Patent Description:
Various tire constructions have been developed which 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 receiving a puncture and a complete or partial loss of pressurized air, for extended periods of time and at relatively high speeds. Non-pneumatic tires may include a plurality of spokes, a webbing, or other support structure that connects an inner ring to an outer ring.

According to its abstract, <CIT> describes a compact all in one tire (intire) gathering multi-tires designs requirements inside it. Mainly the entire main features of the other designs are recreated and developed inside a conventional tire that is easily produced from the elastic rubber, polyurethane. to form a tire with a built-in main pneumatic portion consisting of reinforced linings, reinforced web of elements or single reinforced separate support pads, and pneumatic portion consisting of a secondary annular ring support (carcass). The main non-pneumatic portion is enclosed in-between the tire's crown, <NUM>-<NUM>% sidewalls height, and the carcass of the secondary portion. Chambers with suitable geometrical shapes bored inside the elastomeric main annular solid portion, having metallic embedded lining, or reinforced support pads. While the secondary non-pneumatic portion from the wheel rim side is designed to keep a suitable height of the tire's beads required for removal and installation of the tire.

According to its abstract, <CIT> describes a non-pneumatic tire that may include an inner circumferential barrier configured to be associated with a hub, and an outer circumferential barrier. The tire may also include a plurality of spokes extending between the inner and outer circumferential barriers, and a shear band radially exterior relative to the outer circumferential barrier. The shear band may include an internal tension band associated with the outer circumferential barrier including at least one circumferentially extending reinforcement cord. The shear band may also include an external compression band including at least one circumferentially extending reinforcement cord. The shear band may further include at least one shear module extending between the internal tension band and the external compression band. The shear module may include at least one shear module including a first reinforcement element, a second reinforcement element, and a separator between the first reinforcement element and the second reinforcement element.

According to its abstract, <CIT> describes a non-pneumatic tire includes: an inside annular portion; an outside annular portion coaxially provided on the outside of the inside annular portion; a plurality of coupling portions connected to the inside annular portion and the outside annular portion, and coupling them; and a tread portion provided on the outside of the outside annular portion. In the outside annular portion crest portions projecting toward the inside annular portion, and trough portions projecting toward the tread portion and contacting with the tread portion with trough bottoms are formed in wave shaped alternately aligned in a tire circumferential direction. The coupling portions are connected to parts other than the trough bottom portions of the trough portions of the outside annular portion.

According to its abstract, <CIT> describes a shear band that may be used as part of a structurally supported wheel. More particularly, a shear band constructed from resilient, cylindrical elements attached between inextensible members is described. In certain embodiments, the shear band may be constructed entirely or substantially without elastomeric or polymer-based materials. Multiple embodiments are available including various arrangements of the cylindrical elements between the members as well as differing geometries for the cylindrical elements.

Aspects of the present invention are defined by the appended independent claims <NUM> and <NUM>.

According to the invention, claim <NUM> refers to a green non-pneumatic tire.

According to the invention, claim <NUM> refers to a method for manufacturing a cured non-pneumatic tire from a green non-pneumatic tire of claim <NUM>.

<FIG> is a front view of one embodiment of a non-pneumatic tire <NUM>. The non-pneumatic tire <NUM> includes an inner ring <NUM> having a first diameter, and an outer ring <NUM> having a second diameter greater than the first diameter. The outer ring <NUM> is substantially coaxial with the inner ring <NUM>. In the illustrated embodiment, the inner ring <NUM> is shown as being attached to a hub H. A plurality of spokes <NUM> extend between the inner ring <NUM> and the outer ring <NUM>. In an alternative embodiment, a webbing or other support structure may be employed instead of spokes.

A circumferential tread <NUM> is disposed about the outer ring <NUM> in the illustrated embodiment. The tread <NUM> may include tread elements such as grooves, ribs, blocks, lugs, sipes, studs, and other elements. A shear band or other shear element or reinforcement structure (not shown) may be disposed between the outer ring <NUM> and the tread <NUM>. In an alternative embodiment (not shown), the separate tread may be omitted and instead tread elements may be formed directly on the outer ring.

<FIG> is an enlarged partial front view of the non-pneumatic tire of <FIG>. As can be seen in this view, the spokes <NUM> are formed by a plurality of loops disposed in a series circumferentially about the tire. Each of the individual loops extends laterally from a first side of the non-pneumatic tire <NUM> to second side of the non-pneumatic tire <NUM>. Each of the plurality of loops defines an opening that is visible from the first side of the tire.

In the illustrated embodiment, each of the plurality of loops is in direct contact with both the inner ring <NUM> and the outer ring <NUM>. A plurality of fillets <NUM> are also disposed between the inner ring <NUM> and the outer ring <NUM>. The plurality of fillets <NUM> includes inner fillets 150i and outer fillets 150o. The inner fillets 150i are in direct contact with the inner ring <NUM>, and both a first loop and a second loop in each adjacent pair of loops. The outer fillets 150o are in direct contact with the outer ring <NUM>, and both the first loop and second loop in each adjacent pair of loops.

The inner and outer rings <NUM>, <NUM> may be constructed of a polymeric material, such as natural or synthetic rubber, other elastomeric material. Alternatively, the inner and outer rings <NUM>, <NUM> may be constructed of a harder polymeric material such as polyurethane, polyester, nylon and polyvinyl chloride (PVC). The spokes <NUM> are formed of loops constructed of elastomeric material having a single layer of reinforcement disposed therein. The loops may be constructed from a sheet of elastomeric material, or from a spiraled ribbon of elastomeric material having a single layer of reinforcement disposed therein. Where the loop is formed by a sheet, the ends of the sheet may be butt spliced together. The splice may be located at the inner ring or outer ring of the non-pneumatic tire. Where the loop is formed by a spiraled ribbon, the butt splice may be omitted.

In both instances, the reinforcement may be steel cords. In other embodiments, the reinforcement may be formed by cords constructed of nylon, polyester, fiber glass, carbon fiber, aramid, glass, polyethylene (polyethylene terephthalate), or other reinforcement materials.

The tread <NUM> and the fillets <NUM> are both constructed of an elastomeric material, such as natural or synthetic rubber, other elastomeric material.

Additional details of the loops may be seen in <FIG>, which is a schematic drawing illustrating a partial front view of a non-pneumatic tire <NUM> during its construction. The non-pneumatic tire <NUM> includes an inner ring <NUM> having a first diameter, and an outer ring <NUM> having a second diameter greater than the first diameter. The outer ring <NUM> is substantially coaxial with the inner ring <NUM>. As shown in this figure, a spoke <NUM> is being formed by a first loop 240a and a second loop 240b. The first loop includes a first layer of reinforcement cords 250a, and the first loop forms a first substantially radial extent 260a and a second substantially radial extent 260b. The second loop includes a second layer of reinforcement cords 250b, and the second loop forms a third substantially radial extent 260c and a fourth substantially radial extent 260d.

Additionally, a first fillet 270a is disposed between the first loop 240a, the second loop 240b, and the inner ring <NUM>. A second fillet 270b is likewise disposed between the first loop 240a, the second loop 240b, and the outer ring <NUM>.

At the stage shown in <FIG>, the first loop 240a is spaced from the second loop 240b. This spacing may be exaggerated for illustrative purposes. During the process of forming the non-pneumatic tire, heat and pressure are applied during a curing process. Specifically, pressure is applied to the second extent 260b of the first loop 240a and to the third extent 260c of the second loop 240b, which causes the second extent 260b to contact the third extent 260c. As heat and pressure are applied, the second extent 260b bonds with the third extent 260c, such that the first loop 240a and the second loop 240b form a single spoke <NUM> having two layers of reinforcement cords formed by the first and second layer of reinforcement cords 250a,b. The resulting spoke <NUM> extends in a substantially radial direction, in the same manner as the spokes <NUM> of <FIG> and <FIG>.

In one embodiment, at least half of the second extent 260b is in contact with at least half of the third extent 260c. In an alternative embodiment, at least two-thirds of the second extent 260b is in contact with at least two-thirds of the third extent 260c.

In the illustrated embodiment, each of the first and second layers of reinforcement cords 250a,b extends in a substantially radial direction in the resulting spoke <NUM>. In an alternative embodiment, one or both of the layers of reinforcement cords is biased with respect to the radial direction. In one such embodiment, one or both of the layers of reinforcement cords is biased at an angle between <NUM>° and <NUM>°. In such an embodiment, a butt splice may also be angled.

In an alternative embodiment, the extents between the inner and outer ring are curved rather than linear. Curved extents may be used to control the direction and the magnitude of spoke buckling as the tire rotates. Such curved extents may still be considered substantially radial. In one such embodiment, the reinforcement cords may have the same curve as the extents. In an alternative embodiment, the reinforcement cords may have different curves from the extents. In another alternative embodiment, the reinforcement cords may extend linearly while the extents are curved.

In other alternative embodiments, the extents are substantially linear while one or more of the layers of reinforcement cords are curved with respect to radial direction. Curved layers of reinforcement cords may be used to control the direction and the magnitude of spoke buckling as the tire rotates. In such embodiments, the resulting spoke may still extend linearly when in an uncompressed state, even though one or more of the layers of reinforcement cords are curved. In such an arrangement, the spokes may be described as having a reinforcement pre-curvature.

<FIG> provides an example of a spoke having a reinforcement pre-curvature. <FIG> is a schematic drawing illustrating a partial front view of an alternative embodiment of a non-pneumatic tire <NUM>. A spoke <NUM> is defined by a first loop 320a having a first layer of reinforcement cords 330a and a second loop 320b having a second layer of reinforcement cords 330b. The spoke <NUM> extends in a substantially radial direction. The second layer of reinforcement cords 330b also extends in a substantially radial direction along the length of the spoke <NUM>, but the first layer of reinforcement cords 330a is curved inside of the spoke <NUM>.

In the illustrated embodiment, the first layer of reinforcement cords 330a is curved while the second layer of reinforcement cords is substantially linear. In an alternative embodiment, both the first and second layers of reinforcement cords are curved.

<FIG> are schematic drawings illustrating a partial front views of other alternative embodiments of spokes 400a-c for non-pneumatic tires. In <FIG>, the spoke 400a includes a first layer of reinforcement cords 410a and a second layer of reinforcement cords 420a. Each of the layers of reinforcement cords 410a, 420a has multiple curves along the length of the spoke 400a, and may thus be described as wavy. In the illustrated embodiment, the layers of reinforcement cords 410a, 420a are curved in opposite directions, such that the peaks of the first layer of reinforcement cords 410a correspond with the peaks of the second layer of reinforcement cords 420a. In alternative embodiments (not shown), the curves of the layers of reinforcement cords may be offset, or the layers of reinforcement cords may be curved such that they have waves of differing periodicity.

In <FIG>, the spoke 400b includes a first layer of reinforcement cords 410b and a second layer of reinforcement cords 420b. Each of the layers of reinforcement cords 410b, 420b has a single curve along the length of the spoke 400ab. In the illustrated embodiment, the layers of reinforcement cords 410b, 420b are curved in opposite directions such that they form a biconcave shape. In an alternative embodiment (not shown) the layer of reinforcement cords may be curved in the same direction or have offset curves.

In <FIG>, the spoke 400c includes a first layer of reinforcement cords 410c and a second layer of reinforcement cords 420c. Each of the layers of reinforcement cords 410c, 420c has a single curve along the length of the spoke 400c. In the illustrated embodiment, the layers of reinforcement cords 410c, 420c are curved in opposite directions such that they form a biconvex shape, or an ogive shape. In an alternative embodiment (not shown) the layers of reinforcement cords may be curved in the same direction or have offset curves.

In alternative embodiments, the spokes themselves may be curved. For example, <FIG> is a front view of yet another alternative embodiment of a non-pneumatic tire <NUM>. The non-pneumatic tire <NUM> includes an inner ring <NUM> having a first diameter, and an outer ring <NUM> having a second diameter greater than the first diameter. The outer ring <NUM> is substantially coaxial with the inner ring <NUM>. A plurality of spokes <NUM> extend between the inner ring <NUM> and the outer ring <NUM>. In an alternative embodiment, a webbing or other support structure may be employed instead of spokes. A circumferential tread (not shown in this figure) may be disposed about the outer ring <NUM>. The non-pneumatic tire <NUM> is substantially the same as the non-pneumatic tire <NUM> except for the differences described herein. Like materials may be used for like components.

The spokes <NUM> are formed by a plurality of loops disposed circumferentially about the non-pneumatic tire <NUM>. Each individual loop extends laterally from a first side of the non-pneumatic tire <NUM> to second side of the non-pneumatic tire <NUM>. Each of the plurality of loops defines an opening that is visible from the first side of the tire. In this embodiment, the loops are kidney-shaped, and thus form curved spokes <NUM>. In alternative embodiments (not shown), the loops may have other curvatures. For example, the loops may be circular or oval.

In the illustrated embodiment, each of the plurality of loops is in direct contact with both the inner ring <NUM> and the outer ring <NUM>. A plurality of fillets <NUM> are also disposed between the inner ring <NUM> and the outer ring <NUM>. The plurality of fillets <NUM> includes inner fillets 540i and outer fillets 540o. The inner fillets 540i are in direct contact with the inner ring <NUM>, and both a first loop and a second loop in each adjacent pair of loops. The outer fillets 540o are in direct contact with the outer ring <NUM>, and both the first loop and second loop in each adjacent pair of loops.

<FIG> is a schematic drawing illustrating a partial front view of a spoke <NUM> of the non-pneumatic tire <NUM> of <FIG>. As shown in this figure, the spoke <NUM> is formed by a first loop 560a and a second loop 560b. The first loop includes a first layer of reinforcement cords 570a. The second loop includes a second layer of reinforcement cords 570b. Each of the loops has a pair of curved extents that extend between the inner ring and the outer ring and that are in contact with the curved extents of adjacent loops, thereby forming the spokes <NUM>. In the illustrated embodiment, the curved extents of each loop are substantially parallel to each other. In an alternative embodiment (not shown), each pair of the adjacent curved extents are curved in opposite directions. Such an arrangement would be present in circular or oval loops.

In one embodiment, at least half of the curved extent of the first loop 560a is in contact with at least half of the curved extent of the second loop 560b. In an alternative embodiment, at least two-thirds of the curved extent of the first loop 560a is in contact with at least two-thirds of the curved extent of the second loop 560b.

In the illustrated embodiment, the first and second layers of reinforcement cords 570a,b are curved in the same manner as the extents of the loops 560a,b. In an alternative embodiment (not shown), one or more of the layers of reinforcement cords may be straight. In other alternative embodiments (not shown), the layers of reinforcement cords may be curved in different manners, similar to the curves shown in <FIG> and <FIG>.

To build a non-pneumatic tire, such as the non-pneumatic tire <NUM>, <NUM>, <NUM>, <NUM>, an operator may perform the steps of providing an inner ring of elastomeric material, providing an outer ring of elastomeric material, and arranging the inner ring and the outer ring such that the inner ring is substantially coaxial with the outer ring. In one embodiment, the operator provides sheets of reinforced elastomeric material, and forms a plurality of loops with the sheets of reinforced elastomeric material. Each loop may be formed by butt splicing the ends of the sheet together. The operator then places the loops of reinforced elastomeric material between the inner ring and the outer ring. The loops may be arranged such that the butt splice is tangential to either the inner ring of the outer ring.

In another embodiment, the operator provides a ribbon of reinforced elastomeric material. In one particular embodiment, the operator forms a ribbon by extruding a ribbon of green rubber with exactly two steel cords, thus forming a green rubber ribbon with two steel cords embedded therein.

In yet another embodiment, the operator forms a ribbon by extruding a ribbon of green rubber with one steel cord. In still another embodiment, the operator forms a ribbon by extruding a ribbon of green rubber with three or more steel cords.

In an alternative embodiment, the ribbons may be made by a calendering operation rather than an extruding operation. For example, in one embodiment, the ribbons are made by calendering rubber over cords and the slitting the calendered sheet into thin ribbons containing one, two, or more cords.

In the ribbon embodiments, the operator provides a plurality of cores and spirally winds the ribbon of reinforced elastomeric material about each of the plurality of cores. In one such embodiment, the operator employs a collapsible chuck for winding a ribbon. <FIG> is a perspective view of one embodiment of a collapsible chuck <NUM>. The use of the collapsible chuck <NUM> permits removal of the ribbon of reinforced elastomeric material. An end stop <NUM> and an outer ring <NUM> are used to control the diameter of a winding mandrel. These components may be changed to vary the inner diameter of the loop.

The collapsible chuck <NUM> includes a lathe chuck <NUM> and jaw extensions <NUM> that form a collapsible winding mandrel. In an alternative embodiment (not shown) a gang of collapsible mandrels may be mounted in a winding machine directly at the end of a cord extruder. Such a machine could have multiple heads allowing the simultaneous production of more than one loop.

The machine on which the collapsible chuck <NUM> is mounted provides rotational and transverse control of the position of the collapsible winding mandrel. The ratio between rotational and translational speed controls the spacing of the ribbon. This ratio is used to control the final endcount of the ribbon.

After the ribbon of reinforced elastomeric material is wrapped about the collapsible winding mandrel of the collapsible chuck <NUM>, it is transferred to a core.

<FIG> is a front view of an alternative embodiment of a collapsible chuck <NUM> with a core directly inserted into grips of a collapsible chuck. In such an embodiment, the ribbon of reinforced elastomeric material is wound directly onto the core. The core is subsequently removed from collapsible chuck.

After the ribbon of reinforced elastomeric material is wound about at least one of the cores, the operator arranges the plurality of cores between the inner ring and the outer ring. The cores are arranged such that the spirally wound ribbon of one of the plurality of cores contacts the spirally wound ribbon of an adjacent one of the plurality of cores.

In one embodiment, the cores are expandable cores. <FIG> is a partial front view of one embodiment of a green tire <NUM> having cores <NUM> with a ribbon of reinforced elastomeric material disposed thereon, with the cores <NUM> expanding in a first direction so that the reinforced elastomeric material of adjacent cores <NUM> come into contact.

<FIG> is a partial front view of one embodiment of a green tire <NUM> having cores <NUM> with a ribbon of elastomeric material disposed thereon, with the cores <NUM> expanding in a second direction so that the ribbon of reinforced elastomeric material of the cores <NUM> comes into contact with an inner ring <NUM> and an outer ring <NUM>.

The operator then places a plurality of fillets between the cores, the inner ring, and outer ring. The operator then cures the inner ring, the outer ring, the plurality of fillets, and the ribbon disposed about the plurality of cores to form a cured tire.

In one embodiment, the tire is cured in multiple stages, using multiple sets of cores. For example, the operator may first wind the ribbon of reinforced elastomeric material about a first set of cores, such as the cores <NUM> shown in <FIG>, and expands the cores <NUM> so that the ribbons of reinforced elastomeric material come into contact with each other. The operator then performs a first curing, such that the ribbons of reinforced elastomeric material of each of the cores are partially cured together.

The operator may then transfer the partially cured ribbons of reinforced elastomeric material to a second set of cores, such as the cores <NUM> shown in <FIG>. The operator may then place the second set of cores <NUM> between an inner ring and an outer ring, and expand the cores <NUM> such that the partially cured ribbons of reinforced elastomeric material come into contact with the inner ring <NUM> and the outer ring <NUM>. The operator then performs a second curing, such that the ribbons of reinforced elastomeric material of each of the cores are fully cured together and to the inner ring and outer ring.

In one such embodiment, the fillets are placed between the cores before the first curing. In an alternative embodiment, the fillets are placed between the cores, the inner ring, and the outer ring after the first curing but before the second curing. In yet another alternative embodiment, the fillets are placed between the cores, the inner ring, and the outer ring after the second curing but before a third curing.

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 green non-pneumatic tire (<NUM>; <NUM>; <NUM>; <NUM>) comprising:
an inner ring (<NUM>; <NUM>; <NUM>) having a first diameter;
an outer ring (<NUM>; <NUM>; <NUM>) having a second diameter greater than the first diameter, the outer ring (<NUM>; <NUM>; <NUM>) being substantially coaxial with the inner ring (<NUM>; <NUM>; <NUM>);
support structure (<NUM>; <NUM>; <NUM>; 400a-c; <NUM>) extending between the inner ring (<NUM>; <NUM>; <NUM>) and the outer ring (<NUM>; <NUM>; <NUM>), the support structure (<NUM>; <NUM>; <NUM>; 400a-c; <NUM>) including a plurality of loops (240a, 240b; 320a, 320b; 560a, 560b) extending laterally from a first side of the non-pneumatic tire (<NUM>; <NUM>; <NUM>; <NUM>) to second side of the non-pneumatic tire (<NUM>; <NUM>; <NUM>; <NUM>),
wherein each of the plurality of loops (240a, 240b; 320a, 320b; 560a, 560b) defines an opening that is visible from the first side of the non-pneumatic tire (<NUM>; <NUM>; <NUM>; <NUM>), and has a single layer of reinforcement therein,
wherein each of the plurality of loops (240a, 240b; 320a, 320b; 560a, 560b) is in direct contact with both the inner ring (<NUM>; <NUM>; <NUM>) and the outer ring (<NUM>; <NUM>; <NUM>),
wherein the plurality of loops (240a, 240b; 320a, 320b; 560a, 560b) includes at least a first loop (240a; 320a; 560a) and a second loop (240b; 320b; 560b), the first loop (240a; 320a; 560a) being in direct contact with the second loop (240b; 320b; 560b); and
a plurality of fillets (<NUM>; 270a, 270b; <NUM>) disposed between the inner ring (<NUM>; <NUM>; <NUM>) and the outer ring (<NUM>; <NUM>; <NUM>), the plurality of fillets (<NUM>; 270a, 270b; <NUM>) including at least a first fillet (150i; 270a; 540i) and a second fillet (150o; 270b; 540o),
wherein the first fillet (150i; 270a; 540i) is in direct contact with the inner ring (<NUM>; <NUM>; <NUM>), the first loop (240a; 320a; 560a), and the second loop (240b; 320b; 560b), and
wherein the second fillet (150o; 270b; 540o) is in direct contact with the outer ring (<NUM>; <NUM>; <NUM>), the first loop (240a; 320a; 560a), and the second loop (240b; 320b; 560b).