The manufacturer of cleaning products will help make the tires quieter

Henkel, best known as a manufacturer of cleaning products, and 4JET, specializing in laser surface processing technologies, have jointly developed a new solution to help reduce costs in the production of tires with noise reduction functionality, which will be particularly relevant in the segment of tires for electric vehicles.

"The absence of engine noise in electric vehicles makes tire noise even more noticeable in the vehicle cabin," notes Henkel, adding that at certain speeds and road surfaces, noise can become intrusive and unpleasant. Meanwhile, many electric vehicles are equipped with noise-reducing tires, which have an additional layer of polyurethane foam inside the tire cavity, which, among other things, reduces the acoustic impact on the environment, an important aspect from an ecological point of view.

"This simple concept poses a very complex and responsible task for tire manufacturers worldwide, namely the need to integrate a second logistics line for transporting lightweight but bulky foam," the company says. "This creates a need for significant space for logistics processing of the foam and a number of intermediate stages of its storage. Numerous stages of manual and semi-automated labor are also required for logistics, cutting, adding adhesives, and mounting the foam in the tire."

It is noted that the production costs of companies in the production of noise-reducing tires, in which the foam is installed at the final stage of production, can increase by 25%. In addition, this technology often cannot be implemented at existing plants, and additional waste is generated in the form of foam trim.

The new solution allows for the initial cleaning of the inner cavity using the Laser-FIT laser technology, after which a liquid is applied, the foaming of which, according to reports, occurs in a short time. At the same time, at the final stage, the crust is removed from the foam, which is important because, "like yeast dough, an airtight shell usually forms, preventing sound from penetrating into the porous structure and reducing noise reduction."

4JET says that the quantity, color, and shape of the sound-absorbing insert can be easily changed without the need to modify the original material, and the product name or brand logo can also be applied to it.

According to Rainer Schoenfeld, Director of Strategy for the Automotive Division at Henkel, "without the technology for removing the foam crust developed by 4JET, most of the sound waves would be reflected off its surface instead of being absorbed," he added. "This great idea is a vivid example of the innovative capabilities of the German small and medium-sized business, which remains the driver of our economy's development!"

In turn, George Kazantzis, Head of the Automotive Products Division at Henkel, stated that "the revolutionary technology of foam formation directly in tires reflects our joint commitment to innovation and sustainable development. By eliminating foam transportation and reducing waste volumes, we will allow our customers to reduce their carbon footprint."

The new concept was presented at the Tire Technology Expo in Hanover, Germany in March, and the process was brought to the possibility of use in record time. "With Henkel, we have found an ideal partner during the development of this innovation," said Armin Kraus, Co-CEO of 4JET Group. "Henkel has experience in creating high-tech polyurethanes and their application, which few companies in the world possess. At the same time, they work extensively in the automotive industry and are present in markets around the world, which is necessary for supplying tire manufacturers with products of consistently high quality. What impressed us most was their motivation and speed of work. From idea to implementation, it took a record short time."

Sound absorption technologies using an insert inside the tire are used by many companies, which give them such names as PNCS (Pirelli Noise Cancelling System), SoundComfort (Goodyear), ContiSilent, Acoustic (Michelin), Noise Guard (Davanti), and others.