Non-Pneumatic Tire Composite Bonding With Plasma-Coated Thermoplastic
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Solution Overview
Problem
Existing non-pneumatic tires face challenges in effectively connecting the shearband to the connecting structure, which is crucial for achieving pneumatic tire-like performance without the need for inflation pressure.
Innovation Solution
A method involving plasma polymerization of a carbon-carbon double bond on the thermoplastic part, application of a rubber adhesive, and heat-treatment to bond a rubber part and a thermoplastic part into a composite structure, specifically for non-pneumatic tires, using a shearband and a connecting structure made of curable rubber and thermoplastic material respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the shearband and connecting structure are made of different materials (rubber and thermoplastic), then material optimization for specific functions is achieved, but bonding reliability between the two materials deteriorates
Solution Approach 1:
A plasma polymerized coating layer is introduced as an intermediary between the thermoplastic connecting structure and the rubber shearband. This coating layer, formed by plasma polymerization of a carbon-carbon double bond containing monomer, serves as a bonding intermediary that chemically or physically adheres to both the thermoplastic substrate and the rubber compound, thereby enabling reliable bonding between incompatible materials without direct contact between the rubber and uncoated thermoplastic surfaces.
Solution Approach 2:
The surface properties of the thermoplastic connecting structure are fundamentally changed through plasma polymerization treatment. The plasma process modifies the surface chemistry and morphology, introducing functional groups and a crosslinked network structure that are compatible with rubber adhesion. This parameter change in surface properties enables the thermoplastic to bond effectively to rubber while maintaining its bulk material properties.
2Ease of manufacture
If conventional bonding methods are used between rubber and thermoplastic, then manufacturing simplicity is maintained, but bonding strength deteriorates
Solution Approach 1:
The plasma polymerization coating is applied to the thermoplastic connecting structure before the rubber shearband is attached. This preliminary surface treatment prepares the thermoplastic surface with optimal bonding characteristics in advance, ensuring that when the rubber is subsequently bonded to the thermoplastic, maximum bonding strength is achieved. The coating process creates a receptive surface that enhances adhesion without requiring complex modifications to the rubber compound itself.
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 enhances the bonding strength and durability of the composite structure, ensuring efficient load transfer and maintaining structural integrity, thereby improving the performance of non-pneumatic tires.
Implementation Method 1
providing the thermoplastic part having a surface comprising a plasma polymerized coating comprising a carbon-carbon double bond
Implementation Method 2
heat-treating the composite structure to bond the rubber part to the thermoplastic part
Data Source
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AI summary
A method of assembling a rubber part and a thermoplastic part into a composite structure is disclosed. The method comprises providing a rubber part having a surface; providing a thermoplastic part having a surface comprising a plasma polymerized coating comprising a carbon-carbon double bond; applying a rubber adhesive (28, 29) on the coating; bringing the rubber part surface and the thermoplastic part surface with the rubber adhesive into contact so as to form a composite structure; and heat-treating the composite structure to bond the rubber part to the thermoplastic part. Also, a method for producing a non-pneumatic tire (10) is disclosed. The method comprises providing a shearband (22) having a radially inner surface formed by the curable rubber; providing a connecting structure (16) for connecting the shearband (22) to a wheel hub, the connecting structure (16) comprising an adhesion interphase part made of thermoplastic material with a plasma polymerized coating comprising a carbon-carbon double bond; applying a rubber adhesive (28, 29) on the coating; bringing the radially inner surface and the adhesion interphase part with the rubber adhesive into contact so as to form a composite structure; and heat-treating the composite structure to bond the shearband (22) to the connecting structure (16).