Embedded Tire Sensor Housing With Replaceable Battery Access
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Solution Overview
Problem
Current tire manufacturing processes do not effectively integrate sensors, such as those for tire pressure monitoring systems, into the tire carcass during the vulcanization process without compromising the sensor's functionality or longevity.
Innovation Solution
A partially embedded sensor system where a power source housing and sensing portal are interlocked with the tire's innerliner, using a removable cover and flexible printed circuit board, allowing the sensor to be secured within the tire during vulcanization and ensuring exposure of the power source after curing, with a battery holder and electrodes for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a sensor is integrated into the tire carcass during vulcanization, then real-time monitoring capability is achieved, but the sensor functionality and longevity are compromised
Solution Approach 1:
The sensor system is divided into separate functional modules: a sensor module embedded in the innerliner during vulcanization, a power source module inserted after curing, and a communication module. This segmentation allows the sensor to be integrated during manufacturing while protecting it from damage, and enables separate replacement of the power source without affecting the sensor's longevity and functionality.
2Ease of manufacture
If the sensor is fully embedded in the tire during manufacturing, then integration is achieved, but the power source cannot be accessed or replaced
Solution Approach 1:
The sensor is nested within the innerliner during vulcanization for secure integration, while the power source is placed in a separate accessible compartment within the tire cavity. This nested arrangement allows the sensor to be embedded during manufacturing while keeping the power source separately accessible for replacement and maintenance.
3Ease of manufacture
If the sensor components are exposed during vulcanization, then installation is simplified, but the components are damaged by heat and pressure
Solution Approach 1:
The sensor is pre-installed within the innerliner structure before the vulcanization process begins. The innerliner is then folded over the sensor to enclose and protect it during vulcanization. This preliminary action allows the sensor to be installed during manufacturing while protecting it from heat and pressure damage through the enclosing structure.
4Object-affected harmful factors
If the power source is enclosed during vulcanization, then protection is achieved, but the power source cannot be inserted or removed
Solution Approach 1:
The power source compartment features a removable cover that transitions between closed and open states. During vulcanization, the cover is closed to protect the power source from heat and pressure. After curing, the cover can be opened to allow insertion or removal of the power source. This dynamic design provides both protection during manufacturing and accessibility for operation.
Data Source
AI summary
Disclosed are various embodiments of permanent active sensors in a tire achieved by partially embedding a sensor component in a green tire and adding a removable power source after the tire is cured. The printed circuit board can be encapsulated in the rubber of the tire with a power source housing connected to the electronics through the rubber. In another aspect, the printed circuit board can be directly connected to the power source housing. The sensor interlocks with the rubber of the tire. Various structural features of the sensor, such as a flange or channels for the rubber, can be used to secure the sensor in the rubber of the tire.