Single-Ply Tire Carcass Structure to Prevent Open Threads
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Solution Overview
Problem
The challenge is to reduce the mass of a tire while maintaining its strength and preventing the occurrence of open threads, which can affect the appearance quality, especially when using a single carcass ply instead of the traditional two plies.
Innovation Solution
The tire design incorporates a carcass composed of a single carcass ply with thicker cords (6000 to 9000 dtex) and an insulation layer between the carcass and the inner liner, with a specific ratio of topping rubber thickness to insulation thickness to prevent open threads and maintain strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the number of carcass plies is reduced from two to one to achieve mass reduction, then the tire mass decreases, but the carcass strength decreases
Solution Approach 1:
The patent changes the parameter of cord fineness from conventional values to 6000-9000 dtex, using thicker cords in a single ply to achieve the required strength while maintaining mass reduction benefits
Solution Approach 2:
The patent uses composite material structure by combining thick cords with specific topping rubber coverage and insulation layers to create a single ply that achieves both mass reduction and sufficient strength
2Weight of moving object
If a single carcass ply with thick cords is used to reduce mass, then the tire mass decreases, but open threads occur at the buttress portion
Solution Approach 1:
The patent introduces an insulation layer as an intermediary between the single carcass ply and the inner liner to prevent the inner liner from flowing into cord spaces and causing open threads
Solution Approach 2:
The patent specifies the ratio of topping rubber thickness to insulation thickness (0.2-0.6) to optimize the protective effect against open threads while maintaining mass reduction
3Strength
If thicker cords (6000-9000 dtex) are used in a single carcass ply, then the carcass strength is maintained, but the interval between cords widens at the buttress portion
Solution Approach 1:
The insulation layer acts as a mediator that fills and stabilizes the widened intervals between thick cords at the buttress portion, preventing inner liner flow and maintaining uniform cord distribution
Solution Approach 2:
The patent applies local quality by positioning the insulation specifically between the carcass and inner liner at critical areas, and by specifying topping rubber coverage on cords to address local issues at the buttress portion
Data Source
AI summary
A tire can include a pair of beads, a carcass, an inner liner, and an insulation located between the carcass and the inner liner. The carcass can include one carcass ply. The carcass ply can include a plurality of carcass cords and a topping rubber. Each carcass cord can have a total fineness of not less than 6000 dtex and not greater than 9000 dtex. The insulation can be located between first and second beads. A ratio (ta/td) of a thickness to of the topping rubber located between the insulation and the carcass cords to a thickness td of the insulation can be not less than 0.2 and not greater than 0.6.