Braided Tire Cap Ply for Flat Spotting and Waste Reduction
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Solution Overview
Problem
Existing tire manufacturing processes using nylon cap plies are time-consuming, costly, and result in waste, with non-elastic materials leading to flat spotting due to lack of elongation, rendering tires deformed and inoperable.
Innovation Solution
A pneumatic tire design incorporating a cap ply made of braided strands of substantially non-elastic materials like fiberglass or steel, coated with cement or rubber for adhesion, which can elongate with the tread and prevent flat spotting by eliminating the need for additional weaving and cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If nylon cap ply is used in tire, then tire can be manufactured with traditional weaving process, but tire develops flat spotting and loses roundness after prolonged storage
Solution Approach 1:
The patent changes the material parameter from elastic nylon to substantially non-elastic materials (fiberglass, steel), which do not exhibit the memory effect that causes flat spotting. This parameter change in material elasticity fundamentally resolves the flat spotting issue while maintaining manufacturing feasibility through alternative processes like braiding or direct placement.
Solution Approach 2:
The patent uses composite constructions by combining substantially non-elastic materials (fiberglass or steel strands) with elastic components (rubber coatings, tire structure). This composite approach allows the cap ply to resist flat spotting while still accommodating the tire's operational deformation requirements.
2Reliability
If stronger non-elastic materials are used in tire, then tire durability is improved and flat spotting is avoided, but tire cannot expand with tread during production
Solution Approach 1:
The patent creates a dynamic system where the substantially non-elastic cap ply strands are embedded in an elastic matrix (rubber coating and tire structure). During tire expansion, the elastic components deform to accommodate size changes while the non-elastic strands maintain structural integrity and resist flat spotting, achieving both durability and adaptability.
Solution Approach 2:
The patent uses flexible rubber coatings and thin film structures that surround and connect the non-elastic strands. These flexible elements allow the overall tire structure to expand and contract during manufacturing and operation, while the non-elastic strands provide the flat spotting resistance.
3Ease of manufacture
If nylon cap ply is used, then tire can be produced with established processes, but manufacturing is time-consuming and produces waste
Solution Approach 1:
The patent segments the cap ply into individual strands or cords that can be applied separately or in small groups. This segmentation allows for more efficient application processes compared to handling large woven nylon fabrics, reducing manufacturing time and material waste while maintaining the protective function.
Data Source
AI summary
The various embodiments relate to pneumatic tires including a cap ply of braided strands of yarn. Various embodiments relate to strands of yarn that are fiberglass filaments or steel. The braided strands may include a tight braid or a loose braid. Various embodiments include braids having 1 to 5 stitches per cm.