Non-pneumatic tire with fiber-metal laminate structure

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

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[0001] The present disclosure relates to non-pneumatic tires. More specifically, the present disclosure relates to non-pneumatic tires having a fiber-metal laminate structure.

Background Art

[0002] Various tire structures have been developed that enable a tire to run in a non-inflated or under-inflated state. Non-pneumatic tires do not require inflation, but "run-flat tires" can continue to operate relatively fast for a long time even after being punctured and partially or completely deflated. Non-pneumatic tires may include a support structure 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 a structural reinforcement element in the ring or spokes of a non-pneumatic tire. However, non-pneumatic tires provided with known structural reinforcement elements may be troubled by problems related to tire uniformity, crack propagation, fatigue resistance, or impact resistance.

Summary of the Invention

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

[0007] The accompanying drawings illustrate structures illustrating representative embodiments of the claimed invention, along with the detailed description provided below. Similar elements are identified by the same reference numeral. It should be understood that elements shown as single components may be replaced by multiple components, and elements shown as multiple components may be replaced by single components. The drawings are not to exact scale, and the proportions of certain elements may be exaggerated for illustrative purposes. [Figure 1] This is a front view of one embodiment of a non-pneumatic tire. [Figure 2] Figure 1 is a partially enlarged front view of a non-pneumatic tire. [Figure 3] This is a cross-sectional view of a non-pneumatic tire along section 3-3 in Figure 2. [Figure 4a] Figure 1 is a detailed cross-sectional view of one embodiment of a fiber-metal laminate that can be used in various parts of a non-pneumatic tire. [Figure 4b] Figure 4a is a perspective view of the dissection. [Figure 5] This is a cross-sectional view of another embodiment of a non-pneumatic tire. [Modes for carrying out the invention]

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

[0009] "Axial" and "in the axial direction" refer to the direction parallel to the tire's axis of rotation.

[0010] "Circumferential" and "circumferentially" refer to the direction that extends along the outer periphery of the tread surface, which is 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 the direction perpendicular to the tire's axis of rotation.

[0013] As used herein, "tread" refers to the portion of the tire that is in contact with the road or ground under normal inflation and load conditions.

[0014] While common tire components are described using similar terminology in the following description, it should be understood that, naturally, the terms have slightly different implications, and therefore, those skilled in the art will not consider any one of the following terms to be simply interchangeable with another term used to describe a common tire component.

[0015] In this specification, direction is given with respect to the tire's axis of rotation. The terms “upward” and “towards” refer to the general direction toward the tire's tread, while “downward” and “towards” refer to the general direction toward the tire's axis of rotation. Therefore, when relative directional terms such as “upper” and “lower” or “top” and “bottom” are used in relation to elements, the “upper” or “top” element is spaced further away from the tread than the “lower” or “bottom” element. In addition, when relative directional terms such as “up” or “down” are used in relation to elements, an element “above” another element is closer to the tread than the other element.

[0016] The terms "inner" and "inward" refer to the general direction toward the tire's equatorial plane, while "outer" and "outward" refer to the general direction toward the tire's side, away from the tire's equatorial plane. Therefore, when relative directional terms such as "internal" and "external" are used in relation to elements, "internal" elements are spaced further away from the tire's equatorial plane than "external" elements.

[0017] Figures 1 to 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 with a vehicle hub (not shown) for mounting the non-pneumatic tire 100 to a vehicle.

[0018] The spokes 200 extend between the lower ring 130 and the upper ring 140, connecting the lower ring 130 to the upper ring 140. In the illustrated embodiment, the spokes 200 are curved. In an alternative embodiment, the spokes may have a more pronounced curve, such as being substantially C-shaped. In yet another alternative embodiment, the spokes may be any desired shape. For example, the spokes may be substantially V-shaped or meandering. In yet another alternative embodiment, the non-pneumatic tire may include two or more spokes of different shapes. For example, the non-pneumatic tire may include C-shaped spokes alternating with V-shaped spokes along the circumferential direction of the non-pneumatic tire. In yet another alternative embodiment, the spokes may be replaced by webbing or other support structures.

[0019] A circumferential tread 300 is attached to the upper ring 140. The circumferential tread 300 includes a tread layer 302 and a tread band 304 positioned between the tread layer 302 and the upper ring 140. The tread layer 302 may be made of rubber or other elastomer 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 upper ring.

[0020] 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 elastomer or metal. The spokes 200 may also be made from an elastomer 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 polymer 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 materials 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 an alternative embodiment, the fiber-metal laminate may not be provided as a reinforcement but may be used to manufacture the entire lower ring, upper ring, spokes, or tread band. 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 comprises 11 layers 510-530 provided as metal foil, primer, or a combination of fiber and resin.

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

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

[0024] The third layer 514 and the ninth layer 526 are provided as a combination of fibers and resin. According to an exemplary embodiment, the combination of fibers and resin is provided using a fiber prepreg that includes fibers pre-impregnated with a resin system. In an alternative embodiment, the combination of fibers and resin is provided using plain fibers (i.e., not pre-impregnated with a resin system) and a resin transfer process, whereby the plain fibers are placed in a mold and then the resin is injected into the mold. Compared to fiber prepregs, plain fibers and the resin transfer process allow for increased design flexibility. However, fiber prepregs provide a simpler manufacturing process and time savings compared to plain fibers and the resin transfer process. In either the fiber prepreg or the plain fibers and resin transfer process, the fibers may be polymers, glass, carbon, metal, or any other desired fiber or combination of fibers. In either the fiber prepreg or the plain fibers and resin transfer process, the resin system may be of the thermosetting or thermoplastic type. Examples of resin systems include, but are not limited to, resins derived from epoxy, polyurethane, polyacrylate, polysiloxane, vinyl ester, polyester, 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. An impact modifier can be optionally added to the resin to improve the toughness of the fiber and resin combination layer. According to an exemplary embodiment, the impact modifier includes a multilayer structured polymer particle design produced by KANEACE (registered trademark). In an alternative embodiment, 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 are provided as primers. The primers can facilitate bonding between the metal foil layer and the fiber and resin combination layer. According to one exemplary embodiment, the primer may be produced from a sol-gel type reaction on the surface of the metal foil. In alternative embodiments, the primer may 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 primer may 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 composite 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 composite 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 percentages of the volume fraction of metal may be provided to result in different performance characteristics that may allow for the tuning of non-pneumatic tires for different applications.

[0027] By using the fiber-metal laminate 500 in the lower ring 130, upper ring 140, spokes 200, or tread band 304, the performance and robustness of the non-pneumatic tire 100 can be improved while simultaneously reducing the weight of the non-pneumatic tire 100. By interposing metal foil layers 510, 518, 522, and 530 between the fiber-resin combination layers 514 and 526, the impact and fatigue characteristics of the non-pneumatic tire 100 can be improved. This is because the metal foil layers 510, 518, 522, and 530 can prevent cracks from forming in the fiber-resin combination layers 514 and 526, and prevent crack propagation throughout the non-pneumatic tire 100. Different combinations of metal foil, fiber, and resin, as well as primers, can result in different performance characteristics that can be adapted for different applications of the non-pneumatic tire. For example, the overall strength of a non-pneumatic tire can be improved by replacing specific directional fiber layers within the fiber and resin combination layer, which traditionally prioritize impact performance over composite strength. Specifically, in one example, the fiber orientation is entirely circumferential (i.e., 0 degrees), which provides high strength and, benefiting from the interposed metal foil layer, can support impact performance.

[0028] In alternative embodiments, the fiber metal laminate may contain fewer or more layers. In addition, in other alternative embodiments, the different layers may be provided in any desired order. For example, in the embodiments shown in Figures 4a and 4b, starting from the first layer 510 and moving toward the eleventh layer 530, the layers of metal foil, primer, fiber and resin combination, primer, metal foil, primer, metal foil, primer, fiber and resin combination, primer, and metal foil are provided in sequence. In another embodiment, this arrangement may be layers of 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 embodiments shown in Figures 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, this ratio may be two layers of metal foil, five layers of primer, and four layers of fiber and resin combination. Different numbers of layers, different order of layers, and different ratios of layers can result in different performance characteristics, which can allow for the adjustment of non-pneumatic tires for different applications.

[0029] Figure 5 illustrates another exemplary embodiment of the non-pneumatic tire 1100. The non-pneumatic tire 1100 of Figure 5 is substantially similar to the non-pneumatic tire 100 of Figures 1 to 3, except for the differences described herein. Thus, similar features are identified by similar numbers that are increased by "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 in Figures 1 to 3, the non-pneumatic tire 1100 does not have an upper ring. Therefore, 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 Figures 4a and 4b. According to this embodiment, further advantages can be realized by using a fiber-metal laminate in that the spokes 1200 or other support structures and the tread band 1304 can be manufactured as a single 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 joined, the integrated spoke 1200 and tread band 1304 unit can increase strength and reduce cost by eliminating weaknesses and joints between different materials and by eliminating adhesive joints.

[0031] To the extent used herein or in the claims, the terms “includes” or “including” are intended to be inclusive, similar to how the term “comprising” is interpreted when used as a transitional clause 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.” When the 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). Additionally, to the extent that the terms “in” or “into” are used herein or in the claims, it is intended to additionally mean “on” or “onto.” Furthermore, to the extent that the term “connect” is used herein or in the claims, it is intended to mean not only “directly connected to,” but also “indirectly connected to,” such as by connecting through another component.

[0032] Although this application has been illustrated by descriptions of its embodiments and described in considerable detail, it is not the applicant's intention to limit the scope of the appended claims to such detail or to restrict them in any way. Additional advantages and improvements will be readily apparent to those skilled in the art. Therefore, in its broader aspects, this application is not limited to the specific details, representative apparatus and methods, and exemplary embodiments illustrated and described. For this reason, deviations from such details may be made without departing from the spirit or scope of the applicant's general inventive concept.

Claims

1. Non-pneumatic tires, A lower ring having a first diameter, An upper ring having a second diameter larger than the first diameter, and substantially coaxial with the lower ring, The lower ring is connected to the upper ring by a support structure, 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, A non-pneumatic tire further comprising a circumferential tread attached to the upper ring, wherein the circumferential tread includes a tread layer and a tread band positioned between the tread layer and the upper ring, and the tread band is manufactured from the fiber metal laminate.

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

3. The non-pneumatic tire according to claim 1, wherein each of the lower ring and the upper ring comprises the fiber metal laminate, and the at least one metal foil layer and the at least one fiber and resin combination layer are arranged to extend substantially circumferentially over the non-pneumatic tire and are oriented to build upon each other substantially radially over the non-pneumatic tire.

4. The inflatable tire according to claim 1, wherein the support structure is provided as a plurality of spokes including the fiber-metal laminate, and the at least one metal foil layer and the at least one fiber-resin combination layer are each arranged to extend substantially radially over the inflatable tire and oriented to build upon each other substantially circumferentially over the inflatable tire.

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