Reducing Tire Manufacturing Costs Through Process Optimization

Manufacturing pneumatic tires that have improved cost, performance, and recyclability compared to conventional rubber tires. The manufacturing process involves making the carcass from cured rubber but the sidewalls and tread from thermoplastic elastomer (TPE). This allows the tire to still have the necessary elasticity for road contact while providing benefits like lower rolling resistance, better chemical resistance, improved recyclability, and reduced manufacturing time.

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A lightweight tire inner tube made of thin film material with a wall thickness of 100 to 400 microns. The film is comprised of thermoplastic engineering resins and optionally an elastomer. The film has a low oxygen permeability of 8-15 cm3 O2/m2·day, allowing reduced thickness while still retaining air. The tube is manufactured by cutting and sealing the film to form a tube shape.

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Tire parameter monitoring without batteries to reduce cost and improve the reliability of tire pressure monitoring systems. The monitoring apparatus uses a MASER to reflect an output signal based on the resonance frequency information of the tire. This output signal contains information about the monitoring parameters like pressure or temperature. Another device receives the reflected output signal to obtain the monitored tire parameter without needing a battery-powered sensor in the tire.

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Method to improve tire flatness by aligning the upper and lower structures of the tire assembly during production. The method involves producing a subassembly for the tire by sandwiching the upper and lower structures between a supporting structure. This prevents relative movement between the structures during assembly. The subassembly is then inserted into the tire mold to complete the tire. The aligned structure arrangement improves tire flatness compared to the conventional method where the structures can slip during assembly. The aligned structures provide a more consistent tread shape for better tire performance.

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3D printing a tread molding element for tire molding using a plastic composition that can withstand the heat of vulcanization. The plastic composition is a thermoplastic polymer with a melting point of at least 180° C. The tread molding element is formed by 3D printing the plastic composition into the desired shape. The tread molding element can be used to mold a portion of a tire tread.

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Non-pneumatic tires that can be manufactured in one molding operation using horizontal centrifugal casting (HSC) technology. The tires have a rigid inner rim that is molded together with the elastomeric tire body in a single mold rotation. The mold allows complex tread patterns and radial demolding of the tire. The rigid rim can be metallic. The HSC process enables molding the entire tire in one step without separate tread attachments.

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A modular system for molding tire treads that allows easy repair and replacement of damaged mold segments without needing to replace the entire mold. The system uses interchangeable dual mold segments with replaceable ribs that can be swapped when damaged. The segments have a groove for the ribs. Removable securement allows replacing just the rib instead of the whole segment. This reduces downtime and costs compared to replacing entire molds.

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Tire mold design and manufacturing method to allow random placement of tread patterns on tires. The mold has segmented blocks divided in the circumferential direction with equal length. The blocks have tread patterns of different blade arrangements. Randomly placing these identical-size blocks around the mold circumference allows for forming tires with mixed tread patterns. This enables customizable tire designs using fewer mold segments compared to fixed pattern molds.

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Customizable tire manufacturing system that allows tire dealers to reduce inventory and offer more tailored tires to customers. Instead of stocking complete tires, dealers store separate casings and treads. A computer system lets customers select casing and tread types based on performance characteristics. At the point of sale, a machine assembles the customized tire from the chosen components. This allows dealers to make and sell a wider variety of tires with optimized performance without carrying as many finished tires.

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Double tire tread design for retreading that eliminates the need for buffing and cementing during retreading. The double tread has two opposite tread patterns molded on the same side of the tread body. When cut along the plane between the patterns, it separates into two single treads, each with a unique tread pattern. This allows applying one of the treads to each side of the tire casing without buffing or cementing.

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Wheel design with a separate outer tread section that is mechanically connected to the inner plastic wheel. The outer tread section is made of a different material than the inner wheel. The tread is woven through the rim of the inner wheel at the sides. This provides a separate tread section that covers the ground-facing side of the wheel, extends below the hub, and doesn't touch the hub-facing side. The inner wheel is made of a material that doesn't chemically bond to the tread material. The separate tread section reduces noise, prevents chipping, and improves durability compared to bonded wheels. The weight ratio of the outer tread to the inner wheel is kept low to maintain balance.

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