Non-Pneumatic Tire Co-Vulcanization Without Adhesive Layers
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Solution Overview
Problem
Conventional non-pneumatic tires lack the performance and durability of pneumatic tires due to the use of adhesives in the co-vulcanization process, which is costly and complex, and do not provide the necessary robustness in load-bearing structures.
Innovation Solution
A process involving atmospheric plasma deposition of a polymer layer on thermoplastic surfaces to facilitate co-vulcanization with rubber without the need for adhesives, using a gas mixture that includes sulfur-containing compounds and alkynes, enhancing the adhesion and durability of the tire components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives such as polyisocyanate adhesive layer are used to promote adhesion during co-vulcanization, then adhesion between connecting structures and shear band is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The invention removes the adhesive layer from the co-vulcanization process, achieving direct bonding between thermoplastic connecting structures and rubber shear band through plasma treatment. This extraction of the adhesive component simplifies the manufacturing process while maintaining reliable adhesion through plasma-activated surface chemistry that enables direct co-vulcanization.
Solution Approach 2:
The invention changes the surface energy and chemical state of the thermoplastic material through atmospheric plasma treatment. This parameter change in surface properties enables direct chemical bonding with rubber during co-vulcanization, eliminating the need for adhesive layers while achieving equivalent or superior adhesion.
2Reliability
If adhesives are used in the co-vulcanization process, then adhesion is improved, but manufacturing cost increases
Solution Approach 1:
The invention eliminates the adhesive material cost by using plasma treatment to create direct bonding surfaces. The removal of the adhesive layer reduces material costs while the plasma process itself, though requiring equipment investment, reduces overall manufacturing complexity and associated costs.
3Ease of manufacture
If conventional adhesive-based co-vulcanization is used, then assembly is achieved, but durability under tire service conditions is insufficient
Solution Approach 1:
The invention transforms the surface chemistry of thermoplastic materials through plasma treatment, creating highly reactive surfaces that form strong covalent bonds with rubber during co-vulcanization. This parameter change in surface reactivity enables durable, long-lasting bonds that withstand tire service conditions better than adhesive-based assemblies.
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
This process eliminates the use of adhesives, reducing costs and complexity while improving the durability and performance of non-pneumatic tires by creating a strong, adhesive-free bond between thermoplastic and rubber materials, mimicking the performance of pneumatic tires.
Implementation Method 1
depositing a plasma polymerized coating layer from the atmospheric pressure plasma on the pretreated surface
Implementation Method 2
providing an atmospheric pressure plasma generated from a gas mixture
Implementation Method 3
performing a co-vulcanization of the structure with the rubber material
Implementation Method 4
co-vulcanization of a rubber material to a thermoplastic surface
Data Source
Figure 1~2
Figure 3
AI summary
In one aspect, the present invention is directed to a process for the production of a non-pneumatic tire comprising a structure and a shear band, wherein the process comprises the steps of providing a structure having a surface intended to be brought into contact with a shear band, the structure comprising a thermoplastic material; pretreating the surface of the structure to obtain a pretreated surface; providing an atmospheric pressure plasma generated from a gas mixture; depositing a plasma polymerized coating layer from the atmospheric pressure plasma on the pretreated surface to produce a structure with a coated surface comprising a plasma polymerized coating layer; providing a shear band with a layer of rubber material and contacting the coated surface of the structure with said layer of rubber material; and performing a co-vulcanization of the coated surface of the structure with the layer of rubber material of the shear band.