Tire with acoustic foam and sensor

Abstract

A tire is provided that has a crown with an inner surface, left and right sidewalls, and left and right beads extending from their respective sidewall. A container that has a cavity is included that has a base and a wall that extends from the base. The base is attached to the inner surface. A sensor is located in the cavity of the container. Acoustic foam is provided and is attached to the inner surface. The acoustic foam has an aperture and the wall of the container is located in the aperture and engages the acoustic foam.

Description

DescriptionTitle of Invention: TIRE WITH ACOUSTIC FOAM AND SENSORFIELD OF THE INVENTION

[0001] The present invention relates generally to a tire that includes both acoustic foam and a sensor. More particularly, the present application involves a sensor located in the acoustic foam that is in turn attached to an inner wall of the tire and is capable of providing information such as tire identification, pressure, temperature, or other measurements.BACKGROUND OF THE INVENTION

[0002] It is known to place sensors into the tires of vehicles in order to measure such things as tire inflation pressure, tire temperature, tire acceleration, tire velocity, and other parameters. The sensors may also provide tire identification information and other data in addition to, or alternatively to, just measurement data. Such electronic sensors typically require a container to be fixed inside of the tire into which the sensor is inserted and retained. The container can have a cavity into which the electronic sensor is placed, and one known sensor container includes a lip that surrounds a portion of the top of an electronic sensor and holds it in place in the cavity. The lip is made of a flexible material and is rolled back to allow the sensor to be pushed past it and into the cavity. The flexible lip can then be flipped back into its original position, and in so doing engage the sensor and function to retain it in the cavity. The holding of the electronic sensor within the tire should be strong enough to keep the electronic sensor in place upon being subjected to high acceleration, forces, and temperatures during operation of the vehicle.

[0003] The container can be a piece that is separately formed and then subsequently attached to the tire once the tire has been molded. This attachment can be made by using green rubber or adhesive to bond the rubber container to the inner layer of the tire. Another way of providing a container to the interior of the tire is by molding it into the tire during the production process. This process results in the formation of a flap on the inner surface of the tire, and requires the positioning of additional separating components and the careful removal of such components once the molding is completed. The resulting flap / container is flat and has an aperture immediately adjacent the inner surface of the tire. Although capable of holding a flat sensor, such a manufacturing process cannot produce a flap / container capable of holding a non-flat shaped electronic sensor and limits the location and shape of the container.

[0004] A further method of molding a container onto the inner surface of the tire is disclosed in patent application publication WO 2021 / 126199 entitled “Method of Molding aContainer into a Tire” which is owned by the present Applicant and is incorporated by reference herein in its entirety for all purposes. This method involves the placement of a puck onto a flexible bladder of a mold which is used to mold the container onto the inner surface of the tire when at the same time the rest of the tire is being molded by the mold. Although capable of molding the container onto the inner surface, the disclosed method presents certain manufacturing challenges. For example, in one embodiment the puck is located within a concave cavity of the flexible bladder. The construction of a flexible bladder with such a cavity that can expand and contract during production is not industrially practical. In a different embodiment, the puck is attached to the outside of the flexible bladder by the use of a mechanical fastener that extends through the sidewall of the flexible bladder. Although capable of holding the puck, this arrangement introduces a hole into the flexible bladder through which fluid may leak, and is thus not a practical way of constructing the mold.

[0005] A yet additional way of forming a container within a tire involves providing a solid core drum that has a cavity into which rubber flows during molding of the tire. A container formed by a solid core drum process may be capable of holding electronic sensors that are not of a flat shape. However, the use of a solid core in the production of tires with containers may require variously sized solid cores to be produced when manufacturing tires of different types and sizes.

[0006] It is known to provide tires that have both the aforementioned containers along with an acoustic foam located within the tire for the reduction of noise. These arrangements are described in French patent publications FR 3125249 and FR 3125253 which are owned by the assignee of the present application and are incorporated by reference herein in their entireties for all purposes. These tires feature acoustic foam that is discontinuous within the inner wall of the tire so that the container can be positioned within and free from contact with the acoustic foam. The container and acoustic foam are thus separate components that are individually positioned and formed into the tire without engagement with one another or any structural interaction. Although different techniques are known for producing tires that have containers for holding sensors, there remains room for variation and improvement within the art.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended Figs, in which: [Fig 1]

[0008] [Fig.1] is a perspective view of a tire that has a container and acoustic foam.[Fig 2]

[0009] [Fig.2] is a cross-sectional view of a portion of a tire that includes the container and acoustic foam.[Fig 3]

[0010] [Fig.3] is a cross-sectional view of a sensor and container in which the sensor is not located within the container.[Fig 4]

[0011] [Fig.4] is a perspective view of acoustic foam with an aperture.[Fig 5]

[0012] [Fig.5] is a cross-sectional view of a container and sensor before insertion into the acoustic foam.[Fig 6]

[0013] [Fig.6] is a front view of a portion of the acoustic foam with the container and sensor inserted therein.[Fig 7]

[0014] [Fig.7] is a perspective view of a tire that has beads of adhesive applied to the inner surface of the tire.[Fig 8]

[0015] [Fig.8] is a cross-sectional view of a portion of the tire that shows the container and sensor applied thereto and captured within the acoustic foam.

[0016] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations.

[0018] It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all subranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.

[0019] A tire 10 that has acoustic foam 12 for the reduction of noise is provided that also includes a sensor 56 that could be used for providing information about the tire 10 such as identification, tire temperature, or tire pressure. The sensor 56 can be used tomeasure any type of parameter and can be used to ascertain any type of property of the tire 10 or vehicle to which it is attached. The sensor 56 could be an accelerometer to measure acceleration, may be used to measure wear on the tread 20, or may measure acceleration / speed. The sensor 56 is housed within a container 44 that is in turn located within the acoustic foam 12 on the inner surface 30 of the crown 22 of the tire 10. The container 44 is located within an aperture 58 of the acoustic foam 12, and a wall 50 of the container 44 engages the acoustic foam 12. The acoustic foam 12 and the container 44 are both attached to the inner surface 30 of the crown 22. The arrangement of the container 44 with the acoustic foam 12 provides for a secure attachment of the components into the tire 10 and eliminates gaps or voids of acoustic foam 12 so that noise reduction is enhanced.

[0020] [Fig-1] shows a tire 10 with a central axis 42 that extends in an axial direction 16 and tread 20 that extends completely 360 degrees around the central axis 42 in the circumferential direction 18 of the tire 10. The tread 20 is on the outer surface 26 of the tire 10 and is the portion of the tire 10 configured for engagement with the ground or road surface. The tire 10 has a pair of sidewalls 38, 40 that are included in a carcass portion of the tire 10 onto which the tread 20 is located. An inner surface 30 of the tire 10 is located opposite the tread 20 and extends between the inner sides of the left sidewall 38 and the right sidewall 40. The container 44 is attached to the inner surface 30 and extends through acoustic foam 12 that is likewise attached to the inner surface 30 and is visible in the perspective view of [Fig.l]. The container 44 and the sensor 56 included within the container 44 can both extend through the acoustic foam 12 so as to be located closer to the central aixs 16 in a radial direction 14 of the tire 10 than the acoustic foam 12 is to the central axis 16 in the radial direction 14.

[0021] A cross-section of a tire 10, which in this instance can be described as a radial cut of the tire 10, that includes acoustic foam 12 and a container 44 that houses a sensor 56 is shown with reference to [Fig.2]. Various tissues, sometimes called products, composed of different materials are present throughout the tire 10. The tread 20 of the tire 10 is located farthest from the central axis 42 of the tire 10 in the radial direction 14. A first belt layer 64 and a second belt layer 66 are located below the tread 20 in the radial direction 14 and comprise belts for use in strengthening and holding the form of the tire 10. The reinforcement belts of the layers 64, 66 may be crossed relative to one another, and in some instances they can be arranged at an angle of 20 degrees to one another. The crown 22 of the tire 10 includes the tread 20 along with the belt layers 64, 66, and is located in the center of the tire 10 with respect to the axial direction 16 of the tire 10. Left and right sidewalls 38, 40 extend from the crown 22 in the radial direction 14 and terminate in a pair of beads 24, 34 that are arranged for mounting onto the rim of the wheel of the vehicle. The left bead 24 engages and is located at theend of the left sidewall 38, and the right bead 34 engages and is located at the end of the right sidewall 40 in the radial direction 14. The beads 24, 34 both extend from the sidewalls 38, 40 in the radial direction 14 and are the portions of the tire 10 that are located closest to the central axis 42 in the radial direction 14.

[0022] A left bead core 28 is located in the left bead 24, and a right bead core 86 is located in the right bead 34. The bead cores 28, 86 are present to provide strength and a gripping force in the beads 24, 34 for retention onto the rim. The left bead 24 can be a mirror image of the right bead 34 and both beads 24, 34 can have products that are made of the same material. Some of the tissues / products are located only in the beads 24, 34 while others are located in the beads 24, 34 and extend therefrom. For instance, an inner liner 68 is inside of the beads 24, 34 and extends to inner, exterior sides of the beads 24, 34 before extending up the side walls 38, 40 into which the inner liner 68 forms inner, exterior sides of the sidewalls 38, 40. The inner liner 68 then extends from the two sidewalls 38, 40 across the entire inner side of the crown 22 in the axial direction 16 and forms the inner surface 30 of the crown 22. The inner liner 68 is arranged in a mirror-image manner in the left and right beads 24, 34 and terminates within these two beads 24, 34. The inner liner 68 is a product of the tire 10 that extends all the way from one bead 24 to the other bead 34 and is made of a material that is fluid tight so that fluid between the tire 10 and rim is maintained therein for purposes of maintaining inflation pressure of the tire 10.

[0023] The tire 10 includes a tissue designated as a first reinforcement ply 32 that has an end that is located within the left bead 24 and extends through the left sidewall 38 and crown 22 and into the right sidewall 40 and finally into and terminating within the right bead 34. The first reinforcement ply 32 wraps around the left bead core 28 to a location that is outward in the axial direction 16 from the rod 72. The first reinforcement ply 32 has a main portion that is in the left bead 24 and is inboard from the rod 72. This main portion extends to the bead core 28 to a location of the first reinforcement ply 32 that is closest to the central axis 12 in the radial direction 14. The first reinforcement ply 32 is wrapped around the left bead core 28 and may engage the left bead core 28 in some embodiments. The first reinforcement ply 32 can be arranged in the right bead 34 in a similar manner in which it can wrap around and may engage the right bead core 86. The first reinforcement ply 32 may be outboard from the rod 88 in the axial direction 16 in the right bead 34 and can terminate within the right bead 34 at a position that is completely outboard from the rod 88 in the axial direction 16. The first reinforcement ply 32 may also be completely inboard from the right bead 34 in the radial direction 14 such that it is closer to the central axis 42 in the radial direction 14.

[0024] Relative positions in the axial direction 16 can be described with respect to inboard and outboard positions. The most inboard point of the tire 10 may be the radialdirection line 14 shown in [Fig.2] in its location in [Fig.2] as it is located at the center of the tire 10 in the axial direction 16. The center of the tire 10 is inboard of both the left and right hand beads 24, 34 in the axial direction 16. As used herein, an object described as inboard in the axial direction 16 to another object means that it is located closer to the radial direction line 14 as shown in [Fig.2]. Further, as used herein an object described as being located outboard from another object in the axial direction 16 means that it is located farther from the radial direction line 14 in the axial direction 16 as shown in [Fig.2]. As another example, the first reinforcement ply 32 in the left bead 24 is outboard of the rod 72 in the axial direction 16. Relative positioning in the radial direction 14 may be described in relation to the central axis 42 in which objects may be closer to or farther from the central axis 42 in the radial direction 14 than other objects.

[0025] The left bead 24 has a left bead core 28 that made up of one or more steel rods 72.Left bead filler 36 is present within the left bead 24 and in some embodiments may include padding gum with a wrapping tissue that surrounds the entire left bead core 28. This padding gum and wrapping tissue are not shown in [Fig.2], and instead only bead filler 36 completely surrounds the rod 72, but is to be understood that other arrangements of the left bead 24 are possible. The rod 72 making up the left bead core 28 is shown as a single piece and has a rectangular cross-sectional shape. This single piece can actually be many rods arranged together in the shape of a rectangle. In other embodiments the left bead core 28 can be made of multiple components and these components could have any cross-sectional shape. The wrapping tissue, if present, may have a stiffness of 14 MPa and can be made of a rubber mix and textile which in some instances can be a nylon ply. The padding gum, if present, can be a rubber mix and may have a stiffness of 28 MPa, and the rod 72 can be made of steel or aluminum and can have a stiffness of 30,000,000 MPa in some embodiments. The left bead core 28 can be lightened so that a smaller rod 72 can be used to improve performance properties of the tire 10. Although shown as being a rectangular rod 72, the rod 72 could be circular in other embodiments. In yet further arrangements, the rod 72 could be variously shaped and need not be a rectangular or circular in shape.

[0026] The left bead 24 includes left bead filler 36 that can engage and completely surround the rod 72, and may also engage the first reinforcement ply 32 and be between the main portion and the return casing ply of the first reinforcement ply 32. The left bead filler 36 also engages the second reinforcement ply 74 and the third reinforcement ply 80. The left bead filler 36 may be placed into the left bead 24 as a single layer, or it may be made of multiple layers within the left bead 24. The left bead filler 36 can be a rubber mix that can have a stiffness in the range from 3.6 MPa to 5.6MPa. The left bead filler 36 ends in the left bead 24, or in some instances may extend into the left sidewall 38 of the tire 10. However, the left bead filler 36 does not extend all theway under the belt layers 64, 66 to the other right sidewall 40 of the tire 10. The first reinforcement ply 32 is a composite material that includes metal cords and a rubber mix. The first reinforcement ply 32 in the direction of its cords is stiffer than the left bead filler 36.

[0027] The left bead 24 includes an anti-abrasive strip 46 that is on the outside of the left bead 24 and is designed to engage the rim. The anti-abrasive strip 46 engages the inner liner 68 and the second reinforcement ply 74. A similar anti-abrasive strip 84 is present in the right bead 34 and engages the inner liner 68 and the second reinforcement ply 74. The right bead 34 can be arranged in a similar manner to the left bead 24. In this regard, the rod 88 and the right bead core 86 can be configured in the same manner as previously discussed with respect to the rod 72 and the left bead core 28. The right bead filler 82 may be arranged in the same manner as previously discussed with respect to the left bed filler 36 and a repeat of this information is not necessary. The two anti-abrasive strips 46, 84 can be made of the same material and may be shaped and sized the same as one another, and they can engage the same components and counterpart components in the left and right beads 24, 34. The other components in the right bead 34 can be arranged in a manner similar to that as previously discussed with respect to the left bead 24.

[0028] The present application describes the stiffness of a product or material. The stiffness that is being referred to is the Young’s modulus which is the stiffness of an elastic material, or elastic modulus. The stiffness is provided in measurements of mega pascals (MPa). The stiffness material property in question that is being referred to is MAIO. This stiffness property can be calculated using French standard NF T 46-002, September 1988.

[0029] The tire 10 includes three reinforcement plies 32, 74, and 80 that extend from the left bead 24 across the crown of the tire 10 under the belt layers 64, 66 and into the right bead 34. The first and second reinforcement plies 32, 74 wrap around the bead cores 28, 86, but the third reinforcement ply 80 does not wrap around the two bead cores 28, 86. The second and third reinforcement plies 74, 80 can be configured as previously discussed with respect to the first reinforcement ply 32 and a repeat of this information is not necessary. The reinforcement plies 32, 74, 80 provide strength and flexibility to the tire 10, and provide a support structure for the inflation pressure of the tire 10 which carries the tire 10 load. The third reinforcement ply 80 engages the second reinforcement ply 74 and is spaced from and not in engagement with the first reinforcement ply 32 in the left and right beads 24, 34. The third reinforcement ply 80 is located outboard from the second reinforcement ply 74 in the axial direction 16. The third reinforcement ply 80 engages the first reinforcement ply 32 in the leftand right sidewalls 38, 40, and is spaced from and not in engagement with the second reinforcement ply 74 in the left and right sidewalls 38, 40.

[0030] The second reinforcement ply 74 is in engagement with the first reinforcement ply 32 through most of its length, and these two plies 32, 74 both wrap around the left and right bead cores 28, 86 and act together to provide strength and flexibility benefits. The second reinforcement ply 74 engages on opposite sides the first and third reinforcement plies 32, 80 and a minor portion of the left bead filler 36 and right bead filler 82. It is to be understood that the arrangement of the components making up the tire 10 are only exemplary and others are possible in other embodiments. For example, the third reinforcement ply 80 and / or the second reinforcement ply 74 may be absent from the tire 10 in other arrangements.

[0031] With reference now to the crown 22, in the crown 22 the third reinforcement ply 80 engages the second belt layer 66 and is located inward in the radial direction 14 from the second belt layer 66. The first reinforcement ply 32 engages the third reinforcement ply 80 and is located inward from it in the radial direction 14. The second reinforcement ply 74 engages the first reinforcement ply 32 and is located inward from the first reinforcement ply 32 in the radial direction, and the second reinforcement ply 74 is free from engagement with the third reinforcement ply 80 in the crown 22. The inner liner 68 engages the second reinforcement ply 74 and forms the inner surface 30 of the crown 22. The acoustic foam 12 and container 44 are attached to the inner surface 30 of the crown 22 via adhesive 60 that could be continuous across the entire width of the acoustic foam 12 and container 44 in the axial direction 16, or may be discontinuous along the widths of these two components. The acoustic foam 12 is located only on the crown 22 and does not engage the left or right sidewalls 38, 40 and does not engage the left and right beads 24, 34. The container 44 and its inserted sensor 56 are centered on the crown 22 so that they are at the midpoint of the crown 22 and tire 10 in the axial direction 16. The container 44 extends completely through the acoustic foam 12 and beyond so that it is located closer to the central axis 42 in the radial direction 14 than the acoustic foam 12 is located to the central axis 42 in the radial direction 14. In other embodiments, the container 44 does not extend past the acoustic foam 12 so that the acoustic foam 12 is located closer to the central axis 42 in the radial direction 14 than the container 44 is to the central axis 42. [Fig.l] shows the acoustic foam 12 disposed on the inner surface 30 of the tire 10 with both the container 44 and sensor 56 visible through the acoustic foam 12. The tire 10 can be designed so that only a single container 44 and sensor 56 are present in the tire 10, or it may be the case that from 2-5 containers 44 and associated sensors 56 are present within the tire 10.

[0032] [Fig.3] shows the container 44 that can be made out of the same material as that which makes up the inner surface 30, or could be made out of a different material than the inner surface 30. The container 44 may be made out of plastic or rubber in accordance with different exemplary embodiments. The container 44 is a separate component from the inner surface 30 that is produced or cured and is then subsequently attached to the inner surface 30. The container 44 has a base 48 that forms an end of the container 44 and may be solid such that no apertures are present through the base 48. A wall 50 of the container 44 extends from the base 48 in the radial direction 14 and may be made of the same material as the base 50 and can be integrally formed therewith. The container 44 has a cavity 52 into which a sensor 56, such as an electronic sensor 56, could be located. The wall 50 of the container 44 extends upwards from the base 48 in the radial direction 14 of the tire 10, over 9 millimeters in some arrangements, and can be of any shape such as circular, oval, or rectangular. In other embodiments, the wall 50 of the container 44 extends from 8 to 10 millimeters, from 8 to 13 millimeters, from 12 to 20 millimeters, or greater than 12 millimeters in the radial direction 14 from the base 48. Although shown as extending a greater length in the radial direction 14 than the axial direction 16, the container 44 could extend a greater length in the axial direction 16 than the radial direction 14 in various other embodiments.

[0033] The container 44 has a lip 54 that extends from the wall 50 at the portion of the wall 50 that is closest to the central axis 42 to cover a portion of the cavity 52 of the container 44. An opening into the cavity 52 is defined by the lip 54 to allow the sensor 56 to be placed therein. The lip 54 can be integrally formed with the wall 50 and can be a flexible member capable of being bent. The lip 54 could be peeled up to allow insertion of the sensor 56 and then subsequently pushed back into the Figs. 1 and 2 position to securely hold the sensor 56 into the container 44. The container 44 may be configured so that only a single, and no more than a single, opening into the cavity 52 exists and faces only in the radial direction 14 of the tire 10, and does not face in the axial direction 16 when the container 44 is incorporated into the tire 10.

[0034] The base 48 can be circular, oval, rectangular or variously shaped in different embodiments. The base 48 includes a flange 62 which extends around the entire perimeter of the base 48 and is located outward from the base 48 and the wall 50 in the axial direction 16. The flange 62 has a thickness that is the same as the thickness of the base 48 and may be integrally formed with the base 48. The sensor 56 has a width that is complimentary with the width of the cavity 52 so that when the sensor 56 is located within the cavity 52 it is securely held therein and prevented from sliding or moving out of the cavity 52. The spacing of the wall 50 can be smaller than that of the width of the sensor 56 so that the presence of the sensor 56 deforms or pushes the wall 50 inthe axial direction 16 to generate frictional holding of the sensor 56 within the cavity 52 to prevent the sensor 56 from exiting the cavity 52. The lip 54 as disposed over the sensor 56 further functions to hold the sensor 56 within the cavity 52. The shape of the cavity 52 and sensor 56 are circular, but it is to be understood that other shapes are possible and that they need not be the same shape as one another in accordance with various exemplary embodiments. The wall 50 in [Fig.3] has a circular shape and has an outer diameter 90 that is the diameter of the exterior sides of the wall 50. This diameter 90 is 20 millimeters in one embodiment. In other arrangements, the geometry of the wall 50 is tapered so that the outer diameter 90 gets smaller as the wall 50 gets closer to the central axis 42. In these arrangements the largest outer diameter 90 of the wall 50 is 29.5 millimeters, and the internal diameter of the cavity 52 is consistent and is 22 millimeters.

[0035] The acoustic foam 12 is shown in [Fig.4] in perspective view and is provided as a ring that extends 360 degrees about its axis. A single aperture 58 extends through the acoustic foam 12 from one side to the other so as to form a through aperture 58. The aperture 58 is circular in shape and has a diameter 92. The diameter 92 may be 20 millimeters in one embodiment. Although shown as being circular in shape, the aperture 58 may be variously shaped in other embodiments. The acoustic foam 12 could be formed in the shape of a ring, or it may be a strip of material that is flexible enough to be bent into the shape of a ring with its ends joined to or otherwise abutted next to one another. The acoustic foam 12 thus forms a continuous 360 degree structure that has no ends, or if it has ends they are joined and in contact with one another, and has no discontinuous portions. The aperture 58 is but a single aperture that is spaced from the two axial ends of the acoustic foam 12, but in other arrangements more than one aperture 58 is present. The aperture 58 is not open onto an axial end of the acoustic foam 12 but rather the acoustic foam 12 forms two planar, uninterrupted surfaces that are parallel to one another such that the aperture 58 is completely spaced from the two parallel planer surfaces and not in engagement with either.

[0036] The acoustic foam 12 is a component that is provided in the tire 10 for absorbing the cavity noise of the tire 10. The acoustic foam 12 can be a single piece or may be multilayered in accordance with various embodiments. The acoustic foam 12 may have a density ranging from 10 to 100 kg / m3, the average basis weight of the acoustic foam may be from 0.3 to 3.0 kg / m2 and preferably from 0.5 to 1.5 kg / m2, and the circumferential ends are in engagement with one another or non-existent if formed as a ring. The acoustic foam 12 is made of a material that affords it some degree of flexibility so that it can be compressed and formed into various shapes. The acoustic foam 12 can be a sponge-like porous material that has open or closed cells, and may be made of polyurethane, vegetable fiber, synthetic fibers, animal fibers, or rubberin accordance with various exemplary embodiments. The acoustic foam 12 may be easily deformed and compressed, and has a specific gravity and weight that will not impact the weight of the tire 10 into which it is contained. Examples of materials that can be used to construct the acoustic foam 12 may be found in United States Patent numbers 6,729,373; 6,755,483; and 7,975,740 the contents of which are incorporated by reference herein in their entireties for all purposes.

[0037] [Fig.5] is a cross-sectional view that shows a portion of the acoustic foam 12 ring that has the aperture 58 that in this instance is circular in shape. The aperture 58 has a diameter 92. A cross-sectional view of the container 44 is also shown, and a sensor 56 is inserted into the cavity 52 and the lip 54 is applied over and into engagement with the sensor 56 to capture the sensor 56 within the cavity 52. The wall 50 is circular in shape and has an outer diameter 90 that is the same as the diameter 92. In this regard, a press-fit can be made between the wall 50 and the acoustic foam 12 so that the wall 50 slightly deforms the deformable acoustic foam 12 upon insertion and is held securely via friction therein. In other arrangements, the diameter 92 can be made smaller than the outer diameter 90 so that the acoustic foam 12 deforms to more securely hold the container 44 within the acoustic foam 12 upon insertion of the container 44 therein. [Fig.6] shows the container 44 and sensor 56 upon insertion into the acoustic foam 12 such that these components are disposed within the aperture 58. The flange 62 is circular in shape and has a diameter greater than the outer diameter 90 and the diameter 92 and thus cannot be inserted into the aperture 58. The flange 62 thus engages the outer surface of the acoustic foam 12 and is not disposed within the aperture 58 when the wall 50 and sensor 56 are placed into the aperture 58. A contact surface 94 of the container 44 is visible in [Fig.6] and is a surface of the container 44 that includes the base 48 and flange 62 and faces generally away from the cavity 52 and the inserted sensor 56.

[0038] In order to construct a tire 10 with the acoustic foam 12 and associated sensor 56, the contact surface 94 of the container 44 may be brushed with a brush or otherwise cleaned with a laser to result in a clean contact surface 94 to facilitate adhesion. The sensor 56 can then be placed into the container 44 and these components can be inserted into the aperture 58 as immediately discussed to result in a subassembly as shown in [Fig.6]. This brushing or cleaning of the contact surface 94 can occur at a point in time before the container 44 is inserted into the acoustic foam 12 or may be executed after this insertion. In some instances, the contact surface 94 is not brushed or cleaned.

[0039] With reference now to [Fig.7], a cured tire 10 can be provided and beads of adhesive 60 can be applied to the inner surface 30. Before this application of adhesive 60, the inner surface 30 can be brushed, cleaned, or otherwise prepared with a laser or otherdevice to help facilitate adhesion. The left and right beads 24, 34 can be opened and a brushing device or laser may be positioned into the interior of the tire 10 to execute the brushing or cleaning. Next, the adhesive 60 can be applied as beads on the inner surface 30 and each one of these beads of adhesive 60 can extend completely around the entire inner surface 30 so as to extend 360 degrees about the central axis 42 in the circumferential direction 18. Although four beads of adhesive 60 are shown, any number of beads of adhesive 60 can be applied in other embodiments, or the adhesive 60 can be applied to the inner surface 30 in a non-bead form. The adhesive 60 does not engage the left or right sidewalls 38, 40 and does not engage the left or right beads 24, 34 and is applied only to the inner surface 30 at the crown 22.

[0040] The next step in the formation process after application of the adhesive 60 is the compression of the acoustic foam 12 into a flower petal like shape. In this regard, the ring of acoustic foam 12 is pulled into its axial center to reduce the overall diameter of the ring of acoustic foam 12 and cause this size reduction. The container 44 and sensor 56 are present within the acoustic foam 12 during this compression step and themselves are not compressed. This compressed acoustic foam 12 is then placed within the tire and the compression is released to cause the acoustic foam 12 to engage the beads of adhesive 60. The acoustic foam 12 extends completely around the central axis 42 and a bladder or the device compressing and holding the acoustic foam 12 may function to press the acoustic foam 12 against the inner surface 30 and the applied adhesive 60. After application of a sufficient amount of pressure for a sufficient amount of time, the bladder or device may be released and the acoustic foam 12 remains attached to the inner surface 30 via the adhesive 60. It is to be understood that in this process, the contact surface 94 of the container 44 will also engage the adhesive 60 located on the inner surface 30 and the container 44 will likewise be retained onto the inner surface 30 via the adhesive 60.

[0041] The container 44 is thus not molded into the inner surface 30 but rather is a separate piece that is attached to the inner surface 30 after its formation. The inner surface 30 is likewise the inner surface of a cured tire 10 and is not the inner surface of a green tire 10 when the acoustic foam 12 and the container 44 are applied. [Fig.8] shows the acoustic foam 12 and container 44 attached to the inner surface 30 after the assembly steps. The flange 62 is not inserted into the aperture 58. Instead the flange 62 engages the exterior radial surface of the acoustic foam 12 and compression of the acoustic foam 12 against the inner surface 30 causes the flange 62 to be pressed into the acoustic foam 12 so that it lies at a level in the radial direction 14 that is the same as this exterior radial surface of the acoustic foam 12 that is on opposite sides of the flange 62 in the axial direction 16 as shown in [Fig.8]. This is possible because the acoustic foam 12 itself is a flexible material and accommodates the pressing ofthe flange 62 therein. The beads of adhesive 60 are spread along the inner surface 30 and engage both the contact surface 94 and the acoustic foam 12. The adhesive 60 can be evenly spread between the acoustic foam 12 and the inner surface 30 so that it completely covers and engages all of the inner surface 30 and the engaging surface of the acoustic foam 12. As shown in [Fig.8], the adhesive 60 does not engage all of the inner surface 30 and all of the contact area of the acoustic foam 12, but instead pockets of adhesive 60 are present while some of the areas of the inner surface 30 directly engage the acoustic foam 12 with no adhesive 60 therebetween. In a similar manner, the contact surface 94 may directly engage the inner surface 30 at areas where no adhesive 60 is present between these surfaces 94, 30. In other regions, the adhesive 60 is in fact present between and engages both surfaces 94, 30 so that the contact surface 94 does not directly engage the inner surface 30 at these locations but is retained thereon at these locations by the adhesive 60.

[0042] The flange 62 is captured between the acoustic foam 12 and the inner surface 30 and thus functions to further retain the container 44 to the inner surface 30 as the attachment of the acoustic foam 12 to the inner surface 30 likewise causes the flange 62 to be captured and retained onto the inner surface 30. The lip 54 and the end of the sensor 56 are visible outside of the acoustic foam 12. Although shown as being positioned at the same location in the radial direction 14 as the inward end of the acoustic foam 12, the lip 54 and sensor 56 could be located closer to the central axis 42 in the radial direction 14, or even farther from the central axis 42 in the radial direction 14 in other embodiments. As such, in various exemplary embodiments the lip 54 and sensor 56 are both farther from the central axis 42 in the radial direction 14 than is the acoustic foam 12 to the central axis 42 in the radial direction 14. Although shown as being in the shape of a ring with a rectangular cross-section, the acoustic foam 12 can be variously shaped in other embodiments. The width of the acoustic foam 12 in the axial direction 16 may be the same as or less than the width of the inner surface 30 in the axial direction 16. In yet other arrangements, the width of the acoustic foam 12 is greater than the width of the inner surface 30 in the axial direction 16 thus causing the acoustic foam 12 to engage and be located on the interior surfaces of the left and right sidewalls 38 and 40. The arrangement between the acoustic foam 12 and the container 44 is such that no space is present between the wall 44 and the acoustic foam 12 such that these elements are in contact with one another along the majority of their length in the radial direction 14. This contact may be in some instances at least 90% of the length of the wall 44 in the radial direction 14. With reference back to [Fig.l], it can be seen that the acoustic foam 12 is present around the entire container 44 so that no gap is visible between these elements on the inner surface of the acoustic foam 12. This arrangement maximizes the volume and size of the acoustic foam 12 within the tire 10and thus functions to further minimize the volume of noise generated within the tire 10 when driving. No adhesive is used between the wall 44 and the acoustic foam 12, and in some embodiments no adhesive is used at all between the container 44 and the acoustic foam 12 to directly attach these components to one another.

[0043] While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.

Claims

Claims

1. A tire, comprising: a crown with tread located at an outer surface of the tire, wherein the crown has an inner surface; a left sidewall that extends from the crown in a radial direction of the tire; a right sidewall that extends from the crown in the radial direction; a left bead that extends from the left sidewall in the radial direction; a right bead that extends from the right sidewall in the radial direction; a container that has a base and a wall that extends from the base, wherein the container has a cavity, wherein the base is attached to the inner surface; a sensor that is located in the cavity of the container; acoustic foam that is attached to the inner surface, wherein the acoustic foam has an aperture, wherein the wall of the container is located in the aperture, and wherein the wall of the container engages the acoustic foam.

2. The tire as set forth in claim 1, wherein adhesive is present to attach the acoustic foam to the inner surface and to attach the base to the inner surface.

3. The tire as set forth in claim 1 or 2, wherein the acoustic foam engages the inner surface, and wherein the base engages the inner surface.

4. The tire as set forth in any one of claims 1-3, wherein the base has a flange, and wherein the flange is attached to the inner surface, wherein the flange is not located in the aperture of the acoustic foam, wherein the flange is located between the inner surface and the acoustic foam, wherein the flange engages the acoustic foam.

5. The tire as set forth in any one of claims 1-4, wherein the aperture is a through aperture that extends completely through the acoustic foam, wherein a portion of the sensor and a portion of the wall are located inward in the radial direction from the acoustic foam and are not located within the aperture of the acoustic foam.

6. The tire as set forth in any one of claims 1-5, wherein the acoustic foam extends in a circumferential direction 360 degrees around the inner surface of the crown, and wherein adhesive is not present between the acoustic foam and the left and right sidewalls, and wherein adhesive is not present between the acoustic foam and the container.

7. The tire as set forth in any one of claims 1-6, wherein the sensor provides tire identification information, pressure information, and temperature information.

8. The tire as set forth in any one of claims 1-7, wherein the inner surface is brushed, and wherein the base is brushed, and wherein the container is made out of rubber.

9. The tire as set forth in any one of claims 1-8, wherein both the aperture and the wall have a circular shape, and wherein an outer diameter of the wall is sized relative to a diameter of the aperture so as to define a press fit when the wall is located within the aperture.

10. The tire as set forth in any one of claims 1-9, wherein the wall of the container has a lip that engages and holds the sensor in the cavity, wherein the lip is located inward from the sensor in the radial direction.

Images