screwdriver. In another alternative embodiment, the helical thread 830 may be rotated by an automated system.

[0054] In one embodiment, the width of the band 810 is equal to the width of the ledge of the outer ring of the non-pneumatic tire. In an alternative embodiment, the band is narrower than the ledge of the outer ring of the non-pneumatic tire. In another alternative embodiment, the band is wider than the ledge of the outer ring of the non-pneumatic tire.

[0055] In yet another embodiment, a flanged sealing ring may be employed as the fastener instead of the arc adjustable band or inverted hose clamp. Figures 13 and 14 provide a front view and partial cross-sectional view, respectively, of one embodiment of a sealing ring 900. The sealing ring 900 includes an upper flange 910 having a flat bottom surface 920 and a lower flange 930 having a flat top surface 940. The upper flange 910 and the lower flange 930 are spaced apart a distance substantially equal to the combined height of the upper ring and circumferential tread of a non-pneumatic tire.

[0056] In one embodiment, the entire sealing ring 900 is constructed from an elastomer or other resilient material. In alternative embodiments, the sealing ring 900 may be constructed from multiple materials. For example, the inner core may be constructed from aluminum, other metals, polyethylene, or other rigid materials, and the flanges 910, 930 are constructed from rubber or another elastomeric material.

[0057] In operation, after the curing envelope is placed around the non-pneumatic tire and tread assembly, the sealing ring 900 is secured to the curing envelope and non-pneumatic tire assembly by abutting the upper flange 910 against the curing envelope above the tread and the lower flange 930 against the curing envelope below the ledge of the upper ring. The upper flange 910 and lower flange 930 may be flexed to accommodate the non-pneumatic tire. After they close over the curing envelope, the flanges exert a sealing force against the curing envelope and the tire.

[0058] In one embodiment, the width of the top surface 940 of the bottom flange 930 is equal to the width of the ledge of the outer ring of the non-pneumatic tire. In an alternative embodiment, the width of the top surface 940 of the bottom flange 930 is less than the width of the ledge of the outer ring of the non-pneumatic tire. In another alternative embodiment, the width of the top surface 940 of the bottom flange 930 is greater than the width of the ledge of the outer ring of the non-pneumatic tire.

[0059] In the illustrated embodiment, the top flange 910 has substantially the same width as the bottom flange 930, although in alternative embodiments (not shown), the top flange may be wider or narrower than the bottom flange. Additionally, while the illustrated embodiment shows the top flange 910 as having a sloped top surface and the bottom flange 930 as having a sloped bottom surface, in alternative embodiments (not shown), these surfaces may have any shape.

[0060] Additionally, the flanges 910, 930 are not limited to having flat surfaces 920, 940. In an alternative embodiment (not shown), the bottom surface of the upper flange may be contoured to correspond to the surface of the top surface of the tread of a non-pneumatic tire. Similarly, the top surface of the bottom flange may be contoured to correspond to the surface of the ledge of the top ring of a non-pneumatic tire.

[0061] In yet another embodiment, a snap ring may be employed as the fastener in place of an arc adjustable band, an inverted hose clamp, or a flanged sealing ring. For example, FIG. 15 is a front view of one embodiment of a compressible snap ring 1000. The compressible snap ring 1000 is constructed from a rigid material, such as steel, aluminum, other metals, or a hard polymer material. However, it should be understood that although the compressible snap ring 1000 is constructed from a rigid material, the ring 1000 is flexible enough to be compressed to a smaller diameter.

[0062] In operation, once the compressible snap ring 1000 is compressed to a smaller diameter, it can be inserted into or removed from a sealing position relative to the cure envelope and non-pneumatic tire. When the ring 1000 is in the sealing position, it can then be released to expand to a larger diameter. As the ring 1000 expands to a larger diameter, it abuts the edge of the cure envelope and the ledge of the outer ring of the non-pneumatic tire. In this manner, the ring 1000 seals the cure envelope against the non-pneumatic tire.

[0063] In one embodiment, the width of the compressible snap ring 1000 is equal to the width of the ledge of the outer ring of the non-pneumatic tire. In an alternative embodiment, the compressible snap ring is wider than the ledge of the outer ring of the non-pneumatic tire. In another alternative embodiment, the compressible snap ring is narrower than the ledge of the outer ring of the non-pneumatic tire. In one such embodiment, the snap ring may be significantly narrower than the ledge of the outer ring. For example, the compressible snap ring may have a thickness of 0.25 inches. If the compressible snap ring is significantly narrower than the width of the ledge, the ledge may have a groove sized to receive the ring.

[0064] In yet another embodiment, a rigid expansion ring may be employed as the fastener instead of an arc adjustable band, an inverted hose clamp, a flanged sealing ring, or a snap ring. Figures 16A and 16B are front views of expansion ring 1100 in the closed and open positions, respectively.

[0065] In the illustrated embodiment, the rigid expansion ring 1100 has a release handle 1110. When the expansion ring 1100 is in an expanded state, as shown in Figure 16A, the expansion ring 1100 has a first diameter. As shown in Figure 16B, a user can pull the handle 1110, causing the rigid expansion ring 1100 to deflect and contract from the expanded state having the first diameter to a deformed, compressed state.

[0066] In operation, once the rigid expansion ring 1100 is compressed to a deformed, compressed state, it can be inserted into or removed from a sealing position against the curing envelope and the non-pneumatic tire. When the rigid expansion ring 1100 is in the sealing position, the handle 1110 can then be released to allow the rigid expansion ring 1100 to expand. As the ring 1100 expands, it abuts the edge of the curing envelope and the ledge of the outer ring of the non-pneumatic tire. In this way, the rigid expansion ring 1100 seals the curing envelope against the non-pneumatic tire.

[0067] In one embodiment, the width of the rigid expansion ring 1100 is equal to the width of the ledge of the outer ring of the non-pneumatic tire. In an alternative embodiment, the compressible snap ring is wider than the ledge of the outer ring of the non-pneumatic tire. In another alternative embodiment, the compressible snap ring is narrower than the ledge of the outer ring of the non-pneumatic tire.

[0068] In many of the above-described embodiments, the fastener includes a flat ring or band. For example, the arc-adjustable band 600, the reverse hose clamp 800, and the rigid expansion ring 1100 may each include a flat ring or band. In each of these embodiments, the flat ring or band may be constructed of steel or other metal. Additionally, in each of these embodiments, a flat elastomeric belt may be disposed between the metal ring or band and the curing envelope. For example, FIG. 17 is a front view of the arc-adjustable band 600 having a flat elastomeric belt 1200 disposed around the outer periphery of the band 600. The flat elastomeric belt 1200 may prevent damage to the curing envelope or the arc-adjustable band 600. The flat elastomeric belt 1200 may be attached to the arc-adjustable band 600 by adhesive or through other means. For example, the belt 1200 may be cured onto the arc-adjustable band 600. Alternatively, the flat elastomeric belt 1200 may be removed from the arc-adjustable band 600 and placed separately in a sealed position between the curing envelope and the arc-adjustable band 600 .

[0069] Although FIG. 17 illustrates only a flat elastomeric belt 1200 with an arc adjustable band 600, it should be understood that a flat elastomeric belt may be used with any of the flat rings or bands described above.

[0070] A monorail system may be used to transport non-pneumatic tires both before and after the tread is applied to the non-pneumatic tire structure. A hanger for receiving the tire may extend from the monorail system. Figure 18 is a front view of one embodiment of a hanger 1300 for a non-pneumatic tire. The hanger 1300 includes a pair of rollers 1310 for engaging with a monorail (not shown). The hanger 1300 further includes a vertical member 1320 and a horizontal receiving portion 1330.

[0071] Hangers for pneumatic tires are known in the art. In contrast to conventional hangers, hanger 1300 has a shorter vertical member 1320 and a longer horizontal receiving portion 1330. In one known embodiment, vertical member 1320 is between 8 inches (20 cm) and 12 inches (30 cm) long, and horizontal receiving portion 1330 is between 14 inches (35 cm) and 18 inches (46 cm) long.

[0072] The horizontal receiving portion 1330 has a flat upper surface and may be covered with a rubber hose 1340 to protect the inner ring of the non-pneumatic tire. In an alternative embodiment (not shown), a rubber sleeve may be attached to the horizontal receiving portion. In another alternative embodiment (not shown), a rubber coating may be applied to the horizontal receiving portion.

[0073] The terms "includes" or "including," to the extent that they are used herein or in the claims, are intended to be inclusive, similar to the term "comprising," as interpreted when used as a transitional term 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.

[0074] 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 method of manufacturing a non-pneumatic tire, comprising: a lower ring having a first diameter and a first width; an upper ring having a second diameter greater than the first diameter and a second width, the upper ring being substantially coaxial with the lower ring; a support structure extending between the lower ring and the upper ring, the support structure having a third width less than the second width such that a first side of the upper ring extends outward from the first side of the support structure to define a first ledge and a second side of the upper ring extends outward from the second side of the support structure to define a second ledge; providing a tire structure comprising: providing an elastomeric tread circumferentially around the top of said upper ring; securing a flexible curing envelope around the elastomeric tread, the flexible curing envelope comprising: securing a first side of the flexible curing envelope to a bottom of the first ledge of the top ring; and securing a second side of the flexible curing envelope to a bottom of the second ledge of the top ring; applying heat within the flexible curing envelope; A method comprising:

2. 2. The method of claim 1, wherein securing the flexible curing envelope around the elastomeric tread includes securing each end of the flexible curing envelope to the first ledge and the second ledge with an arc adjustable band.

3. 2. The method of claim 1, wherein securing the flexible curing envelope around the elastomeric tread comprises securing each end of the flexible curing envelope to the first ledge and the second ledge with an inverted hose clamp.

4. 2. The method of claim 1, wherein securing the flexible curing envelope around the elastomeric tread includes securing each end of the flexible curing envelope to the first and second ledges with a sealing ring having an upper flange and a lower flange, the upper flange and the lower flange being spaced apart a distance substantially equal to the combined height of the upper ring and the elastomeric tread.

5. 2. The method of claim 1, wherein securing the flexible curing envelope around the elastomeric tread comprises securing each end of the flexible curing envelope to the first ledge and the second ledge with an elastomeric belt.

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