Embedded Tire Sensor Encapsulation for Curing Durability
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Solution Overview
Problem
Existing tire sensor units attached to the inside surface of pneumatic tires cannot accurately monitor temperature and other parameters at specific locations within the tire structure during use, and they often detach or crack during curing or operation, leading to reduced durability and lifespan.
Innovation Solution
An encapsulated sensor unit with a three-layer encapsulation structure, comprising a thermosetting polymer first layer, a vulcanizing adhesive second layer, and a soft gum rubber third layer, which allows for embedding within the tire structure, protecting components, ensuring adhesion, and enabling efficient signal transmission while withstanding tire curing and operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor units are attached to the inside surface of pneumatic tires, then they can continuously sense temperature and pressure inside the tire cavity, but they cannot accurately monitor parameters at specific locations within the tire structure
Solution Approach 1:
The sensor unit is divided into separate functional components (sensor element, substrate, encapsulating layers) that can be independently positioned and embedded at specific locations within the tire structure, enabling precise temperature monitoring at targeted areas such as the belt package edge
Solution Approach 2:
The sensor unit is embedded within the tire structure by nesting it between the belt package and the tire cavity, allowing the sensor to be positioned at specific structural locations while remaining protected and functional
2Measurement precision
If sensor component size is increased to collect more data and monitor parameters with greater sensitivity, then measurement capability improves, but the sensor unit cannot withstand tire curing conditions or operating conditions
Solution Approach 1:
The sensor unit is pre-encapsulated in multiple protective layers (first encapsulating layer, second encapsulating layer, third encapsulating layer) before being embedded in the tire, providing advance protection against the harsh curing conditions and subsequent operational stresses
Solution Approach 2:
The encapsulation system uses composite material structures with different layers providing different protective functions, combining the benefits of multiple materials to protect the sensor components while allowing the sensor to maintain its size for adequate measurement capability
3Measurement precision
If sensor units are permanently embedded into the tire structure, then accurate measurement of temperature at specific locations is achieved, but the sensor unit experiences detachment or cracking during curing or operation
Solution Approach 1:
The sensor unit is pre-encapsulated in multiple protective layers before embedding, providing advance protection against the harsh curing conditions and subsequent operational stresses that would otherwise cause detachment or cracking
Solution Approach 2:
The encapsulation layers are designed as flexible protective shells that can accommodate the deformation and stress experienced by the tire during curing and operation, preventing cracking while maintaining sensor integrity
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 encapsulated sensor unit maintains durability and extends lifespan by providing accurate temperature monitoring at specific tire locations, preventing detachment, and enhancing signal transmission, thus improving tire performance prediction and reducing curing time.
Implementation Method 1
a first encapsulating layer is disposed about the sensor portion
Implementation Method 2
a vulcanizing adhesive second layer
Implementation Method 3
a soft gum rubber third layer is disposed about the second encapsulating layer
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
An encapsulated sensor unit for embedding in a tire (120) is disclosed. The encapsulated sensor unit (100 comprises a sensor portion (102); an antenna portion (104); a first encapsulating layer (106) disposed about the sensor portion (102); a second encapsulating layer (112) disposed about the first encapsulating layer (106) and the antenna portion (104); and a third encapsulating layer (116) disposed about the second encapsulating layer (112). Also, a tire comprising such a sensor unit (100) is disclosed and a method of manufacturing a tire comprising inserted the sensor unit (100) into the tire (100) before curing of the tire.