Patent Description:
Various tire constructions have been developed that enable a tire to run in an uninflated or underinflated condition. Non-pneumatic tires do not require inflation, while "run flat tires" may continue to operate after being punctured and becoming partially or completely depressurized, for extended periods of time and at relatively high speeds. Non-pneumatic tires may include support structure, such as spokes, that connects a lower ring to an upper ring. In some non-pneumatic tires, a circumferential tread is attached to the upper ring of the tire.

It is known to provide the rings or spokes of non-pneumatic tires with structural reinforcing elements. Non-pneumatic tires provided with known structural reinforcing elements, however, may suffer from problems regarding tire uniformity, crack propagation, fatigue resistance, or impact resistance.

According to a machine translation of its abstract, <CIT> describes a flexible spoke type non-pneumatic tire with high buffering and damping performance. The non-pneumatic tire comprises a tire crown, a flexible spoke made of a polyurethane material and a rigid rim from outside to inside. The tire crown comprises a tire tread, a crown belt layer, a first belt ply and a second belt ply; the tread comprises tread patterns and tread pattern grooves; the flexible spoke comprises a flexible spoke inner ring, a flexible spoke outer ring, a flexible spoke side spoke plate and a flexible spoke peripheral spoke plate; the flexible spoke side spoke plate is configured into a wavy line shape; the flexible spoke circumferential spoke plate is arranged to be of a layered structure; chamfers are arranged at the sharp corners of the peripheral and side radial plates, the bearing capacity of an automobile can be greatly improved, and vibration generated by the automobile relative to the road surface in the driving process is efficiently absorbed so that the driving safety and riding comfort are improved, stress concentration is reduced, the fatigue life is prolonged, the rim is connected with a half shaft of the automobile, the non-pneumatic tire is in interference fit from inside to outside, and the structure is compact.

According to a machine translation of its abstract, <CIT> describes a non -inflated tyre, wherein, this non -inflated tyre includes annular inner ring portion, overlaps the annular outer loop portion of outlying in inner ring portion that establishes to and be located the supporting part between inner ring portion and the outer loop portion, the supporting part includes support piece in a plurality of arches of a plurality of settings on inner ring portion outer peripheral face, outer support piece and lie in support piece and outer support piece between middle support piece, outer support piece and middle support piece are wavy extension and center on inner ring portion along circumference, outer support piece's crest links to each other with the inner peripheral surface of outer loop portion, and outer support piece's trough is continuous with neighbouring middle support piece's crest, among double-phase neighbour's the middle support piece, the middle support piece's of neighbouring outer loop portion trough links to each other with the middle support piece's of neighbouring inner ring portion crest, interior support piece's both ends link to each other with the outer peripheral face of inner ring portion, and interior support piece's top is continuous with neighbouring middle support piece's trough.

According to its abstract, <CIT> describes a non-pneumatic tire which is provided with an attachment body attached to an axle, a ring-shaped body which surrounds the attachment body from the outside in a tire radial direction, and a coupling member which displaceably couples the attachment body and the ring-shaped body, wherein the coupling member is formed of a synthetic resin material and a reinforcing member is embedded in the coupling member.

According to a machine translation of its abstract, <CIT> describes a non-pressure tire that comprises: an inside annular part; an outside annular part which is provided outside of the inside annular part in a concentric state; and a connection part for connecting the inside annular part <NUM> and the outside annular part. The inside annular part, the outside annular part and the connection part comprise respectively, a base material part formed of an elastic material, and a fiber reinforced plastic embedded in the base material part, flexure elastic moduli of the fiber reinforced plastics of the inside annular part and the outside annular part are <NUM> GPa or larger, and a tension elastic modulus of the fiber reinforced plastic of the connection part is <NUM> GPa or larger.

According to its abstract, <CIT> describes an integral splice concept and a method for manufacturing a laminate employing the concept. Specifically, a fiber/metal laminate sheet is provided having at least two metal plies and at least one fiber layer. Each of the metal plies comprises at least two metal sheets which are arranged side-by-side and have sheet metal breaks therebetween. All of the sheet metal breaks lie within the integral splice. An important feature is that the sheet metal breaks in each metal ply are staggered widthwise across the laminate with respect to the sheet metal breaks in the remaining metal plies, in accordance with a predetermined metal break staggering pattern, thereby maximizing the bond engagement of the discontinuous metal plies with the adjacent fiber layers. Another important feature is that the fiber layers are continuous through the integral splice region.

In one embodiment, a non-pneumatic tire includes a lower ring having a first diameter and an upper ring having a second diameter greater than the first diameter. The upper ring is substantially coaxial with the lower ring. Support structure connects the lower ring to the upper ring. At least one of the lower ring, the upper ring, and the support structure includes a fiber metal laminate having at least one metal foil layer and at least one fiber and resin combination layer.

In another embodiment, a method of manufacturing a non-pneumatic tire includes providing a lower ring having a first diameter, an upper ring having a second diameter that is greater than the first diameter, and support structure. The method further includes connecting the lower ring to the upper ring using the support structure. Providing the lower ring, the upper ring, and the support structure includes manufacturing at least one of the lower ring, the upper ring, and the support structure with a fiber metal laminate that includes at least one metal foil layer and at least one fiber and resin combination layer.

In yet another embodiment, a non-pneumatic tire includes a lower ring and a circumferential tread disposed above the lower ring. The circumferential tread includes a tread layer and a tread band. Support structure interconnects the lower ring to the tread band to attach the circumferential tread to the lower ring. At least one of the lower ring, the tread band, and the support structure includes a fiber metal laminate having at least one metal foil layer and at least one fiber and resin combination layer.

The definitions include various examples or forms of components that fall within the scope of a term and that may be used for implementation.

"Axial" and "axially" refer to a direction that is parallel to the axis of rotation of a tire.

"Circumferential" and "circumferentially" refer to a direction extending along the perimeter of the surface of the tread perpendicular to the axial direction.

"Prepreg" refers to a composite material made from pre-impregnated fibers and a partially cured polymer matrix.

"Radial" and "radially" refer to a direction perpendicular to the axis of rotation of a tire.

"Tread" as used herein, refers to that portion of the tire that comes into contact with the road or ground under normal inflation and normal load.

While similar terms used in the following descriptions describe common tire components, it should be understood that because the terms carry slightly different connotations, one of ordinary skill in the art would not consider any one of the following terms to be purely interchangeable with another term used to describe a common tire component.

Directions are stated herein with reference to the axis of rotation of the tire. The terms "upward" and "upwardly" refer to a general direction towards the tread of the tire, whereas "downward" and "downwardly" refer to the general direction towards the axis of rotation of the tire. Thus, when relative directional terms such as "upper" and "lower" or "top" and "bottom" are used in connection with an element, the "upper" or "top" element is spaced closer to the tread than the "lower" or "bottom" element. Additionally, when relative directional terms such as "above" or "below" are used in connection with an element, an element that is "above" another element is closer to the tread than the other element.

The terms "inward" and "inwardly" refer to a general direction towards the equatorial plane of the tire, whereas "outward" and "outwardly" refer to a general direction away from the equatorial plane of the tire and towards the side of the tire. Thus, when relative directional terms such as "inner" and "outer" are used in connection with an element, the "inner" element is spaced closer to the equatorial plane of the tire than the "outer" element.

<FIG> illustrate one embodiment of a non-pneumatic tire <NUM>. The non-pneumatic tire <NUM> includes a lower ring <NUM> having a first diameter, and an upper ring <NUM> having a second diameter greater than the first diameter. The upper ring <NUM> is coaxial with the lower ring <NUM>. The lower ring <NUM> may engage a vehicle hub (not shown) for attaching the non-pneumatic tire <NUM> to a vehicle.

Spokes <NUM> extend between and connect the lower ring <NUM> to the upper ring <NUM>. In the illustrated embodiment, the spokes <NUM> are curved. In an alternative embodiment, the spokes may have a more pronounced curve, such that they are substantially C-shaped. In other alternative embodiments, the spokes may be any desired shape. For example, the spokes may be substantially V-shaped or serpentine shaped. In yet other alternative embodiments, the non-pneumatic tire may include spokes of two or more different shapes. For example, the non-pneumatic tire may include C-shaped spokes that alternate with V-shaped spokes along a circumferential direction of the non-pneumatic tire. In still another alternative embodiment, the spokes may be replaced with a webbing or other support structure.

A circumferential tread <NUM> is attached to the upper ring <NUM>. The circumferential tread <NUM> includes a tread layer <NUM> and a tread band <NUM> positioned between the tread layer <NUM> and the upper ring <NUM>. The tread layer <NUM> may be made out of rubber or other elastomeric material, and may include tread elements (not shown) such as grooves, ribs, blocks, lugs, sipes, studs, or any other desired elements. In an alternative embodiment, the tread layer may be omitted and tread elements may be formed directly on the upper ring.

Other components of the non-pneumatic tire <NUM> may be made of various materials. The lower ring <NUM> or the upper ring <NUM> may be made of an elastomeric material or metal. The spokes <NUM> may also be made of an elastomeric material or metal. The tread band <NUM> may be made of rubber, metals including, without limitation, ultra-high strength steel, stainless steel, aluminum, brass, or copper, rubber, or polymeric materials including, without limitation, polyurethane, polyester, or polyvinyl chloride. In alternative embodiments, the lower ring, the upper ring, or the tread band may be made of any desired material. Certain materials may be selected for certain components in order to provide the non-pneumatic tire with desired performance characteristics.

Regardless of the material used to manufacture the non-pneumatic tire <NUM>, the lower ring <NUM>, the upper ring <NUM>, the spokes <NUM>, or the tread band <NUM> may be reinforced with a fiber metal laminate. In alternative embodiments, rather than being provided as reinforcement, fiber metal laminate may be used to manufacture the entire lower ring, upper ring, spokes, or tread band. <FIG> and <FIG>, illustrate one example embodiment of a fiber metal laminate <NUM> that may be used to reinforce or manufacture components of the non-pneumatic tire <NUM>. In the illustrated embodiment, the fiber metal laminate <NUM> includes eleven layers <NUM>-<NUM> that are provided as a metal foil, a primer, or a fiber and resin combination.

When the fiber metal laminate <NUM> is used in the lower ring <NUM>, the upper ring <NUM>, or the tread band <NUM>, the layers <NUM>-<NUM> may be arranged so that each layer extends in a substantially circumferential direction of the non-pneumatic tire <NUM>, with the layers being oriented such that the layers are built upon one another in a substantially radial direction of the non-pneumatic tire <NUM>. An exemplary orientation of the fiber metal laminate <NUM> in the lower ring <NUM> and the upper ring <NUM> is shown with dashed lines in <FIG> and <FIG>. When the fiber metal laminate <NUM> is used in the spokes <NUM> or other support structure, the layers may be arranged so that each layer extends in a substantially radial direction of the non-pneumatic tire <NUM>. An exemplary orientation of the fiber metal laminate <NUM> in the spokes <NUM> is shown with dashed lines in <FIG>. According to this example, the layers may be oriented such that the layers are built upon one another in a substantially circumferential direction of the non-pneumatic tire <NUM>. In alternative embodiments, the layers may have any desired arrangement or orientation. For example, when the fiber metal laminate is used in the spokes or other support structure, the layers may be arranged so that each layer extends in a substantially radial direction of the non-pneumatic tire, with the layers being oriented such that the layers are built upon one another in a substantially axial direction of the non-pneumatic tire.

A first layer <NUM>, a fifth layer <NUM>, a seventh layer <NUM>, and an eleventh layer <NUM> are provided as a metal foil. According to one example embodiment, the metal foil is formed from stainless steel. In alternative embodiments, the metal foil may be formed from high strength aluminum, hard coated steel, or passivated steel (e.g., <NUM> with aluminum silicon hypereutectic alloys or carbide/nitride coating).

A third layer <NUM> and a ninth layer <NUM> are provided as a fiber and resin combination. According to one example embodiment, the fiber and resin combination is provided utilizing a fiber prepreg that includes fibers pre-impregnated with a resin system. In alternative embodiments, the fiber and resin combination is provided utilizing plain fibers (i.e., not pre-impregnated with a resin system) and a resin transfer process, whereby the plain fibers are placed into a mold and the resin is subsequently injected into the mold. Compared to the fiber prepreg, the plain fiber and resin transfer process allows for increased design flexibility. The fiber prepreg, however, offers a simpler manufacturing process and time savings compared to the plain fibers and resin transfer process. In either the fiber prepreg or the plain fibers and resin transfer process, the fiber may be polymeric, glass, carbon, metallic, or any other desired fiber or combination of fibers. In either the fiber prepreg or the plain fibers and resin transfer process, the resin system may be a thermosetting or thermoplastic type. Examples of resin systems include, but are not limited to epoxy, polyurethane, polyacrylate, polysiloxane, vinyl ester, polyester, resins derived from dicyclopentadiene or norbornene monomers, or any other desired resin system or combination of resin systems. Specific examples of resins derived from norbornene monomers include Proxima Syntatic Thermoset Resins (STR), High Performance Resins (HPR), and Advanced Composites Resins (ACR) from MATERIA INC. Impact modifiers may optionally be added to the resin to improve toughness of the fiber and resin combination layers. According to one example embodiment, the impact modifier includes a multilayer-structure polymer particle design as produced by KANEACE®. In alternative embodiments any desired impact modifier may be used.

A second layer <NUM>, a fourth layer <NUM>, a sixth layer <NUM>, an eighth layer <NUM>, and a tenth layer <NUM> are provided as a primer. The primer may promote bonding between the metal foil layers and the fiber and resin combination layers. According to one example embodiment, the primer may be produced from a sol-gel style reaction onto the surface of the metal foil. In alternative embodiments, the primer may be produced from a chelating process, brass coating process, zinc phosphating coating process, or any other desired process. In other alternative embodiments, the primer may be omitted.

According to one example embodiment, the thickness of each of the metal foil layers <NUM>, <NUM>, <NUM>, <NUM> and the fiber and resin combination layers <NUM>, <NUM> may be <NUM>-<NUM>, and the number of interfaces between the metal foil layers and the fiber and resin combination layers may be <NUM>-<NUM>. According to this example embodiment, the volume fraction of the metal with these properties is <NUM>% or less of the total volume of the fiber metal laminate <NUM>. In alternative embodiments, different layer thicknesses, interface numbers, and percentages of the volume fraction of the metal may be provided to yield different performance characteristics that may allow tuning of the non-pneumatic tire for different applications.

Using the fiber metal laminate <NUM> in the lower ring <NUM>, the upper ring <NUM>, the spokes <NUM>, or the tread band <NUM> may improve the performance and robustness of the non-pneumatic tire <NUM> while at the same time reducing the weight of the non-pneumatic tire <NUM>. Interlaying the metal foil layers <NUM>, <NUM>, <NUM>, <NUM> between the fiber and resin combination layers <NUM>, <NUM> may improve impact and fatigue properties of the non-pneumatic tire <NUM>, as the metal foil layers <NUM>, <NUM>, <NUM>, <NUM> may arrest cracks that develop in the fiber and resin combination layers <NUM>, <NUM> and prevent the propagation of cracks throughout the non-pneumatic tire <NUM>. Different metal foils, fiber and resin combinations, and primers may yield different performance characteristics that may allow tuning of the non-pneumatic tire for different applications. For example, the overall strength of the non-pneumatic tire may be improved by replacing certain directional fiber layers within the fiber and resin combination layers that traditionally prioritize impact performance over composite strength. Specifically, according to one example, the direction of the fibers is fully circumferential (i.e., zero degree), which may provide high strength and benefit from the interlaid metal foil layers to assist in impact performance.

In alternative embodiments, the fiber metal laminate may include a fewer or greater number of layers. Additionally, in other alternative embodiments, the different layers may be provided in any desired order. For example, in the embodiment shown in <FIG> and <FIG>, beginning at the first layer <NUM> and moving toward the eleventh layer <NUM>, there are provided, in sequence, a layer of metal foil, primer, fiber and resin combination, primer, metal foil, primer, metal foil, primer, fiber and resin combination, primer, and metal foil. In the alternative embodiments, this sequence may be a layer of metal foil, primer, metal foil, primer, fiber and resin combination, primer, fiber and resin combination, primer, metal foil, primer, and metal foil. Furthermore, in other alternative embodiments, the ratio of the different layers may be any desired ratio. For example, in the embodiment shown in <FIG> and <FIG>, there are four layers of metal foil, five layers of primer, and two layers of fiber and resin combination. In the alternative embodiments, this ratio may be to two layers of metal foil, fiver layers of primer, and four layers of fiber and resin combination. Different numbers of layers, different sequencing of layers, and different ratios of layers may yield different performance characteristics that may allow tuning of the non-pneumatic tire for different applications.

<FIG> illustrates another example embodiment of a non-pneumatic tire <NUM>. The non-pneumatic tire <NUM> of <FIG> is substantially similar to the non-pneumatic tire <NUM> of <FIG>, except the differences described herein. Accordingly, like features will be identified by like numerals increased by a value of "<NUM>.

The non-pneumatic tire <NUM> includes a lower ring <NUM> and a circumferential tread <NUM>. The circumferential tread <NUM> includes a tread layer <NUM> and a tread band <NUM>. Unlike the non-pneumatic tire <NUM> of <FIG>, the non-pneumatic tire <NUM> does not have an upper ring. Thus, the circumferential tread <NUM> is attached to the lower ring <NUM> by spokes <NUM> or other support structure that interconnect the lower ring <NUM> to the tread band <NUM>. The lower ring <NUM>, the spokes <NUM>, or the tread band <NUM> may be manufactured from the fiber metal laminate <NUM> described above and shown in <FIG> and <FIG>. According to this embodiment, a further benefit may be realized by using fiber metal laminate in that the spokes <NUM> or other support structure and the tread band <NUM> may be manufactured as an integral unit by a single winding process. Compared to known manufacturing techniques that require support structure and a tread band to be manufactured separately and subsequently connected, the integral spokes <NUM> and tread band <NUM> unit may increase strength and reduce costs by eliminating weak points and junctures between dissimilar materials, and eliminate adhesive joints.

To the extent that the term "includes" or "including" is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term "comprising" as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term "or" is employed (e.g., A or B) it is intended to mean "A or B or both. " When the applicants intend to indicate "only A or B but not both" then the term "only A or B but not both" will be employed. Thus, use of the term "or" herein is the inclusive, and not the exclusive use. See, <NPL>). Also, to the extent that the terms "in" or "into" are used in the specification or the claims, it is intended to additionally mean "on" or "onto. " Furthermore, to the extent the term "connect" is used in the specification or claims, it is intended to mean not only "directly connected to," but also "indirectly connected to" such as connected through another component or components.

Claim 1:
A non-pneumatic tire comprising:
a lower ring having a first diameter;
an upper ring having a second diameter greater than the first diameter, the upper ring being substantially coaxial with the lower ring; and
support structure connecting the lower ring to the upper ring;
characterised in that at least one of the lower ring, the upper ring, and the support structure includes a fiber metal laminate having at least one metal foil layer and at least one fiber and resin combination layer.