Tire Sensor Rubber Mount With Air Gap for Inner Liner Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for integrating electronic devices into tires face issues such as sensor detachment, exposure to foreign matter, difficulty in replacing sensors, and damage to the tire's inner liner due to uneven pressure application and stress during rotation.
Innovation Solution
A manufacturing method involving injection molding or compression molding of unvulcanized rubber around an electronic device mockup within a mold unit, forming a rubber mount with an insertion hole to create an air layer between the device and the tire's inner liner, allowing for secure attachment and reduced friction, and enabling easy replacement of the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sensor is directly attached to a tire using adhesive, then the sensor can be easily installed, but the sensor may detach during tire rotation and cause damage
Solution Approach 1:
The system is divided into separate functional components: a rubber mount with mounting structure attached to the tire, and a sensor unit that couples to the mounting structure. This segmentation allows the sensor to be securely fixed through mechanical coupling while maintaining ease of installation and replacement.
Solution Approach 2:
The rubber mount with its mounting structure is pre-attached to the tire before the sensor is installed. This preliminary action ensures that the mounting infrastructure is already in place and securely fixed, providing a stable foundation for subsequent sensor attachment during tire rotation.
2Object-affected harmful factors
If a sensor is embedded inside the tire structure, then the sensor is protected from foreign matter, but the sensor cannot be replaced and may damage the inner liner
Solution Approach 1:
The sensor unit is nested within the rubber mount structure, which itself is attached to the tire. This nested arrangement provides protection for the sensor while maintaining accessibility - the sensor is shielded by the rubber mount but can be easily removed by detaching from the mounting structure without damaging the tire or inner liner.
Solution Approach 2:
The rubber mount acts as an intermediary between the tire and the sensor. It provides a protective interface that shields the sensor from direct exposure to foreign matter and tire interior conditions, while also serving as a removable coupling mechanism that enables easy sensor replacement without tire damage.
3Strength
If a fastener is inserted before vulcanization to fix the sensor, then adhesion is increased, but pressure is ununiformly applied during vulcanization
Solution Approach 1:
The rubber mount is vulcanized to the tire first, establishing a strong, uniform bond. After vulcanization is complete, the sensor unit is then coupled to the pre-formed mounting structure. This sequence ensures uniform pressure distribution during vulcanization while still achieving strong adhesion through the two-stage process.
Solution Approach 2:
The attachment process is segmented into two independent stages: first vulcanizing the rubber mount to the tire, then separately coupling the sensor to the mount. This segmentation allows each stage to be optimized independently - vulcanization for uniform adhesion and mechanical coupling for precise sensor positioning without interfering with pressure distribution.
4Reliability
If a foam strip is formed at the tire inner surface to position the sensor, then the sensor is protected from direct acceleration forces, but acceleration information transmission is reduced
Solution Approach 1:
The rubber mount is formed as a thin, flexible structure that attaches to the tire inner surface. This flexible construction provides protection for the sensor while maintaining direct mechanical coupling to the tire, allowing acceleration forces to be transmitted effectively to the sensor without the dampening effect of thick foam materials.
Solution Approach 2:
The rubber mount is constructed from composite materials that combine protective properties with high mechanical coupling efficiency. The material composition provides sufficient cushioning and protection for the sensor while maintaining rigid enough characteristics to accurately transmit acceleration forces from the tire to the sensor.
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 method prevents damage to the tire's inner liner, ensures secure attachment of the electronic device, and allows for accurate measurement of acceleration without detachment, enhancing durability and longevity of the tire-integrated electronic system.
Implementation Method 1
unvulcanized rubber which has elasticity and deformability
Implementation Method 2
an air layer is formed between the inner liner and the electronic device, so that it is possible to avoid a problem of causing the inner liner to be damaged
Data Source
Figure 1~2
Figure 3~5
Figure 6(a)~7
AI summary
The invention relates to a manufacturing method of a tire integrated electronic device that includes: a) step of positioning an electronic device mockup portion (110) inside a first mold unit and a second mold unit; b) step of performing injection molding or compression molding by injecting unvulcanized rubber inside the first mold unit and the second mold unit such that the unvulcanized rubber encloses the electronic device mockup portion; c) step of unmolding a rubber mount unit (120) molded to enclose the electronic device mockup portion; d) step of inserting an electronic device unit into a lower end portion of the unmolded rubber mount unit; and e) step of attaching the electronic device unit-inserted rubber mount unit to an inner liner of a tire wherein the rubber mount unit has an insertion hole, through which the electronic device unit is to be inserted at a lower portion of the rubber mount unit.