FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
AND
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION (See section 10; rule 13)
TITLE OF THE INVENTION
NEW PACKAGING SYSTEM FOR ALL TYRES WITH SENSITIVE AND
DELICATE STRUCTURE
APPLICANT
CEAT LIMITED
of RPG HOUSE, 463, Dr. Annie Besant Road,
Worli, Mumbai 400 030, India;
Nationality: India
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is to be performed

FIELD OF THE INVENTION
[0001] The present invention relates to a development of a tyre packaging material having a shape which is covering all polygons, including circle.
BACKGROUND OF THE INVENTION
[0002] CEAT developed and proved puncture proof technology. During the commercialization stage, one of the major hurdle was logistic for such special category tyres. With the highly sticky, sealant gel material inside the tire, transportation was very difficult as chances of dust accumulation, foreign material contamination were high. Also, chances were there of damage in sealant gel material during transits.
[0003] To overcome the above mentioned problems, CEAT designed “Carry bags” to do logistics of these tyres. This would save sealant gel material from foreign material contamination and resist impact damages during transit as the tyres were transported & delivered to desired location more than or equal to 5000 kms from the source location. But the results were not encouraging. The issue of sealant gel damage observed during transit due to impact damages on coated tyres during transportation and multiple handling at different locations. During transportation, tyres get damaged because of deformative forces acting on it. A protective packaging system is required in order to prevent and resist all deformative forces for cured and uncured material.
[0004] In normal tyres deformative forces act on the tyres which damages the bead area. This will affect the fitment of said deformed tyre on the wheel rim. During transit the tyres are loaded one above other the tyres at the bottom gets deformed in shape. This impacts the fitment of the tyre on the wheel rim as well as it will result in the wobbling effect to the wheel and vehicle on which such tyres are fitted.

[0005] To eliminate the impact damages and deformative damages on tyres and prevent sealant material of tubeless tyres from deformation, CEAT replaced Carry bags by “Rectangular shaped packaging box”. In this packaging box, tyre is placed inside the box with 04nos. corner buffers to resist impact damages during transit. Rectangular box type packaging is similar to packaging box material, which is used for electronic/fragile material. The packaging boxes proved to be better than bags on the basis of a transit trial done.
[0006] But, the rectangular shaped packaging box developed has increased the product cost. Additional drawbacks identified with this packaging are - excess space for storage required in plant, dispatch quantity reduced from 1200nos to 750nos, tyre packaging time increased and difficulty in handling.
[0007] To overcome the demerits of rectangular packaging box, CEAT decided to explore for high strength but low cost packaging concept which is easy to handle.
OBJECT OF THE INVENTION
[0008] The object of the present invention is to safeguard the tyre and the gel from external damages & heavy load imposed on the tyre during transportation with the help of packaging material.
[0009] Another object of the present invention is to make the packaged tyre handling easy.
[0010] Yet another object of the present invention is to provide a low cost & environmental friendly packaging material for a tyre.
BRIEF DESCRIPTION OF THE DRAWINGS
In accordance to this invention the figures are described as follows:

[0011] Figure 1 shows a Polygonal Shape segment in opened form.
[0012] Figure 2 shows a Polygonal Shape packaging Segment in assembled form
[0013] Figure 3 shows a Tyre partly inscribed in the polygonal shape.
[0014] Figure 4 shows a full Tyre inscribed in the polygonal shape.
[0015] Figure 5 shows a Buckle Type Locking Mechanism.
DETAILED DESCRIPTION OF THE INVENTION
[0016] For the purposes of the following detailed description, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, dimensions mentioned in the figures are to be understood as being modified in all instances. It is to be noted that, unless otherwise stated, all polygonal shapes given in this specification and appended claims refer to the part of the material and the recitation of all the polygonal shapes is meant to include.
[0017] Thus, before describing the present invention in detail, it is to be understood that this invention is not limited to particularly exemplified shape that may of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments of the invention only, and is not intended to limit the scope of the invention in any manner.
[0018] CEAT developed a high strength but low cost corrugated box packaging concept which is easy to handle. Polygonal shape concept for packing a single tyre, which is hollow at centre, was developed. This stiff corrugated material is designed to sustain impact damages during transit and also to resist multiple handling damages. It can sustain a weight of approx. 70-80 kgs. Additional benefits of polygonal shaped packaging material, when compared with rectangular box, are –it is low in cost, can withstand impact damages imposed on coated tyres,

less space for storage required in plant and more no. of tyres can be dispatched as compared to rectangular type packaging material.
[0019] Polygonal packaging caters flimsy with structural differences, with foam, with gel, foldable type, Tyres with chip inside and all kind of such sensitive materials and structure to be taken care of till the inflation point.
[0020] Accordingly the present invention discloses a new packaging system for all tyres with sensitive and delicate structure comprising at least one flat polygonal shape material (8) provided with predetermined shapes of polygons (2,3,4) configured to be bended at the longest side of each of the said predetermined shapes of polygons (2,3,4) to form a polygonal shape segment (10) to cover a section of the tyre; at least one locking mechanism provided on said polygonal shaped material (8) for locking said flat polygonal shaped segment (10); plurality of said polygonal shape segments (10) are configured to be mounted on the tyre in a series to form packing box assembly (9) to safeguard and wrap the whole tyre and to withstand the heavy loads and resist the impact damages on the tyre.
[0021] The flat polygonal shape segment (10) of packaging material (8) is configured with various shapes of polygons like trapezoids (2,4), rectangle (4), etc. The flat polygonal shape material (8) is bent on machine or manually at the longest side shared by each of the predetermined shapes of polygon (2,3,4) on said flat polygonal shape material (8) to form polygonal shape segment (10). The plurality of said polygonal shape segments (10) are configured to be mounted on the tyre in a series to safeguard and wrap the whole tyre and to withstand the heavy loads and resist the impact damages on the tyre. The flat polygonal shape segment (10) consists of at least two locks on both ends of the flat polygonal shaped material (8) to form single rectangular base part (11) configured for locking of said flat polygonal shaped segment (10).

[0022] The rectangular base part (11) is configured to cover bead portion of the tyre and plurality of polygonal shaped segments (10) are wrapped throughout the circumference of the circle to cover the whole tyre to form a regular polygon (9). The polygonal shaped material (8) is configured with a locking mechanism which is a buckle type locking mechanism consisting of a rectangular slot (buckle (7)) and a foldable lock (flap (6)) capable of inserting into said buckle (7) ensuring locking of said flat polygonal shaped segment (10) on tyre. The tyre packed inside is inscribed in the polygonal shape packaging box assembly (9) formed by joining the number of packing segments (10). The tyre packed in packaging box assembly (9) is configured to sustain weight in a range of 80 to 90 kgs protecting the tyre from any deformation in said packing box assembly (9). The tyre packed in packaging box assembly (9) are configured to be stacked one above other during transportation or otherwise and to resist any kind of deformation of tyre packed in said packaging box assembly (9)
[0023] Figure 1 shows the general steps carried out in packing a tyre with polygonal shaped packaging material (8). All the polygons i.e. trapezoids(2,4), rectangle (3) and locks share their longest side and when joined together make a flat polygonal shape.
[0024] Flat Polygonal Shape is a part of a polygonal shaped material developed which may be a regular or irregular polygon. This polygonal shape is again formed integrating regular or irregular polygons
[0025] Flat polygonal shape segment (Fig.1) is bent manually or on machine at the longest side shared by each of the pre-provided polygonal on said flat polygonal shape segment. It is then wrapped on the tyre covering a section of the tyre. The whole tyre is wrapped with a series of polygonal shape segment (10). The tyre is safeguard with this wrapping which has the ability to withstand the heavy loads and resist the impact damages.

[0026] This polygonal shaped material (8) consist of a locking mechanism which is a buckle type design. It locks the flat polygonal shaped segment (10). A flat polygonal shape segment (10) consist of 02nos. of locks, both ends of the flat polygonal shape are locked with each other (fig-1) (Lock 1& lock 2 same dimensions) to form single base part.
[0027] The following definitions are used in connection with the present application unless the context indicates otherwise. As used herein,
[0028] The term “Polygonal” refers to shape of the material developed- which is wrapped on the tyre gives the indication of a regular or irregular polygon
[0029] The term “Flat Polygonal” refers to the shape of the segment of polygon which is covers the section of the tyre
[0030] The term “Trapezoid (2&4)” refers to a part of the flat polygonal shape material which covers the sidewall of a tyre from both sides. It prevents tyres from the heavy loads imposed when tyres stacked horizontally (Refer fig.1)
[0031] The term “Rectangle (3)” refers to a part of the flat polygonal shape material which covers the tread part of a tyre. It resist the longitudinal and radial loads imposed on the tyres which is closely stacked with other tyres during transportation (Refer fig.1)
[0032] The term “Lock (1&5)” refers to a part of the flat polygonal shape which locks the polygonal segment forming the base part of the segment. Both locks when joined together form a rectangle (11). It covers bead portion of the tyre and prevents the gel from contamination and deformation (Refer fig.1)
[0033] Flat polygonal shape material (8) is folded to form a polygonal shape segment (10). Both locks are joined together to form a rectangle. It covers bead

portion of the tyre and prevents the gel from contamination and deformation (Refer Fig.2)
[0034] As tyre is circular in shape, it is wrapped by the polygonal shape segment (10). Therefore, number of segments are wrapped throughout the circumference of the circle. These segments (10) holding a tyre inside combine to form a regular polygon. Tyre packed inside is inscribed in the polygonal shape formed by joining the number of packing segments (Refer Fig.3 & 4)
Description of Locking Mechanism (Refer Fig.5)
[0035] Buckle Type locking mechanism designed for locking the packaging material, which covers the whole section of the tyre. Buckle type locking mechanism consists of a rectangular slot (buckle (7)) and a foldable lock (Flap (6)). Flap is inserted into buckle ensuring that lock didn’t get open when packed tyres are transported from one location to other.
[0036] The tyre packed in packaging box assembly is capable of sustaining around 80 to 90 kgs of weight to avoid any deformation in said packing box assembly (9) thereby allowing the stacking of tyres one above other during transportation or otherwise to resist any kind of deformation in tyre packed in said packaging box assembly.
E → Total width of the locking mechanism when both locking system joined (1&5) (Refer Fig.1)
G → Width of the locking mechanism. It covers bead to bead end of the tyre. Both ends are locked with each other (Fig. b) (having the same width) to form single base part. It prevents bead area of the tyre from deformation caused due to heavy load. It also prevents any foreign material from entering inside the tyre.
H → Length of the locking mechanism. It covers base part of a tyre.

I →Half length of the locking mechanism. Foldable lock is attached to it. It covers the base part of the tyre.
J → It is the integrated part holding both I & foldable lock.
K-I → "K minus I" is the foldable lock system. It is inserted into the rectangular slot for locking the mechanism.
L→ Half length of locking mechanism. It is half of 'G'. It covers bead to bead end of the tyre.
P → P is the length of the buckle, which holds the inserted foldable lock ensuring the proper locking.
Q→ Q is width of the buckle, which holds the inserted foldable lock ensuring the proper locking.

WE CLAIM:
1. New packaging system for all tyres with sensitive and delicate structure
comprising
at least one flat polygonal shape material (8) provided with predetermined shapes of polygons (2,3,4) configured to be bended at the longest side of each of the said predetermined shapes of polygons (2,3,4) to form a polygonal shape segment (10) to cover a section of the tyre;
at least one locking mechanism provided on said polygonal shaped material (8) for locking said flat polygonal shaped segment (10);
plurality of said polygonal shape segments (10) are configured to be mounted on the tyre in a series to form packing box assembly (9) to safeguard and wrap the whole tyre and to withstand the heavy loads and resist the impact damages on the tyre.
2. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 1 wherein said flat polygonal shape segment (10) of packaging material (8) is configured with various shapes of polygons like trapezoids (2,4), rectangle (4), etc.
3. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 1 wherein said flat polygonal shape material (8) is bent on machine or manually at the longest side shared by each of the predetermined shapes of polygon (2,3,4) on said flat polygonal shape material (8) to form polygonal shape segment (10).
4. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 1 wherein plurality of said polygonal shape segments (10) are configured to be mounted on the tyre in a series to safeguard and wrap the whole tyre and to withstand the heavy loads and resist the impact damages on the tyre.

5. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 1 wherein said flat polygonal shape segment (10) consists of at least two locks on both ends of the flat polygonal shaped material (8) to form single rectangular base part (11) configured for locking of said flat polygonal shaped segment (10).
6. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 5 wherein said rectangular base part (11) is configured to cover bead portion of the tyre and plurality of polygonal shaped segments (10) are wrapped throughout the circumference of the circle to cover the whole tyre to form a regular polygon (9).
7. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 1 wherein said polygonal shaped material (8) is configured with a locking mechanism which is a buckle type locking mechanism consisting of a rectangular slot (buckle (7)) and a foldable lock (flap (6)) capable of inserting into said buckle (7) ensuring locking of said flat polygonal shaped segment (10) on tyre.
8. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 1 wherein said tyre packed inside is inscribed in the polygonal shape packaging box assembly (9) formed by joining the number of packing segments (10).
9. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 1 wherein said tyre packed in packaging box assembly (9) is configured to sustain weight in a range of 80 to 90 kgs protecting the tyre from any deformation in said packing box assembly (9).
10. The new packaging system for all tyres with sensitive and delicate structure as claimed in claim 1 wherein said tyre packed in packaging box assembly (9)

are configured to be stacked one above other during transportation or otherwise and to resist any kind of deformation of tyre packed in said packaging box assembly (9).

ABSTRACT
NEW PACKAGING SYSTEM FOR ALL TYRES WITH SENSITIVE AND
DELICATE STRUCTURE
Accordingly the present invention discloses a new packaging system for all tyres with sensitive and delicate structure comprising at least one flat polygonal shape material (8) provided with predetermined shapes of polygons (2,3,4) configured to be bended at the longest side of each of the said predetermined shapes of polygons (2,3,4) to form a polygonal shape segment (10) to cover a section of the tyre; at least one locking mechanism provided on said polygonal shaped material (8) for locking said flat polygonal shaped segment (10); plurality of said polygonal shape segments (10) are configured to be mounted on the tyre in a series to form packing box assembly (9) to safeguard and wrap the whole tyre and to withstand the heavy loads and resist the impact damages on the tyre.