Non-pneumatic Tire Interference Fit Assembly
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Solution Overview
Problem
Current methods for constructing non-pneumatic tires face challenges such as distortion and damage to shear band rings due to pressure during injection molding, difficulty in material flow along the axial length, and precise adhesive attachment requirements, which lead to variations and equipment fouling.
Innovation Solution
The method involves constructing intermediate sections with inner shear band rings that are compressed and inserted into an outer shear band ring, achieving an interference fit, and using adhesives that are thermally cured for a permanent connection, minimizing material usage and eliminating the need for precise fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If injection molding is used to form the supporting structure onto the shear band ring, then the supporting structure can be integrated with the shear band ring, but the large pressure causes distortion and damage to the shear band ring
Solution Approach 1:
The tire assembly is divided into separate components (shear band ring and supporting structure) that are manufactured independently and then assembled together, avoiding the need for high-pressure injection molding that would damage the shear band ring
Solution Approach 2:
The intermediate section with the supporting structure is inserted into the shear band ring, creating a nested assembly where one component fits within another, achieving integration without high-pressure molding
2Area of stationary object
If injection molding is used across the entire axial length, then complete coverage is achieved, but material flow along the axial length is difficult and thin mold sections are damaged by pressure variations
Solution Approach 1:
The manufacturing process is segmented into separate steps: forming the supporting structure independently, then assembling it with the shear band ring. This eliminates the need for high-pressure injection molding across the entire axial length, preventing damage to thin mold sections
Solution Approach 2:
The supporting structure is pre-formed as a separate component before assembly with the shear band ring, allowing independent optimization of each component's manufacturing process and avoiding pressure-related damage during final assembly
3Ease of manufacture
If adhesive attachment is used to connect the supporting structure to the shear band ring, then flexible assembly is achieved, but precise control of temperature, humidity, coating thickness, application pressure, and clamping time is required
Solution Approach 1:
The components are manufactured as separate segments and assembled through mechanical interference fit rather than adhesive bonding, eliminating the need for precise control of adhesive application parameters such as temperature, humidity, coating thickness, pressure, and clamping time
Solution Approach 2:
The interference fit mechanism creates its own bonding through elastic deformation and friction, eliminating the need for external adhesives and the complex parameter control they require
4Manufacturing precision
If precise fixtures are used for adhesive attachment, then accurate placement is achieved, but the fixtures are very expensive and complex
Solution Approach 1:
The assembly process uses simple modular components that can be easily positioned and assembled without requiring complex, expensive fixtures, reducing both device complexity and cost while maintaining assembly accuracy
Solution Approach 2:
The interference fit design allows components to self-align and secure themselves during assembly, eliminating the need for expensive precision fixtures to maintain placement accuracy
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 reduces distortion, simplifies the manufacturing process, minimizes material usage, and ensures accurate placement and bonding of components, resulting in a more reliable and efficient assembly of non-pneumatic tires.
Implementation Method 1
The intermediate section can be compressed and inserted into the outer shear band ring. The compression can be released in order to allow the intermediate section to move to a state of interference fit
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method of forming a non-pneumatic tire is provided that includes the steps of providing an outer shear band ring (12) that has an inner diameter. An intermediate section (14) is provided that has a supporting structure. An outer diameter (102) of the intermediate section (14) in the uncompressed state is greater than the inner diameter (70) of the outer shear band ring (12). The intermediate section is compressed from the uncompressed state to a compressed state, and is inserted inside of the outer shear band ring (12). Compression of the intermediate section is released when the intermediate section is inside of the outer shear band ring, and the intermediate section (14) moves from the compressed state to a state of interference fit with the outer shear band ring (12).