Patent Publication Number: US-6705365-B1

Title: Apparatus and method of providing electrical power to an active electronic device embedded within a tire

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation application of currently U.S. patent application, Ser. No. 09/302,069, filed Apr. 29, 1999, now U.S. Pat. No. 6,192,746, the disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention generally relates to monitoring devices that monitor engineering conditions of pneumatic tires and, more particularly, to an apparatus and method for connecting the power supply to an active, programmable electronic monitoring device mounted on the inside of a pneumatic tire. Specifically, the present invention relates to an apparatus and method for attaching a battery to the components of an active monitoring device after the components are cured into a patch that is attached to the innerliner of a pneumatic tire. 
     2. Background Information 
     It is often desired in the art to monitor various engineering conditions of a pneumatic tire. These measurements are preferably taken while the tire is in use on the vehicle without having to remove the tire from the vehicle or specifically position the tire to take the measurement. Numerous types of monitoring devices are known in the art to perform these measurements. One type of monitoring device uses a passive integrated circuit embedded within the body of the tire that is activated by a radio frequency transmission that energizes the circuit by inductive magnetic coupling. Other prior art devices used for monitoring tire conditions include self-powered circuits that are positioned external of the tire, such as at the valve stem. Other active self-powered programmable electronic devices are disclosed in U.S. Pat. Nos. 5,573,610, 5,562,787, and 5,573,611 which are assigned to the assignee of the present application. 
     Each of the active self-powered programmable electronic devices includes an antenna that is used to transmit the data created by the monitoring device to a data gathering device positioned outside of the tire. One of the problems in the art is to position the antenna such that the data created by the monitoring device is accurately and reliably transmitted to the data gathering device outside of the tire. It is desired to position the antenna as close to the outside of the pneumatic tire as possible so that the transmissions pass through as little of the tire as possible. In the past, the antenna of the monitoring device generally extended into the interior chamber of the tire such that the radio waves had to first pass through the air inside the tire, through the innerliner, through the tire sidewall, and then through the air to the data gathering device. It is desired in the art to provide an antenna for an active, self-powered programmable electronic device that is positioned so that the radio waves do not have to first pass through the inner chamber of the tire before entering the tire sidewall. The bead ring and apex filler of the tire tend to interfere with the radio transmission from the monitoring device. It is thus desired in the art to position the antenna away from the bead ring and apex filler so that the transmission through the tire sidewall is as strong as possible. On the other hand, it is also desirable to position the monitoring device as close to the bead ring as possible because that area of the sidewall is a low flex area that stretches less than the middle portion of the tire sidewall. It is thus desired in the art to ideally locate the antenna and the monitoring device with respect to the tire sidewall. 
     The monitoring devices known in the art are typically encapsulated with an encapsulation material that provides structural support to the monitoring device so that the device is not destroyed by the forces normally encountered and experienced by a pneumatic tire. Another problem with these electronic monitoring devices is the problem of attaching the encapsulated monitoring device to the tire. The attachment problem is difficult because the forces on the electronic device are significant and numerous. The tires are not only subjected to rotational forces when the vehicle is moving but are also subjected to various impact forces when the tire contacts bumps or surface irregularities. The attachment of the monitoring device to the tire must be strong enough and secure enough to maintain the position of the monitoring device with respect to the tire while experiencing all of these forces while also protecting the monitoring device from damage resulting from these forces. 
     One method of anchoring the components of the monitoring device as well as the antenna of the monitoring device within a pneumatic tire is to cure these components and antenna within the body of the tire. For instance, the components of the monitoring device and the antenna may be cured within the innerliner of the tire. The components may also be cured within a patch that is then connected to the innerliner. A significant problem with curing these elements in the body of the tire or into a patch is that the battery used to supply power to the components of the monitoring device is damaged or destroyed by the heat of the curing process. The damage to the battery caused by the heat of the curing process has prevented electronic monitoring devices from being embedded within a green tire and then cured into the tire during the green tire cure process. The damage to the battery is especially unfortunate because positioning the antenna and monitoring device components within the innerliner or within a patch that is connected to the innerliner allows the components and antenna to be ideally positioned and secured for use with the tire. It is thus desired in the art to provide an apparatus and method for connecting the monitoring device to the tire by curing the components and antenna of the monitoring device within the tire or a patch that is connected to the tire and then subsequently connecting the battery to the components. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, it is an objective of the present invention to provide an apparatus and method of providing electrical power to an active electronic monitoring device embedded within the body of the tire or a patch connected to the tire. 
     Another objective of the present invention is to provide an apparatus for monitoring an engineering condition of a pneumatic tire where the monitoring components and antenna of an active monitoring device are cured within a first patch that is cured to the innerliner of a tire and where the battery is connected to a second patch that is subsequently connected to the first patch carrying the monitoring device components. 
     Another objective of the present invention is to provide a monitoring device that allows the battery to be selectively connected to the electronic monitoring package so that different batteries may be used and so that the batteries may be replaced after a battery wears out. 
     Another objective of the present invention is to provide a monitoring device that allows the antenna to be positioned in a manner that causes the transmission signal to pass directly into the tire sidewall away from the bead ring and apex filler of the tire. 
     Another objective of the present invention is to provide an electronic monitoring package having a connector that allows the connection between the battery and the monitoring package to be selectively formed after the monitoring package has been connected to the innerliner of the tire. 
     Another objective of the present invention is to provide a monitoring device for a pneumatic tire where the electronic monitoring package of the monitoring device is provided with a plug or a receptacle and the battery that powers the electronic monitoring package is provided within the corresponding receptacle or plug so that the connection between the battery and electronic monitoring package may be made after the electronic monitoring package has been cured within a patch or the innerliner of the tire. 
     Another objective of the present invention is to provide a method of connecting a monitoring device to a pneumatic tire wherein the electronic monitoring package of the monitoring device is first cured within the innerliner, or a patch that is cured to the innerliner of a tire, and the battery that powers the electronic monitoring package is subsequently connected to the monitoring package. 
     Another objective of the present invention is to provide a method and apparatus that are of simple construction, that achieve the stated objectives in a simple, effective, and inexpensive manner, that solve the problems, and that satisfy the needs existing in the art. 
     These and other objectives and advantages of the present invention are obtained by a method of connecting an electronic monitoring device to a pneumatic tire including the steps of providing a green tire having an innerliner; providing an anchoring patch and an electronic monitoring package; attaching the electronic monitoring package to the anchoring patch; mounting the anchoring patch having the electronic monitoring package on the innerliner of the green tire; curing the green tire and the anchoring patch; providing a battery; and forming a direct electrical connection between the electronic monitoring package and the battery after the green tire is cured. 
     Other objectives and advantages of the invention are obtained by a method of connecting an electronic monitoring device to a pneumatic tire including the steps of providing a green tire having an innerliner with an electronic monitoring package connected to the innerliner; curing the green tire; providing a battery; and forming a direct electrical connection between the electronic monitoring package and the battery after the green tire is cured. 
     Further objectives and advantages of the invention are obtained by a monitoring device and pneumatic tire in combination, the combination including a pneumatic tire having an innerliner; an anchoring layer mounted on the innerliner; an electronic monitoring package connected to the anchoring layer; and a battery selectively electrically connected to the electronic monitoring package. 
     Still other objectives and advantages of the invention are achieved by a monitoring device and pneumatic tire in combination, the combination including a pneumatic tire having an innerliner; an electronic monitoring package connected to the innerliner; and a battery selectively electrically connected to the electronic monitoring package. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred embodiments of the invention, illustrative of the best mode in which applicant has contemplated applying the principles of the invention, are set forth in the following description and are shown in the drawings and are particularly and distinctly pointed out and set forth in the appended claims. 
     FIG. 1 is a sectional view of a pneumatic tire with an electronic monitoring device mounted on the innerliner of the tire; 
     FIG. 2 is an enlarged sectional view of the electronic monitoring device and a portion of the pneumatic tire; 
     FIG. 3 is a view similar to FIG. 2 showing an alternate configuration of the monitoring device; 
     FIG. 4 is a view similar to FIG. 2 showing an alternate embodiment of an electronic monitoring device and tire combination; 
     FIG. 5 is a view similar to FIG. 4 showing an alternate configuration of the combination of FIG. 4; 
     FIG. 6 is a view of a green tire with an anchoring patch mounted on the innerliner of the green tire; and 
     FIG. 7 is a view of the tire of FIG. 6 after the green tire has been cured and the cover of the anchoring patch has been removed. 
    
    
     Similar numerals refer to similar parts throughout the drawings. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The first embodiment of the monitoring device and pneumatic tire combination of the present invention is depicted in FIGS. 1-3 and is indicated generally by the numeral  10 . Combination  10  includes a pneumatic tire  12  that has a sidewall  14  and an innerliner  16 . Sidewall  14  includes a bead ring  18 , an apex filler  20 , and a reinforcing cord package  22 . A monitoring device  24  having an electronic monitoring package  26  is attached to innerliner  16  in a position where the antenna of electronic monitoring package  26  is positioned away from bead ring  18  and apex filler  20  while monitoring device  24  is positioned close to bead ring  18  in the low flex area of sidewall  14 . Monitoring device  24  is disposed in the pressurized chamber of tire  12  when tire  12  is in use. 
     Electronic monitoring package  26  may include a variety of components that are known in the art to monitor at least one engineering condition of pneumatic tire  12  and transmit information about the condition through tire sidewall  14  to a data gathering device (not shown) positioned outside the tire. Electronic monitoring package  26  includes at least one sensing element that monitors or measures an engineering condition of a tire and transmits the gathered data through an antenna. Monitoring device  24  is attached to innerliner  16  by any of the variety of methods that are known in the art. For instance, monitoring device  24  may be attached to innerliner  16  with a suitable adhesive. In another embodiment described in more detail below, monitoring device  24  is attached to innerliner  16  through a curing process. 
     In accordance with one of the objectives of the present invention, monitoring device  24  is constructed to allow a power source such as a battery  30  that supplies power to electronic monitoring package  26  to be selectively electrically connected after electronic monitoring package  26  is cured within innerliner  16  or a patch, the invention also allows electronic monitoring package  26  to be connected to tire  12  by any method with battery  30  connected at a later time. In the first embodiment of the present invention, electronic monitoring package  26  is embedded within an anchoring layer  32  which is connected to innerliner  16 . A socket  34  is electrically connected to electronic monitoring package  26  by a suitable connector  36 . Socket  34  is disposed adjacent the outer surface of anchoring layer  32  so that a plug  38  electrically connected to battery  30  may selectively connect with socket  34  to provide direct electrical connection between battery  30  and electronic monitoring package  26 . A pair of plug  38  and socket  34  combinations may be provided for both poles of battery  30  if desired. The connection between plug  38  and socket  36  is made when battery  30  is connected to anchoring layer  32  as will be described in more detail below. 
     In the first embodiment of the invention, electronic monitoring package  26  is encapsulated by an encapsulation material  40  to create an encapsulated monitoring package  42 . Encapsulation material  40  provides a rigid protective shell about the components of electronic monitoring package  26  that prevents them from being damaged when subjected to the numerous forces that package  26  will likely encounter during its life. Encapsulated monitoring package  42  is embedded within anchoring layer  32  that is a layer of cured rubber. Encapsulated monitoring package  42  may also be directly connected to tire  12 . Battery  30  is also encapsulated with an encapsulation material  40  to provide an encapsulated battery  44 . Encapsulated battery  44  may be mounted on an attachment patch  46  that may be fabricated from a variety of rubbers that have the ability to be adhered to anchoring layer  32 . Plug  38  extends through attachment patch  46  so that it may be securely fit into socket  36  when attachment patch  46  and encapsulated battery  44  are mounted on anchoring layer  32 . 
     An alternative configuration of monitoring device  24  is depicted in FIG.  3 . The components of this configuration are substantially the same as monitoring device  24  described above with the exception that plug  38 , connector  36 , and socket  34  are reversed such that plug  38  extends from anchoring layer  32  with socket  34  being carried in attachment patch  46 . 
     An alternative embodiment of an electronic monitoring device and tire combination is depicted in FIG.  4  and is indicated generally by the numeral  50 . The components of combination  50  are similar to the components described above and the same numbers are used to indicate the same parts. In combination  50 , encapsulated monitoring package  42  is cured within innerliner  16  during the cure process of tire  12 . This allows the antenna and components of monitoring package  26  to be ideally positioned within sidewall  14 . 
     After the green tire is cured to form tire  12 , encapsulated battery  44  is directly electrically connected to electronic monitoring package  26  by connecting plug  38  with socket  34  as depicted in FIG.  4 . Encapsulated battery  44  may be mounted on an attachment patch  46  that allows encapsulated battery  44  to be mounted on innerliner  16 . 
     An alternative configuration of combination  50  is depicted in FIG. 5 with the only difference being that components  34 ,  36  and  38  are reversed such that plug  38  extends out of innerliner  16  and socket  34  is carried by attachment patch  46 . 
     The apparatus and method of using anchoring layer  32  is disclosed and described in U.S. patent applications Ser. Nos. 09/205,931 and 09/206,273, filed Dec. 4, 1998 which are owned by the assignee of the present application. The method of using an anchoring patch  60  having anchoring layer  32  that carries electronic monitoring package  26  is depicted in FIGS. 6 and 7. Electronic monitoring package  26  is first encapsulated with encapsulation material  40  by methods known in the art. During the encapsulation process, the position of socket  34  is noted so that plug  38  may later form the connection between battery  30  and monitoring package  26 . The position of socket  34  may be noted by providing a temporary plug  62  in the cover  64  of anchoring patch  60 . A layer of cure material  66  (such as cure paper or cure cloth) is disposed between cover  64  and anchoring layer  32  to prevent cover  64  from curing to anchoring layer  32 . Anchoring patch  60  having electronic monitoring package  26  is then connected to innerliner  16  of a green tire before the green tire cure process. Patch  60  may be aggressively stitched to innerliner  16  to provide a secure connection between the two elements. 
     The green tire is then cured by a known green tire curing process to form tire  12 . The cure process cures the uncured rubber of anchoring layer  32  of anchoring patch  60 . In accordance with one of the objectives of the present invention, the green tire cure process thus cures electronic monitoring package  26  in anchoring layer  32 . The curing process also cures anchoring layer  32  to innerliner  16  such that anchoring layer  32  is securely connected to tire  12 . Cover  64  and layer  66  are then removed to expose socket  34 . Encapsulated battery  44  is then mounted on attachment patch  46  with plug  38  protruding through attachment patch  46 . A suitable adhesive is then used to connect attachment patch  46  to anchoring layer  32  with plug  38  snugly received in socket  34  to form a direct electrical connection between battery  30  and electronic monitoring package  26 . This method allows electronic monitoring package  26  to be cured within anchoring layer  32  without subjecting battery  30  to the heat of the cure process. 
     Another advantage with the configuration of this invention is that battery  30  may be relatively easily removed and replaced when it loses power. Battery  30  may be replaced because the connection between battery  30  and electronic monitoring package  26  is a selective connection that may be broken at a later date by removing battery  30  and plug  38  and replacing them with a new battery. The configuration also allows batteries to be connected to package  26  that have different sizes or powers. 
     Accordingly, the improved apparatus and method of providing electrical power to an active electronic device embedded within a tire is simplified, provides an effective, safe, inexpensive, and efficient device which achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art. 
     In the foregoing description, certain terms have been used for brevity, clearness and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. 
     Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described. 
     Having now described the features, discoveries and principles of the invention, the manner in which the improved apparatus and method of providing electrical power to an active electronic device embedded within a tire is construed and used, the characteristics of the construction, and the advantageous, new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts and combinations, are set forth in the appended claims.