Corrugated Metal Tire Web Structure With Vacuum-Brazed Rings

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Solution Overview

Problem

Existing non-pneumatic tire constructions lack an efficient method for forming robust and durable web structures that can maintain tire integrity and performance without inflation.

Innovation Solution

A method involving the pre-forming of elongated steel sheets into corrugated web layers, which are then heat-treated and assembled into annular shapes to form interconnected webbing rings, utilizing vacuum brazing for attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If spokes or webbing are molded as a single unitary piece or assembled from multiple molded rings, then the tire structure can be formed, but the manufacturing process becomes complex and time-consuming

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The webbing structure is divided into multiple corrugated rings that can be manufactured separately and then assembled together through brazing. This segmentation allows each ring to be produced independently using efficient corrugation and bending processes, rather than requiring complex single-piece molding or multiple molding operations with assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The corrugated rings are pre-formed by corrugating flat steel sheets and bending them into annular shapes before final assembly. This preliminary formation of individual rings simplifies the overall manufacturing process, as the complex corrugation pattern is created on flat material before shaping, rather than attempting to form the complete three-dimensional webbing structure in one operation.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If traditional molding processes are used to form spokes or webbing, then the tire structure is created, but the structural integrity and durability are insufficient for non-pneumatic tire applications

Engineering Contradiction:

Improvetire integrityVSAvoidmanufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The material is heat-treated and quenched in an oil bath to achieve specific mechanical properties and hardness. This parameter change in the material treatment process enhances the structural integrity and durability of the webbing rings, making them suitable for non-pneumatic tire applications that require high reliability under load.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Traditional mechanical molding processes are replaced with a combination of corrugation, bending, heat treatment, and vacuum brazing. This substitution of manufacturing methods allows for superior structural integrity through precise control of material properties and joint strength, while the modular approach actually simplifies the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If multiple webbing rings are assembled together, then the tire structure is formed, but the joints between rings may compromise structural integrity

Engineering Contradiction:

Improvejoint strengthVSAvoidstructural integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

Vacuum brazing is used to join the corrugated rings together in a vacuum environment. This inert atmosphere prevents oxidation and contamination during the joining process, ensuring strong, clean metallurgical bonds between rings that maintain structural integrity. The vacuum environment protects the steel material from atmospheric contamination that would weaken the joints.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

The webbing structure combines corrugated steel rings with brazing material to create a composite joint structure. The brazing material bonds the steel rings together while accommodating thermal expansion differences and creating a strong, durable connection that maintains the overall structural integrity of the tire webbing assembly.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The method produces a non-pneumatic tire with enhanced structural integrity and durability, capable of maintaining performance and ride comfort even under load and deformation.

Implementation Method 1

corrugating the first elongated sheet of spring steel material to form a first plurality of peaks and a first plurality of valleys

Methodology Applied

Scientific EffectCorrugation: Corrugation

Implementation Method 2

heat treating the first webbing ring and quenching the first webbing ring in an oil bath

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Implementation Method 3

the second plurality of valleys are affixed to the first plurality of peaks by vacuum brazing

Methodology Applied

Scientific EffectVacuum brazing: Brazing

Data Source

PatentUS12337627B2Metal web for a non-pneumatic tire and method of making same

Publication Date: 2025.06.24 BRIDGESTONE AMERICAS TIRE OPERATIONS LLC

AI summary

A web structure for a non-pneumatic tire includes a first corrugated ring having a first plurality of peaks and a first plurality of valleys. The first corrugated ring is a metal ring. The web structure further includes a second corrugated ring having a second plurality of peaks and a second plurality of valleys. The second corrugated ring is a metal ring. The second plurality of valleys are affixed to the first plurality of peaks by brazing or welding.