WO2025053916A1

WO2025053916A1 - Polyurethane flexure-elongated composite spoke bonded combination for non-pneumatic tire and methods of producing same

Info

Publication number: WO2025053916A1
Application number: PCT/US2024/039494
Authority: WO
Inventors: Vishal K. Chaurasia; Daniel Hunt; Nicholas J. HARP
Original assignee: Bridgestone Americas Tire Operations, Llc
Priority date: 2023-09-08
Filing date: 2024-07-25
Publication date: 2025-03-13

Abstract

A method for producing a polyurethane flexure-elongated composite spoke bonded combination for use in a non-pneumatic tire, the polyurethane flexure-elongated composite spoke bonded combination produced by the method, and a polyurethane flexure-elongated composite spoke bonded combination for use in a non-pneumatic tire. The method includes abrading the first surface (at an end) of a cured elongated composite spoke and ultimately insert molding a polyurethane flexure onto the cured elongated composite spoke. Also disclosed are non-pneumatic tires incorporating a polyurethane flexure-elongated composite spoke bonded combination made by the disclosed methods, resulting from the disclosed methods, or as otherwise disclosed herein. The polyurethane flexure-elongated composite spoke bonded combination has a specified peel strength.

Description

POLYURETHANE FLEXURE-ELONGATED COMPOSITE SPOKE BONDED COMBINATION FOR NONPNEUMATIC TIRE AND METHODS OF PRODUCING SAME

FIELD

[0001] The present application is directed to a polyurethane flexure-elongated composite spoke bonded combination for use in non-pneumatic Ores and to related methods of producing the polyurethane flexure-elongated composite spoke bonded combination and non-pneumatic tires containing the bonded combination.

BACKGROUND

[0002] Conventional (pneumatic) tires are inflated with air. Non-pneumatic tires can be considered airless because they do not rely upon air inflation to support vehicle weight or to absorb shock from a road surface. A non-pneumatic tire offers advantages including lower maintenance and lack of puncture risk. Various designs have been proposed for non-pneumatic tires including those which make use of a network of spokes connected to an inner rim-like structure and covered by an outer band or ring and a relatively thin layer of rubber as tread. In such a design, the spokes function to provide support for the vehicle weight.

SUMMARY

[0003] Disclosed herein is a polyurethane flexure-elongated composite spoke bonded combination for use in non-pneumatic tires, methods of producing the same, and non-pneumatic tires incorporating the polyurethane flexure-elongated composite spoke bonded combination.

[0004] In a first embodiment, a method for producing a polyurethane flexure-elongated composite spoke bonded combination for use in non-pneumatic tires is disclosed. This method of the first embodiment comprises providing a cured elongated composite spoke having an end with a first surface and a second surface, wherein the cured elongated composite spoke is comprised of fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, and combinations thereof and an epoxy resin; abrading the first surface of the cured elongated composite spoke to produce a roughened first surface; and insert molding a polyurethane flexure onto at least a portion of the roughened first surface of the cured elongated composite spoke, thereby producing a polyurethane flexure-elongated composite spoke bonded combination having a peel strength of at least 70 pli (at least 12000 N/m), preferably at least 90 pli (at least 16000 N/m), more preferably at least 100 pli at 17000 N/m, as determined using a 90 degree peel strength test (in accordance with ASTM D6892/D903).

[0005] In a second embodiment, a polyurethane-flexure elongated composite spoke bonded combination produced by the method of the first embodiment is disclosed.

[0006] In a third embodiment, a non-pneumatic tire incorporating the polyurethane- flexure elongated composite spoke bonded combination of the second embodiment is disclosed.

[0007] In a fourth embodiment, a polyurethane flexure-elongated composite spoke bonded combination for use in non-pneumatic tires is disclosed. This polyurethane flexure- elongated composite spoke bonded combination comprises a cured elongated composite spoke having an end with a first surface and a second surface, wherein the cured elongated composite spoke is comprised of fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, and combinations thereof and an epoxy resin; and a polyurethane flexure bonded to the end of the cured elongated composite spoke at its first surface with a peel strength of at least 70 pli (at least 12000 N/m), preferably at least 90 pli (at least 16000 N/m), more preferably at least 100 pli at 17000 N/m, as determined using a 90 degree peel strength test (in accordance with ASTM D6892/D903), wherein the end of the elongated composite spoke has a roughened surface upon at least its first surface underneath the bonded polyurethane flexure..

[0008] In a fifth embodiment, a non-pneumatic tire incorporating the polyurethane- flexure elongated composite spoke bonded combination of the fourth embodiment is disclosed.

DETAILED DESCRIPTION

[0009] In a first embodiment, a method for producing a polyurethane flexure-elongated composite spoke bonded combination for use in non-pneumatic tires is disclosed. This method of the first embodiment comprises providing a cured elongated composite spoke having an end with a first surface and a second surface, wherein the cured elongated composite spoke is comprised of fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, and combinations thereof and an epoxy resin; abrading the first surface of the cured elongated composite spoke to produce a roughened first surface; and insert molding a polyurethane flexure onto at least a portion of the roughened first surface of the cured elongated composite spoke, thereby producing a polyurethane flexure-elongated composite spoke bonded combination having a peel strength of at least 70 pli (at least 12000 N/m), preferably at least 90 pli (at least 16000 N/m), more preferably at least 100 pli at 17000 N/m, as determined using a 90 degree peel strength test (in accordance with ASTM D6892/D903).

[0010] In a second embodiment, a polyurethane-flexure elongated composite spoke bonded combination produced by the method of the first embodiment is disclosed.

[0011] In a third embodiment, a non-pneumatic tire incorporating the polyurethane- flexure elongated composite spoke bonded combination of the second embodiment is disclosed.

[0012] In a fourth embodiment, a polyurethane flexure-elongated composite spoke bonded combination for use in non-pneumatic tires is disclosed. This polyurethane flexure- elongated composite spoke bonded combination comprises a cured elongated composite spoke having an end with a first surface and a second surface, wherein the cured elongated composite spoke is comprised of fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, and combinations thereof and an epoxy resin; and a polyurethane flexure bonded to the end of the cured elongated composite spoke at its first surface with a peel strength of at least 70 pli (at least 12000 N/m), preferably at least 90 pli (at least 16000 N/m), more preferably at least 100 pli at 17000 N/m, as determined using a 90 degree peel strength test (in accordance with ASTM D6892/D903), wherein the end of the elongated composite spoke has a roughened surface upon at least its first surface underneath the bonded polyurethane flexure..

[0013] In a fifth embodiment, a non-pneumatic tire incorporating the polyurethane- flexure elongated composite spoke bonded combination of the fourth embodiment is disclosed.

Uncured Elongated Composite Spoke

[0014] According to the first-fifth embodiments, an uncured elongated composite spoke is provided which will become part of the polyurethane flexure elongated composite spoke bonded combination. According to the first-fifth embodiments, the spoke is comprised of a composite material and has an elongated shape. It should be understood that the elongated composite spoke is cured prior to abrading (as discussed below). In certain embodiments of the first-fifth embodiments, the elongated shape of the spoke can be understood as being a rod or rod-like. According to the first-fifth embodiments, the elongated composite spoke can be understood as having a first end and a second end, with the first end being the end which will attach to the outer ring of a non-pneumatic tire (via the polyurethane flexure) and the second end being the end which will attach (either directly or indirectly) to an inner rim-like structure of a non-pneumatic tire. According to the first-fifth embodiments, the elongated composite spoke has an end (the first end) with a first surface and a second surface. As discussed in more detail below, abrading is used upon at least the first surface of the spoke to produce a roughened first surface.

[0015] The spoke is elongated in that it extends radially between the first end and the second end. In certain embodiments of the first-fifth embodiments, the elongated composite spoke has a substantially rectangular cross section that includes a first surface and a second surface facing opposite the first surface. In other alternative embodiments of the first-fifth embodiments, the spoke may have any desired cross section shape (e.g., circle, ellipse, diamond, hexagon, etc.) or may have a combination of different cross section shapes; in certain embodiments of the foregoing when the cross section shape is circular or ell iptical, the first end of the spoke has a first flattened surface and optionally a second flattened surface. In certain embodiments of the first-fifth embodiments, the spoke has a constant thickness between the first end and the second end. In alternative embodiments of the first-fifth embodiments, the thickness of a spoke may vary between the first and second ends; for example, the spoke may have relatively thicker portions at the first and second ends and a relatively thinner portion between the ends.

[0016] According to the first-fifth embodiments, the composite spoke is comprised of fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, and combinations thereof, and an epoxy resin. Thus, the term composite can be understood as referring to a combination of one or more of such fibers with an epoxy resin. In certain embodiments of the first-fifth embodiments, the composite spoke is comprised of carbon fibers and an epoxy resin. In other embodiments of the first-fifth embodiments, the composite spoke is comprised of glass fibers and an epoxy resin. In yet other embodiments of the first-fifth embodiments, the composite spoke is comprised of aramid fibers and an epoxy resin.

[0017] As mentioned above, the elongated composite spoke of the first-fifth embodiments is comprised of materials which include an epoxy resin. The properties of the epoxy resin may vary. In preferred embodiments of the first-fifth embodiments, the epoxy resin of the cured elongated composite spoke has a cure time (/.e., prior to curing or in an uncured form) of no more than 15 minutes (e.g., 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5 minutes or less) at 150 °C, 5-15 minutes at 150 °C, preferably no more than 12 minutes (e.g., 12, 11, 10, 9, 8, 7, 6, 5 minutes or less) at 150 °C or 5-12 minutes at 150 °C. In other embodiments of the first-fifth embodiments, the epoxy resin of the uncured elongated composite spoke has a cure time (i.e., prior to curing or in an uncured form) of more than 15 minutes (e.g., 16 minutes, 30 minutes, 45 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, 6 hours, 7 hours, 8 hours, 9 hours, 10 hours, 11 hours, 12 hours, 13 hours, 14 hours, 15 hours, 16 hours, 17 hours, 18 hours, 19 hours, 20 hours, 21 hours, 22 hours, 23 hours, 24 hours, or more) at 150 °C, 16 minutes to 24 hours, or 16 minutes to 6 hours (e.g., 16 minutes, 30 minutes, 45 minutes, 1 hour, 2 hours, 3 hours, 4 hours, 5 hours, or 6 hours) at 150 °C. It should be understood that the same epoxy resin will be present in the elongated spoke present in the polyurethane flexure-elongated composite spoke bonded combination and the non-pneumatic tire incorporating the combination.

Abrading

[0018] As mentioned above, the method of the first embodiment includes abrading at least the first surface of the uncured composite spoke to produce a roughened surface upon at least its first surface. In certain embodiments of the first embodiment, the method includes abrading (only) the first surface of the uncured composite spoke to produce a roughened surface upon the first surface of the uncured composite spoke. In other embodiments of the first embodiment, the method incudes abrading both the first surface and the second surface of the uncured composite spoke to produce a roughened surface upon both the first surface and second surface of the uncured composite spoke combination; in certain such embodiments, abrading includes abrading the entire outer surface of the first end of the elongated spoke (i.e., both the first surface and the second surface as well as any other surfaces between those two surfaces). As should be apparent from the discussion below (e.g., insert molding), the polyurethane flexure- elongated composite spoke bonded combination of the second and fourth embodiments includes a roughened surface (resulting from the abrading) upon at least its first surface (at the first end) which will be underneath the bonded polyurethane flexure and facilitate secure bonding of the polyurethane flexure. The non-pneumatic tire of the third embodiment has incorporated the polyurethane flexure-elongated composite spoke bonded combination of the second embodiment, and, thus, will include the same roughened surface as the second embodiment. It should be understood that the foregoing particulars of abrading may also be used to produce the polyurethane flexure-elongated composite spoke bonded combination of the second and fourth embodiments, as well as the bonded combination used in the non-pneumatic tire of the third and fifth embodiments.

[0019] According to the method of the first embodiment, the particulars of abrading may vary. In certain embodiments of the first embodiment, the abrading comprises grit blasting; in certain such embodiments, the abrading consists of grit blasting. In other embodiments of the first embodiment, the abrading comprises using abrasive paper to produce the roughened surface; in certain such embodiments, the abrading consists of using abrasive paper to produce the roughened surface. It should be understood that the foregoing particulars of abrading may also be used to produce the polyurethane flexure-elongated composite spoke bonded combination of the second and fourth embodiments, as well as the bonded combination used in the non-pneumatic tire of the third and fifth embodiments.

[0020] In those embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the particular particles used, the particles size, and the pressure applied during grit blasting may vary. In certain embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the grit blasting uses particles selected from the group consisting of aluminum oxide, alumina zirconia, silicon carbide, silica sand, garnet, steel, iron, quartz, walnut shells, and combinations thereof. In preferred embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the grit blasting uses particles comprising aluminum oxide. In those embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the size of the particles used in grit blasting may vary. In certain embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the grit blasting comprises using particles having a grit of 50 to 120 (e.g., 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, or 120 grit) or 330 to 120 microns (e.g., 330, 320, 310, 300, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, or 120 microns). In those embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, various pressures can be applied during grit blasting. In certain embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, a pressure of 30 to 80 psi (e.g., 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 psi) or 200 to 550 kPa (e.g., 200, 250, 300, 350, 400, 450, 500, or 550 kPa) is used. In certain embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the grit blasting uses particles of a type or types as discussed above in combination with a grit size as discussed above. In other embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the grit blasting uses particles of a type or types as discussed above, having a grit size as discussed above, and using a pressure as discussed above. In other embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the grit blasting uses particles of a type or types as discussed above in combination with using a pressure as discussed above. In yet other embodiments of the first embodiment wherein abrading comprises or consists of grit blasting, the grit blasting uses particles having a grit size as discussed above in combination with a pressure as discussed above. It should be understood that the foregoing particulars relating to particles may also be used to produce the polyurethane flexure-elongated composite spoke bonded combination of the second and fourth embodiments, as well as the bonded combination used in the non-pneumatic tire of the third and fifth embodiments.

[0021] In those embodiments of the first embodiment wherein abrading comprises or consists of using abrasive paper, the particular particles used and their size may vary. In certain embodiments of the first embodiment wherein abrading comprises or consists of using abrasive paper, the abrasive paper comprises particles selected from the group consisting of aluminum oxide, alumina zirconia, silicon carbide, silica sand, garnet, steel, iron, quartz, walnut shells, and combinations thereof. In certain embodiments of the first embodiment wherein abrading comprises or consists of using abrasive paper, the abrasive paper comprises using particles having a grit of 50 to 120 (e.g., 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, or 120 grit) or 330 to 120 microns (e.g., 330, 320, 310, 300, 290, 280, 270, 260, 250, 240, 230, 220, 210, 200, 190, 180, 170, 160, 150, 140, 130, or 120 microns). In those embodiments of the first embodiment wherein abrading comprises or consists of using abrasive paper, the pressure used with the abrasive paper may vary. In certain embodiments of the first embodiment wherein abrading comprises or consists of using abrasive paper, the pressure used corresponds to the pressures mentioned above for grit blasting. In certain embodiments of the first embodiment wherein abrading comprises or consists of using abrasive paper, the abrasive paper has particles of the type or types as discussed above in combination with particles having a grit as discussed above; in certain such embodiments, the abrasive paper is also used with one of the pressures mentioned above. It should be understood that the foregoing particulars relating to particles may also be used to produce the polyurethane flexure-elongated composite spoke bonded combination of the second and fourth embodiments, as well as the bonded combination used in the non-pneumatic tire of the third and fifth embodiments.

Roughened Surface

[0022] As mentioned above, the method of the first embodiment uses abrading to produce a roughened surface upon the surface of the cured elongated composite spoke. According to the first embodiment, the roughened surface is produced upon the surface or surfaces of the cured elongated spoke where abrading has been used. Locations where abrading is used include at least the first surface of the cured elongated composite spoke, and in certain embodiments include other surfaces of the cured elongated composite spoke, as discussed in detail above. In other words, if (only) the first surface of the cured elongated composite spoke is abraded then, only the first surface of the cured elongated composite spoke will have a roughened surface.

[0023] According to the first-fifth embodiments, the configuration and roughness of the roughened surface may vary depending upon the type of abrading utilized. The roughness of the texture imprint surface can be determined by profilometry (/.e., using a Profilometer) using standard methods such as ISO 4287 and commercially available equipment including portable surface roughness testers such as those available from Taylor Hobson such as the Surtronic® Duo. Exemplary values obtained by profilometry include the roughness average (Ra) which can be understood as the arithmetic average of the absolute values of profile heights over the evaluation length and average maximum height of the profile or average maximum profile height (Rz) which can be understood as the average of successive values of Rd calculated over the evaluation length; Rz is the same as Rz(DIN) when there are five sampling lengths within the evaluation length. The evaluation length is the length over which the values of surface parameters are evaluated and may also be referred to as assessment length. Rti refers to the maximum heights within a sampling length and can be understood as the vertical distance between the highest and lowest points of the profile within a sampling length. Sampling length is the nominal wavelength used for separating roughness and waviness. Evaluation length refers to the overall length over which the values of surface parameters are evaluated. Measurements of Ra and Rz referred to herein were measured using a Surtronic® Duo portable surface roughness tester configured as follows: diamond type stylus with a radius of 5 micrometers (200 microinches), gauge force of 200 mg, gauge measurement type skidded, Gaussian filter type, 0.8 mm filter cut-off, evaluation or traverse length of 4 mm (0.157 inches), evaluation or traverse speed of 2 mm/seconds (0.08 inches/second), and a continuous measurement mode over the traverse length.

[0024] In certain embodiments of the first-fifth embodiments, the roughened surface has a roughness average Ra of 50 to 200 microinches (e.g., 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, or 200 microinches) or 1.3 to 5 micrometers (e.g., 1.3, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, or 5 micrometers), preferably 70 to 170 microinches (e.g., 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, or 170 microinches) or 2 to 4 micrometers (e.g., 2, 2.5, 3, 3.5, or 4 micrometers), more preferably 90 to 150 microinches (e.g., 90, 100, 110, 120, 130, 140, or 150 microinches) or 2.3 to 3.8 micrometers (e.g., 2.3, 2.5, 3, 3.5, or 3.8 micrometers), as determined by profilometry, as discussed above. In certain embodiments of the first-fifth embodiments, the roughened surface has an average maximum height of the profile or average maximum profile height Rz of 300 to 1000 microinches (e.g., 300, 400, 500, 600, 700, 800, 900, or 1000 microinches) or 8 to 25 micrometers (e.g., 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, or 25 micrometers), preferably 400 to 800 microinches (e.g., 400, 450, 500, 550, 600, 650, 700, 750, or 800 microinches) or 10 to 20 micrometers (e.g., 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 micrometers), more preferably 500 to 700 microinches (e.g., 500, 525, 550, 575, 600, 625, 650, 675, or 700 microinches) or 13 to 18 micrometers (e.g., 13, 14, 15, 16, 17, or 18 micrometers), as determined by profilometry, as discussed above. In certain embodiments of the first-fifth embodiments, the roughened surface has a surface roughness average Ra and an average maximum height of the profile Rz according to the foregoing respective ranges, preferably according to the foregoing respective preferred ranges, more preferably according to the foregoing respective more preferred ranges.

Insert Molding

[0025] The method of the first embodiment includes insert molding a polyurethane flexure onto at least a portion of the roughened surface (of the cured elongated composite spoke). As discussed in more detail below, the insert molding results in a polyurethane flexure- elongated composite spoke bonded combination wherein the polyurethane flexure is bonded to the end of the cured elongated composite spoke at the roughened surface (/.e., at at least the first surface of the spoke). In preferred embodiments of the first embodiment, the insert molding takes place directly after abrading (/.e., without application of any surface treatment to the roughened surface). By surface treatment is meant chemical treatments (e.g., application of an adhesive or an activator) as well as mechanical treatments (e.g., grit blasting or sanding) upon the roughened surface prior to insert molding. In other words, in such embodiments, the roughened surface is not subjected to any surface treatment prior to insert molding. It should be understood that the foregoing particulars of insert molding may also be used to produce the polyurethane flexure-elongated composite spoke bonded combination of the second and fourth embodiments, as well as the bonded combination used in the non-pneumatic tire of the third and fifth embodiments.

[0026] As used herein, insert molding refers to a method of injection molding that adds molten or liquid materials into a mold and then allows them to cool and solidify. As part of insert molding a component is present within the mold and when the molten or liquid materials are added to the mold, the materials flow over the component and mold around not only the mold walls but also around or onto the component piece, thereby forming a bond with the component piece. According to the first embodiment disclosed herein, the component present within the mold for the insert molding is at least a portion of the (first) end of the elongated composite spoke and the molten or liquid materials are polyurethane. More specifically, the elongated composite spoke is present within the mold to an extent necessary to allow for the polyurethane materials to form a bond with the roughened surface (upon at least the first surface of the end of the elongated composite spoke). It should be understood that the foregoing particulars of insert molding may also be used to produce the polyurethane flexure-elongated composite spoke bonded combination of the second and fourth embodiments, as well as the bonded combination used in the non-pneumatic tire of the third and fifth embodiments. In certain embodiments of the first embodiment, the polyurethane materials used are liquid or at least pourable at room temperature. In other embodiments of the first embodiment, the polyurethane materials are gel or solid at room temperature.

[0027] Generally, polyurethanes such as the polyurethane used to insert mold the flexure onto the roughened surface of the elongated composite spoke can be understood to be polymers comprised of organic units joined by carbamate (urethane) links. Polyurethane can be produced from a wide range of starting materials. The polyurethanes suitable for use in (insert molding) the flexure, as described herein, will include an isocyanate component and a diol component. It should be understood that the foregoing particulars of polyurethanes may also be applicable to producing the polyurethane flexure-elongated composite spoke bonded combination of the second and fourth embodiments, as well as the bonded combination used in the non-pneumatic tire of the third and fifth embodiments.

[0028] Generally, according to the first-fifth embodiments disclosed herein, one or more than one type of diol can be utilized (or present in) the diol component of the polyurethane of the flexure. The diol may be aromatic or aliphatic. In certain embodiments of the first-fifth embodiments, the diol component of the polyurethane of the flexure is aromatic. In other preferred embodiments of the first-fifth embodiments, the diol component of the polyurethane of the flexure is aliphatic. Generally, the diol used in the diol component of the polyurethane may vary and suitable diols include those having 2 to 20 carbon atoms (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 carbon atoms), preferably 2 to 10 carbon atoms, even more preferably 2 to 6 carbon atoms. According to the first-fifth embodiments, the diol component of the polyurethane of the flexure may be selected from the group consisting of simple diols, and complex polyols including polyester polyols, polyether polyols, polycarbonate polyols, polycaprolactone polyols, polybutadiene polyols, and polysulfide polyols. In certain embodiments of the first-fifth embodiments, the polyurethane of the flexure includes a diol component selected from the group consisting of simple diols, polyester polyols, polyether polyols, polycarbonate polyols, polycaprolactone polyols, polybutadiene polyols, polysulfide polyols, and combinations thereof. Non-limiting examples of aliphatic diols include ethylene glycol, 1,4-butanediol, and 1,6- hexanediol, each of which can be understood as simple diols. In certain embodiments of the first- fifth embodiments, the diol component of the polyurethane of the flexure is selected from the group consisting of ethylene glycol, 1,4-butanediol, 1,6-hexanediol, and combinations thereof. In certain embodiments of first-fifth embodiments, the diol component of the polyurethane of the flexure consists of ethylene glycol. In certain embodiments of first-fifth embodiments, the diol component of the polyurethane of the flexure consists of 1,4-butanediol. In certain embodiments of first-fifth embodiments, the diol component of the polyurethane of the flexure consists of 1,6- hexanediol. Non-limiting examples of aromatic diols include those based upon terephthalic acid including diesters of terephthalic acid with diols having 2-4 carbon atoms.

[0029] Generally, according to the first-fifth embodiments disclosed herein, one or more than one type of isocyanate can be utilized (or present in) the isocyanate component of the polyurethane of the flexure. The isocyanate may be aliphatic or aromatic. In certain embodiments of the first-fifth embodiments, the isocyanate component of the polyurethane of the flexure is aromatic or includes an aromatic isocyanate. In other embodiments of the first-fifth embodiments, the isocyanate component is aliphatic or includes an aliphatic isocyanate. In certain embodiments of the first-fifth embodiments, the isocyanate component of the polyurethane is an aromatic diisocyanate selected from the group consisting of 4,4'- diphenylmethane diisocyanate (also known as methylene diphenyl diisocyanate), toluene diisocyanate, paraphenyl diisocyanate, and combinations thereof.

[0030] Exemplary aliphatic isocyanates suitable for use as the isocyanate component of the polyurethane of the flexure of the first-fifth embodiments include, but are not limited to, hexamethylene diisocyanate (HDI), ethylene diisocyanate, methylene dicyclohexyl diisocyanate (MDI), hydrogenated methylene dicyclohexyl diisocyanate (HMDI) or 4,4'-diisocyanato dicyclohexylmethane, isophorone diisocyanate (IPDI) or l-isocyanato-3-isocyanatomethyl-3,5,5- trimethyl-cyclohexane, 1,6-diisocyanatohexane, tetramethylxylylene diisocyanate (TMXDI), alkylene diisocyanates with 4-12 carbon atoms in the alkylene radical (e.g., 1,2-dodecane diisocyanate, 1,4-tetramethylene diisocyanate), 1,4-cyclohexane diisocyanate, 1,3-cyclohexane diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, 2,2'-dicyclohexylmethane diisocyanate, 2,4'-dicyclohexylmethane diisocyanate, and combinations thereof. In certain embodiments of the first-fifth embodiments, the isocyanate component of the polyurethane is an aliphatic diisocyanate containing an aliphatic ether group. In certain embodiments of the first-fifth embodiments, the isocyanate component of the polyurethane of the flexure is selected from the group consisting of hexamethylene diisocyanate (HDI), methylene dicyclohexyl diisocyanate (MDI), hydrogenated methylene dicyclohexyl diisocyanate (HMDI) or 4,4'-diisocyanato dicyclohexylmethane, isophorone diisocyanate (IPDI) or l-isocyanato-3-isocyanatomethyi-3,5,5- trimethyl-cyclohexane, 1,6-diisocyanatohexane, tetramethylxylylene diisocyanate (TMXDI), alkylene diisocyanates with 4-12 carbon atoms in the alkylene radical (e.g., 1,2-dodecane diisocyanate, 1,4-tetramethylene diisocyanate), 1,4-cyclohexane diisocyanate, 1,3-cyclohexane diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, 2, 2' -dicyclohexylmethane diisocyanate, 2,4'-dicyclohexylmethane diisocyanate, and combinations thereof.

[0031] In certain embodiments of the first-fifth embodiments disclosed herein, the polyurethane of the flexure includes (further comprises) at least one chain extender. In other embodiments of the first-fifth embodiments, the polyurethane of the flexure contains no chain extender. In those embodiments of the first-fifth embodiments wherein the polyurethane of the flexure includes (further comprises) at least one chain extender, the particular chain extender or extenders utilized may vary. In preferred embodiments of the first-fifth embodiments, the chain extender comprises a diol having 2 to 20 carbon atoms (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 carbon atoms), preferably 2 to 10 carbon atoms, even more preferably 2 to 6 carbon atoms. Generally, the chain extender may be either aliphatic or aromatic. In preferred embodiments of the first-fifth embodiments, any chain extender utilized is aliphatic. Non-limiting examples of aliphatic diols include ethylene glycol, 1,4-butanediol, and 1,6- hexanediol. In certain embodiments of the first-fifth embodiments, the chain extender of the polyurethane of the flexure comprises at least one aliphatic diol, preferably selected from the group consisting of ethylene glycol, 1,4-butanediol, 1,6-hexanediol, and combinations thereof; in certain such embodiments, the chain extender of the polyurethane of the flexure consists of at least one aliphatic diol, preferably selected from the preceding group. Non-limiting examples of aromatic diols include those based upon terephthalic acid including diesters of terephthalic acid with diols having 2-4 carbon atoms. In certain embodiments of the first-fifth embodiments, the chain extender of the polyurethane of the flexure comprises at least one aromatic diol; in certain such embodiments, the chain extender of the polyurethane of the flexure consists of at least one aromatic diol.

[0032] The particular properties of the polyurethane flexure of the first-fifth embodiments may vary. For example, in certain embodiments of the first-fifth embodiments, the polyurethane flexure is capable of functioning without cracking or tearing in temperatures ranging from -65 °F to 160 °F (-55 to 70 °C).

Polyurethane Flexure-Elongated Composite Spoke Bonded Combination

[0033] According to the method of the first embodiment, the insert molding, as discussed above, results in a polyurethane flexure-elongated composite spoke bonded combination wherein the polyurethane flexure is bonded to the end of the cured elongated composite spoke at at least its first surface. According to the second-fifth embodiments, the polyurethane flexure- elongated composite spoke bonded combination also includes a polyurethane flexure bonded to the end of the elongated composite spoke at at least its first surface. In certain embodiments of the first-fifth embodiments, the polyurethane flexure is bonded to the end of the elongated composite spoke at its first surface. In other embodiments of the first-fifth embodiments, the polyurethane flexure is bonded to the end of the elongated composite spoke at its first surface and its second surface; in certain such embodiments the polyurethane flexure is bonded to the entire outer surface of the (first) end of the elongated spoke (i.e., both the first surface and the second surface as well as any other surfaces between those two surfaces).

[0034] According to the method of the first embodiment, and in the second-fifth embodiments, the polyurethane flexure is bonded to the end of the elongated composite spoke (i.e., at at least its first surface, as discussed above) with a peel strength of at least 70 pli (e.g., 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, etc.), 70- 250 pli, at least 12000 N/m (e.g., 12000, 13000, 14000, 15000, 16000, 17000, 18000, 19000, 20000, 21000, 22000, 23000, 24000, 25000, 26000, 27000, 28000, 29000, 30000, 31000, 32000, 33000, 34000, 35000, 36000, 37000, 38000, 39000, 40000, 41000, 42000, 43000, 44000 N/m, etc.), or 12000-44000 N/m. As used herein, pli refers to pounds per linear inch and N/m refers to Newtons per meter. In preferred embodiments of the first-fifth embodiments, the peel strength is at least 90 pli (e.g., 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, pli, etc. ), 90-250 pli, at least 16000 N/m (e.g., 16000, 17000, 18000, 19000, 18000, 19000, 20000, 21000, 22000, 23000, 24000, 25000, 26000, 27000, 28000, 29000, 30000, 31000, 32000, 33000, 34000, 35000, 36000, 37000, 38000, 39000, 40000, 41000, 42000, 43000, 44000 N/m, etc.), or 16000-44000 N/m. In more preferred embodiments of the first-fifth embodiments, the peel strength is at least 100 pli (e.g., 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250 pli, etc.), 70-250 pli or at least 17000 N/m (e.g., 17000, 18000, 19000, 20000, 21000, 22000, 23000, 24000, 25000, 26000, 27000, 28000, 29000, 30000, 31000, 32000, 33000, 34000, 35000, 36000, 37000, 38000, 39000, 40000, 41000, 42000, 43000, 44000 N/m, etc.), or 17000-44000 N/m. The foregoing peel strengths can be measured in accordance with ASTM D6892/D903 and at room temperature (i.e., 25 °C).

[0035] The shape of the polyurethane flexure that results from insert molding and/or that is bonded to the end of the elongated composite spoke, as discussed above, may vary. In certain embodiments of the first-fifth embodiments, the polyurethane flexure has a shape selected from the group consisting of a rectangular cuboid; a curved hourglass; a polygon with an inner surface, an outer surface, and a perimeter edge between the inner and outer surfaces, wherein at least a portion of the perimeter edge curves inward; and combinations thereof. As used herein, the phrase curves inward is meant to refer to a portion of the perimeter edge having a concave profile that can be selected from various shapes including elliptical, partial circular, or irregular. In certain embodiments of the first-fifth embodiments, the polyurethane flexure has a rectangular cuboid shape. In certain embodiments of the first-fifth embodiments, the polyurethane flexure has a curved hourglass shape. In certain embodiments of the first-fifth embodiments, the polyurethane flexure has a polygon shape with an inner surface, an outer surface, and a perimeter edge between the inner and outer surfaces, wherein at least a portion of the perimeter edge curves inward. As well, the polyurethane flexure that results from insert molding can be understood as having two facing surfaces, more specifically a spoke facing surface (where the polyurethane flexure portion of the polyurethane flexure-elongated composite spoke bonded combination will contact and be bonded to the spoke, as discussed above) and a band facing surface (where the polyurethane flexure will contact and be bonded to the inner surface of the outer ring (also referred to herein as the annular ring) of the non-pneumatic tire). The bonding or attachment between the polyurethane flexure and the outer ring may be achieved using welding, brazing, soldering, adhesive, mechanical fasteners (e.g., bolts, rivets), key/keyway connections, or any other desired arrangement. In those embodiments of first-fifth embodiments where adhesive is used to bond the polyurethane flexure to the outer ring, the particular adhesive used may vary. In certain embodiments of the first-fifth embodiments, an epoxy adhesive is used to bond the polyurethane flexure to the outer ring. In other embodiments of the first-fifth embodiments, a hot melt adhesive is used to bond the polyurethane flexure to the outer ring.

Curing

[0036] As discussed above, according to the method of the first embodiment disclosed herein, abrading takes place on the first surface of the cured elongated composite spoke. In other words, the elongated composite spoke that is subjected to abrading is cured. Various methods for curing the elongated composite spoke can be utilized, including various temperatures, depending upon the particular ingredients used to prepare the composite spoke (e.g., the fiber(s) and epoxy resin, as discussed above).

[0037] The cured elongated composite spoke used in the method of the first embodiment and in also the second-fifth embodiments disclosed herein may be cured using various methods. In certain embodiments of the first-fifth embodiments, the elongated composite spoke (in an uncured form) is cured using heat and pressure to produce a cured elongated composite spoke. The pressure used as part of such a curing process may vary. In certain embodiments of the first- fifth embodiments, curing includes applying a pressure of 1 to 300 psig (e.g., 1, 10, 20, 30, 40, 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 210, 220, 230, 240, 250, 260, 270, 280, 290 or 300 psig) or 7 to 2100 kPa (e.g., 7, 50, 100, 101, 200, 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, or 2100 kPa), preferably 5 to 100 psig (e.g., 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 100 psig) or 35 to 700 kPa (e.g., 35, 50, 100, 200, 300, 400, 500, 600, or 700 kPa). As used herein psig refers to pounds per square inch in gauge and kPa refers to kiloPascals. The heat used as part of the curing process may vary. In certain embodiments of the first-fifth embodiments, curing includes heating at a temperature of 75 to 400 °F (e.g., 7E>, 80, 85, 90, 95, 100, 110, 120, 125, 130, 140, 150, 160, 170, 175, 180, 190, 200, 210, 220, 225, 230, 240, 250, 260, 270, 275, 280, 290, 300, 310, 320, 325, 330, 340, 350, 360, 370, 375, 380, 390, or 400 °F) or 24 to 200 °C (e.g., 24, 25, 30, 40, 50, 60, 70, 75, 80, 90, 100, 110, 120, 125, 130, 140, 150, 160, 170, 175, 180, 190, or 200 °C). In other embodiments of the first-fifth embodiments, curing includes heating at a temperature of 250 to 350 °F (e.g., 250, 260, 270, 275, 280, 290, 300, 310, 320, 325, 330, 340, or 350 °F) or 120 to 175 °C (e.g., 120, 130, 140, 150, 160, 170, or 175 °C). In certain embodiments of the first embodiment, the curing includes the application of heat at one of the foregoing temperatures and pressure at one of the forgoing values.

Fourth and Fifth Embodiments

[0038] As mentioned above, the fourth embodiment disclosed herein is directed to a polyurethane flexure-elongated composite spoke bonded combination for use in a nonpneumatic tire, the combination comprising: a cured elongated composite spoke having an end with a first surface and a second surface, wherein the elongated composite spoke is comprised of fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, and combinations thereof and an epoxy resin; and a polyurethane flexure bonded to the end of the cured elongated composite spoke at its first surface with a peel strength of at least 70 pli (at least 12000 N/m), preferably at least 90 pli (at least 16000 N/m), more preferably at least 100 pli at 17000 N/m, as determined using a 90 degree peel strength test (in accordance with ASTM D6892/D903), wherein the end of the cured elongated composite spoke has a roughened surface upon at least its first surface underneath the bonded polyurethane flexure. As also mentioned above, the fifth embodiment disclosed herein is directed to a non-pneumatic tire incorporating the polyurethane flexure-elongated composite spoke bonded combination of the fourth embodiment. The paragraphs which follow and are specifically directed to the fourth and fifth embodiments disclosed herein should not be understood as limiting the fourth and fifth embodiments to only those options discussed immediately below. Instead, the fourth and fifth embodiments should be understood to be disclosed as broadly as stated above with respect to 1 the fourth and fifth embodiments as well as would be understood to result from the method of the first-third embodiments as discussed above.

[0039] In certain embodiments of fourth and fifth embodiments, the roughened surface has a roughness average Ra of 50-200 microinches (1.3 to 5 micrometers), preferably 70-170 microinches (2 to 4 micrometers), more preferably 90-150 microinches (2.3 to 3.8 micrometers), as determined by profilometry.

[0040] In certain embodiments of fourth and fifth embodiments, the roughened surface has an average maximum height of the profile Rz of 300 to 1000 microinches (8 to 25 micrometers), preferably 400 to 800 microinches (10 to 20 micrometers), more preferably 500 to 700 microinches (13 to 18 micrometers), as determined by profilometry. In certain such embodiments, the average maximum profile height Rz is combined with a value for the roughness average Ra as discussed above.

[0041] In certain embodiments of fourth and fifth embodiments, the epoxy resin of the elongated composite spoke has a cure time of no more than 15 minutes at 150 °C, preferably no more than 12 minutes at 150 °C.

[0042] In certain embodiments of fourth and fifth embodiments, the first surface of the elongated composite spoke is flattened.

[0043] In certain embodiments of fourth and fifth embodiments, the polyurethane flexure has a shape selected from the group consisting of a rectangular cuboid; a curved hourglass; a polygon with an inner surface, an outer surface, and a perimeter edge between the inner and outer surfaces, wherein at least a portion of the perimeter edge curves inward; and combinations thereof.

Non-Pneumatic Tire Including The Polyurethane Flexure-Elongated Composite Spoke Bonded Combination

[0044] As mentioned above, the third embodiment disclosed herein is directed to a nonpneumatic tire incorporating the polyurethane flexure-elongated composite spoke bonded combination of the second embodiment, which combination is made by the method of the first embodiment. As also mentioned above, the fifth embodiment disclosed herein is directed to a non-pneumatic tire incorporating the polyurethane flexure-elongated composite spoke bonded combination of the fourth embodiment. Also disclosed herein is an embodiment of the method of the first embodiment, wherein the method furthercomprises addingthe polyurethane flexure- elongated composite spoke bonded combination to a non-pneumatic tire, preferably by bonding the polyurethane flexure-elongated composite spoke bonded combination to an outer ring within the non-pneumatic Pre, wherein the outer ring has an outer surface and an inner surface and is covered on its outer surface by a tread and bonded on its inner surface to via the polyurethane flexure to the polyurethane flexure-elongated composite spoke bonded combination. The non- pneumatic tire of the fifth embodiment disclosed herein can be understood as including the polyurethane flexure-elongated composite spoke bonded combination of the fourth embodiment, wherein the polyurethane flexure- elongated composite spoke bonded combination is bonded to an outer ring within the non-pneumatic tire, wherein the outer ring has an outer surface and an inner surface and is covered on its outer surface by a tread and bonded via the polyurethane flexure to the polyurethane flexure-elongated composite spoke bonded combination.

[0045] This application discloses several numerical range limitations that support any range within the disclosed numerical ranges, even though a precise range limitation is not stated verbatim in the specification, because the embodiments of the compositions and methods disclosed herein could be practiced throughout the disclosed numerical ranges. With respect to the use of substantially any plural or singular terms herein, those having skill in the art can translate from the plural to the singular or from the singular to the plural as is appropriate to the context or application. The various singular or plural permutations may be expressly set forth herein for sake of clarity.

[0046] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims are generally intended as "open" terms. For example, the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to." It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., “a" or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “ a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B."

[0047] All references, including but not limited to patents, patent applications, and nonpatent literature are hereby incorporated by reference herein in their entirety.

[0048] While various aspects and embodiments of the compositions and methods have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the claims.

Claims

What is claimed is:

1. A method for producing a polyurethane flexure-elongated composite spoke bonded combination for use in a non-pneumatic tire, the method comprising providing a cured elongated composite spoke having an end with a first surface and a second surface, wherein the cured elongated composite spoke is comprised of fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, and combinations thereof and an epoxy resin; abrading the first surface of the cured elongated composite spoke to produce a roughened first surface; and, insert molding a polyurethane flexure onto at least a portion of the roughened first surface of the cured elongated composite spoke, thereby producing a polyurethane flexure-elongated composite spoke bonded combination having a peel strength of at least 70 pli (at least 12000 N/m), preferably at least 90 pli (at least 16000 N/m), more preferably at least 100 pli at 17000 N/m, as determined using a 90 degree peel strength test (in accordance with ASTM D6892/D903).

2. The method of claim 1, wherein the roughened first surface has a roughness average Ra of 50-200 microinches (1.3 to 5 micrometers), preferably 70-170 microinches (2 to 4 micrometers), more preferably 90-150 microinches (2.3 to 3.8 micrometers) as determined by profi lorn etry.

3. The method of claim 1 or claim 2, wherein the roughened first surface has an average maximum height of the profile Rz of 300 to 1000 microinches (8 to 25 micrometers), preferably 400 to 800 microinches (10 to 20 micrometers), more preferably 500 to 700 microinches (13 to 18 micrometers), as determined by profilometry.

4. The method of any one of claims 1-3, wherein the abrading comprises grit blasting.

5. The method of any one of claims 1-3, wherein the abrading comprises using abrasive paper against the first surface of the cured elongated composite spoke to produce the roughened first surface.

6. The method of claim 4, wherein the grit blasting meets at least one of the following, preferably each of the following: (a) uses particles selected from the group consisting of aluminum oxide, alumina zirconia, silicon carbide, silica sand, garnet, steel, iron, quartz, walnut shells, and combinations thereof, preferably particles comprising aluminum oxide, (b) uses particles having a grit of 50 to 120 (330 to 120 microns), or (c) uses a pressure of 30-80 psi (200 to 550 kPa), preferably 30-70 psi (200 to 500 kPa).

7. The method of claim 5, wherein the abrasive paper meets at least one of the following, preferably each of the following: (a) comprises particles selected from the group consisting of aluminum oxide, alumina zirconia, silicon carbide, silica sand, garnet, steel, iron, quartz, walnut shells, and combinations thereof, or (b) has a grit of 50 to 120 (330 to 120 microns).

8. The method of any one of claims 1-7, wherein the epoxy resin of the uncured elongated composite spoke has a cure time of no more than 15 minutes at 150 °C, preferably no more than 12 minutes at 150 °C.

9. The method of any one of claims 1-8, wherein the first surface of the uncured elongated composite spoke is flattened.

10. The method of any one of claims 1-9, wherein the polyurethane flexure has a shape selected from the group consisting of a rectangular cuboid; a curved hourglass; a polygon with an inner surface, an outer surface, and a perimeter edge between the inner and outer surfaces, wherein at least a portion of the perimeter edge curves inward; and combinations thereof.

11. The method of any one of claims 1-10, further comprising adding the polyurethane flexure-elongated composite spoke bonded combination to a non-pneumatic Pre, preferably by bonding the polyurethane flexure-elongated composite spoke bonded combination to an outer ring within the non-pneumatic tire, wherein the outer ring has an outer surface and an inner surface and is covered on its outer surface by a tread and bonded on its inner surface via the polyurethane flexure to the polyurethane flexure-elongated composite spoke bonded combination.

12. A polyurethane flexure-elongated composite spoke bonded combination produced by the method of any one of claims 1-11.

13. A non-pneumatic tire incorporating the polyurethane flexure-elongated composite spoke bonded combination of claim 12.

14. A polyurethane flexure-elongated composite spoke bonded combination for use in a non-pneumatic Pre, the combination comprising: a cured elongated composite spoke having an end with a first surface and a second surface, wherein the elongated composite spoke is comprised of fibers selected from the group consisting of carbon fibers, glass fibers, aramid fibers, and combinations thereof and an epoxy resin; and a polyurethane flexure bonded to the end of the cured elongated composite spoke at its first surface with a peel strength of at least 70 pli (at least 12000 N/m), preferably at least 90 pli (at least 16000 N/m), more preferably at least 100 pli at 17000 N/m, as determined using a 90 degree peel strength test (in accordance with ASTM D6892/D903), wherein the end of the cured elongated composite spoke has a roughened surface upon at least its first surface underneath the bonded polyurethane flexure.

15. The polyurethane flexure-elongated composite spoke bonded combination of claim 14, wherein the roughened surface has a roughness average Ra of 50-200 microinches (1.3 to 5 micrometers), preferably 70-170 microinches (2 to 4 micrometers), more preferably 90-150 microinches (2.3 to 3.8 micrometers), as determined by profilometry.

16. The polyurethane flexure-elongated composite spoke bonded combination of claim 14 or claim 15, wherein the roughened surface has an average maximum height of the profile Rz of 300 to 1000 microinches (8 to 25 micrometers), preferably 400 to 800 microinches (10 to 20 micrometers), more preferably 500 to 700 microinches (13 to 18 micrometers), as determined by profilometry.

17. The polyurethane flexure-elongated composite spoke bonded combination of any one of claims 14-16, wherein the epoxy resin of the elongated composite spoke has a cure time of no more than 15 minutes at 150 °C, preferably no more than 12 minutes at 150 °C.

18. The polyurethane flexure-elongated composite spoke bonded combination of any one of claims 14-17, wherein the first surface of the elongated composite spoke is flattened.

19. The polyurethane flexure-elongated composite spoke bonded combination of any one of claims 14-18, wherein the polyurethane flexure has a shape selected from the group consisting of a rectangular cuboid; a curved hourglass; a polygon with an inner surface, an outer surface, and a perimeter edge between the inner and outer surfaces, wherein at least a portion of the perimeter edge curves inward; and combinations thereof.

20. A non-pneumatic Pre incorporating the polyurethane flexure-elongated composite spoke bonded combination of any one of claims 14-19.