Cord-Reinforced Polymer Spokes for Durable Non-Pneumatic Tires
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Solution Overview
Problem
Existing non-pneumatic tires with polymer composition spokes lack sufficient durability due to the exposure of cord reinforcements on the surface and the challenge of achieving uniform material properties throughout the spoke.
Innovation Solution
A method of manufacturing cord-reinforced polymer composition spokes for non-pneumatic tires, involving the use of a mold with polymer composition layers to encase cord reinforcements, ensuring they are fully covered and positioned accurately within the spoke.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cord reinforcement is applied onto the surface of polymer composition layer, then durability is improved, but cord reinforcement exposure occurs leading to reduced reliability
Solution Approach 1:
The patent applies nesting by placing the cord reinforcement inside the polymer composition spoke structure. The cord is positioned within grooves or channels formed in the polymer material, and additional polymer layers are applied over the cord to fully encase it. This nested configuration ensures the cord reinforcement is protected and fully covered, preventing exposure while maintaining its strengthening function.
Solution Approach 2:
The patent uses grooves or channels formed in the polymer composition as an intermediary structure to hold and position the cord reinforcement. These grooves act as a mediator between the cord and the surrounding polymer material, ensuring proper positioning and full coverage while allowing the cord to be securely integrated into the spoke structure.
2Strength
If cord reinforcement is applied onto polymer composition layer, then structural strength is improved, but positioning precision becomes challenging
Solution Approach 1:
The patent applies preliminary action by pre-forming grooves or channels in the polymer composition layer before applying the cord reinforcement. These pre-formed features serve as guides that automatically position the cord in the correct location during the manufacturing process, ensuring precise and consistent placement without requiring complex positioning mechanisms.
Solution Approach 2:
The patent applies local quality by creating specific grooves or channels only in the regions where cord reinforcement needs to be positioned. These localized features provide precise positioning guidance exactly where needed, while the rest of the polymer composition maintains its general structural properties. This approach ensures accurate cord placement without compromising the overall spoke design.
3Strength
If multiple polymer composition layers are used to encase cord reinforcement, then durability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies merging by combining multiple polymer composition layers into a single integrated molding process. The cord reinforcement is positioned within the mold, and the polymer material is molded in layers that automatically encase the cord as it is being applied or positioned. This combined approach achieves full encasement and multi-layer construction without requiring separate manufacturing steps for each layer.
Solution Approach 2:
The patent creates a composite structure by integrating cord reinforcement within polymer composition layers through a unified manufacturing process. The cord and polymer materials are combined in a single molding operation, creating a composite spoke structure where the cord is fully encased and bonded to the surrounding polymer material, achieving both durability and manufacturing efficiency.
Data Source
AI summary
The invention is directed to advanced methods of manufacturing a supporting structure for a non-pneumatic tire comprising at least one cord-reinforced polymer composition spoke. One method comprises providing a first mold member at least partially covered by a first polymer composition layer, applying at least one cord reinforcement onto the first polymer composition layer, and over-molding a second polymer composition layer onto the first polymer composition layer to enclose said cord reinforcement between the first polymer composition layer and the second polymer composition layer so as to obtain at least a portion of the cord-reinforced polymer composition spoke. In some of the methods, the supporting structure comprises X-shaped spokes and the provision of corresponding mold inserts and/or mold members. Furthermore, the present invention is directed to a method of manufacturing a tire including molding of at least a circumferential sector of a supporting structure comprising cord-reinforced polymer composition.