Non-Pneumatic Tire Mold Cavities for Variable Spoke Geometry
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Solution Overview
Problem
The manufacturing of non-pneumatic tires is hindered by the need for complex designs and increased production time and cost due to the limitations of conventional molding tools, which are constrained by simple, unidirectional geometries and lack the ability to efficiently manage cyclic compression and tension in spokes.
Innovation Solution
The development of a mold with non-uniform spoke cavities and conformal thermal control channels, allowing for additive manufacturing techniques that enable the creation of non-pneumatic tires with varying thickness, width, and surface patterns, enhancing durability and thermal control, thereby improving spoke performance and tire durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional metal casting and machining techniques are used to make molding tools, then the manufacturing process is simple and cost-effective, but the tire designs are limited to simple, unidirectional, uniform geometries
Solution Approach 1:
The molding tool is divided into multiple separable components including inserts that can be independently manufactured and assembled. This segmentation allows each component to be optimized separately using conventional techniques while the assembled tool achieves complex geometries through the combination of simpler parts.
Solution Approach 2:
Complex tire geometries are achieved by nesting multiple molding components within each other. The inserts are placed within the main mold cavity, and various features are built through layered assembly of mold components, enabling complex shapes while maintaining manufacturing simplicity at each level.
2Adaptability or versatility
If removable molding inserts or modular assemblies are used to add complexity to non-pneumatic tire designs, then design versatility is improved, but production time and cost increase
Solution Approach 1:
Complex geometric features are pre-formed into the molding tool inserts during tool manufacturing rather than being created during each tire production cycle. This preliminary action embeds the complexity into the tool itself, allowing rapid production of complex tires without adding per-unit manufacturing time.
Solution Approach 2:
Multiple molding functions are merged into integrated insert components that perform multiple operations simultaneously. Rather than using separate modular assemblies for different features, the inserts combine various molding capabilities in single components, reducing the number of steps and lowering production cost.
3Ease of manufacture
If uniform spoke geometries are used in non-pneumatic tires, then manufacturing is simpler, but the spokes cannot effectively manage cyclic compression and tension loads
Solution Approach 1:
The spoke geometry transitions from uniform to non-uniform with varying thickness and width along the spoke length. Specific regions are locally optimized with increased thickness at locations experiencing highest stress during cyclic loading, while other regions maintain thinner profiles to reduce weight and material usage.
Solution Approach 2:
The spoke cross-sectional dimensions are varied continuously or in steps along the length of the spoke, changing parameters such as thickness and width to match the local stress distribution. This parameter variation allows the spoke to better withstand cyclic compression and tension while maintaining manufacturing feasibility through techniques like selective material deposition or layered construction.
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
The solution enables the production of non-pneumatic tires with enhanced durability and performance by allowing for complex designs and improved thermal management, reducing the impact of cyclic loading on spokes and increasing the tire's flexibility and resistance to wear.
Implementation Method 1
The conformal thermal control channels are configured to remove heat from the mold cavities during tire manufacturing
Data Source
AI summary
A molding tool for forming a non-pneumatic tire includes a wheel portion cavity, a tread ring portion cavity, and a plurality of spoke cavities extending between the wheel portion cavity and the tread ring portion cavity. At least a subset spoke cavities within the plurality of spoke cavities include at least one of a non-uniform thickness, a non-uniform width, and a non-uniform surface. Also, the molding tool can include a conformal thermal control channel, e.g., a conformal cooling channel and/or a conformal heating channel, proximate to at least one mold cavity.