Method of manufacturing supporting structures with cord-reinforced polymer composition spokes for non-pneumatic tires

A method of manufacturing a supporting structure for a non-pneumatic tire comprising at least one X-shaped and cord-reinforced polymer composition spoke, wherein the X-shaped spoke has a pair of upper legs and a pair of lower legs connected by a crossing portion, wherein the method comprises the steps of:

• A) Providing a mold comprising mold members comprising i) a first prism-shaped mold insert for defining inner surfaces of the X-shaped spoke between its upper legs, ii) a second prism-shaped mold insert for defining inner surfaces of the X-shaped spoke between its lower legs, and iii) at least one further mold member defining outer surfaces of the X-shaped spoke essentially opposite to the inner surfaces defined by the first and second mold inserts, wherein at least one of the mold members is at least partially covered by at least one polymer composition layer;
• B) Applying a cord reinforcement onto the polymer composition layer;
• and
• C) Injection molding a further polymer composition onto the cord reinforcement and the polymer composition layer to encase the cord reinforcement with the further polymer composition and the polymer composition layer.

A method of manufacturing a non-pneumatic tire comprising a radially outer circumferential tread band, a radially inner hub portion and a circumferential supporting structure supporting the radially outer circumferential tread band on the radially inner hub portion, wherein the supporting structure comprises a circumferential and radially outer ring portion, a circumferential and radially inner ring portion, a plurality of cord-reinforced polymer composition spokes provided along the circumferential direction and arranged between the radially outer ring portion and the radially inner ring portion, wherein the method comprises the steps of:

• Providing a mold for molding at least a circumferential sector of the circumferential supporting structure, the mold comprising a radially outer mold ring member for molding a radially outer side of at least a circumferential segment of the radially outer ring portion, and a radially inner mold ring member for molding a radially inner side of at least a circumferential segment of the radially inner ring portion, and mold inserts for molding spokes of the plurality of spokes between the mold ring members, wherein a majority of the mold inserts is covered by a polymer composition layer;
• Applying a cord reinforcement at least onto portions of the polymer composition layer, wherein the cord reinforcement reinforces and connects multiple of the spokes provided along the circumferential direction to be molded;
• and
• Injection molding a further polymer composition onto the cord reinforcement and the polymer composition layer to encase the cord reinforcement with the further polymer composition and the polymer composition layer.