Apparatus and method of using the same for setting preload of a spoke

Abstract

A fixture configured to facilitate the formation of a through-hole in a boot of a spoke. The fixture includes a base. A first tower is provided on the base. The first tower is configured to support a first end of the spoke and locate the boot at a first height. The first tower includes a retainer block having a drill guide and a boot support. The retainer block and the boot support are configured to clamp the boot. A second tower is provided on the base. The second tower is configured to support a second end of the spoke and locate the boot at a second height different from the first height.

Description

APPARATUS AND METHOD OF USING THE SAME FOR SETTING PRELOAD OF A SPOKEFIELD OF INVENTION

[0001] The present disclosure relates to non-pneumatic tires. More particularly, the present disclosure relates to an apparatus and method of using the same for setting the preload of a spoke in anon-pneumatic tire.BACKGROUND

[0002] Various tire constructions have been developed that enable a tire to run in an uninflated or underinflated condition. Non-pneumatic tires do not require inflation, while “run flat tires” may continue to operate after being punctured and becoming partially or completely depressurized, for extended periods of time and at relatively high speeds. Non-pneumatic tires may include spokes that connects a lower nng to an upper ring. In some non-pneumatic tires, a circumferential tread may be attached to the upper ring of the tire.

[0003] Tire design, for both pneumatic and non-pneumatic tires, involves the balancing of many factors including, but not limited to, load capacity, handling, and ride quality. Regardless of the balance that is selected between these factors, non-pneumatic tires must be durable and be able to withstand high impact events, such as hitting a curb, pothole, or other obstruction or road imperfection.

[0004] While various components of the non-pneumatic tire such as the spokes, lower ring, and upper ring have specific design values, it is understood that manufacturing tolerances may result in the components deviating from the design values. The manufacturing tolerances may result in the undesirable introduction of pre-stresses into the spoke during manufacture of the non-pneumatic tire.

[0005] Certain spoke designs have been developed to address the aforementioned manufacturing tolerances issue. These designs, however, also require the precise placement of certain features to ensure that the goal of avoiding pre-stresses in the spoke is realized.SUMMARY OF THE INVENTION

[0006] In one embodiment, a fixture for manufacturing a spoke for a nonpneumatic tire having a lower ring and an upper ring, the spoke being one of a plurality of spokes that connect the lower ring to the upper ring, the spoke having a first end, a second end, and a boot at the first end. the fixture being configured to facilitate the formation of a through-hole in the boot. The fixture includes a base. A first tower is provided on the base. The first tower is configured to support the first end of the spoke and locate the boot at a first height. The first tower includes a retainer block having a drill guide and a boot support. The retainer block and the boot support are configured to clamp the boot. A second tower is provided on the base. The second tower is configured to support the second end of the spoke and locate the boot at a second height different from the first height.

[0007] In another embodiment, a method of manufacturing a spoke for a non-pneumatic tire having a lower ring and an upper ring, the spoke being one of a plurality of spokes that connect the lower ring to the upper ring, the spoke having a first end, a second end, and a boot at the first end. The method includes the steps of providing a fixture having a first tower configured to locate the boot at a first height. The first tower includes a retainer block and a boot support. The retainer block has a drill guide. The fixture further has a second tower that is configured to locate the boot at a second height different from the first height. The method further includes clamping the boot between the retainer block and the boot support, moving the spoke so that the second tower supports the second end of the spoke, and inserting a drill bit into the drill guide and forming a through-hole in the boot.

[0008] In yet another embodiment, a fixture for manufacturing a spoke for a non-pneumatic tire having a lower ring and an upper ring. The fixture includes a first tower configured to support a first end of the spoke. The first tower has a retainer block and a boot support that are configured to clamp a boot of the spoke. The retainer block has an engagement foot that engages the boot. The boot support has a rotatable hub that engages the boot and the spoke. A second tower configured to support a second end of the spoke.BRIEF DESCRIPTION OF DRAWINGS

[0009] In the accompanying drawings, structures are illustrated that, together with the detailed description provided below, describe exemplary' embodiments of the claimed invention. Like elements are identified with the same reference numerals. It should be understood that elements shown as a single component may be replaced with multiple components, and elements shown as multiple components may be replaced with a single component. The drawings are not to scale and the proportion of certain elements may be exaggerated for the purpose of illustration.

[0010] Figure l is a side view of one embodiment of a non-pneumatic tire,

[0011] Figure 2 is a sectional view' along 2-2 of Figure 1,

[0012] Figure 3 is a side view of a single spoke that may be used in the non-pneumatic tire of Figure 1.

[0013] Figure 4 is a partial side view of another embodiment of a non- pneumatic tire that uses the spoke of Figure 3,

[0014] Figure 5 is a partial perspective view' of the non-pneumatic tire of Figure 4,

[0015] Figure 6 is another partial perspective view of the non-pneumatic tire of Figure 4

[0016] Figure 7 is a perspective view' of a fixture being used with the spoke of Figure 3 to facilitate assembly of a non-pneumatic tire,

[0017] Figure 8 is a partial exploded view of the fixture of Figure 7 with the spoke being omitted,

[0018] Figure 9 is a side view of the fixture of Figure 7,

[0019] Figure 10 is a top view' of the figure of Figure 7,

[0020] Figure 11 is a partial side view of the Figure 7 with some elements omitted.

[0021] Figure 12 is another partial side view of the fixture of Figure 7,

[0022] Figure 13 is a partial sectional view' of the fixture of Figure 7,

[0023] Figure 14 is a flow' chart illustrating an exemplary' method of using the fixture of Figure 7,

[0024] Figure 15 shows an exemplary arrangement for using multiple fixtures of the type shown in Figure 7 to improve manufacturing speed and efficiency,

[0025] Figure 16 shows another exemplary arrangement for using multiple fixtures of the type shown in Figure 7 to improve manufacturing speed and efficiency, and

[0026] Figure 17 shows yet another exemplary arrangement for using multiple fixtures of the type show n in Figure 7 to improve manufacturing speed and efficiency.DETAILED DESCRIPTION OF THE INVENTION

[0027] The following includes definitions of selected terms employed herein. The definitions include various examples or forms of components that fall within the scope of a term and that may be used for implementation. The examples are not intended to be limiting. Both singular and plural forms of terms may be within the definitions.

[0028] “Axial” and “axially” refer to a direction that is parallel to the axis of rotation of a tire.

[0029] “Circumferential” and “circumferentially” refer to a direction extending along the perimeter of the surface of the tread perpendicular to the axial direction.

[0030] “Radial” and “radially” refer to a direction perpendicular to the axis of rotation of a tire.

[0031] “Tread” as used herein, refers to that portion of the tire that comes into contact with the road or ground under normal load.

[0032] While similar terms used in the following descriptions describe common tire components, it should be understood that because the terms carry slightly different connotations, one of ordinary skill in the art would not consider any one of the following terms to be purely interchangeable with another term used to describe a common tire component.

[0033] Directions are stated herein with reference to the axis of rotation of the tire. The terms “upward” and “upwardly” refer to a general direction tow ardsthe tread of the tire, whereas '‘downward” and "downwardly" refer to the general direction towards the axis of rotation of the tire. Thus, when relative directional terms such as “upper” and “lower” or “top” and “bottom” are used in connection with an element, 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 an element, an element that is “above” another element is closer to the tread than the other element.

[0034] The terms “inward"’ and “inwardly” refer to a general direction towards the equatorial plane of the tire, whereas “outward” and “outwardly” refer to a general direction away from the equatorial plane of the tire and towards the side of the tire. Thus, when relative directional terms such as “inner” and “outer” are used in connection with an element, the “inner” element is spaced closer to the equatorial plane of the tire than the “outer” element.

[0035] Figure 1 illustrates one embodiment of a non-pneumatic tire 10. The non-pneumatic tire 10 is merely exemplary and not intended to be limiting. The non-pneumatic tire 10 includes a generally annular lower ring 15 and a generally annular upper ring 20. The lower ring 15 may engage a vehicle hub (not shown) to attach the non-pneumatic tire 10 to a vehicle. The upper ring 20 has a diameter that is greater than a diameter of the lower ring 15 and is substantially coaxial with the low er ring 15. A circumferential tread 25 is attached to the upper ring 20.

[0036] Support structure 100 connects the lower ring 15 and the upper ring 20. The support structure is made up of a plurality of spokes 200, an exemplary embodiment of which is shown in Figures 2-6. The plurality of spokes 200 are arranged into tw o axially spaced spoke groups, including a first spoke group 205 and a second spoke group 210. All of the spokes 200 have the same configuration. Accordingly, further description of the spokes 200 will be made with reference to a single spoke 200. In alternative embodiments, however, the non-pneumatic tire may use different types of spokes (e.g., different materials, different geometries).

[0037] Each spoke 200 extends between a first end 215 and a second end 220. The first end 215 of the spoke 200 is connected to the lower ring 15. Thesecond end 220 of the spoke 200 is connected upper ring 20. A knee portion 225 is provided between the first end 215 and the second end 220. A first connecting portion 230 connects the first end 215 of the spoke 200 to the knee portion 225. A second connecting portion 235 connects the knee portion 225 to the second end 220 of the spoke 200.

[0038] A flexure member 240 is provided at the second end 220 of the spoke200. The flexure member 240 connects the second end 220 of the spoke 200 to the upper ring 20. A boot 245 is provided at the first end 215 of the spoke 200. The boot 245 connects the first end 215 of the spoke 200 to the lower ring 15.

[0039] The boot 245 includes a first part 250 and a second part 255. The first and second parts 250, 255 define a gap 260 that receives the spoke 200.

[0040] The first part 250 includes a roof portion 265 and a floor portion 270. The floor portion 270 has a radius of curvature r / pthat is substantially equal to a radius of curvature rsof a corresponding scallop 30 provided on the lower ring 15. The first part 250 is connected to the lower ring 15 by first fasteners 275. The first part 250 includes through-holes 280 that receive the first fasteners 275. In alternative embodiments, these holes may be provided as a blind hole rather than a through-hole. In other alternative embodiments, these holes may be provided with a clearance hole portion that receives a nut or other arrangement that engage with a threaded fastener.

[0041] The second part 255 is attached to the first part 250 by second fasteners 285. The second fasteners 285 also attach the spoke 200 to the boot 245. In particular, the second fasteners 285 cooperate with the first and second parts 250, 255 to clamp the spoke 200 in the gap 260.

[0042] Further details of the non-pneumatic tire 10 and spoke 200 may be found in International Application No. PCT / US2023 / 067802, the entirety' of which is herein incorporated by reference.

[0043] As discussed above, accepted manufacturing tolerances for various components of a non-pneumatic tire (i.e., spokes, lower ring, and upper ring) may result in the undesirable introduction of pre-stresses into the spoke during manufacture of the non-pneumatic tire. The spoke 200 discussed above addressesthese manufacturing tolerances by allowing for the adjustment of the rotational position of each spoke 200 relative to the lower and upper rings 15, 20 to avoid prestresses in the spoke 200.

[0044] The spokes 200, however, are not immune to manufacturing variances. Consequently, avoiding pre-stresses in the spoke 200 may require, among other things, precisely locating the through-holes 280 that receive the fasteners 275 that attach the first part 250 of the boot 245 to the lower ring 15. While it is possible to locate the through-holes 280 by placing the spokes 200 in a desired position relative to the lower and upper rings 15, 20, the process of doing so is burdensome and inefficient. In particular, fitting the spokes 200 one by one and forming the through-holes 280 individually is a labor intensive and time intensive task. Thus, it is desired to devise a process for more efficiently forming the through-holes in the proper location.

[0045] An exemplary process for forming the through-holes 280 may be performed using a fixture 1000, which is shown in Figures 7-13. The fixture 1000 is meant to generally emulate an envelope in which the spokes 200 are received in the non-pneumatic tire 10; the envelope being defined by the upper and lower rings 15, 20. The fixture 1000 can be used to facilitate the formation of the through-holes 280.

[0046] The fixture 1000 includes a base 1005. A first tower 1010 is provided at a first end of the base 1005 and a second tower 1015 is provided at a second end of the base 1005. The first tower 1010 is configured to support the first end 215 of the spoke 200 and the second tower 1015 is configured to support the second end 220 of the spoke 200. The base 1005 may be provided with handles 1020 to facilitate transportation of the fixture 1000.

[0047] The first tower 1010 includes a first upright 1025 and a second upright 1030. Braces 1035 may be provided to tie the first and second uprights 1025, 1030 to one another to improve structural stability. An end of each of the first and second uprights 1025, 1030 includes an alignment channel 1040. The alignment channel 1040 receives a retainer block 1045. Two thumb screws 1050 removably attach the retainer block 1045 to the first and second uprights 1025,1030, with one thumb screw being provided for each upright. Each thumb screw 1050 extends through a through-hole 1055 on a mounting ear 1060 provided at opposite ends of the retainer block 1045 and into a threaded hole 1062 provided on the alignment channel 1040 of a respective upright 1025, 1030. In alternative embodiments, either of these holes may be provided as a blind hole or a through- hole. In other alternative embodiments (not shown) other types of screws or other fasteners may be employed.

[0048] The retainer block 1045 is movable relative to the first and second uprights 1025, 1030. The mounting ears 1060 cooperate with a respective one of the alignment channels 1040 to locate the retainer block 1045 relative to the first and second uprights 1025, 1030 and facilitate alignment of the through-holes 1055 with the threaded holes.

[0049] In alternative embodiments, the retainer block may be attached to the first and second uprights using any desired arrangement (e.g., toggle clamps, spring-loaded lever mechanism). For example, there may be a fewer or greater number of thumb screws. In other alternative embodiments the thumb screws or alignment channels and mounting ears may be provided at any appropriate location on the retainer block. In yet other alternative embodiments, the thumb screws, alignment channels, or mounting ears may be omitted.

[0050] The retainer block 1045 includes two spoke engagement feet 1065 that extend from a bottom surface 1070 of the retainer block 1045. Each engagement foot 1065 is adjacent and inboard of a respective one of the mounting ears 1060. Each engagement foot 1065 includes an engagement surface 1075 having a radius of curvature res. The radius of curvature res of the engagement surface 1075 is equal to the radius of curvature r / pof the floor portion 270 of the boot 245 of the spoke 200 meant for use in the fixture 1000.

[0051] In alternative embodiments, the retainer block may include a fewer or greater number of spoke engagement feet. In other alternative embodiments, the spoke engagement feet may be provided at any appropriate location on the retainer block. In yet other alternative embodiments, the radius of curvature of the engagement surface may be unequal to the radius of curvature of the floor portionof the spoke. In still yet other alternative embodiments, the engagement surface may be flat.

[0052] The retainer block 1045 includes three drill guides 1080. The drill guides 1080 are aligned with one another along a width of the fixture 1000 and located inboard of the spoke engagement feet 1065. The drill guides 1080 are provided on a recessed portion 1085 located on a top surface 1090 of the retainer block 1045. Each drill guide 1080 includes a bushing 1095 and a lock screw 1100. The bushing 1095 is received in a bushing hole 1105 that extends through the retainer block 1045 from the top surface 1090 to the bottom surface 1070. The lock screw 1100 threads into a threaded hole 1110 that is adjacent a respective one of the bushing holes 1105. A head 1115 of the lock screw 1100 engages a flange portion 1120 of a respective bushing 1095 to hold the bushing 1095 in the retainer block 1045. The lock screw 1100 may be removed from the retainer block 1045 to allow for replacement of the bushing 1095.

[0053] In alternative embodiments, the retainer block may include a greater or fewer number of drill guides and the drill guides may be provided at any appropriate location on the retainer block. In other alternative embodiments, the bushings or the lock screws may be omitted. In still yet other alternative embodiments, the recessed portion may be omitted.

[0054] A boot support 1125 is provided at the first tower 1010. The boot support 1125 is located between the retainer block 1045 and the base 1005. The boot support 1125 includes a shaft 1130 that extends between the first and second uprights 1025, 1030. In the illustrated embodiment, the shaft 1130 is supported by optional support bushings 1135 that are provided in the first and second uprights 1025, 1030.

[0055] The boot support 1125 further includes first and second hubs 1140a, 1140b that are mounted on the shaft 1130. The first and second hubs 1140a, 1140b are configured to engage the first part 250 of the boot 245 and part of the spoke 200. The first hub 1140a is located inboard of and adjacent to the first upright 1025, and the second hub 1140b is located inboard of and adjacent to the second upright 1030. The first and second hubs 1140a, 1140b are keyed to shaft 1130 so that they cannotrotate relative to the shaft 1130 or to one another. The shaft 1130, however, is rotatable to allow the first and second hubs 1140a, 1140b to rotate relative to the first and second uprights 1025, 1030. Each one of the first and second hubs 1140a, 1140b includes a neck portion 1145 and a flange portion 1150. A snap ring 1155 may be provided on the shaft 1130 adjacent to the neck portion 1145 to prevent movement of the hubs 1140a, 1140b along a longitudinal axis of the shaft 1130. The periphery' of the flange portion 1150 is generally circular except for the provision of a first flat 1160 and a second flat 1165. The first and second flats 1160, 1165 are partial chords extending through the flange portion 1150 that extend at non-parallel angles relative to one another. A step portion 1170 is located at an end of the second flat 1165. A cutout portion 1175 is located adjacent to the step portion 1170.

[0056] The first flat 1160 is configured to support part of the roof portion 265 of the first part 250 of the boot 245 of the spoke 200 meant for use in the fixture 1000, with the cutout portion 1175 providing clearance for the second fasteners 285. The step portion 1170 supports the first part 250 of the boot 245 to facilitate positioning the spoke 200 relative to the first tower 1010. The second flat 1165 is configured to support part of the first connecting portion 230 of the spoke 200 meant for use in the fixture 1000. The angle at which the first and second flats 1160, 1165 extend relative to one another is equal to the angle at which the roof portion 265 and the first connecting portion 230 extend relative to one another. In other words, a profile of a part of the flange portion 1150 is a negative of the part of the spoke 200 that is supported by the flange portion 1150.

[0057] In alternative embodiments, the boot support may include a fewer or greater number of hubs provided at any desired location on the shaft. In other alternative embodiments, the first hub or second hub may have any desired arrangement. For example, the first or second hubs may not be keyed to the shaft. As another example, the angle at which the first and second flats extend relative to one another may be unequal to the angle at which the roof portion and the first connecting portion extend relative to one another. As yet another example, the first and second hubs may be formed integrally (i.e. , single piece).

[0058] The second tower 1015 includes a first upright 1180 and a second upright 1185. A flexure support 1190 is connected to an end of the first and second uprights 1180, 1185 by four hex socket head screws 1195. In an alternative embodiment (not shown) other screws may be employed. In another alternative embodiment, other fastening means may be employed.

[0059] The flexure support 1190 has a support face 1200. The support face 1200 is curved and has a radius of curvature rsfthat is equal to a radius of curvature rurof an upper ring 20 (see Figure 1) of a non-pneumatic tire 10 employing spokes 200 used in the fixture 1000. The second tower 1015 may include a clamping arrangement (not shown) fix the second end 220 of the spoke 200 to the second tower 1015.

[0060] In alternative embodiments, the support plate may be attached to the first and second uprights using any desired arrangement. In other alternative embodiments, the support plate may be integrally formed with the first or second uprights. In yet other alternative embodiments, the radius of curvature of the support face may be unequal to the radius of curvature of the upper ring. In still yet other alternative embodiments, the support face may be flat.

[0061] The fixture is 1000 is configured so that the first tower 1010 locates the floor portion 270 of the boot 245 at a first height Hi relative to the base 1005 and the second tower 1015 locates the second end 220 of the spoke 200 at a second height Ih relative to the base 1005 to create a height differential Hd. Changing the height differential Hd may change performance characteristics of the nonpneumatic tire 10 on which the spokes 200 are installed. For example, increasing the first height Hi while maintaining the second height H2 and thus increasing the height differential Hd compresses the spoke 200 when the nonpneumatic tire 10 is assembled, which may increase the effective spring rate of the spoke 200 and thereby increase the relative stiffness of the non-pneumatic tire 10. As another example, decreasing the first height Hi while maintaining the second height H2 and thus decreasing the height differential Hd tensions the spoke 200 when the nonpneumatic tire 10 is assembled, which may decrease the effective spring rate of the spoke 200 and thereby decrease the relative stiffness of the nonpneumatic tire10. As will be appreciated by one of ordinary skill in the art, the second height Hi may also be adjusted while maintaining the first height Hi to provide a desired height differential Hd. As will also be appreciated by one of ordinary skill in the art, the desired height differential Hdmay be achieved by simultaneously adjusting the first and second heights. Hi, H2.

[0062] A method of using the fixture 1000 to form the through-holes 280 in the spoke 200 will now be described with reference to Figure 14. At 1400, the boot 245 is inserted between the retainer block 1045 and the boot support 1125. If the thumb screws 1050 were previously tightened to securely attach the retainer block 1045 to the first and second uprights 1025, 1030, this step may include, first, loosening the thumb screws 1050. The retainer block 1045 may be moved relative to the boot support 1125 to create a gap therebetween to provide a space for insertion of the boot 245. When so inserted, the roof portion 265 of the first part 250 of the boot 245 engages the first flat 1160 and step portion 1170 and the first connecting portion 230 of the spoke 200 rests against the second flat 1165. Additionally, the engagement feet 1065 of the retainer block 1045 engage the floor portion 270 of the boot 245.

[0063] At 1405. the thumb screws 1050 are tightened to clamp the first part 250 of the boot 245 between the retainer block 1045 and the boot support 1125. Once the thumb screws 1050 are tightened, at 1410, the spoke 200 is moved so that the second tower 1015 supports the second end 220 of the spoke 200. In particular, the spoke 200 is rotated to bring the flexure member 240 into contact with the support face 1200 of the flexure support 1190. Thus, the support face 1200 supports the flexure member 240. Depending on the configuration and orientation of the spoke 200 and the fixture 1000, this may naturally happen under the force of gravity. If the second tower 1045 is equipped with a clamping arrangement, the clamping arrangement may be actuated to secure the spoke 200 to the second tower 1015

[0064] At 1415, the through-holes 280 are then drilled by inserting a drill bit into the bushing 1095 of each drill guide 1080. The bushing 1095 guides the drill bit and. in combination with the overall structure of the fixture 1000. ensuresthe precise location of the through-holes 280 in an easy, efficient manner. At 1420, a tap forms threads in the through-holes 280. The bushing 1095 also guides the tap. The relative positions of each engagement foot 1065 facilitates the drilling and tapping process. In particular, spacing the engagement feet 1065 away from one another creates a gap that can be used to discharge or otherwise evacuate material removed during the drilling and tapping process. The removed material may fall away under the force of gravity or there may be a vacuum or compressed air to facilitate movement of the material.

[0065] At 1425, once the through-holes 280 are formed and tapped, the boot 245 is unclamped by loosening the thumb screws 1050. The clamping arrangement (if so equipped) is also removed. At 1430, the boot 245 is removed from the retainer block 1045 and the boot support 1125 and the completed spoke 200 may be taken out of the fixture 1000.

[0066] The general concept behind the fixture 1000 may be modified or expanded to facilitate forming the through-holes 280 for multiple spokes 200, thereby increasing manufacturing speed and efficiency. One such arrangement is shown in Figure 15, which may be generally referred to as a tray arrangement 2000. The tray arrangement 2000 includes a plurality of fixtures 1000 mounted in a tray 2005. Each fixture 1000 has a configuration substantially the same as the fixture 1000 described above and shown in Figures 7-13. In the illustrated embodiment, the tray arrangement 2000 includes ten fixtures 1000 mounted in the tray 2005. In alternative embodiments, the tray arrangement may include a greater or fewer number of fixtures.

[0067] The retainer block 1045 or clamping arrangement (not shown) may be connected to a single actuator arrangement (not shown) that moves the retainer block 1045 or clamping arrangement for each fixture 1000. Such an actuator arrangement may facilitate the loading and subsequent clamping of multiple spokes 200. It is contemplated that the spokes 200 may be loaded into each fixture 1000 using an automated system (not shown), such as a robotic arm, a pick and place gantry system, or the like. Once the spokes 200 are loaded, the tray arrangement 2000 may be shuttled into, for example, a CNC mill, which can be programmed todrill and tap the through-holes 280 for each spoke 200. The speed and efficiency of the tray arrangement 2000 may be further increased by using multiple tray arrangements 2000, whereby a first tray arrangement 2000 is loaded with spokes 200, shuttled into a CNC mill, where the drilling and tapping operations are started. While the drilling and tapping operations are being performed with respect to the first tray arrangement 2000, a second tray arrangement 2000 is loaded with spokes 200 so that, as soon as the first tray arrangement 2000 is completed, it can be removed and replaced with the second tray arrangement 2000.

[0068] Another arrangement for forming the through-holes for multiple spokes is shown in Figure 16. The arrangement shown in Figure 16 may generally be referred to as the turntable arrangement 3000. The turntable arrangement 3000 includes a plurality of fixtures 1000 mounted on a turntable 3005. Each fixture 1000 has a configuration substantially the same as the fixture 1000 described above and shown in Figures 7-13. In the illustrated embodiment, the turntable arrangement 3000 includes six fixtures 1000 mounted on the turntable 3005. In alternative embodiments, the turntable arrangement may include a greater or fewer number of fixtures.

[0069] The turntable arrangement 3000 includes six stations 3010. 3015, 3020, 3025, 3030, 3035, and the turntable 3005 may be rotated using a motor or other drive (not shown) to index the fixtures 1000 between the stations 3010, 3015, 3020, 3025, 3030, 3035. In the illustrated embodiment, the first station 3010 is for loading a spoke 200 into a fixture 1000. Similar to the tray arrangement 2000 discussed above, the turntable arrangement 3000 may include an automated system for loading the spoke 200. The second station 3015 is for securing the spoke 200 to the fixture 1000. Also similar to the tray arrangement 2000 discussed above, the turntable arrangement 3000 may include an actuator (not shown) that moves the retainer block 1045 or clamping arrangement if so equipped. The third station 3020 is for drilling the through-holes 280 for the spoke 200. The fourth station 3025 is for tapping threads in the through-holes. The fifth station 3030 is for releasing the spoke 200 from the fixture 1000. The sixth station 3035 is for unloading the spoke200 from the fixture 1000. In alternative embodiments, the turntable arrangement may include a greater or fewer number of stations.

[0070] Y et another arrangement for forming the through-holes for multiple spokes is shown in Figure 17. The arrangement shown in Figure 17 may generally be referred to as the conveyer arrangement 4000. The conveyer arrangement 4000 includes a plurality of fixtures 1000 mounted on a conveyer system 4005. Each fixture 1000 has a configuration substantially the same as the fixture 1000 described above and shown in Figures 7-13. In the illustrated embodiment, the conveyer arrangement 4000 includes eight fixtures 1000 mounted on the conveyer system 4005. In alternative embodiments, the conveyer arrangement may include a greater or fewer number of fixtures.

[0071] The conveyer arrangement 4000 includes eight stations 4010, 4015, 4020, 4025, 4030, 4035, 4040, 4045 and the conveyer system 4005 may be advanced using a motor or other drive (not shown) to index the fixtures 1000 between the stations 4010, 4015, 4020, 4025, 4030, 4035, 4040, 4045. In the illustrated embodiment, the first station 4010 is for loading a spoke 200 into a fixture 1000. Similar to the tray arrangement 2000 discussed above, the conveyer arrangement 4000 may include an automated system for loading the spoke 200. The second station 4015 is for securing the spoke 200 to the fixture 1000. Also similar to the tray arrangement 2000 discussed above, the conveyer arrangement 4000 may include an actuator (not shown) that moves the retainer block 1045 or clamping arrangement if so equipped. The third station 4020 is for drilling the through-holes 280 for the spoke 200. The fourth station 4025 is for tapping threads into the through-holes. The fifth station 4030 is for releasing the spoke 200 from the fixture 1000. The sixth station 4035 is for unloading the spoke 200 from the fixture 1000. The seventh and eighth stations 4040, 4045 may be used as a general queue or for cleaning or servicing of the fixture 1000.

[0072] The fixture 1000 described herein provides an arrangement for more efficiently forming the through-holes 280 for the spokes 200. In particular, the ability to form the through-holes 280 prior to assembling the non-pneumatic tire 10 provides a substantially more efficient assembly process. Additionally, asdiscussed above, the fixture 1000 may allow for fine tuning of desired performance characteristics. Furthermore, in addition to providing desired tire performance characteristics, the fixture 1000 may also be used to aid manufacturing processes. For example, the fixture 1000 may be used to introduce a controlled compressive preload into the non-pneumatic tire 10, which may aid in adhesion of the flexure member 240 to the upper ring 20 through control of adhesive flow and the formation of a desired adhesive film thickness.

[0073] To the extent that the term “includes” or “including” is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (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” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See, Bryan A. Gamer, A Dictionary of Modem Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into” are used in the specification or the claims, it is intended to additionally mean “on” or “onto.” Furthermore, to the extent the term “connect” is used in the specification or claims, it is intended to mean not only “directly connected to,” but also “indirectly connected to” such as connected through another component or components.

[0074] While the present application has been illustrated by the description of embodiments thereof, and while the 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 detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the application, in its broader aspects, is not limited to the specific details, the representative apparatus and method, and illustrative 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

CLAIMSWhat is claimed is:

1. A fixture for manufacturing a spoke for a non-pneumatic tire having a lower ring and an upper ring, the spoke being one of a plurality of spokes that connect the lower ring to the upper ring, the spoke having a first end, a second end, and a boot at the first end, the fixture being configured to facilitate the formation of a through-hole in the boot, the fixture comprising: a base; a first tower provided on the base, the first tower configured to support the first end of the spoke and locate the boot at a first height, the first tower including: a retainer block having a drill guide; and a boot support; wherein the retainer block and the boot support are configured to clamp the boot; and a second tower provided on the base, the second tower configured to support the second end of the spoke and locate the boot at a second height different from the first height.

2. The fixture of claim 1, wherein the first tower includes a first upright and a second upright, the first upright and the second upright each having an alignment channel, and wherein the retainer block includes mounting ears at opposite ends, each one of the alignment channels receiving a respective one of the mounting ears to locate the retainer block relative to the first and second uprights.

3. The fixture of claim 1, wherein the retainer block includes an engagement foot that engages a floor portion of the boot, the engagement foot having an engagement surface with a first radius of curvature that is equal to a second radius of curvature of the floor portion.

4. The fixture of claim 1, wherein the drill guide includes a bushing and a lock screw, the lock screw being configured to hold the bushing in the retainer block.

5. The fixture of claim 1, wherein the first tower includes a first upright and a second upright, and wherein the boot support includes a hub mounted on a shaft supported by the first and second uprights, the hub being rotatable relative to the first and second uprights, the hub being configured to engage the boot and the spoke.

6. The fixture of claim 5, wherein the hub includes a first flat configured to support a roof portion of the boot and a second flat configured to support the spoke, the first flat and the second flat extending at non-parallel angles relative to one another.

7. The fixture of claim 6, wherein the first flat and the second flat extend relative to one another at a first angle and the roof portion and the spoke extend relative to one another at a second angle, the first angle being equal to the second angle.

8. The fixture of claim 6, wherein the hub includes a cutout portion between the first flat and the second flat, the cutout portion being configured to provide clearance for a fastener that connects a first part of the boot to a second part of the boot.

9. The fixture of claim 1, wherein the second tower includes a support having a curved support face, the support face being configured to support a flexure member provided at the second end of the spoke.

10. The fixture of claim 9, wherein the support face has a first radius of curvature that is equal to a second radius of curvature of the upper ring.

11. A method of manufacturing a spoke for a non-pneumatic tire having a lower ring and an upper ring, the spoke being one of a plurality of spokes that connect the lower ring to the upper ring, the spoke having a first end, a second end, and a boot at the first end. the method comprising the steps of:providing a fixture comprising: a first tower configured to locate the boot at a first height, the first tower including a retainer block and a boot support, the retainer block having a drill guide; and a second tower configured to locate the boot at a second height different from the first height; clamping the boot between the retainer block and the boot support; moving the spoke so that the second tower supports the second end of the spoke; and inserting a drill bit into the drill guide and forming a through-hole in the boot.

12. The method of claim 11 further comprising the step of inserting a tap into the drill guide and tapping the through-hole in the boot.

13. The method of claim 11 , wherein the step of moving the spoke so that the second tower supports the second end of the spoke includes rotating the spoke.

14. The method of claim 11, wherein the drill guide includes a bushing and a lock screw, the lock screw being configured to hold the bushing in the retainer block.

15. The method of claim 11, wherein the retainer block includes an engagement foot that engages a floor portion of the boot, the engagement foot having an engagement surface with a first radius of curvature that is equal to a second radius of curvature of the floor portion.

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