High Load-Bearing Tire Construction
Modern tire designs must accommodate increasing vehicle weights while maintaining safety margins. Heavy-duty applications now require tires to support static loads exceeding 7,500 kg per tire, with dynamic loads during acceleration and cornering introducing additional stress factors. These demands push traditional pneumatic designs to their structural limits.
The fundamental challenge lies in developing tire architectures that can transfer higher loads while maintaining acceptable deflection characteristics, heat generation, and wear patterns.
This page brings together solutions from recent research—including reinforced non-pneumatic support structures, advanced shear band designs, optimized belt configurations, and novel bead architectures. These and other approaches demonstrate how load capacity can be enhanced while preserving tire durability and performance characteristics.
1. Vehicle Tire with Functionalized Carbon Nanoparticle-Enhanced Rubber Matrix
HAYDALE COMPOSITE SOLUTIONS LTD, 2025
Tyres for vehicles with improved grip, wear resistance, and low weight. The tyres contain a rubber matrix with functionalized carbon nanoparticles like graphene and carbon nanotubes. The functionalization improves dispersion of the carbon nanoparticles in the rubber. This provides better grip, structural and chemical properties, and abrasion resistance compared to unfunctionalized carbon nanoparticles. The functionalization involves treating the carbon nanoparticles with chemicals like nitric acid to modify their surface.
2. Radial Tire with Dual-Layer Carcass Reinforcement and Controlled Interlayer Spacing
COMPAGNIE GENERALE DES ETABLISSEMENTS MICHELIN, 2025
A radial tire for heavy-duty vehicles like dump trucks that improves load capacity and reduces pressure requirements compared to standard tires. The tire has a unique carcass reinforcement structure with two layers, one inside the other, instead of the usual single layer. The inner layer wraps around the bead wires and extends from bead to bead. The outer layer is outside the inner layer in the crown region. The distance between the layers is controlled to balance bending stresses. The inner layer has smaller diameter steel cords compared to standard tires for flexibility. This allows higher load or lower pressure compared to single layer tires.
3. Non-Pneumatic Tire with Coaxial Rings and Looped Spoke Structure
BRIDGESTONE AMERICAS TIRE OPERATIONS LLC, 2025
Non-pneumatic tire with a unique looped spoke design that allows the tire to run without inflation. The tire has an inner ring and outer ring coaxially arranged. Looped spokes extend between the rings. Each loop has an opening visible from one side. The loops directly contact both rings. This looped spoke structure provides support without air. Fillets between the rings further reinforce the tire. The loops have reinforced rubber inside and contact each other. The spoke design allows the tire to be run flat without air pressure.
4. Polydiene Rubbers with Alkoxy Silyl Functionalized Comonomers
ARLANXEO DEUTSCHLAND GMBH, 2025
Polydiene rubbers with improved properties for tire applications, made by polymerizing diene monomers with functionalized comonomers containing alkoxy silyl groups. The functionalized comonomers have repeating units derived from the functionalizing comonomer. The functionalized rubber polymers have better interactions with fillers and improved tire properties compared to non-functionalized diene polymers.
5. Rubber Composition with Diene-Based Rubber, Carbon Black, and Phosphoric Acid-Modified Cellulose Nanofiber
TOYO TIRE CORP, 2025
Rubber composition for pneumatic tires with improved durability without sacrificing elongation. The composition contains a diene-based rubber, carbon black, and phosphoric acid-modified cellulose nanofiber. Adding the modified cellulose nanofiber to the rubber composition enhances rubber strength without reducing elongation compared to using just carbon black. This provides better tire durability without compromising tire flexibility.
6. Rubber Composition with Diene-Based and Phosphoric Acid-Modified Cellulose Nanofiber Components
TOYO TIRE CORP, 2025
Rubber composition for pneumatic tires that improves durability without sacrificing elongation. The composition contains a diene-based rubber, modified diene-based rubber, carbon black, and phosphoric acid-modified cellulose nanofiber. The modified diene-based rubber improves rubber strength, while the nanofiber further enhances strength. The composition allows reducing filler like silica to improve elongation. The composition can be used in vulcanized rubber parts of tires.
7. Toroidal Tire Assembly Incorporating Shape Memory Alloy and Polymer Composite Structure
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.
8. Pelletizable Fiber Blends with Short Fibers and Binder Featuring Low-Wax Content
DOWCO LLC, 2025
Pelletizable fiber blends containing short fibers and a binder that can be directly added to polymers or rubbers without melting the pellets to disperse the fibers. The pelletized fiber blends improve fiber dispersion during polymer processing, reduce fiber clumping, and provide better interfacial bonding between fibers and the matrix. The blends have less than 1% wax to prevent sticking during pelletization. The pellets can be used to prepare composites with improved physical properties like tensile modulus, elongation, tear strength, and abrasion resistance compared to unpelletized fiber blends.
9. Tire with Multiple Body Plies and Stabilizer Ply Inserts Featuring Decreasing Width Turn-Ups and Overlap Prevention Configuration
BRIDGESTONE AMERICAS TIRE OPERATIONS LLC, 2025
Tire design with multiple body plies and stabilizer ply inserts to improve durability and reduce weight compared to conventional tire construction. The tire has three body plies wrapping around the beads with decreasing widths. The innermost ply has the widest turn-up, the middle ply has a narrower turn-up inside the wider one, and the outermost ply has a wider turn-up inside the narrower one. Stabilizer inserts are placed between the body plies and beads to prevent overlaps. This configuration provides stability and prevents ply overlap without needing excessively wide outer plies. The inserts also reduce weight compared to overlapping plies.
10. Conjugated Diene-Based Polymer with Controlled Molecular Characteristics and Modifier Reaction
LG CHEM LTD, 2025
Modified conjugated diene-based polymer for rubber compositions with optimized properties like modulus and tensile strength. The polymer has specific viscosity, molecular weight, and molecular weight distribution ranges. It is prepared by controlled polymerization conditions. The polymerization step involves using an organometallic compound and stopping at low conversion. The modified polymer is then reacted with a modifier. This provides a rubber composition with improved properties like modulus and tensile strength compared to unmodified diene polymers.
11. Micronized Rubber Powder Activation via Silane and Silica Treatment for Enhanced Vulcanization and Dispersion
ATLANTIS RUBBER POWDERS BV, 2025
Upgrading micronized rubber powder (MRP) for large-scale reuse in tires by chemically activating the powder to improve performance. The activation involves treating the powder with silane during grinding to prevent sticking and using silica as a dusting agent. This functionalizes the powder surface to enhance vulcanization and dispersion in rubber compounds. The activation step involves contacting the powder with silane, silica, peroxides, or other activators. This allows using lower amounts of MRP in tire formulations compared to unactivated powder, which improves properties like tear strength, abrasion resistance, and dynamic performance.
12. Silica-Filled Natural Rubber Composition with Functionalized Synthetic Polyisoprene and Silica-Interactive Functional Groups
BRIDGESTONE CORP, 2025
Silica-filled natural rubber compositions for tire treads that provide improved properties like tensile strength, tear resistance, wear resistance, and impact resistance compared to traditional natural rubber treads. The compositions contain natural rubber, functionalized synthetic polyisoprene, and a silica filler. The functionalized synthetic polyisoprene has silica-interactive functional groups that impart polymer-filler interaction to the natural rubber domains in the composition, resulting in enhanced properties from both the natural rubber and the functionalized synthetic polyisoprene.
13. Polysaccharide-Elastomer Masterbatch with Coagulated and Dried Composition
NUTRITION & BIOSCIENCES USA 4 INC, 2025
Polysaccharide-elastomer masterbatch for making reinforced rubber compositions with reduced water content. The masterbatch is made by mixing a polysaccharide dispersion with an elastomer latex and then coagulating and drying the mixture. This avoids adding water during masterbatch production, allowing lower water content in the final rubber compound. The polysaccharide provides reinforcement and reduces rolling resistance compared to carbon black. The masterbatch can be used in applications like tires, belts, footwear, coatings, etc.
14. Silica-Filled Rubber Compound with Dipole-Enhanced Additive for Controlled Stiffness and Dispersion
BRIDGESTONE EUROPE NV/SA [BE/BE], 2025
Silica-filled rubber compound for tires with high stiffness and reduced rolling resistance. The compound contains a specific additive with a dipole moment over 2 Debye, polar groups at one end of a hydrophobic carbon chain, and crosslinks only at the other end. This additive enhances silica dispersion and stiffness without increasing hysteresis compared to traditional plasticizers. The compound has a balance of stiffness and rolling resistance exceeding 1.15 in E'/TanD ratio.
15. Non-Pneumatic Tire with Interlocking Spoke Support Structure and Curved Foot Adaptation
BRIDGESTONE AMERICAS TIRE OPERATIONS LLC, 2025
Non-pneumatic tire design that allows the tire to withstand high impact events without failure. The tire has a support structure with spokes that are designed to contact each other during high impact events. The spokes have curved foot portions that adapt to the curvature of the lower ring when bonded. This allows the spokes to flex and contact each other when the tire encounters a pothole or obstacle, distributing the force and preventing spoke failures. The spokes also have curved surfaces that match the ring scallops, allowing rotation adjustment without pre-stress.
16. Light Truck Tire with Dual Ring-Shaped Metal Braided Reinforcements and Symmetrical Sidewall Patterns
HUBEI JINTIAN TYRE CO LTD, 2024
A high wear-resistant light truck tire with two metal braided structures inside the tire body. The tire has symmetrical stripes and patterns on the outer sidewall. The metal braids are ring-shaped and evenly placed inside the tire. They provide reinforcement to resist wear in high load and rough road conditions.
17. Passenger Car Tire with Extended Inward Carcass Reinforcement and Optimized Sidewall Height
Compagnie Générale des Établissements Michelin, COMPANY GENERAL DETA BRISSMAN MICHELIN, 2023
A passenger car tire with higher load capacity than standard tires of the same size without sacrificing space or comfort. The tire has a carcass reinforcement that extends further inward than usual relative to the tire's size. This allows the tire to withstand higher loads than a standard tire of the same size without increasing inflation pressure. The tire also has a sidewall height and carcass construction that enable it to maintain similar space and performance characteristics compared to the standard tire.
18. Passenger Car Tire with Enhanced Load Index and Standard Dimensions
Compagnie Générale des Établissements Michelin, COMPANY GENERAL DETA BRISSMAN MICHELIN, 2023
Tire design that allows a passenger car tire to carry higher loads without needing higher inflation pressures. The tire has a load index greater than that of a standard tire of the same size and construction. This provides increased load capacity without sacrificing compactness or comfort. The tire maintains the same dimensions as a standard tire of the same size and aspect ratio. The higher load capacity allows using larger batteries for electric vehicles without needing larger tires or higher pressures. The tire can have a distinctive marking like "HL" or "XL+" to indicate the higher load capacity.
19. Curved Flexible Membrane Support Structure with Reinforced Joints for Non-Pneumatic Tires
COMPAGNIE GENERALE DES ETABLISSEMENTS MICHELIN, 2023
Resilient, reinforced support structure for non-pneumatic tires that improves durability and load transmission. The support has a curved, flexible membrane connecting the inner and outer joints. The curved shape allows the support to flex and absorb impacts while maintaining radial stiffness. The joints connect to tire components like hubs and tread bands.
20. Spring Tire with Shape Memory Alloy Springs and Variable Stiffness Tread
The SMART Tire Company Inc., 2023
A spring tire that provides improved load-carrying capacity, climbing ability, flotation, and traction compared to previous non-pneumatic tires. The tire uses shape memory alloy springs in the main body, tread, and bump stop. The tread has variable stiffness springs to create uneven deflection and form tread lugs when pressured. The bump stop contacts the rim to prevent over-deflection. The springs are interconnected to distribute the load around the rim. This allows top and bottom loading for increased capacity. The tire also has a spoked rim and integrated lugs for weight reduction.
New developments in tire design show how much progress has been made in increasing load capacity in a variety of applications. The issues of carrying enormous loads while maintaining safety and performance are addressed by these innovations through the integration of new materials and structural systems.
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