Patent Publication Number: US-2020282447-A1

Title: Method of manufacturing hub for a non-pneumatic wheel

Description:
FIELD OF THE INVENTION 
     The subject matter of the present disclosure relates generally to a method of manufacturing a hub for a non-pneumatic wheel. 
     BACKGROUND OF THE INVENTION 
     The pneumatic tire is a known solution for compliance, comfort, mass, and rolling resistance. However, the pneumatic tire has disadvantages in complexity, the need for maintenance, and susceptibility to damage. A device that improves on pneumatic tire performance could, for example, provide more compliance, better control of stiffness, lower maintenance requirements, and resistance to damage. 
     Non-pneumatic tire or wheel constructions provide certain such improvements. The details and benefits of non-pneumatic tire or non-pneumatic wheel constructions are described in e.g., U.S. Pat. Nos. 6,769,465; 6,994,134; 7,013,939; and 7,201,194. Certain non-pneumatic tire and wheel constructions propose incorporating a resilient, annular shear band, embodiments of which are described in e.g., U.S. Pat. Nos. 6,769,465 and 7,201,194. Such non-pneumatic tire and wheel constructions provide advantages in performance without relying upon a gas inflation pressure for support of the loads applied to the tire or wheel. 
     In some non-pneumatic constructions, vehicle load is applied to a Wheel hub that is connected with an annular shear band through load bearing members in the form of e.g., a web or spoke. These members can transmit the load to the annular shear band through e.g., tension, compression, or both. A layer of tread can be applied to the shear band to provide protection against from the travel surface. 
     The non-pneumatic wheel may wear or suffer damage during use. For example, the tread may wear, the load bearing members may be cut or nicked, and other effects from usage may occur. For certain constructions, the tread, load bearing members, and annular band may be constructed from various polymeric materials that wear or age from use while the hub may be constructed from one or more metals and could potentially be reused. 
     However, replacement or repair of the tread or the load bearing members may not be practical or economical. For example, because of the integral construction of the hub and load bearing members, prior non-pneumatic wheels may not be readily amenable to substituting different spokes or an annular band into the non-pneumatic wheel, substituting different hubs into the non-pneumatic wheel, or both. Such a substitution would require e.g., destructive steps to cut or extricate the spoke from the annular band or the hub of the non-pneumatic wheel. 
     Accordingly, a method of manufacturing a hub for a non-pneumatic; wheel having spokes that can be removably attached to the hub would be helpful. Such a method that can utilize relatively inexpensive materials and economical processes would be particularly useful. 
     SUMMARY OF THE INVENTION 
     The present invention provides a method for manufacturing a wheel hub for a non-pneumatic. wheel. A sheet of material may be folded, cut, bent, and otherwise processed to form portions of the desired wheel hub. The wheel hub may be connected with an annular band through load supporting members that can be selectively connected and disconnected from the hub. Additional objects and advantages of the invention will be set forth in part in the following description, or may be apparent from the description, or may be learned through practice of the invention. 
     In one exemplary aspect of the present invention, a method of manufacturing a wheel hub is provided that includes bending a sheet of material into a plurality of precursor elements that repeat along a predetermined direction; attaching the sheet from the bending to an annular member having axial, radial, and circumferential directions such that the precursor elements repeat along the circumferential direction; and cutting each precursor element along the axial direction so as divide each precursor element into pairs of opposing fingers and create a plurality of channels extending along the axial direction. This exemplary method may include shaping each opposing finger so as to form the channels into a predetermined shape along the axial direction. 
     These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which: 
       FIG. 1  illustrates a perspective view of an exemplary embodiment of a non-pneumatic wheel including an exemplary wheel hub of the present invention. 
         FIG. 2  illustrates a side view of the exemplary embodiment of  FIG. 1 . 
         FIG. 3  is a perspective view of an exemplary non-pneumatic tire may as be used with the exemplary wheel of  FIGS. 1 and 2 . 
         FIG. 4  is a perspective view of an exemplary, annular receiver of the present invention. 
         FIG. 5  is a close-up, side view of a portion of the exemplary annular receiver of  FIG. 4  along with the radially-inner ends of exemplary spokes. 
         FIGS. 6, 7, 8, 9, and 10  depict exemplary steps in a process for manufacturing an exemplary hub of the present invention. 
         FIG. 11 . depicts a close-up, side view of a portion of another exemplary annular receiver along with the radially-inner ends of exemplary spokes. 
     
    
    
     DETAILED DESCRIPTION 
     For purposes of describing the invention, reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such. modifications and variations as come within the scope of the appended claims and their equivalents. 
     As used herein, the following definitions apply. 
     Axial direction A refers to a direction parallel to an axis about which a referenced exemplary wheel or tire rotates during use. 
     Radial direction R refers to a direction perpendicular to axial direction A with radially-outer or radially outward referring to a general direction away from axial direction A, and radially-inner or radially inward referring to a general direction towards axial direction A. 
     Circumferential direction C refers to a direction defined by defined by the circumference of the wheel or tire, or the direction of rotation the wheel or tire about an axis. 
     FIGS. I and  2  illustrate an exemplary embodiment of a non-pneumatic wheel  100  of the present invention defining radial direction R, circumferential direction C, and axial direction A. Wheel  100  includes a non-pneumatic tire  102  supported on a hub  300 , which includes an annular receiver  304  that may be connected with a central portion  302 .  FIG. 3  depicts non-pneumatic tire  102  without hub  300  positioned in central opening  110 .  FIG. 4  depicts annular receiver  304  of hub  300  without central portion  302  in place. Annular receiver  304  includes a cylindrically-shaped annular member  330  to which a metal sheet has been attached to in order to create multiple channels  318  as will be further described herein. 
     Referring now to  FIGS. 1, 2, and 3 , non-pneumatic tire  102  includes an annular shear band  104  that extends circumferentially around wheel  100  and has an axial width Tire  102  includes a plurality of load supporting members or spokes  106  that are connected with shear band  102 , connected with annular receiver  304  of hub  300 , and spaced apart along circumferential direction C as will be further described. Spokes  106  may have other shapes and configurations from what is shown in the figures. For example, although shown as somewhat linear in the figures, spokes  106  may also have a curved shape. In one exemplary embodiment, each spoke  106  is provided with substantially the same curvature along radial direction R (as viewed along axial direction A) so that e.g., spokes  106  may buckle in the same way as they pass through the contact patch. By way of further example, the axial edges of spokes  106  may also be provided with non-linear shapes to provide a profile different from what is shown in the figures. 
     Central portion  302  of hub  300  is configured for supporting wheel  100  on a vehicle. In this exemplary embodiment, hub  300  includes a plurality of spokes or arms  306  extending radially outward from a centroid  308  ( FIG. 1 ), or from the axis of rotation of hub  300 , to annular receiver  304 . A plurality of openings  310  allow for insertion of fasteners to secure hub  300  (and thereby non-pneumatic wheel  100 ) to e.g., an axle of a vehicle. Hub  300  may be e.g., welded to annular receiver  304  or, in an alternative, formed integrally therewith. In still another embodiment, central portion  302  may be secured to receiver  304  using fasteners extending through openings  312  in tabs  314  spaced apart along radially-inner surface  316  of annular receiver  304  as depicted in  FIG. 4 . The appearance and features of hub  300 , and particularly central portion  302 , are provided by way of example only and other configurations may be used as well. 
     Annular shear band  104  may include one or more reinforcing bands, reinforcing plies, shear layers, and other components (not shown). For example, shear band  104  may be constructed with a radially-inner reinforcing band, a radially-outer reinforcing band, and a shear layer positioned therebetween. Shear band  102  provides a stiffness that allows spokes  106  to support hub  300  during use of wheel  100  on a vehicle. At the same time, shear band  102  provides a resiliency or compliance over the ground surface that provides for a smoother, more comfortable ride. 
     Shear band  102  is depicted in  FIGS. 1, 2, and 3 , as having a smooth, radially-outer surface  108 . However, outer surface  108  may be provided with a tread having e.g., grooves, ribs, blocks, or other features for enhancing traction performance. The tread can be molded directly into outer surface  108  or may be provided as a tread portion wrapped around wheel  100  and attached thereto. Other configurations may be used as well. 
     As shown in  FIGS. 2 and 3 , each spoke  106  includes a radially-outer end  118  that is connected with annular shear band  104 . Radially-outer end  118  may be attached directly to shear band  104  or indirectly through a ring or feature connected to shear band  104 . Spoke  106  may be one continuous piece along radially-outer end  118  or may be separated into portions in other embodiments. For the exemplary embodiment shown, each spoke  106  is constructed from three portions  112 ,  114 , and  116  having radially inner ends  112   E ,  114   E , and  116   E , ( FIG. 3 ). Other configurations and constructions may be used as well. 
     Referring now to  FIGS. 4 and 5 , annular receiver  304  includes a plurality of channels  318  spaced apart from each other along circumferential direction C. Each channel  318  defines a longitudinal axis L extending parallel to axial direction A. For this exemplary embodiment, each channel  318  is formed by a pair of fingers  320 ,  322  and bottom  324  that give channel  318  a triangular shape when viewed along axial direction A as shown in  FIG. 5 . Each finger  320  and  322  forms an acute angle a with bottom  324  in the range of 30 degrees≤α≤60 degrees for this exemplary embodiment. As such, channels  318  have a triangular cross-sectional shape configured for complementary receipt of radially-inner ends (such as  112   E ,  114   E , and  116   E ) of spokes  106 . Other cross-sectional shapes (as view along axial direction A) may be used for channels  318  as will be further discussed herein. For this exemplary embodiment, channels  318  and fingers  320 ,  322  each maintain a constant profile along the axial width W AR  ( FIG. 4 ) between front F and back B of annular receiver  304 . 
     An exemplary method as may be used to manufacture a hub  300  with annular receiver  304  will now be further described with reference to  FIGS. 6 through 10 . Beginning with  FIGS. 6 and 7 , a plurality of precursor elements  334  are formed by bending a sheet of material  332  into the predetermined shape of precursor elements  334 . Various techniques may be used for such bending including e.g., roll forming, stamping, or others. Sheet  332  be constructed from various materials including e.g., steel. Sheet  332  may have a width S W  ( FIG. 6 ) along axial direction A that is the same as width AM W  ( FIG. 4 ) along axial direction A of annular member  330 . In other configurations, width S W  and width AM W  may be different. 
     For this exemplary embodiment, precursor elements repeat along predetermined direction P and have a continuous profile along axial direction A. After forming, each precursor element  334  may have a trapezoidal shape and is connected to adjacent precursor elements by a base  336 . The particular shape of precursor element  334  and base  336  shown in the figures is by of example only. Other shapes may also be used depending upon e.g., the shape desired for channels  318 . For example, each precursor element could be shaped as a triangle, semi-circle, and other shapes as well. 
     As shown in  FIG. 8 , formed sheet  332  is attached to cylindrically-shaped annular member  330 , creating a plurality of cavities  338  formed between each precursor element  334  and annular member  330 . For example, sheet  332  could be attached to annular member  330  by welding, mechanical fastening, or other means as well. For this exemplary embodiment, each base  336  of sheet  332  is attached to annular member  330 . In alternative embodiments, not all of the bases are attached to annular member  330 . 
     Referring now to  FIG. 9 , once sheet  332  is attached to annular member  330 , precursor elements  334  are cut along axial direction A. For this embodiment, such cutting divides each precursor element  334  into adjacent pairs  340  of opposing fingers  320  and  322 . The cutting may be followed by removal of material from sheet  332  forming caps  342  ( FIG. 8 ). Alternatively, all material may be left in place and the cutting may occur along the center-line C/L ( FIG. 8 ) of each precursor element  334 . Depending upon e.g., the shape of each precursor element  334 , other cutting procedures may also be used in other exemplary aspects of the invention, In other embodiments of the invention, not every precursor element may be cut. For example, precursor elements  334  may be cut intermittently by e.g., cutting every other precursor element  334 . 
     As shown in  FIG. 9 , the cutting of precursor elements  334  also creates a plurality of channels  318  that extend along axial direction A. Each channel  318  is formed within a precursor element  334  between a pair of opposing fingers  320 ,  322 , In one embodiment of the invention, channels  318  can each receive e,g,, one or more ends  112   E ,  114   E , and  116   E  of spokes  106 . For the embodiment shown in  FIG. 9 , each channel  318  has a circumferential width CH W  that increases along a radially inward direction and matches the profile along axial direction A of spoke ends  112   E ,  114   E , and  116   E . Each pair  340  of opposing fingers  320 ,  322  forms a trough  344  between adjacent pairs  340 . As shown, for this embodiment, trough  344  has a circumferential. width T W  that increases along a radially outward direction. 
     The shape (as viewed e.g., along axial direction. A shown in  FIG. 9 ) of each channel  318  is not limited to what is shown in  FIG. 9 . For example, a shape for channel  318  such as what is shown in  FIGS. 1, 2, and 4  may also be used along. with. other shapes as well. As will be understood by one of skill in the art, the resulting shape of channel  318  will depend on e.g., how sheet  330  is bent to form precursor elements, how sheet  330  is cut, how fingers  320 ,  322  are bent, and combinations thereof. 
     In yet another exemplary aspect of the present invention, fingers  320  and  322  can be further processed to provide additional options for determining the shape of channels  318 . Returning to  FIG. 9 , for this exemplary embodiment, each finger  320  and  322  includes linear segments connected to each other. For example, finger  320  includes linear segments  320   a  and  320   b  while finger  322  includes linear segments  322   a  and  322   b . Linear segments  320   a  and  322   a  are each attached to base  336 . Referring now to  FIG. 10 , fingers  320  and  322  have been shaped so as to further configure channel  318  into a desired predetermined shape along axial direction A. Specifically, for this embodiment, segments  320   b  and  322   b  have each been shaped into a curve so that fingers  320  and  322  of a given pair  340  have tips  320   t  and  322   t  pointing away from each other along circumferential direction C. Such shaping provides yet another overall shape for channels  318  along axial direction A. 
       FIG. 11  provides yet another embodiment of hub  300  in which channels  318  have still another overall shape along axial direction A. Here, segments  320   a  and  322   a  have an arcuate shape formed by bending or otherwise shaping fingers  320  and  322 . In addition, tips  320   t  and  322   t  point outwardly along radial direction R. Still other shapes for channel  318  may be used as well. 
     While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent, to one of ordinary skill in the art using the teachings disclosed herein.