Non-Pneumatic Tire Carcass Curing for Spoke Alignment
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Solution Overview
Problem
Current methods for manufacturing non-pneumatic tires are time-consuming, labor-intensive, and costly due to the need for multiple stages of vulcanization and assembly, which introduces thermal stresses, misalignments, and quality issues such as trapped gases.
Innovation Solution
A method and apparatus for forming a non-pneumatic tire carcass by arranging an inner hub, outer band, and spokes in a curing assembly within a forming apparatus, where the spokes are simultaneously forced radially outward and inward to align and cure against both the inner hub and outer band, allowing for contemporaneous assembly and pressure application, evacuation of trapped air, and reduction of thermodynamic stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If components are individually vulcanized and assembled in multiple stages, then each component can be cured separately, but additional thermal stresses and misalignments are introduced and production time increases
Solution Approach 1:
The patent combines multiple vulcanization operations into a single simultaneous curing cycle. The forming apparatus allows the inner hub, outer band, and spokes to be vulcanized together in one continuous process, eliminating the need for separate curing cycles and reducing total production time while maintaining component quality through controlled forcing mechanisms.
Solution Approach 2:
The patent applies preliminary forcing actions to the spokes before final curing. The forcing mechanisms position and align the spokes radially between the inner hub and outer band prior to the curing cycle, ensuring proper alignment is established before the vulcanization process begins, which prevents misalignment issues during assembly.
2Ease of manufacture
If components are individually formed and assembled, then flexibility in manufacturing is maintained, but product quality consistency deteriorates and additional effort is required
Solution Approach 1:
The forming apparatus serves multiple functions simultaneously: it positions components, applies radial forcing to align spokes, maintains concentricity during curing, and controls the vulcanization process. This multi-functional integrated system ensures consistent product quality while maintaining manufacturing flexibility for different non-pneumatic tire designs.
Solution Approach 2:
The patent employs forcing mechanisms that apply controlled radial forces to the spokes during curing. These mechanisms provide feedback control to maintain proper spoke positioning and alignment throughout the vulcanization process, ensuring uniform product quality by compensating for any deviations that occur during manufacturing.
3Manufacturing precision
If spokes are forced radially outward and inward simultaneously, then concentricity and alignment are improved, but device complexity increases
Solution Approach 1:
The forcing apparatus is divided into multiple independent forcing members that can be individually controlled. Each forcing member applies radial force to specific spokes or groups of spokes, allowing precise control over spoke alignment. This segmented approach enables complex alignment tasks to be broken down into manageable, independently controllable actions.
Solution Approach 2:
The patent uses forcing members as intermediary elements between the forming apparatus and the spokes. These intermediaries transmit and control the radial forces applied to the spokes, mediating the interaction between the complex apparatus and the components being formed. This allows the system to achieve precise spoke alignment while isolating the complexity within the forcing mechanism 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
This approach enables efficient, high-quality production of non-pneumatic tires by reducing assembly stages, minimizing thermal stresses, and ensuring concentricity, thus improving manufacturing efficiency and product uniformity.
Implementation Method 1
curing the plurality of spokes to each of the inner hub and outer band
Data Source
AI summary
This disclosure includes methods and apparatus for forming a non-pneumatic tire carcass comprising an inner hub, an outer band, and a plurality of spokes. The method includes arranging the inner hub, the plurality of spokes, and the outer band to form a curing assembly arranged in a first arrangement within a forming apparatus, where the inner hub is arranged concentrically within a radially inner annular side of the outer band and the plurality of spokes are arranged between the outer band and the inner hub. The plurality of spokes are forced in opposite radial directions from the first arrangement and to a second arrangement, where each spoke of the plurality of spokes is forced in a curing position against the inner hub and towards the outer band in a curing arrangement. The plurality of spokes are then cured to each of the inner hub and outer band.