Tire Tread Intermediate Layer Microsphere Dispersion Weight Reduction
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Solution Overview
Problem
Current tire technologies face challenges in achieving reduced weight and cost while maintaining essential physical properties, particularly in the tread area, which affects fuel efficiency and durability.
Innovation Solution
Incorporating a multilayered tire tread design with an intermediate rubber layer containing a dispersion of high-strength hollow glass and/or ceramic microspheres, along with a coupling agent, to reduce weight and enhance physical properties such as stiffness and traction, and using this layer to extend the service life by exposing a new running surface as the outer tread cap layer wears down.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the tread cap rubber layer is made thinner to reduce weight, then fuel efficiency is improved, but the service life and durability of the tire are reduced
Solution Approach 1:
The tread is divided into multiple layers: an outer tread cap layer for initial service, an intermediate transition layer with microspheres for extended service, and a tread base layer for structural support. This segmentation allows the tire to progress through different layers as the outer layer wears, extending overall service life while keeping individual layers thinner for weight reduction.
Solution Approach 2:
The intermediate transition layer is pre-positioned between the tread cap and base layers during manufacturing, containing high-strength hollow microspheres that provide enhanced properties. This preliminary preparation ensures that when the outer layer wears, the intermediate layer is already in place to extend service life without requiring additional manufacturing steps later.
2Strength
If high-strength hollow microspheres are added to the intermediate rubber layer, then stiffness and strength are improved, but the complexity of the rubber composition increases
Solution Approach 1:
The high-strength hollow microspheres are concentrated specifically in the intermediate transition layer rather than being distributed throughout the entire tread. This localized placement provides enhanced strength and stiffness where needed for durability extension, while keeping the overall composition manageable by limiting the complex ingredients to a specific zone.
Solution Approach 2:
The intermediate transition layer uses a composite material system combining rubber matrix with high-strength hollow microspheres (glass or ceramic) and coupling agents. This composite approach provides superior strength-to-weight ratio and stiffness, allowing the intermediate layer to compensate for the thinner overall tread design while maintaining manageable composition complexity through specialized material selection.
3Loss of energy
If the intermediate rubber layer contains microsphere dispersion, then rolling resistance is reduced, but the manufacturing process becomes more complex
Solution Approach 1:
The microsphere dispersion is pre-prepared and incorporated into the intermediate transition layer during the rubber compounding stage before vulcanization. This preliminary incorporation ensures proper distribution of microspheres throughout the intermediate layer, achieving reduced rolling resistance through optimized material properties while maintaining standard manufacturing processes for tire production.
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 results in a lighter, cost-effective tire tread with improved durability and reduced rolling resistance, maintaining traction and physical properties throughout the tire's service life by extending the use of the intermediate rubber layer as the outer tread cap layer wears, thereby reducing waste and enhancing fuel efficiency.
Implementation Method 1
a coupling agent (to couple the microspheres to the diene-based elastomers of the intermediate tread rubber) having a moiety interactive with hydroxyl groups contained on the microspheres and another, different moiety interactive with diene-based elastomers
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
The invention relates to a tire with a tread having an intermediate rubber layer (6) which contains a dispersion of high strength hollow microspheres, preferably glass and/or ceramic microspheres. In particular, such tire tread is comprised of at least three radially disposed zones of rubber layers composed of a radially outer tread rubber cap layer (4), a radially inner tread base rubber layer (5) and an intermediate, transition rubber layer (6) positioned between said outer rubber cap layer and said inner rubber base layer. The intermediate tread rubber contains a dispersion of glass and/or ceramic microspheres together with a coupling agent.