The subject matter of the present disclosure relates to non-pneumatic wheels and methods of constructing such.
The details and benefits of non-pneumatic wheels are described e.g., in U.S. Pat. Nos. 6,769,465; 6,994,134; 7,013,939; and 7,201,194, herein incorporated by reference in their entirety. Some non-pneumatic tire constructions incorporate a shear band, embodiments of which are described in e.g., U.S. Pat. Nos. 6,769,465 and 7,201,194, herein incorporated by reference in their entirety. Such non-pneumatic tires provide advantages in tire performance without relying upon a gas inflation pressure for support of the loads applied to the tire.
In one example of a non-pneumatic wheel, a compliant band with a ground contacting portion can be connected with a plurality of tension-transmitting, web-like elements (also referred to as “spokes”) extending radially from a center element or hub. By way of example, such non-pneumatic wheel may be formed by open cast molding in which a material such as e.g., polyurethane is poured into a mold that forms all or part of the non-pneumatic tire. One or more reinforcement structures such as cords may be molded in place in the compliant band.
Typically, in such prior constructions, the spokes and the hub are molded as an integral, single-piece construction. Alternatively, the spokes may be integrally joined by a band that is then bonded with a hub or wheel center. In either construction, the spokes are not readily removable from either the radially-outer end attached with the compliant band or the radially inner end attached to the hub or wheel center.
Because of e.g., the integral construction, prior non-pneumatic wheel constructions are not readily amenable to substituting different spokes into the non-pneumatic wheel. Such a substitution would require destructive steps to cut or extricate both ends of the spoke from the wheel. Additionally, because the spokes are joined or attached with the wheel hub, the substitution of different wheels hubs of different materials or configuration is not readily feasible. Prior manufacturing methods have not been conducive to incorporating reinforcements, shapes, layers of material, and other features into the construction of the spoke.
Accordingly, a method of constructing a tire incorporating spokes for a non-pneumatic wheel that can be more readily molded with reinforcements, various shapes, one or more layers of material, and other features would be useful. A wheel hub incorporating such a spoke into a non-pneumatic wheel without integral construction with the hub would also be beneficial. A hub that can be more readily connected and disconnected from the wheel spoke, the compliant band, or both, would also be useful.
Aspects and advantages will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
A first exemplary embodiment is disclosed of a non-pneumatic wheel which includes: an outer annular band; a hub; a plurality of radially reinforced spokes extending between the outer annular band and the hub; a plurality of retainers positioned around the circumference of the hub, each retainer comprising a first retaining surface and a second retaining surface; wherein the radially outer portion of the first retaining surface and the second retaining surface possesses a flared edge such that the radially outer portion of the first retaining surface curves away from the radially outer portion of the second retaining surface.
A second exemplary embodiment of a non-pneumatic wheel having the characteristics of the first exemplary embodiment wherein each individual radially reinforced spoke possesses a thickened radially inner end which engaged the retaining surfaces of the retainers.
A third exemplary embodiment of a non-pneumatic wheel having the characteristics of the second exemplary embodiment wherein each thickened radially inner end of each reinforced spoke possesses a triangular shape.
A fourth exemplary embodiment of a non-pneumatic wheel having the characteristics of the second exemplary embodiment wherein each radially inner end of each reinforced spoke possesses a circular shape.
A fifth exemplary embodiment of a non-pneumatic wheel having the characteristics of the second exemplary embodiment wherein each radially inner end of each reinforced spoke possesses a bulbous shape.
A sixth exemplary embodiment of a non-pneumatic wheel having the characteristics of the second exemplary embodiment wherein each radially inner end of each reinforced spoke possesses a quadrilateral shape.
A seventh exemplary embodiment of a non-pneumatic wheel having the characteristics of the second exemplary embodiment wherein the second retaining surface curves away from the radially outer portion of the first retaining surface.
An eighth exemplary embodiment of a non-pneumatic wheel having the characteristics of the any one of the above exemplary embodiments wherein the spoke reinforcement is comprised of nylon cord.
A ninth exemplary embodiment having of a non-pneumatic wheel the characteristics of the any one of the first through seventh exemplary embodiments wherein the spoke reinforcement is comprised of a fiber reinforced composite.
A tenth exemplary embodiment of a non-pneumatic wheel having the characteristics of the ninth exemplary embodiment wherein the spoke reinforcement is comprised of a fiber reinforced plastic.
An eleventh exemplary embodiment of a non-pneumatic wheel having the characteristics of the any one of the above exemplary embodiments wherein the spokes are retained to the hub using detachable retaining clip that are attached to the hub.
A twelfth exemplary embodiment of a non-pneumatic wheel having the characteristics of the any one of the above exemplary embodiments wherein the spokes are retained by retainers of a unitary construction with the hub.
A first exemplary method of constructing non-pneumatic wheel, the method which includes: securing a plurality of spokes around the outer circumference of hub, each spoke secured by at least one retainer, wherein each retainer comprises a first retaining surface and a second retaining surface and the radially outer portion of the first retaining surface and the second retaining surface possesses a flared edge such that the radially outer portion of the first retaining surface curves away from the radially outer portion of the second retaining surface; positioning at least one spoke support at the radially outer end of each spoke, at least one spoke support on either side of each spoke, the adjacent pair of spoke supports supporting each spoke in a radially outward position; applying a bonding layer to the radially outer surface of each spoke; placing an outer annular band concentrically over the bonding layer; expanding the spoke supports radially outward so that the outer surface of the bonding layer contacts, and bonds with, the inner surface of the outer annular band
A second exemplary method of constructing non-pneumatic wheel, the method having the characteristics of the first exemplary method wherein the bonding layer outer surface is attached by curing the bonding layer to the outer annular band by the application of pressure and heat.
A third exemplary method of constructing non-pneumatic wheel, the method having the characteristics of the first exemplary method wherein the outer bonding layer is an adhesive which bonds the radially outer surface of each spoke to the outer annular band.
A fourth exemplary method of constructing non-pneumatic wheel, the method including: securing a plurality of spokes around the outer circumference of hub, each spoke secured by at least one retainer, wherein each retainer comprises a first retaining surface and a second retaining surface and the radially outer portion of the first retaining surface and the second retaining surface possesses a flared edge such that the radially outer portion of the first retaining surface curves away from the radially outer portion of the second retaining surface; positioning at least one spoke support at the radially outer end of each spoke, at least one spoke support on either side of each spoke, the adjacent pair of spoke supports supporting each spoke in a radially outward position; building the outer annular band upon the radially outer surface of each spoke of the spoke substructure; placing the outer annular band and spoke substructure into a mold; curing the outer annular band.
A fifth exemplary method of constructing non-pneumatic wheel, the method having the characteristics of the fourth exemplary method wherein each plurality of spoke supports are able to translate in a radial direction to radially expand and contract the radial outer surface of the plurality of spokes.
A sixth exemplary method of constructing non-pneumatic wheel, the method having the characteristics of the fourth or fifth exemplary method wherein the building of the outer annular band comprises the laying of layers of rubber.
A seventh exemplary method of constructing non-pneumatic wheel, the method having the characteristics of any one of the fourth, fifth or sixth exemplary methods wherein the curing occurs under pressure and heat.
An eighth exemplary method of constructing non-pneumatic wheel, the method having the characteristics of any one of the fourth, fifth, sixth or seventh exemplary methods wherein the mold imprints a tread pattern on the radially outer surface of the outer annular band.
These and other features, aspects and advantages 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 and, together with the description, serve to explain the principles of the invention.
A full and enabling disclosure, 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:
The use of identical or similar reference numerals in different figures denotes identical or similar features.
The present embodiments provide a novel construction of a non-pneumatic tire. For purposes of describing, reference now will be made in detail to embodiments and/or methods, one or more examples of which are illustrated in or with the drawings. Each example is provided by way of explanation of the embodiments, 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 embodiments without departing from the scope or spirit of the invention. For instance, features or steps illustrated or described as part of one embodiment, can be used with another embodiment or steps to yield a still further embodiments or methods. 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.
The following terms are defined as follows for this disclosure:
“Axial direction” or the letter “A” in the figures refers to a direction parallel to the axis of rotation of for example, the shear band, tire, and/or wheel as it travels along a road surface.
“Radial direction” or the letter “R” in the figures refers to a direction that is orthogonal to the axial direction and extends in the same direction as any radius that extends orthogonally from the axial direction.
“Circumferential direction” or the letter “C” in the figures refers to a direction that is perpendicular to the axial direction and perpendicular to a radial plane.
“Equatorial plane” means a plane that passes perpendicular to the axis of rotation and bisects the shear band and/or wheel structure.
“Radial plane” means a plane that passes perpendicular to the equatorial plane and through the axis of rotation of the wheel.
“Fiber” applies to any type of reinforcing fiber, that can be used as long as the latter is compatible with its matrix. Such a fiber is, for example, chosen from the group constituted by polyvinyl alcohol fibers, aromatic polyamide (or “aramid”) fibers, polyamide-imide fibers, polyimide fibers, polyester fibers, aromatic polyester fibers, polyethylene fibers, polypropylene fibers, cellulose fibers, rayon fibers, viscose fibers, polyphenylene benzobisoxazole (or “PBO”) fibers, polyethylene naphthenate (“PEN”) fibers, glass fibers, carbon fibers, silica fibers, ceramic fibers, and mixtures of such fibers.
As used herein, “inextensible” is a relative term used to refer to one material having at least a ten-fold higher tensile modulus than the material it is embedded within. It should be appreciated that generally in the art of tire construction, it is understood by one of ordinary skill that nylon cords are referred to as inextensible, while the surrounding rubber in which the nylon cords are embedded are considered by one skilled in the art as extensible.
The attachment of the spokes to the hub by mechanical means allows the outer portion of the tire to be removed and reattached in the event of a desired change or repair of the outer portion of the tire. Furthermore, an individual spoke from the outer compliant band may be removed and a new individual replacement spoke may be bonded in its place, thereby making replacement of a single spoke. This technique may be useful for repairing a single damaged spoke where it may be undesirable to remove the entire wheel from, say, a vehicle or other apparatus to which it is attached.
The attachment of the spokes to the hub by mechanical means allows for the spokes to be formed of rubber and optionally reinforced using methods of construction that are similar to the methods of construction of conventional pneumatic tires. It can be appreciate that the individual spoke formation allows construction of rubber spokes by positioning rubber components of the same or similar formulations along with optional reinforcements within a mold and then curing the rubber with heat and pressure. Such construction allows for layering of the materials or positioning of the materials side by side and permits multiple types of rubber and optionally reinforcement to be positioned with a precision that would be very difficult to achieve using casting or injection molding manufacturing techniques. The outer band, which may be constructed with rubber and reinforcements, can then be secured to the spokes by bonding the rubber spokes to the rubber outer band by curing the green rubber outer band onto the radially outer surfaces of the rubber spokes. By using materials within the same family, a very strong bond can be formed without the use of adhesives. For example, the spokes may be formed and cured or partially cured then arranged with the outer radial surfaces positioned along the circumference of a circle, then green rubber may be used to build the outer band around the circumference and the assembly then cured. Alternatively, a cured or partially cured rubber outer band may be attached to a cured or partially cured plurality of spokes by laying a layer of green rubber between the radially outer surfaces of the spokes and the radially inner surface of the outer band. Alternatively an adhesive or other bonding agent may be applied, for example, when bonding dissimilar materials such as a polyurethane to rubber.
The outer annular band 400 provides a radially outer surface 450 which may have a tread pattern, such as grooves 452, divots, slits or other features, or a combination of features, for ornamental and/or a utilitarian purpose. The outer annular band 400 in the present embodiment is compliant, in that it will deform under loading to absorb momentary deflections such as bumps in the surface, such as the ground, that the wheel is placed against.
The outer annular band 400, may include reinforcements, including such reinforcements having a high modulus in compression and tension such as metal cords, fiberglass, fiber reinforced plastics, or carbon fiber. The spokes 300, as shown in the embodiment here are compliant membranes of a elastomeric materials, such as a natural, synthetic rubber, polyurethane, silicone, and may be reinforced with cords having a higher tensile modulus including nylon, polyester, aramid fibers or other reinforcements such as metal cord. When a load is applied to the wheel 10, the load is transmitted through the hub 100 and spokes 300 positioned around the hub through the outer annular band 400 to the ground. Since the spokes, are largely deformable and will buckle under loading, a significant portion of the load is transferred through the spokes on the top half of the wheel. This is generally referred to herein as a “top loading” wheel, as opposed to a “bottom loading” wheel that would carry the load through the bottom of the tire, such as might be found in a solid tire, or a foam filled pneumatic tire.
The radially inner end 330 of the spoke 300 is thicker in a circumferential direction (a direction perpendicular to the radial plane and axial direction) than the web 310 of the spoke 300. Shown here, the radially inner end 330 possesses a generally triangular shape when viewed from the axial direction having a flat radially inner surface 332. The thickened portion extends axially across the lateral width of the spoke. While the shape shown in the embodiment shown in
The radially outer end 370 of the spoke 300 is thicker in a circumferential direction than the web 310 of the spoke. Shown here, the radially outer end 370 possesses a generally triangular shape when viewed from the axial direction having a flat radially outer surface 372. While the shape shown in the present embodiment is triangular, having a thickness that flares out to a radially outer surface 372, it should be recognized that other thickened geometries could be substituted, such as a rectangular shape. As shown here, the radially outer end 370 is more than double the thickness of the thinnest portion of the spoke web 310.
The spoke 300, and it's web 310 may possess a curvature, such as an arcuate shape, when viewed from the axial direction. Such a curvature predisposes the spoke to buckle and fold in a desired direction when compressed. The spokes width, measured in the axial direction, may also vary along the radial direction of the spoke 300. Shown in the present embodiment, the spoke is wider at the radially outer end 370 than at the radially inner end 330.
In this embodiment the radially outer portion 210 of the clip 200 possesses a flared edge. The term “flared edge” means that the outer portion 210 of the clip curves away from the center radial plane, forming a curvature 212 having a radius R1. The curvature 212 of the outer portion 210 of the first half 202 (and corresponding retaining surface 222) away from the second half 204, and the curvature 212 of the outer portion 210 of the second half 204 (and corresponding retaining surface 224) away from the first half 202 prevents a concentration of bending stresses within the spoke web 310 providing for improved durability. Where the spoke is predisposed to only bend in a single circumferential direction, only one of the two halves 202, 204 need to possess a curvature 212 to provide a reduction of bending stresses within the spoke web 310.
The retaining clip's 200 interior surfaces possess a similar shape to the shape of the radially inner end 330 of the spoke 300. The sidewalls 214, 216 form a generally triangular shape when viewed from the axial direction, widening near the radially inner end 220 of the retaining clip 200. Tabs 230 extend radially inward from the inner end 220 of the retaining clip. Spoke stop tabs 206, 208 are shown bent at a 90-degree angle from the sidewall of each clip half 202, 204. In the embodiment shown, at least one spoke stop tab 206, 208 is positioned on each clip half 202, 204.
The retaining clip 200 of the current embodiment shown is formed from sheet metal, which allows for economical construction and modular replacement of the retaining clip in case of damage or wear. Other materials and construction methods are contemplated such as using metal or plastics and formation by machining, casting, injection molding, etc.
Once the radially inner portion 330 of the spokes 300 are secured to the hub 100 or 100′, the attachment of an outer annular band is needed. Since the spokes have little compressive resistance, an apparatus to hold them in position is needed to proceed in applying the outer annular band and to provide a desired level of spoke tension for the wheel in the unloaded state.
In alternative embodiments, spiral grooves 642 are not cut completely through the second plate 631, and the lower tips of the pins 641 are each provided with a small ball bearing which rides in spiral grooves 642. In yet another alternative embodiment, the spoke supports 601 are moved by individual actuators, such as pneumatic, hydraulic or electromechanical linear actuators
Upon completion of curing and or bonding of the spokes to the outer annular band, a non-pneumatic tire is formed.
Spoke tension affects the performance of the tire, much like how air pressure in a pneumatic tire may affect a pneumatic tires performance The final spoke tension of an unloaded wheel can be changed by designing the tire with a specific spoke length for the distance it must span between the hub and outer band. For example, by molding shorter spokes for a tire having the same diameter hub and outer band, the spoke tension is increased. Likewise molding longer spokes for a tire having the same dimensioned hub and outer band, would result in a lower spoke tension.
Alternatively, or in addition with choosing a specific spoke length, the spoke tension can be increased by applying a greater tension when forming the outer band, or attaching an outer band of a greater inner diameter. Attaching an outer band of a smaller inner diameter, or applying a smaller amount of tension when forming the outer band would result in spokes having a reduced tension.
Alternatively, or in addition, the hub diameter may be chosen so as to arrive at the desired spoke tension. Choosing a hub diameter which is greater would result in reduced spoke tension, while choosing a hub diameter which is smaller would result in a greater spoke tension.
Alternatively, or in addition, spoke tension may be changed by choosing reinforcements having a known shrinkage rate. For example, it is known that certain fibers are known to have a thermal shrinkage rate greater than other fibers, resulting in shrinkage upon the application of heat during curing of the rubber surrounding the fibers. This shrinkage results in increased spoke tension. By choosing fibers having a known thermal shrinkage rate, the finished spoke tension may be determined and adjusted by choosing alternative fibers having a different known thermal shrinkage rate. For example, substituting an aramid fiber reinforcement having a greater thermal shrinkage rate for a polyester fiber reinforcement having a lower thermal shrinkage rate would result in spokes in the finished assembled tire having a greater spoke tension than the spokes reinforced with the polyester fiber reinforcement.
While spoke tension may be adjusted during construction of the tire by adjusting one or more of the parameters discussed above, deradialization of the spokes may also be used to adjust spoke tension. Increasing the deradialization of the spokes for a hub of a given outer diameter and an outer band of a given inner diameter increases spoke tension. Likewise decreasing the deradialization of the spokes for a hub of a given outer diameter and an outer band of a given inner diameter increases spoke tension.
Circumferential rotational adjustment allows the radially inner portion of the spokes 300′ to be secured within the slots of the second annular ring portion 170 and then the second annular ring portion 170 may be rotated to increase or decrease spoke tension as desired. Increasing spoke tension increases circumferential compressive forces in the outer band, which results in less deformation of the outer band and a smaller footprint of the tire for a given load. Decreasing spoke tension decreases circumferential compressive forces in the outer band, which results in larger deformation of the outer band and a larger footprint of the tire for a given load.
Reducing or increasing the spoke tension allows the tire to be tuned for the type of use the operator will expose it to. Reduced deformation of a tire results in reduced rolling resistance, while increased deformation results in higher shock absorption and comfort. Higher spoke tension is desirable in certain instances, for example: Higher spoke tension would be desirable for on-road use of a tire over a smooth surface where reduced rolling resistance is beneficial. Lower spoke tension may be desirable in certain instances, for example: Lower spoke tension would be desirable for off road use where the deformation of the outer band allows for conformation to uneven surfaces and absorption of shock. Lower spoke tension also allows for greater footprint pressure which reduces compaction and can increase traction when traversing off-road terrain.
It should be understood that it may be desirable to maintain the same spoke tension throughout the tires operational life, or it may be desirable to periodically allow for changes in the spoke tension as desired by the operator. It also should be understood that actuators, such one or more mechanical actuator, could be attached to the rim to allow for adjustment of the spoke tension by rotating one annular ring portion relative to the adjacent annular ring portion. The system to adjust the spoke tension could be controlled by the operator, or by a computer control system, or by some combination thereof.
It should be understood that a plurality of ring portions are possible, hence a web that has been separated into three web portions would have a corresponding three ring portions which could rotate relative to one another. In such an embodiment the outer two ring portions could rotate relative to the middle ring portion, or each ring portion could rotate independent of each other. Tires having four ring portions and a corresponding four web portions, or five ring portions and a corresponding five web portions, or other number or ring portions and web portions could be possible and within the scope of this embodiments.
It should be understood that other web element configurations and geometries may be used within the scope of the embodiments, including web elements which are interconnected such as where they may form a honeycomb or other pattern.
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.
Filing Document | Filing Date | Country | Kind |
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PCT/US17/12030 | 1/3/2017 | WO | 00 |
Number | Date | Country | |
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Parent | PCT/US15/68264 | Dec 2015 | US |
Child | 16067772 | US |