Non-pneumatic Tire Assembly via Intermediate Section Compression
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Solution Overview
Problem
The existing methods for constructing non-pneumatic tires face challenges such as distortion and damage to the shear band ring during injection molding, difficulty in material flow along the axial length, and precise attachment requirements with adhesives, which lead to variations and equipment fouling.
Innovation Solution
A method involving the formation of intermediate sections with inner shear band rings that can be collapsed and inserted into an outer shear band ring, allowing for precise attachment and minimizing material usage, using a compression device to deform the sections for assembly, and employing adhesives for a secure bond.
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 supporting structure is divided into multiple segments that can be assembled in a stepwise manner. Each segment is attached to the shear band ring sequentially, allowing the structure to be built up without subjecting the entire assembly to high injection molding pressures that would cause distortion or damage to the shear band ring.
Solution Approach 2:
The shear band ring is pre-formed and stabilized before the supporting structure is attached. This preliminary preparation ensures the shear band ring maintains its shape and integrity during the subsequent assembly process, preventing distortion and damage that would occur if attachment attempts were made on an unstable or improperly prepared ring.
2Area of stationary object
If injection molding is used to form the supporting structure across the entire axial length, then complete coverage is achieved, but material flow difficulty prevents easy flow along the entire axial length
Solution Approach 1:
The supporting structure is divided into multiple segments positioned at different locations along the axial length. Each segment can be manufactured and attached independently, eliminating the need for material to flow across the entire axial length in a single injection molding operation. This segmentation resolves the material flow difficulty while achieving complete axial coverage.
Solution Approach 2:
Instead of attempting to mold the entire supporting structure in one operation, the invention applies partial action by forming and attaching segments incrementally. This approach makes the manufacturing process feasible by breaking down the complex material flow requirement into manageable portions that can be successfully injected and attached.
3Manufacturing precision
If adhesives are used to attach the supporting structure to the shear band ring, then precise control of critical parameters is required, but this leads to variation and equipment fouling
Solution Approach 1:
The adhesive attachment process is extracted and replaced with a mechanical attachment method. The supporting structure segments are designed with features that enable direct mechanical connection to the shear band ring, eliminating the need for adhesives entirely. This resolves both the precision control issues and the fouling problems associated with adhesive application.
Solution Approach 2:
The chemical bonding system (adhesive) is replaced with a mechanical bonding system. The supporting structure segments incorporate mechanical attachment features such as interlocking elements or friction-fit interfaces that provide precise attachment without requiring adhesive control parameters. This substitution eliminates adhesive fouling and reduces process variation.
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 method reduces distortion, improves material flow, and eliminates the need for expensive fixtures, providing a more consistent and efficient assembly process with reduced equipment fouling, while maintaining precise control over the attachment of the supporting structure to the shear band ring.
Implementation Method 1
A compression device is used to deform the intermediate section for assembly
Implementation Method 2
The compression is released in order to allow the inner shear band ring to return to its uncollapsed state
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 (56) and an intermediate section (14) that has a supporting structure (16). The intermediate section (14) is collapsed from an uncollapsed state to a collapsed state. The intermediate section in the collapsed state is inserted inside of the outer shear band ring such that the outer shear band ring is located outward from the intermediate section in a radial direction of the tire. Compression of the intermediate section (14) is released when the intermediate section (14) is inside of the outer shear band ring (56) so that the intermediate section returns to the uncollapsed state from the collapsed state. In one embodiment, the compressing step of the intermediate section (14) is performed by a compression device (68) that has a plurality of gripping members.