The development of new, high-performance materials is essential to the development of new, high-performance tires. However, developing new materials is no easy task, as the interlocking relationships between the molecular structures of rubber materials and the properties of their various compounds are exceedingly complex.
"4D NANO DESIGN," our cutting-edge proprietary simulation technology, supports the development of new materials for high-quality, high-performance FALKEN tires.
Utilizing the K Computer, one of the world's most powerful supercomputers, 4D NANO DESIGN combines "Investigation," "Prediction," "Production" and "Extraction" technologies to unlock the performance of new materials at the nano scale, allowing us to extract the full hidden potential of each material.
Low rolling resistance, outstanding safety and durability are the three main requirements that car tyres need to fulfil, both today and in the future. To drive progress in this area, the scientists and engineers at Sumitomo Rubber Industries Ltd. conducted pioneering research into the molecular structure of tyres, using particle accelerators and advanced simulation computers. They succeeded in simulating and controlling the molecular structure of rubber compounds used for tyres at nano level; for example, they analysed where and how superfluous heat was generated in the tyre and how this development could be minimised. Heat means loss of energy for the tyre, and thus rolling resistance – which is ultimately responsible for fuel consumption. Advanced 4D-Nano Design technology is the result of these advanced findings in molecular structures. It enables savings in fuel consumption of up to five per cent to be achieved compared to conventional tyre models, and significantly improves the tyre’s performance in wet conditions.
Next-Generation Manufacturing System to Produce Ultra-High-Precision Tires
When a tire is rotating at high speed, its degree of circularity has a major impact on its overall performance. Tires produced using NEO-T01 achieve an extremely high degree of circularity, which greatly improves their stability at high speeds. This technology is used in the manufacture of our FK453 Runflat tires and other high-performance FALKEN tires.
This production method involves precisely attaching the various components of a tire to a "Metal Core," a molding former in the shape of a tire. This process vastly improves a tire's degree of circularity, which in turn significantly reduces tire vibration at high speeds.
This technology uses a computerized control system to control the tire formation process with great precision, accurate to .01mm. The ability to form tires precisely using the optimal amount of materials enables us to achieve a significant reduction in overall tire weight compared to conventional production methods.
Because NEO-T01 allows for the use of stronger materials than conventional production methods, tires produced with NEO-T01 are less prone to deformation on the road, giving them greatly improved handling stability performance.
NEO-T01 production process is a recently developed Falken production system for manufacturing ultra-high-precision runflat tyres. In NEO-T01, each tyre is built around a precision moulded metal core known as a ‘former’ in the exact shape and size of the finished tyre’s interior. What makes this method so special is that the tyres are manufactured using a ‘ribbon’ method, which wraps the tread and sidewall material around the former to extremely high-precision specifications without any overlapping or joins, and without the need for additional manufacturing tolerances. The dimensions of the raw tyre correspond exactly to those of the completed product; there is no deformation of the compound during vulcanisation. All the components are assembled fully automatically by the computer-driven system. NEO-T01 thus raises the bar for quality and consistency in the serial production of premium tyres.
In the majority of situations, the drive-by noise generated by the tyres on a car is louder than any aerodynamic noise from motion or noise created by the car’s powertrain. Drive-by noise is caused by air vibrating in the tyre’s interior, which generates tyre cavity resonance and, accordingly, noise levels. To minimise these vibrations in the tyre interior, Falken’s engineers have developed an innovative polyurethane foam layer that lines the tyre interior and slashes drive-by noise generation by up to 10 decibels. The foam lining is featherlight and does not impair tyre performance in any way. It is extremely durable and lasts for the entire life of the tyre.
Sustainable tyres give a better drive. Sumitomo Rubber Industries is committed to improving global environmental protection in tyre production. The core topics involved in the issue are fuel savings, use of sustainable raw materials and careful husbanding of resources. Under these watchwords, Falken continuously analyses and optimises the manufacturing processes and components used to produce Falken tyres. A key part of the company’s activities in this respect comprises advanced research into biosynthetic mechanisms that extends into the nanostructure level of the tyre’s structure. This research is making it possible to produce natural rubber using environmentally compatible methods, and thus manufacture products that are both sustainable and at the forefront of technology.
If a conventional tyre loses air, its shape begins to deform on the wheel rim, generating heat that destroys the tyre within a very short time. As early as 1970, Sumitomo Rubber Industries found a solution to combat the problem, and launched the world’s first runflat tyre with ‘limp-home mode’. Runflat tyres have reinforced sidewalls that reduce deformation if the tyre sustains damage or a puncture; they can thus continue to be driven for at least a further 80 km at a maximum speed of 80 km/h. Falken Runflat Tyres combine this ‘limp-home’ mode with top performance in all areas. Incidentally, manufacturers specify that runflat tyres must be used with a tyre pressure monitoring system, because the tyres are so effective that drivers may not actually notice their tyre has a puncture. (Vehicle must have a tyre pressure monitoring system)
Wouldn’t it be great if flat tyres were a thing of the past? Now the future is just around the corner with Falken Gyroblade. This all-new airless tyre technology banishes not only flat tyres but also the laborious processes of tyre inflation and pressure monitoring. Look forward to a whole new dimension of comfortable, safe driving!