Tire with Variable Rubber Thickness and Shoulder Reinforcement
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Solution Overview
Problem
Heavy-duty tires face endurance and wear issues under high-speed, long-distance road conditions and overload conditions, with existing solutions providing insufficient durability and resistance to cyclical stresses.
Innovation Solution
A tire design featuring a radial carcass reinforcement with additional circumferentially oriented layers of reinforcing elements in the shoulders, combined with specific rubber compound thicknesses and metal cord constructions, enhancing the tire's circumferential rigidity and resistance to fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional circumferential reinforcing layers are added in the shoulders, then circumferential rigidity and resistance to cyclical stresses improve, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The reinforcing structure is segmented into distinct functional zones: standard crown reinforcement in the central area and additional circumferential reinforcing layers specifically positioned in the shoulder regions. This segmentation allows the tire to have enhanced strength where needed (shoulders under cyclical stress) while maintaining simpler construction in less critical areas, thus resolving the contradiction between strength improvement and complexity increase.
Solution Approach 2:
Additional circumferential reinforcing layers are applied locally only in the shoulder regions rather than uniformly across the entire tire. This local quality approach provides targeted reinforcement where cyclical stresses are most severe during mounting/dismounting operations, improving resistance to fatigue without unnecessarily increasing overall structural complexity and manufacturing difficulty.
2Reliability
If variable thicknesses of rubber mixtures are used inside the carcass reinforcement, then durability and resistance to crack propagation improve, but manufacturing precision requirements increase
Solution Approach 1:
The rubber compound is formulated with locally variable thicknesses, specifically thicker layers positioned at critical locations inside the carcass reinforcement where crack initiation and propagation are most likely. This local quality approach enhances durability in high-stress regions while accepting that manufacturing precision requirements are increased, as the variable thickness profile demands more sophisticated molding and quality control processes.
Solution Approach 2:
Thicker rubber compound layers are strategically placed beforehand in regions prone to crack development, creating a cushioning effect that prevents crack initiation and propagation. This prior cushioning approach improves reliability by preemptively addressing weakness points, though it necessitates higher manufacturing precision to ensure the thicker sections are positioned accurately during tire construction.
3Duration of action of stationary object
If metal cords with specific diameter constraints are used, then fatigue resistance improves, but manufacturing complexity increases
Solution Approach 1:
Specific parameter constraints are imposed on the metal cords, particularly diameter limitations (e.g., cords with diameter less than 1 mm and preferably less than 0.20 mm), to optimize fatigue resistance. These parameter changes improve the duration of action and fatigue life of the tire, but they increase manufacturing complexity by requiring precise control of cord specifications during the tire building process.
Data Source
AI summary
A tire comprises two working crown layers of reinforcing elements and, in each shoulder, an end of a layer of parallel reinforcing elements oriented circumferentially, said end being axially outside the working crown layers. The reinforcing elements have a diameter less than 1 mm and comprise threads with a diameter strictly greater than 0.16 mm, and, in a radial plane, the ratio between the thicknesses of rubber compound between the inner surface of the tire cavity and that point of a metal reinforcing element of the carcass reinforcement that is closest to said inner surface of the cavity, of the two parts of the tire profile that are centered on the respective orthogonal projections onto the inner surface of the tire cavity of the axially outer ends of said additional layers, and of the parts of the tire profile that have the smallest thicknesses, being greater than 1.15.


