METHOD OF USING ULTRASONIC DEVICE TO ATTACH SUPPORTING STRUCTURE OF

A NON-PNEUMATIC TIRE TO A HUB

FIELD OF THE INVENTION

[0001] The present invention relates generally to a method of constructing a non-pneumatic tire. More particularly, the present application involves a method of constructing a non-pneumatic tire that includes the step of attaching the supporting structure to the hub through the use of an ultrasonic device.

BACKGROUND

[0002] Non-pneumatic tires for vehicles and other applications are known that may include a hub surrounded circumferentially by an outward radially disposed tread that includes an annular shear band ring. A supporting structure that may have a series of spokes can be disposed radially between the hub and shear band ring and can function to connect these two components. As the tire rotates under load, the spokes experience bending, extension and compression deformation when they are located downward near the contact patch of the tire. The spokes straighten outside the contact patch relieving the bending and compression deformation.

[0003] The step of attaching the hub to the spokes in the assembly process may be accomplished by using adhesion to bond the spokes 360 degrees about the hub. However, the use of adhesion has process limitations with added costs. The attachment may result in unwanted fretting or wear of the end of the spokes. Mechanical clamps may also be used to connect the spokes to the hub. Contact between the spokes and the clamps also lead to fretting and wear of the spoke which results in failure of the spoke. As such, there remains room for variation and improvement within the art. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, which makes reference to the appended Figs, in which:

[0005] Fig. 1 is a perspective view of a non-pneumatic tire.

[0006] Fig. 2 is a perspective exploded assembly view of a non-pneumatic tire composed of a hub and a series of intermediate sections inserted into an outer shear band ring.

[0007] Fig. 3 is a perspective view of a portion of an intermediate section with three attachment tabs before engagement with a portion of the hub.

[0008] Fig. 4 is a perspective view of a portion of the intermediate section of Fig. 3 but with the attachment tabs inserted through attachment tab receiving features of the hub.

[0009] Fig. 5 is a side elevation view of an intermediate section, outer shear band ring, and hub before reception of the attachment tabs.

[0010] Fig. 6 is a side elevation view of the assembly of Fig. 5 after the attachment tabs are received by the attachment tab receiving features of the hub.

[0011] Fig. 7 is a side view elevation view of the assembly of Fig. 6 after an ultrasonic process has been applied to the attachment tabs.

[0012] Fig. 8 is a front elevation view of a portion of the inside of the hub after the ultrasonic process has been performed in order to show attachment of the attachment tabs to the hub.

[0013] Fig. 9 is a front elevation view of the non-pneumatic tire as assembled with a series of three intermediate sections.

[0014] Fig. 10 is a perspective view of a bank of ultrasonic stacks within a hub that can be used in order to execute a method of attaching the attachment tabs to the hub.

[0015] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention.

DETAILED DESCRIPTION OF REPRESENTATIVE EMBODIMENTS

[0016] Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations.

[0017] It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170- 190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.

[0018] The present invention provides for a method of forming a non-pneumatic tire 10 that includes a hub 20, a supporting structure 16, and a shear band ring 12, 18. The method involves the provision of an intermediate section 14 with a supporting structure 16 that has an attachment tab 46. The intermediate section 14 is assembled with the shear band ring 12, 18 and the hub 20 is moved inside of the intermediate section. The hub 20 has an attachment tab receiving feature 48 that receives the attachment tab 46. Once received, an ultrasonic process is carried out in which a portion or all of the attachment tab 46 is melted and bonded to the hub 20 at the attachment tab receiving feature 48. In this manner, the supporting structure 16 of the intermediate section 14 is attached to the hub 20 to complete assembly of these components of the non-pneumatic tire 10. Attachment of the hub 20 to the supporting structure 16 through the use of an ultrasonic process ensures longevity of the connection with optimal performance and reduces or eliminates fretting and wear of the connection.

[0019] With reference to Fig. 1, a non-pneumatic tire 10 is shown through which a central axis 58 extends. The central axis 58 is identified with other components of the non-pneumatic tire 10 and relates to the position of these components once assembled into the non-pneumatic tire 10. The other directions identified herein, such as the radial direction 22, axial direction 24, and the circumferential direction 26, likewise relate to the position of the non-pneumatic tire 10 and its components when assembled. An axial direction 24 is defined as the direction along the central axis 58 or the direction parallel to the central axis 58. The radial direction 22 extends at a 90 degree angle to the axial direction 24, and the circumferential direction 26 extends around the arc length of the non-pneumatic tire 10, or its components, so as to circle 360 degrees the central axis 58. The axial direction 24, the radial direction 22 and the circumferential direction 26 are identified with other components in the drawings that are then subsequently assembled into the non-pneumatic tire 10 as their orientations would be upon assembly. The non-pneumatic tire 10 includes a hub 20 that can be mounted onto a wheel of the vehicle. The central axis 58 extends through the center of the hub 20.

[0020] Located outward from the hub 20 in the radial direction 22 is a supporting structure 16. The supporting structure 16 may be designed in a variety of manners. As shown, the supporting structure 16 includes an inner V pair spoke section 40, an interface ring 42, and an outer V pair spoke section 44. The spokes are V shaped with apexes that are oriented to and are located at one another between the inner and outer V pair spoke sections 40 and 44. However, it is to be understood that the supporting structure 16 can be provided in a variety of manners and need not include V shaped spokes, and need not include inner 40 and outer 44 sections in other embodiments. Instead, the supporting structure 16 may include simply a plurality of spokes that are linear in shape and that are arranged completely around the supporting structure 16 in the circumferential direction 26. As such, it is to be understood that the configuration of the supporting structure 16 illustrated and described is only exemplary and that other arrangements are possible in other configurations of the non-pneumatic tire 10 and method disclosed herein.

[0021] The non-pneumatic tire 10 also has a shear band ring, made up of an outer shear band ring 12 and an inner shear band ring 18, that engages the supporting structure 16 and is located radially outward from the supporting structure 16 in the radial direction 22. Tread 60 is also included in the non-pneumatic tire 10 and is attached to the shear band ring 12, 18. The supporting structure 16 may be formed as a single component, or can be made by individually constructing two or three subcomponents and then assembling these two or three modular pieces together to form the supporting structure 16. Construction in two or three modular pieces may allow for benefits in cost and performance to be realized.

[0022] An exploded perspective view of a non-pneumatic tire 10 is shown in Fig. 2. The tire 10 includes a plurality of intermediate sections 14, 28 and 34 that can all be formed in the same manner with the same components. The intermediate sections 14, 28, 34 include supporting structures 16, 30 and 36 that are located inward in the radial direction 22 from corresponding inner shear band rings 18, 32 and 38. The intermediate sections 14, 28 and 34 are positioned into an outer shear band ring 12 so as to lie against one another in the axial direction 24. The shear band ring is thus made up of an outer shear band ring 12 and a number of inner shear band rings 18, 32 and 38 and is not formed as a single component. However, in other versions, the intermediate sections 14, 28 and 34 may lack inner shear band rings 18, 32 and 38 and thus the entire shear band ring is made up of the outer shear band ring 12. In the version shown in Fig. 2, the various spokes of the supporting structures 16, 30, and 36 do not directly engage the outer shear band ring 12 but are instead offset therefrom by the inner shear band rings 18, 32 and 38. A hub 20 is located within and is attached to the intermediate sections 14, 28 and 34.

[0023] The method for forming the non-pneumatic tire 10 may first involve the building and curing of the outer shear band ring 12 and the inner shear band rings 18, 32 and 38. The number of inner shear band rings 18, 32 and 38 may vary depending upon the width of the outer shear band ring 12 which is the length of the outer shear band ring 12 in the axial direction 24. Any number of inner shear band rings 18, 32 and 38 may be utilized and they may or may not be sized the same in the axial direction 24. The number and size of the inner shear band rings 18, 32 and 38 may be dependent upon molding constraints of other features of the non-pneumatic tire 10 such as the spokes. The outer shear band ring 12 may include any number of layers of the resulting shear band ring. Likewise, the inner shear band rings 18, 32 and 38 can include any number of layers of the resulting shear band ring. In some embodiments, the inner shear band rings 18, 32 and 38 include two layers of the resulting shear band ring. The inner shear band rings 18, 32 and 38 are portions of the shear band ring and are not portions of the spokes and are not rings of the supporting structures, 16, 30 and 36 in that they can include the same materials as other portions of the shear band ring such as the outer shear band ring 12. The number of layers and the thickness in the radial direction 22 of the inner shear band rings 18, 32 and 38 can be selected so that the inner shear band rings 18, 32 and 38 can flex inward some amount in the radial direction 22 so that they can be inserted into the outer shear band ring 12 when the intermediate sections 14, 28 and 34 are inserted.

[0024] The next step in the assembly process may be the formation of the intermediate section 14. Once the inner shear band ring 18 is formed, it may be placed as an insert within a mold for the formation of the supporting structure 16. The mold into which the inner shear band ring 18 may be placed can be an injection mold. The supporting structure 16 may include an inner V pair spoke section 40, an interface ring 42, and an outer V pair spoke section 44. These sections 40, 42 and 44 can be injection molded and upon their formation by injection molding the outer V pair spoke section 44 can bond directly to the inner surface of the inner shear band ring 18. This type of process is known as overmolding in the injection molding process. The inner surface of the inner shear band ring 18 may be primed by being chemically prepared either by plasma or chemical adhesion promoter, or through the application of cushion gum.

[0025] The components of the supporting structure 16 such as the inner V pair spoke section 40, interface ring 42, and outer V pair spoke section 44 can be made out of thermoplastic elastomers such as thermoplastic urethanes, polyether block amides, copolyester ethers, polyolefin elastomers, and plastomers. In some embodiments, other materials may be used to construct the inner V pair spoke section 40, interface ring 42, and outer V pair spoke section 44 could be more rigid

thermoplastic materials such as polyethylene, polypropylene, and nylon. Although described as being molded with or otherwise formed with an inner shear band ring 18, it is to be understood that the intermediate section 14 need not include an inner shear band ring 18 in other embodiments. In some instances, the outer V pair spoke section 44 can include a ring of material to which the V shaped spokes engage, and this ring may be made of the same material as the V shaped spokes. In other instances, the ring may not be present, and the V shaped spokes could terminate at the outer diameter of the intermediate section 14.

[0026] The outer shear band ring 12 can include a series of metal belts, and the various inner shear band rings 18, 32 and 38 may likewise include a series of metal belts. The shear band rings 12, 18, 32 and 38 are all part of the shear band and are not portions of the outer V pair spoke sections 44 of the supporting structures 16, 30 and 36. The assembly described herein may thus feature the shear band being provided as multiple parts that are subsequently assembled with one another into the resulting shear band. The inner shear band rings 18, 32 and 38 may not be rings that are of the same material as the outer V pair spoke sections 44 of the supporting structures 16, 30 and 36, but may instead be actual portions of the completed shear band ring.

[0027] The second intermediate section 28 may be constructed in a similar manner as the first intermediate section 14 as previously discussed. In this regard, the components of the second supporting structure 30 such as the outer V pair spoke section of the second supporting structure 30 may be molded onto the inner surface of the second inner shear band ring 32 through an

overmolding in the injection molding process. The third intermediate section 34 may likewise be constructed in a similar manner as the first intermediate section 14 previously discussed.

Components of the third supporting structure 36 such as the outer V pair spoke section can be molded onto the inner surface of the third inner shear band ring 38. The inner surfaces of the second and third inner shear band rings 32 and 38 may be prepped in the same manners as the inner surface of the inner shear band ring 18, and the materials making up the second and third intermediate sections 28 and 34 may be the same as the intermediate section 14 as previously discussed and a repeat of this information is not necessary. If additional intermediate sections are needed in other embodiments, they may be provided as previously discussed with respect to the first intermediate section 14. The various intermediate sections 14, 28 and 34 can be configured in a similar manner as one another so that their supporting structures 16, 30, and 36 are identical, or these supporting structures 16, 30 and 36 may differ from one another.

[0028] Adhesive can be applied onto the outer surfaces of the intermediate sections 14, 28 and 34 so as to extend 360 degrees around the central axis 58 to be present on the entire outer surfaces. The adhesive can be any type of adhesive that can be used to connect the intermediate sections 14, 28 and 34 to the outer shear band ring 12. The adhesive may be a rubber based crosslinking material, such as cushion gum, that can be applied in a solid/skim or liquid form. Other adhesives used to make up the adhesive could be polyurethane, cyanoacrylate, or epoxy based glue. The adhesive can be applied in any manner such as through the use of a roll or gun applicator.

Additionally or alternatively, adhesive of the same types as previously discussed may be applied to the inner surface of the outer shear band ring 12 in other embodiments. Once the adhesive is applied, the intermediate section 14 may be collapsed some amount in the radial direction 22 to move the intermediate section 14 into a collapsed state. This collapsing may be into any type of shape. This collapsing allows the intermediate section 14 to be inserted into the interior of the outer shear band ring 12 as the exterior diameter of the intermediate section 14 will be less than the inner diameter of the outer shear band ring 12.

[0029] Once inserted, the collapsing forces may be removed to allow the intermediate section 14 to expand so that the outer surface of the intermediate section 14 engages the inner surface of the outer shear band ring 12. Any type of mechanism may be employed to collapse the intermediate section 14 to move the intermediate section 14 from the uncompressed state to the compressed state, and then to remove the compression.

[0030] The second and third intermediate sections 28 and 34 can likewise be collapsed, inserted, and expanded for assembly with the outer shear band ring 12. Fig. 9 shows the positioning of the second and third intermediate sections 28 and 34 into the outer shear band ring 12. The second intermediate section 28 engages both the first intermediate section 14 and the third intermediate section 34, and the first and third intermediate sections 14 and 34 are located at the axial ends of the outer shear band ring 12. The three intermediate sections 14, 28 and 34 when inserted extend along the entire width of the outer shear band ring 12 in the axial direction 24. The second and third intermediate sections 28 and 34 can have adhesive applied to their outer surfaces, or the adhesive may otherwise be applied to the inner surface of the outer shear band ring 12 in the same manners as previously discussed with respect to the first intermediate section 14. All of the intermediate sections 14, 28 and 34 can be collapsed, inserted and expanded at the same time, or they may be individually collapsed, inserted and expanded one after the other. The features of the intermediate sections 14, 28 and 34 can be arranged so that they are in register with one another, or they may be offset such that features such as spokes of the various intermediate sections 14, 28 and 34 are not aligned with one another in the axial direction 24.

[0031] Once the intermediate sections 14, 28 and 34 are positioned within the outer shear band ring 12 regardless of whether it is simultaneous or one after the other, the adhesive at the interface between the intermediate sections 14, 28 and 34 and the outer shear band ring 12 can be treated based upon the particular type of adhesive employed. The adhesive at the interface can be cured by being treated with temperature, pressure and time sufficient to attain optimal curing as per the type of material used in the adhesive. The intermediate sections 14, 28 and 34 may be simultaneously cured, or they may be cured one at a time based upon their order of insertion into the outer shear band ring 12. If thermal curing is not needed, the attachment between the intermediate sections 14, 28 and 34 and the outer shear band ring 12 may be achieved through chemical vulcanization or through adhesives that do not require thermal curing.

[0032] After attachment of sections 14, 28, 34 to the outer shear band ring 12, the next step in the assembly process may involve the attachment of the hub 20 to the intermediate section 14 and any other intermediate sections 28 and 34 present. Fig. 3 shows the intermediate sections 14, 28 and 34 as each having a single spoke 62 instead of the V shaped spokes sections previously illustrated. Only a portion of the intermediate sections 14, 28 and 34 are shown. The end of the supporting structure 16 that is closest to the central axis 58 in the radial direction 22 has an attachment tab 46. Although illustrated as being rectangular in configuration, it is to be understood that the attachment tab 46 may be variously configured in other exemplary embodiments and need not be a single component with a single cross-sectional shape. The attachment tab 46 can be made out of the same material as the supporting structure 16. Further, the attachment tab 46 can be formed with the other portions of the supporting structure 16 such as being molded as a unitary structure with the rest of the supporting structure 16. The second intermediate section 28 has a second attachment tab 50, and the third intermediate section 34 has a third attachment tab 52. The second and third attachment tabs 50, 52 can be configured in a similar manner to the first attachment tab 46 as previously discussed. The spokes 62 of the supporting structures 16, 30 and 36 can extend 360 degrees completely around the central axis 58, and the various attachment tabs 46, 50 and 52 may likewise be arranged completely around the central axis 58 in the circumferential direction 26, and an attachment tab can be located at the ends of all of the spokes 62. If the supporting structure 16 is arranged as shown in Fig. 2 with the inner V pair spoke section 40, then the attachment tab 46 can be located at the end of the inner V pair spoke section 40 that is the most inward in the radial direction 22.

[0033] The hub 20 includes a series of attachment tab receiving features 48 that likewise extend 360 degrees around the central axis 58 in the circumferential direction 26. The attachment tab receiving features 48 are slots that extend through the hub 20 that are sized and shaped in a manner to receive the attachment tabs 46. Fig. 4 is a perspective view similar to Fig. 3 in which the intermediate section 14 is moved into interaction with the hub 20 so that the attachment tabs 46 extend through the attachment tab receiving features 48. The hub 20 also has a series of second attachment tab receiving features 54 and a series of third attachment tab receiving features 56 that can be arranged in a similar manner to the first attachment tab receiving features 48. The second attachment tabs 50 are received by the second attachment tab receiving features 54, and the third attachment tabs 52 are received by the third attachment tab receiving features 56. The attachment tabs 46, 50 and 52 extend through the attachment tab receiving features 48, 54 and 56 and are located inside of the hub 20 so as to be located closer to the central axis 58 in the radial direction 22 than an inner surface 66 of the hub 20. The tabs 46, 50 and 52 may be shaped along with the features 48, 54 and 56 to allow for interlocking such as dovetail shaped, round, triangular, or hook shaped. The attachment tab receiving features 48, 54 and 56 can be located next to one another in the circumferential direction 26 and may be symmetrical all the way around the hub 20. In other arrangements, the attachment tab receiving features 48, 54 and 56 are not symmetrical with respect to one another in the circumferential direction 26 such that some or all of the features 48, 54 and 56 are not aligned next to adjacent ones in the axial direction 24.

[0034] The step of attaching the hub 20 can be accomplished in a variety of manners. With reference to Fig. 5, a force F can be applied to the intermediate section 14 in order to force the various spokes 62 outward in the radial direction 22. The force F may be applied to all of the spokes 62 so that all of them, and in turn all of the attachment tabs 46, are moved outward in the radial direction 22. With the spokes 62 moved away from the central axis 58, the hub 20 may then be moved in the axial direction 24 to be positioned inside of the intermediate section 14. The hub 20 may be oriented so that the attachment tab receiving features 48 are located at the same position in the circumferential direction 26 as the attachment tabs 46. In other exemplary embodiments of the assembly, the force F is supplied by the insertion of the hub 20 so that the hub 20 itself forces the spokes 62 outward in the radial direction 22.

[0035] The next step in the assembly process involves the removal of the force F so that the spokes 62 expand inward in the radial direction 22 and thus towards the central axis 58. The attachment tabs 46 will likewise move inward in the radial direction 22 when the force F is removed. The aligned attachment tabs 46 are received by the attachment tab receiving features 48. If the force F was applied by the hub 20, then the hub 20 can be rotated in the circumferential direction 26 about the central axis 58 and when alignment with the attachment tab receiving features 48 occurs, the force F on the alignment tabs 46 is released and they are received by the attachment tab receiving features 48. As shown, upon release of the force F, a portion of the attachment tabs 46 extends beyond the inner surface 66 of the hub 20 and is located closer to the central axis 58 in the radial direction 22 than the inner surface 66. Engagement of the alignment tabs 46 with the attachment tab receiving features 48 may cause pretension to be imparted onto the spokes or other portions of the supporting structure 16.

[0036] Other portions of the spoke 62 may engage the outer surface 64 of the hub 20 when the force F is released so that portions of the attachment tab 46 extend beyond the inner surface 66. However, in yet other arrangements, the only portion of the spokes 62 and thus the only portion of the supporting structure 16 of the intermediate section 14 that engages the hub 20 is the attachment tab 46.

[0037] With the attachment tabs 46 received by the attachment tab receiving features 48, the next step of the assembly process is conducted in which an ultrasonic process is applied to the attachment tabs 46. The ultrasonic process may be performed by an ultrasonic stack 68 that can be located within the hub 20 so that it is located closer to the central axis 58 in the radial direction 22 than the hub 20. The ultrasonic stack 68 has a converter 70 that may be a piezoelectric transducer in some embodiments and may have an optional booster. The ultrasonic stack 68 may also have a horn 72 in communication with the converter 70. The components of the ultrasonic stack 68 can be tuned to resonate at the same ultrasonic frequency that can be 20kHz, 30kHz, 35kHz, 40kHz, from 20- 30kHz, from 30-40kHz, or up to 50kHz in accordance with certain exemplary embodiments. The hub 20 may be made out of a material that is not the same as the material making up the attachment tab 46. In some instances the hub 20 is made out of a metal such as steel or aluminum while the attachment tab 46 is made out of the materials previously discussed with reference to this part of the supporting structure 16. The horn 72 may be moved into engagement with the attachment tab 46 and ultrasonic frequency from the horn 72 can be transferred into the attachment tab 46 to have the transferred ultrasonic energy melt the contact points between the attachment tab 46 and the hub 20. In this regard, the portion of the attachment tab 46 that extends beyond the inner surface 66 can be melted by the ultrasonic stack 68 so that it is removed. The ultrasonic process may be capable of melting the end of the attachment tab 46 within 5 to 10 seconds in order to form the retaining attachment. In some embodiments, the only portion of the assembly that the horn 72 engages is the attachment tab 46 such that the horn 72 does not engage the hub 20. In other versions of the process, the horn 72 engages both the attachment tab 46 and the hub 20.

[0038] The ultrasonic process described herein can be ultrasonic welding or any other type of ultrasonic process capable of attaching the attachment tab 46 to the hub 20. Any type of device may be used to carry out the ultrasonic process, and the ultrasonic stack 68 described is but one example of a device capable of carrying out an ultrasonic process for attaching two components.

[0039] Fig. 7 shows the assembly after the application of the ultrasonic process. The attachment tab 46 is melted so that the portion interior of the inner surface 66, which is closer to the central axis 58 in the radial direction 22, is removed. The ultrasonic process thus modifies the attachment tab 46 so that it is shaped differently after application of the ultrasonic process than before the application of the ultrasonic process. It is to be understood that some embodiments exist in which portions of the attachment tab 46 in fact remain radially inward of the inner surface 66, or are disposed onto the inner surface 66. The ultrasonic stack 68 and other components used in carrying out the ultrasonic process on the attachment tab 46 can be removed from the interior of the hub 20. All of the various attachment tabs 46 of the intermediate section 14 may be subjected to the ultrasonic process in order to attach the attachment tabs 46 to the hub 20 at their respective attachment tab receiving feature 48. Although described as being applied to the attachment tabs 46 of the intermediate section 14, if the assembly is provided with other sections such as a second intermediate section 28 and a third intermediate section 34, the ultrasonic process may also be applied to these sections 28 and 34 as well. Here, the ultrasonic process may be applied to the second attachment tabs 50 and the third attachment tabs 52 in a similar manner as previously discussed in order to melt them and effect attachment of the second and third intermediate sections 28 and 34 to the hub 20. Although not shown, other components of the non-pneumatic tire 10, such as tread 60, could be subsequently attached after the ultrasonic process, or may be assembled at any point before the application of the ultrasonic process.

[0040] Fig. 8 shows the attachment formed by the ultrasonic process. The attachment tab 46 is melted so that may be flush with the inner surface 66. In the ultrasonic process, portions of the attachment tab 46 may be melted and can fill any voids present between the attachment tab 46 and the attachment tab receiving feature 48 into which the attachment tab 46 is disposed. In this manner, the entire attachment tab receiving feature 48 may be completely filled with the material making up the attachment tab 46 and in effect may be completely filled with the attachment tab 46 so that no voids within the attachment tab receiving feature 48 are present. The attachment tab receiving feature 48 may be completely encapsulated by the material that formed the attachment tab 46. The resulting joint may not be susceptible to fretting or wear.

[0041] In some arrangements, melted attachment tab 46 from the ultrasonic process may move through the attachment tab receiving feature 48 back onto the outer surface 64. In other exemplary embodiments, the ultrasonic process may result in some melting of the attachment tab 46 into the voids of the attachment tab receiving feature 48, but not complete filling of the attachment tab receiving feature 48 so that voids are present within the attachment tab receiving feature 48 after the ultrasonic process. In yet other arrangements, none of the attachment tab 46 is melted into the attachment tab receiving feature 48 but is instead located outside of the attachment tab receiving feature 48 and on or radially inward of the inner surface 66.

[0042] All of the attachment tabs 46, 50, and 52 may be melted by the ultrasonic process in the same manner so that they all melt into their respective attachment tab receiving features 48, 54, and 56. However, other arrangements are possible in which one or more of the attachment tabs 46, 50, and 52 are melted into any voids present of their respective attachment tab receiving features 48, 54, and 56, while other ones of the attachment tabs 46, 50, and 52 are not melted into the features 48, 54, and 56 but instead are on the inner surface 66. All of the attachment tabs 46, 50, 52 and their respective attachment tab receiving features 48, 54, 56 are positioned with respect to one another so that they are at the same arc length positions about the central axis 58 in the circumferential direction 26. As such, they are in a line in the axial direction 24 in Fig. 8. However, in other arrangements they may be misaligned with one another in the circumferential direction 26 so that they are not in effect in a line in the axial direction 24 as shown in Fig. 8 but some are higher and lower than others in this view.

[0043] Fig. 8 also shows the shape of the attachment tab receiving features 48, 54 and 56. As shown, they each have upper and lower edges in the circumferential direction 26 that are linear in the axial direction 24. The side edges that connect the upper and lower edges and that extend in the circumferential direction 26 are curved in shape so as to be convex/concave in shape. The inserted attachment tabs 46, 50 and 52 have rectangular cross-sectional shapes that are linear both in the circumferential direction 26 and in the axial direction 24. It is to be understood that these shapes are only exemplary and that other shapes are possible in other embodiments of the attachment tabs 46, 50, 52 and the attachment tab receiving features 48, 54, 56.

[0044] Fig. 9 shows the non-pneumatic tire 10 as assembled with three intermediate sections 14, 28 and 34 assembled into the outer shear band ring 12. The hub 20 is located within the three intermediate sections 14, 28 and 34 so as to be inward in the radial direction 22. The length of the assembled intermediate sections 14, 28 and 34 extends in the axial direction 24 so that the assembled length may extend along the axial lengths of the hub 20 and the outer shear band ring 12.

[0045] Fig. 10 is a perspective view of a hub 20 with a series of ultrasonic stacks 68 located within the hub 20 and positioned so as to be oriented at various attachment tab receiving features 48, 54 and 56. Although but a single ultrasonic stack 68 can be employed to attach all of the attachment tabs to the hub 20, a series of ultrasonic stacks 68 can be positioned within the hub 20 in order to increase the speed at which the attachment process can be executed. If three attachment tab receiving features 48, 54, 56 are disposed in the axial direction 24 and aligned in the circumferential direction 26 then three ultrasonic stacks 68 can be assembled side by side in the axial direction 24 to attach the three attachment tabs 46, 50 and 52. An additional three ultrasonic stacks 68 can be located 180 degrees opposite from the first three ultrasonic stacks 68 in order to attach attachment tabs 46, 50 and 52 that are likewise located 180 degrees from the first set of attachment tabs 46, 50 and 52. In yet other arrangements additional set-ups of the ultrasonic process are possible.

Additional ultrasonic stacks 68 could be positioned 90 degrees from those shown in Fig. 10 in the circumferential direction 26. In still other embodiments, additional ultrasonic stacks 68 may be present that are in yet other orientations about the central axis 58. The use of multiple ultrasonic stacks 68 in the assembly process functions to decrease the process time of assembling the non- pneumatic tire 10.

[0046] The attachment tab 46 and attachment tab receiving feature 48 are shown as being a rectangular tab that is received within a rectangular slot in which the attachment tab 46 is disposed within the attachment tab receiving feature 48 and thus located inside of the material making up the hub 20. However, it is to be understood that this is but one embodiment of how the attachment tab 46 and the attachment tab receiving feature 48 can be arranged. Other arrangements are possible in accordance with other exemplary embodiments. The attachment tab receiving feature 48 need not be a void into which the attachment tab 46 is disposed. Instead, the attachment tab receiving feature 48 can be a surface that engages the attachment tab 46 and is adhered thereto by the ultrasonic process. Additionally, the attachment tab 46 and the attachment tab receiving feature 48 may interlock some amount with one another without the application of the ultrasonic process so that some attachment of the hub 20 and the supporting structure 16 is achieved without the application of the ultrasonic process. Here, the ultrasonic process is used to enhance and complete the attachment of the attachment tab 46 and the attachment tab receiving feature 48.

[0047] The attachment process of the attachment tab 46 to the attachment tab receiving feature 48 can be accomplished without the use of a heated element that is used to melt the attachment tab 46 and/or the attachment tab receiving feature 48. The attachment of these components may be effected solely with the use of the ultrasonic process. Further, the attachment may not include the use of a mechanical fastener such as a clamp. Still further, the attachment of the attachment tab 46 to the attachment tab receiving feature 48 may be achieved without the use of adhesive.

[0048] Although previously described as being cured at this point, if the adhesive of the various intermediate sections 14, 28 and 34 has not yet been cured before attachment of the hub 20 and requires curing, the adhesive may be attached at this point in the assembly. Although shown as employing three intermediate sections 14, 28 and 34, it is to be understood that this number is only exemplary and that any number of intermediate sections may be used in the non-pneumatic tire 10 in accordance with various exemplary embodiments. For instance, two intermediate sections are used in the non-pneumatic tire 10 in accordance with certain exemplary embodiments. In other embodiments, from 4-6, from 7-10, or up to 15 intermediate sections may be employed in the construction of the non-pneumatic tire 10. Further, the attachment process described herein can be used in non-pneumatic tires 10 that are assembled with supporting structures in sections or those assembled with supporting structures one at a time.

[0049] While the present invention has been described in connection with certain preferred embodiments, it is to be understood that the subject matter encompassed by way of the present invention is not to be limited to those specific embodiments. On the contrary, it is intended for the subject matter of the invention to include all alternatives, modifications and equivalents as can be included within the spirit and scope of the following claims.