DESC:TECHNICAL FIELD
The present invention relates to the field of inner tube used in pneumatic tyres. The present invention in particular relates to a puncture resistant inner tube.
BACKGROUND
A tube type pneumatic tyre has an annular inner tube that is filled with air or a gas. Unless fitted with special support facilities, in the event of a puncture due to a physical damage to the tube, the tube gets deflated and the vehicle on which the tyre/tube combination is fitted becomes inoperable. This can be rectified only by removing or separating the affected tyre/tube combination from the rim, repairing the tube to address the puncture, and restoring its air or gas holding capabilities. In a vehicle provided with spare tyres, the vehicle can be used after fitting the spare tyre. However, in the case of two-wheeled or three wheeled vehicles that do not carry any spares, the immediate need to repair the puncture arises. Punctures are not always caused by external object penetration into the tyre/tube but also caused by pinching of the tube due to overloading of vehicle, and deflection of tyre/tube. The problems of puncture are also magnified in three wheeled vehicles that carry passenger or cargo where the tube gets pinched due to high load and high heat, at times leading to tyre burst. Hence, there is needed a tube with effective puncture resistance system and method which can also be used in severe applications like a three wheeled passenger or cargo vehicles.
Numerous patents have been filed on the shape and design of the inner tube for easing this process.
Reference made to the following:
Publication no. WO9725215 discloses an inner tube for use with a pneumatic tyre casing having an internal volume with a specific mean length and a specific cross section; the inner tube is in the form of a thin flexible cylinder with closed ends; the ends being tapered or stepped so that when located within a pneumatic tyre as aforesaid the ends of the inner tube are adapted to overlay one another to provide a scarfed joint between the ends, the overlapping section having a cross section substantially similar to that of the remainder of a non-overlapping section of tube. Alternatively, the inner tube can receive between the tapered or stepped ends an intermediate member such that each tapered or stepped end of the inner tube is adapted to overly a complementary tapered section of the intermediate member; the intermediate member being shaped so that in use the inner tube and the intermediate member serve to provide in combination an inner tube having a cross section of substantially uniform section along the axial.
Publication no. CN2098400 discloses an inflation-free inner tube of a tyre against pricking, which is composed of rubber (cloth curtain is adhered in the rubber). The middle of the inner tube is provided with two symmetric hole channels, and the wall thickness of the inner tube is between 0.4 to 0.8 cm. The elasticity and the weight loading ability of the inner tube are enlarged increasing the hole channels and the wall thickness of the inner tube. The inner tube is in disconnection shape, and the inner tube is provided with two endpoints which are convenient for installation or disassembly. The inner tube is fit for preparing a newly appeared base well rim, and the utility model is suitable for a bicycle and other small size vehicles.
Publication no. CN101959701 relates to an inner tube for a tyre, in particular for a bicycle, characterised in that the tube comprises a gas-tight elastomer layer comprising an elastomer composition that contains at least one so-called SIBS, a styrene/ isobutylene/ styrene thermoplastic elastomer, and in that the tube comprises a self-clogging material located inside the cavity defined by the sealed elastomer layer.
Publication no. IN1761/DEL/1997 discloses tube tire capable of simply, positively preventing the generation of a puncture due to contact of opposing portions of the wall surface of a tube. Double wall portions are formed at rim striking portions of a tube contained in a tire, and the internal spaces of the double wall portions are filled with a sealant. When the tire rides over an obstacle and the tire and the tube are clamped between the flange portions of a rim and the obstacle, the shock is damped by the double wall portions to prevent damage of the tube. Even if the double wall portions are damaged, the damaged portion is repaired with the sealant, thereby eliminating the generation of leakage of air.
Publication no. US7744789 discloses finite element analysis or thermocouple probes are used to determine the state of cure for each zone of a non-uniform, thick rubber article, such as a large tire or a tread for a tire. From this knowledge of those cure-limiting zones, heat transfer elements are added to the mold to enhance the transfer of heat into these cure-limiting zones and to provide a more optimum cure. The use of heat transfer pins and/or mini-sipes are an efficient and practical means of reducing total cure time in the press and optimizing cure state without substantially affecting the performance of the article such as the tire. Reductions in cure time of 10% or more are demonstrated.
Publication no. CN2327556 relates to a product of a non-aerated tyre, which is composed of a tyre cover and a unicellular rubber inner tube, wherein, the unicellular rubber inner tube is arranged in the tyre cover and arranged on a wheel hub. The utility model can be suitable for tyres of various vehicles, such as bicycles, tricycles, light motorcycles, etc. and has the advantages of convenience for users, favorable cushioning effect, no need of inflation, no care for puncture, time saving, labor saving, uniform stress for the inner tube and the tyre cover, and long service life of the tyre cover.
Indian Publication no. 7015/DELNP/2015 relates to a lightweight tire inner tube comprising a film tube with a wall thickness of 100 to 400 microns pneumatic tires containing the lightweight tire inner tube and related methods for manufacturing the light weight tire inner tube. The film tube is comprised of a film material comprising at least one thermoplastic engineering resin and optionally at least one saturated elastomer and the film material of the film tube has an oxygen permeability of 8 15 cm O/m•per day at 25° C.
Indian Publication no. IN559/DEL/2005 discloses small sacs, conterminous to each other in a particular assemblage and supplied compressed air by unfeigned integrated supplying system as described and shown in the figure.
Publication no. GB190619590 relates to the pneumatic. Non-continuous air-tubes are formed of uniform section throughout their length, the ends being closed by flat caps and adapted to overlap each other inside the tyre cover by at least eight inches.
In view of the above, there is a need for a technology to overcome the limitations in the listed prior art.

SUMMARY
In one aspect of the present disclosure, a puncture-resistant pneumatic tyre tube assembly is provided.
The puncture-resistant pneumatic tyre tube assembly includes a tyre and a hollow toroidal tube with a toroidal structure. The hollow toroidal tube includes a bottom area with an increased thickness designed to resist pinching when it comes into contact with the rim and the tyre during puncture or heavy load conditions and a top area with a standard thickness configured to make contact with the inner side of the tyre, wherein the tyre is configured to enclose the hollow tube within its inner circumference, ensuring full contact between the hollow tube and the tyre’s inner surface, thereby facilitating even pressure distribution during use.
In some aspects of the present disclosure, the bottom area of the hollow tube is designed with a gradually increasing thickness in the range of 15% to 25% greater than the top area, thereby providing additional reinforcement to reduce puncture risks and damage during high-impact or heavy-load conditions.
In some aspects of the present disclosure, the variable thickness in the bottom area of the hollow tube provides increased durability and resistance in the specific area where the tube contacts the rim, that is prone to pinching under heavy loads.
In some aspects of the present disclosure, the puncture-resistant pneumatic tyre tube assembly further includes a valve that is integrated into the tube, allowing for the filling of air or gas to inflate the tube and maintain the necessary internal pressure during operation.
In some aspects of the present disclosure, the tube's pinch area is reinforced with a thicker gauge to mitigate failure risks when subjected to heavy loads, ensuring enhanced puncture resistance in a variable gauge design.
In second aspect of the present disclosure, a method for improving puncture resistance in a pneumatic tyre tube assembly is provided. The method includes providing a hollow toroidal tube with a top area and a bottom area. The method further includes designing the bottom area of the hollow toroidal tube with a gradually increasing thickness in the range of 15% to 25% greater than the top area. The method further includes positioning the tube within a tyre such that the top area makes contact with the inner surface of the tyre. The method further includes mounting the tyre and tube on a rim in such a way that the bottom area of the tube directly contacts the rim. The method further includes reinforcing the bottom area to enhance puncture resistance and mitigate failure risks in the tube's pinch area. The method further includes ensuring even pressure distribution across the tyre to improve durability during high-impact or heavy-load conditions.
In some aspects of the present disclosure, the gradual increase in thickness in the bottom area of the hollow toroidal tube is designed to provide additional reinforcement in the region most prone to punctures, particularly in the area that makes contact with the rim.
In some aspects of the present disclosure, the tyre is configured to enclose the hollow tube in such a way that the hollow tube ensures full contact with the inner surface of the tyre, facilitating even pressure distribution during use.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations. In the drawing,
Figure 1A illustrates cross-section of an unfitted tube, in accordance with an aspect of the present disclosure;
Figure 1B illustrates a cross-sectional view of a conventional tyre, tube and rim assembly, in accordance with an aspect of the present disclosure;
Figure 1C illustrates a cross-sectional view of a puncture resistance tube assembly, in accordance with an aspect of the present disclosure; and
Figure 1D illustrates a tyre, tube and rim assembly with the improvement to overcome pinching and resultant puncture under impact load or heavy load conditions, in accordance with an aspect of the present disclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Various embodiments of the disclosure are discussed in detail below. While specific implementations are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without parting from the spirit and scope of the disclosure. Thus, the following description and drawings are illustrative and are not to be construed as limiting. Numerous specific details are described to provide a thorough understanding of the disclosure. However, in certain instances, known details are not described in order to avoid obscuring the description.
References to one or an embodiment in the present disclosure can be references to the same embodiment or any embodiment; and, such references mean at least one of the embodiments.
Reference to "one embodiment", "an embodiment", “one aspect”, “some aspects”, “an aspect” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others.
The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Alternative language and synonyms may be used for any one or more of the terms discussed herein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided.
A recital of one or more synonyms does not exclude the use of other synonyms.
The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only, and is not intended to further limit the scope and meaning of the disclosure or of any example term. Likewise, the disclosure is not limited to various embodiments given in this specification. Without intent to limit the scope of the disclosure, examples of instruments, apparatus, methods and their related results according to the embodiments of the present disclosure are given below. Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure. Unless otherwise defined, technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions will control.
Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims or can be learned by the practice of the principles set forth herein.
As mentioned before, there is a need for technology that overcomes these drawbacks associated with the prior arts. The present disclosure therefore provides an effective puncture resistance device, system and method. The present disclosure has variable gauge tube thickness for puncture resistance.
Figure 1A illustrates cross-section of an unfitted tube 10A, in accordance with an aspect of the present disclosure. Figure 1B illustrates a cross-sectional view of a conventional tyre, tube and rim assembly 100A, in accordance with an aspect of the present disclosure. Figure 1C illustrates a cross-sectional view of a puncture resistance tube 10B, in accordance with an aspect of the present disclosure. Figure 1D illustrates a tyre, tube and rim assembly 100B with the improvement to overcome pinching and resultant puncture under impact or heavy load conditions, in accordance with an aspect of the present disclosure. The term “system” and “assembly” refers to puncture-resistant pneumatic tyre tube assembly 100B and are interchangeably used across the context.
The puncture-resistant pneumatic tyre tube assembly includes a tyre (102) and a hollow toroidal tube (104) with a toroidal structure.
The toroidal structure includes a bottom area (104A) and a top area (104B). Herein the bottom area (104A) refers to side of the puncture-resistant pneumatic tube (104) adjacent to the rim (106) during usage. The top area (104B) refers to side of the puncture-resistant pneumatic tube (104) away from the rim (106) and adjacent to tyre (102) during usage.
The bottom area (104A) has an increased thickness compared to the existing tubes and designed to resist pinching when it comes into contact with the rim (106) and the tyre (102) during puncture or heavy load conditions
The top area (104B) with a standard thickness configured to make contact with the inner side of the tyre (102). The tyre (102) is configured to enclose the hollow tube (104) within its inner circumference, ensuring full contact between the hollow tube (104) and the tyre’s (102) inner surface, thereby facilitating even pressure distribution during use.
The bottom area (104A) of the hollow tube (104) is designed with a gradually increasing thickness in the range of 15% to 25% greater than the top area (104B), thereby providing additional reinforcement to reduce puncture risks and damage during high-impact or heavy-load conditions. In some aspects of the present disclosure, the variable thickness in the bottom area (104A) of the hollow tube (104) provides increased durability and resistance in the specific area where the tube (104) contacts the rim (106), that is prone to pinching under heavy loads.
The tyre (102) that is configured to enclose the hollow tube (104) that fits within a inner circumference, ensuring full contact between the hollow tube (104) and the tyre's (102) inner surface, facilitating even pressure distribution on use.
The puncture-resistant pneumatic tyre tube assembly (100B) further includes a valve (110) that is integrated into the tube (104), allowing for the filling of air or gas to inflate the tube (104) and maintain the necessary internal pressure during operation.
In some aspects of the present disclosure, the tube's pinch area (108) is reinforced with a thicker gauge to mitigate failure risks when subjected to heavy loads, ensuring enhanced puncture resistance in a variable gauge design. As illustrated in Figure 1A, the tube pinching area (108A) features a thin gauge of the tube (104) that is pinched. In contrast, Figure 1D depicts the tube pinching area (108B) with a thicker gauge of the tube (104) (shown in dotted circle), that has thicker bottom area (104A) which resists pinching in this area.
In another aspect of the present disclosure, a method for improving puncture resistance in a pneumatic tyre tube assembly (100B) includes the following steps:
- providing a hollow toroidal tube (104) with a bottom area (104A) and a top area (104B);
- designing the bottom area (104A) of the hollow toroidal tube (104) with a gradually increasing thickness in the range of 15% to 25% greater than the top area (104B);
- positioning the tube (104) within a tyre (102) such that the top area (104B) makes contact with the inner surface of the tyre (102);
- mounting the tyre (102) and tube (104) on a rim (110) in such a way that the bottom area (104A) of the tube directly contacts the rim (110);
- reinforcing the bottom area (104A) to enhance puncture resistance and mitigate failure risks in the tube's pinch area (108A); and
- ensuring even pressure distribution across the tyre (102) to improve durability during high-impact or heavy-load conditions.
In some aspects of the present disclosure, the gradual increase in thickness in the bottom area (104A) of the hollow toroidal tube (104) is designed to provide additional reinforcement in the region most prone to punctures, particularly in the interface area of tyre that makes contact with the rim (106).
In some aspects of the present disclosure, the tyre (102) is configured to enclose the hollow tube (104) in such a way that the hollow tube (104) ensures full contact with the inner surface of the tyre (102), facilitating even pressure distribution during use.
The tube (104) which has a hollow torroidal structure has a bottom area (104A) and a top area (104B) having differing and variable thickness and fits inside the tyre (102) making full contact with the tyre inner portion and a rim (106) on which the tyre is mounted, the hollow portion in which air needs to be filled, a valve (110) for filling the air, and the tube (104) having a thicker gauge at the tube pinch area (108).
The present disclosure introduces a variable gauge tube with a gradually increasing thickness along its sectional periphery, specifically targeting the bottom area, which represents the contact area of tube with rim, and the merging point of tyre rim interface. By increasing the thickness of the tube in this region by 15% to 25%, the system significantly improves puncture resistance and load-bearing capabilities.
In Figure 1A, a cut section of a standard tube is depicted, illustrating the conventional design. Traditional tubes often suffer from deflection or failure under heavy load conditions, leading to punctures and reduced tire performance. However, the present disclosure overcomes these drawbacks by incorporating a special tyre, tube and rim assembly that prevents pinching and puncture under impact load conditions.
The variable gauge tube is a key component of the system, which is made of rubber or elastomeric material.
It is important to note that the variable gauge tube is specifically designed for applicability with different tire sizes. The system ensures enhanced puncture resistance and load carrying capacity, thereby increasing the overall performance and longevity of the tires.
The present disclosure offers an effective puncture resistance system and method for tires, employing a variable gauge tube with a gradually increasing thickness and a special tube and rim assembly. The system enhances puncture resistance, load capacity, and overall tire performance, making it ideal for heavy-duty applications in various industries.
The improved tube (increased gauge at failure area) field tested and 70 to 80 % of tested tyres have worn-out completely with no tube pinching issues. Thus, pinching complaint is zero.
In an exemplary scenario, the puncture-resistant pneumatic tyre tube assembly (100B) is utilized in a commercial transportation vehicle that frequently carries heavy cargo over long distances. In this scenario, during puncture the vehicle is subject to continuous heavy loads and repeated stress, which increases the risk of punctures and pinching, particularly at the points where the tube (104) contacts the rim (106) as well as the contact point of tyre with rim. As the vehicle moves with the loaded cargo, the hollow toroidal tube (104) experiences significant pressure, especially in the bottom area (104A), where the contact with the rim (106) occurs. The variable thickness of the bottom area (104A), which is 15% to 25% greater than the top area (104B), provides extra reinforcement to withstand the increased stress from the heavy cargo, preventing the tube from pinching or collapsing. When the vehicle is carrying heavy loads, the tyre tends to lift or rock from its interface area with rim, thereby creating a gap into which the tube may get pushed and get pinched. This pinch area (108), a critical section prone to punctures, is further protected due to the reinforced gauge, which prevents pinched punctures of tube caused by the weight of the cargo pressing the tyre against the rim and catching the tube in between. The tyre (102) is designed to fully enclose the tube (104), facilitating even pressure distribution throughout the tyre’s inner surface. This ensures a smoother ride despite the heavy load, reducing the overall wear on the tyre and tube. The structural design also prevents uneven wear and tear, extending the lifespan of both the tyre and tube, which is especially important in commercial vehicles that rely on durability and minimal downtime. Additionally, the valve (110) integrated into the tube (104) allows for easy adjustment of the internal pressure, enabling the operator to inflate or deflate the tyre based on load requirements. This adaptability ensures that the tyre maintains optimal pressure during various stages of the journey, further reducing the risk of puncture and maintaining efficiency.
,CLAIMS:1. A puncture-resistant pneumatic tyre tube assembly (100B), comprising:
a tyre (102); and
a hollow toroidal tube (104) with a toroidal structure comprises:
a bottom area (104A) with an increased thickness designed to resist pinching when it comes into contact with the rim (106) and the tyre (102) during puncture or heavy load conditions; and
a top area (104B) with a standard thickness configured to make contact with the inner side of the tyre (102),
wherein the tyre (102) is configured to enclose the hollow tube (104) within its inner circumference, ensuring full contact between the hollow tube (104) and the tyre’s (102) inner surface, thereby facilitating even pressure distribution during use.

2. The puncture-resistant pneumatic tyre tube assembly (100B) as claimed in claim 1, wherein the bottom area (104A) of the hollow tube (104) is designed with a gradually increasing thickness in the range of 15% to 25% greater than the top area (104B), thereby providing additional reinforcement to reduce puncture risks and damage during high-impact or heavy-load conditions.

3. The puncture-resistant pneumatic tyre tube assembly (100B) as claimed in claim 2, wherein the variable thickness in the bottom area (104A) of the hollow tube (104) provides increased durability and resistance in the specific area where the tube (104) contacts the rim (106), that is prone to pinching under heavy loads.

4. The puncture-resistant pneumatic tyre tube assembly (100B) as claimed in claim 2, further comprising a valve (110) that is integrated into the tube (104), allowing for the filling of air or gas to inflate the tube (104) and maintain the necessary internal pressure during operation.

5. The puncture-resistant pneumatic tyre tube assembly (100B) as claimed in Claim 4, wherein the tube's pinch area (108) is reinforced with a thicker gauge to mitigate failure risks when subjected to heavy loads, ensuring enhanced puncture resistance in a variable gauge design.

6. A method for improving puncture resistance in a pneumatic tyre tube assembly (100B), comprising:
a) providing a hollow toroidal tube (104) with a bottom area (104A) and a top area (104B);
b) designing the bottom area (104A) of the hollow toroidal tube (104) with a gradually increasing thickness in the range of 15% to 25% greater than the top area (104B);
c) positioning the tube (104) within a tyre (102) such that the top area (104B) makes contact with the inner surface of the tyre (102);
d) mounting the tyre (102) and tube (104) on a rim (110) in such a way that the bottom area (104A) of the tube directly contacts the rim (110);
e) reinforcing the bottom area (104A) to enhance puncture resistance and mitigate failure risks in the tube's pinch area (108); and
f) ensuring even pressure distribution across the tyre (102) to improve durability during high-impact or heavy-load conditions.
7. The method for improving puncture resistance in a pneumatic tyre tube assembly (100B) as claimed in claim 7, wherein the gradual increase in thickness in the bottom area (104A) of the hollow toroidal tube (104) is designed to provide additional reinforcement in the region most prone to punctures, particularly in the area that makes contact with the rim (106).

8. The method for improving puncture resistance in a pneumatic tyre tube assembly (100B) as claimed in claim 1, wherein the tyre (104) is configured to enclose the hollow tube (102) in such a way that the hollow tube (102) ensures full contact with the inner surface of the tyre (102), facilitating even pressure distribution during use.