Modern passenger vehicle tires face penetration forces exceeding 800N from road debris, while maintaining internal pressures of 220-350 kPa under dynamic loading conditions. Traditional approaches to puncture resistance often rely on increasing material thickness, which adds weight and affects performance characteristics like rolling resistance and fuel efficiency.

The fundamental challenge lies in developing tire structures that prevent penetration while maintaining the complex balance of flexibility, durability, and performance properties that modern vehicles demand.

This page brings together solutions from recent research—including triangulated reinforcement architectures, fiber-reinforced rubber compounds, optimized carcass ply configurations, and innovative sidewall protection systems. These and other approaches demonstrate how material science and structural engineering are advancing tire puncture resistance without compromising essential performance characteristics.

1. Pneumatic Tire Sealant with Crosslinker and Plasticizer Dispersion for Enhanced Sealing and Handling

CONTINENTAL REIFEN DEUTSCHLAND GMBH, 2025

Self-sealing tire sealant for pneumatic vehicle tires that improves sealing performance and handling compared to conventional sealants. The sealant contains a dispersion of crosslinker and plasticizer instead of adding powdered crosslinker directly. This provides homogeneous distribution and prevents explosive powder handling issues. The crosslinker dispersion is added to the sealant during production. The sealant composition includes specific amounts of butyl rubber, carbon black, oil, zinc oxide, and potentially sulfur. The dispersion allows controlled crosslinking for better sealing and elasticity. The tire sealant can be used in all types of vehicle tires, including passenger, commercial, agricultural, etc.

2. Reciprocating Applicator System for Uniform Sealing Compound Application in Tire Cavities

BRIDGESTONE EUROPE NV/SA, 2025

Method and system for applying sealing compound to the inner surface of tire cavities to seal punctures. The method involves using a reciprocating applicator device inside the tire cavity to apply a uniform bead of sealing compound to the inner surface. The device is moved back and forth between the cavity ends while the tire rotates. This allows precise and uniform coating of the inner surface to prevent imbalance and weight variations. The reciprocating movement combined with tire rotation provides consistent sealing compound thickness.

3. Tire Inner Liner with Removable Sealant Layer Incorporating Rubber Matrix and Tackifiers

BRIDGESTONE AMERICAS TIRE OPERATIONS LLC, 2025

Sealant layer in tire inner liners to prevent punctures. The sealant layer is adhered to the inner liner of a tire. It contains a rubber matrix with tackifiers, hydroscopic substances, and a cure package. When a puncture occurs, the sealant layer fills the hole, sealing the tire. The layer can be added during tire manufacturing or repair. The sealant layer is removable for tire recycling.

4. Performance Analysis and Multi-Objective Optimization of Functional Gradient Honeycomb Non-pneumatic Tires

haichao zhou, haifeng zhou, hui ren - China Machine Press, 2025

Abstract The spoke as a key component has significant impact on the performance of non-pneumatic tire (NPT). current research focused adjusting structures to improve single NPT. Few studies have been conducted synergistically multi-performance by optimizing structure. Inspired concept functionally gradient structures, this paper introduces honeycomb NPT and its optimization method. Firstly, completes parameterization structure establishes numerical models NPTs with seven different gradients. Subsequently, accuracy is verified using experimental methods. Then, static dynamic characteristics these are thoroughly examined finite element findings highlight that NPT-3 superior performance. Building upon this, study investigates effects parameters, such thickness length, load-carrying capacity, stress mass. Finally, multi-objective method proposed uses response surface model (RSM) Nondominated Sorting Genetic Algorithm - II (NSGA-II) further optimize functional NPTs. optimized NPT-OP shows 23.48% reduction in radial stiffness, 8.95% maximum 16.86% mass compared initial NPT-1. damping also ... Read More

5. Tire Assembly with Inner Hooks and Rapid-Mount Spare Tire Featuring Elastic Ring-Connected Blocks

SHUI-CHEN HSU, 2025

A puncture-proof and run-flat tire design that allows a vehicle to continue driving even if the tire is punctured. The tire has an inner tire body with hooks protruding from the inner edges. A separate spare tire can be rapidly attached to the hooks using fine-adjustment wires. This allows the spare tire to be quickly mounted on the hooks if the inner tire goes flat, preventing immediate deflation. The spare tire has blocks connected by elastic rings that can be adjusted to fit the hooks. This provides a simple and rapid assembly method for the spare tire to convert a regular tire into a puncture-proof run-flat tire.

US2025162353A1-patent-drawing

6. Pneumatic Tire with Layered Sealant and Noise Dampening Structure

THE GOODYEAR TIRE & RUBBER CO, 2025

Pneumatic tire with puncture sealing and noise reduction. The tire has a sealant layer on the inner surface to prevent air leakage after punctures. It also has noise dampening strips attached to the sealant layer. The sealant layer has plateau regions where the strips are attached and adjacent bottom regions. The plateau regions have thicker sealant than the bottom regions. This allows more sealant below the noise dampening strips for puncture protection, while thinner sealant below the strips improves heat dissipation. The thicker plateau region also provides better sealing with less restriction.

US12304253B2-patent-drawing

7. Tire Assembly Incorporating Toroidal Shape Memory Alloy Structure Encapsulated in Polymer

THE SMART TIRE COMPANY INC, 2025

A tire assembly using shape memory alloys (SMAs) combined with polymers to create structures with combined properties of elasticity and strength. The tire assembly replaces the inner tube in a pneumatic tire with a toroidal SMA structure encapsulated in polymer. The SMA structure absorbs load like a spring and prevents punctures. The polymer encloses and bonds the SMA to the tread.

US2025115078A1-patent-drawing

8. Characterization of ply bulge failures in truck bus radial tyres

ankush yadav, chen jiju, prashant kumar - Frontiers Media, 2025

Ply bulge failure in Truck and Bus Radial (TBR) tyres, predominantly observed the shoulder region, is a critical issue impacting tyre performance safety. This study investigates root cause of such failures through comprehensive analysis 13 field-return tyres varying patterns sizes. A multi-step methodology, including visual inspection, X-ray analysis, shearography, microscopy, FTIR, adhesion testing, was employed to characterize mechanism. Visual inspection used identify external factors as punctures, overloading, or bead damage, while confirmed absence structural defects, cord spacing irregularities belt offset, indicating that intrinsic material interactions were primary drivers failure. Shearography pinpointed incipient separation areas, which further examined microscopically. Microscopic revealed debonding mode at carcass ply-rubber interface crack initiation mode, followed by propagation along surfaces then transferring adjacent cords. To distinguish between rubber degradation adhesive layer aging, forensic combining FTIR 90 peel test (adhesion test) conducted. compounds ... Read More

9. Puncture Protection Insert with Circumferential Dips and Protrusions and Rim-Proximal Enlarged Portion

OSCAR ETTORE GNALI, 2025

A puncture protection insert for off-road vehicle wheels that allows easy inflation and prevents obstruction while also avoiding interference when the tire is properly inflated. The insert has dips and protrusions on its circumference that align with valve locations when installed. This allows inflation air to flow through the insert at those points, preventing obstruction. The insert also has an enlarged portion near the rim that creates a decreasing space between the insert and tire as it approaches the rim. This allows the insert to compress against the tire when deflated or under low pressure, providing puncture protection, but doesn't contact the tire when properly inflated.

10. Triangulated Layer Arrangement in Passenger Vehicle Tire Reinforcement Structure

COMPAGNIE GENERALE DES ETABLISSEMENTS MICHELIN, 2023

A passenger vehicle tire with improved resistance to penetration and puncture while also being lighter weight than conventional tires. The tire reinforcement design uses a triangulated arrangement of the carcass, working, and hooping layers. The carcass layer angle is optimized for flexibility while the hooping layer angle is shallow to provide radial stiffness. The hooping layer has narrow-spaced reinforcements with high strength. The resulting tire has reduced susceptibility to puncture while using less material.

US11766895B2-patent-drawing

11. Dual-Ply Carcass Structure in Pneumatic Tire for Enhanced Sidewall Reinforcement

The Goodyear Tire & Rubber Company, 2023

A pneumatic tire with improved puncture resistance and durability, particularly in the sidewall area. The tire has two carcass reinforcing plies. The first ply extends radially between the bead portions. The second ply wraps around the bead and apex forming a turn-up portion. This configuration provides increased strength and puncture resistance in the sidewall compared to a single ply. The two plies work together to distribute loads and prevent cuts and penetration.

US20230191839A1-patent-drawing

12. Carcass Reinforcement with Unbalanced Twist Cords for Cut-Resistant Tire Sidewall Structure

The Goodyear Tire & Rubber Company, 2023

Tire structure for light trucks and off-road vehicles with enhanced cut and puncture resistance. The tire has a carcass reinforcement with at least one ply wrapped around bead cores and through sidewalls. A cut/puncture-resistant sidewall layer, adjacent to the carcass reinforcement, contains cords twisted together with an unbalanced twist. One example is nylon and aramid cords twisted together with nylon S twist (4-8 tpi) and aramid Z twist (4-8 tpi). This provides a cord with extensibility like nylon at low elongation and modulus and cut resistance like aramid at high elongation.

13. Fiber-Reinforced Rubber Layer in Pneumatic Tire with Dithiodicarboxylic Acid and Dimaleimide Additives

The Goodyear Tire & Rubber Company, 2023

Pneumatic tire with a fiber-reinforced rubber layer beneath the tread to prevent foreign object penetration. The layer is made of rubber reinforced with fibers like nylon or aramid along with specific chemicals like dithiodicarboxylic acid and dimaleimide. The fiber reinforcement and chemical additives make the layer act as a barrier to stop objects from penetrating deeper into the tire.

14. Off-Road Tire with Enlarged Sidewall Protruding Blocks in Shoulder Region

Toyo Tire Corporation, 2023

Off-road tire design to improve puncture resistance and reduce sidewall cutting on rough surfaces. The design includes larger side blocks protruding from the sidewall in the shoulder region of the tire. These side blocks provide extra protection against rocks and debris impacting the sidewall and help prevent cuts and punctures in off-road conditions. The larger size of these side blocks compared to the shoulder blocks also helps maintain traction over time while reducing sidewall damage.

US20230126634A1-patent-drawing

15. Bicycle Tire with Reinforced Tread Using Modified Silicate and Fibrillated Polymer Fibers

PIRELLI TYRE S.p.A., 2023

A bicycle tire with improved puncture resistance and rolling resistance. The tire tread contains modified silicate fibers and fibrillated polymer fibers as reinforcement instead of conventional materials like carbon black or silica. The modified silicate fibers have needle-like nanometric morphology while the fibrillated polymer fibers have micrometric size.

16. Bicycle Tire with Fibrillated Fiber Tread and Angled Cord Reinforcement Layers

Pirelli Tyre S.p.A., 2023

A bicycle tire with improved puncture resistance without sacrificing performance. The tire uses a tread compound containing fibrillated polymeric fibers to provide puncture protection. It also has protective layers under the tread that contain angled cords or fabrics to stop punctures from reaching the inner carcass. These layers extend beyond the tire's axial length. The angled reinforcements and extended layers complement the fiber-filled tread to provide comprehensive puncture resistance for all bike types.

17. Modified Rubber Tire with UV-Exposed Fiber Reinforcement and Twisted Long Fiber Cord Ply

Zhejiang Geely Holding Group Co., LTD., Zhejiang Geely Automobile Research Institute Co., LTD., 2023

A bulletproof and puncture-resistant tire with lightweight, riding stability, and bulletproof/puncture resistance for vehicles like military and armored cars. The tire uses modified rubber containing high-performance short fibers. The fiber modification involves exposing the fibers to UV light to incorporate coupling agents. The modified rubber is used in the tire's tread, belt ply, and inner liner. The tire also has a buffer layer made of modified rubber. The cord ply uses twisted high-performance long fibers.

18. Self-Sealing Pneumatic Tire with Silicone-Based Self-Sealing Layer and Integrated Sound-Absorbing Layer

DOW SILICONES CORPORATION, 2023

Self-sealing pneumatic tire with improved puncture sealing and noise reduction by using a specific silicone composition for the self-sealing layer. The silicone composition contains silyl terminated polymers, cross-linkers, catalysts, and fillers. The molar ratios of hydroxyl groups, hydrolyzable groups, and catalysts are controlled to optimize curing properties. The composition is applied as a two-part mixture that adheres, seals punctures, and cures on the inner tire surface. A sound-absorbing layer is adhered to the self-sealing layer.

19. Aircraft Tire with Cut/Puncture-Resistant Breaker Layer Comprising Parallel Monofilaments

The Goodyear Tire & Rubber Company, 2023

Aircraft tire with improved cut and puncture resistance for heavy load and high-speed conditions. The tire has a cut/puncture-resistant breaker layer between the crown reinforcement and tread. The breaker layer is made of parallel monofilaments inclined at 0-10 degrees to the equatorial plane. This configuration protects against cuts and punctures without sacrificing ride comfort or tire life.

US20230055170A1-patent-drawing

20. Counter-Wound Reinforced Tire Cord with Gapped External Strand and Varied Diameter Internal Strand

COMPAGNIE GENERALE DES ETABLISSEMENTS MICHELIN, 2023

A reinforced tire cord that balances strength and flexibility while allowing good elastomer penetration. The cord has an internal strand surrounded by an external strand. The external strand is wound in the opposite direction to the internal strand. The external strand has an incomplete layer - the outer wires don't touch. This creates gaps for elastomer to penetrate between the strands. The internal strand's wires have larger diameters towards the center to help elastomer flow. The cord is used in heavy-duty vehicle tires.

US11578459B1-patent-drawing

To fulfill the demands of contemporary driving conditions, advancements like strengthened sidewalls, improved tread compositions, and self-sealing capabilities are essential. The discussed patents are a reflection of the continuous efforts of leading tire manufacturers to produce more dependable and long-lasting tires that offer improved puncture resistance without sacrificing overall tire performance.

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