Optimizing Tire Bead Winding for Better Durability

Method to reduce waste in manufacturing tires with reinforcing cords that are wound multiple times around the tire circumference while extending in the tire width direction. The method involves feeding and joining the reinforcing cords in a specific order to avoid cords becoming too short during tire formation. First, a cord is fed ahead to form the desired section. Then, the next cord is fed and joined to the first cord at a splice mechanism. This continues, joining the trailing end of the first cord to the leading end of the next cord, until the desired length is reached. This allows using shorter cords without waste since they are continuously joined together.

Source

Production method for lightweight bead cores for pneumatic tires with improved productivity and shape flexibility compared to winding resin-coated bead wire. The method involves forming multiple annular bodies, each made by winding resin-coated bead wire, and then joining them together in the axial direction to create the final bead core shape. This allows efficient production of bead cores with customized shapes by combining pre-formed annular sections instead of winding the wire continuously.

Source

Method for making high elongation assemblies of filamentary elements for tires without preforming the filaments. The method involves winding multiple filaments together around a temporary core in a helical layer. The temporary core is then split between the wound assemblies, leaving each with a layer of filaments. This allows simultaneous assembly of multiple high elongation assemblies using a single winding step. The temporary core is recycled rather than separating and winding each assembly separately.

Source

A method and device for manufacturing tires with improved durability and efficiency in forming the cord reinforcing layer between the bead and shoulder. The method involves winding a wavy steel cord around the forming drum to create the cord reinforcing layer. The key step is reducing the cord extension as you move further from the bead core locations. This maintains consistent amplitude and wavelength of the wavy cord over the entire layer, preventing non-uniformity issues that can arise during tire expansion.

Source

Forming method for making an assembly of a bead core and an apex rubber in a tire, where the apex rubber has a triangular cross section on the outer surface of the bead core. The method involves winding a thin, narrow strip of rubber around the bead core in a spiral shape to create the triangular apex shape. This allows making the apex rubber in a strip winding process, rather than molding separately, for advantages like avoiding intermediate storage, reducing machine size, and easier integration with the bead core. The strip width is 5-20 mm and thickness 0.5-2.0 mm to balance precision and efficiency.

Source

A method to manufacture pneumatic tires using wound rubber tapes instead of extruding shapes. The method involves winding unvulcanized rubber tapes around drums to create tire components like sidewalls, beads, and treads. This reduces the need for multiple extruders and allows flexible, compact tire production. The tapes can contain short fibers to improve reinforcement. The green tire is assembled from wound components before vulcanization. This allows making some tire components from wound tapes, rather than extruded shapes, reducing the number of different rubber compounds needed.

Source

Method and device for manufacturing circumferential reinforcements for tires that allows simultaneous winding of thread and elastomeric strip onto the tire form. This eliminates the need for coated threads or bare threads by interleaving the thread and elastomer strip as they are wound. The device has separate conveying systems for the thread and strip that can simultaneously feed them onto the rotating tire form. This allows continuous winding of the reinforcing layers without stops or tool changes. The result is a tire with a circumferential reinforcement where each turn of thread is sandwiched between layers of elastomer.

Source

A method for making reinforcing elements for vehicle tire sidewalls that involves winding a continuous thread-like element around the tire in concentric layers. The thread is crossed over itself at multiple points as it is wound. This creates a reinforcing network that provides strength to the tire sidewalls without requiring separate sidewall components. The wound thread replaces the sidewall material. This allows the tire to be built directly without separate sidewall parts. The concentric winding path allows the thread to follow the tire's shape and curvature.

Source

A method to manufacture tire beads that allows faster production and better shape versatility compared to conventional methods. The method involves winding a tape made of parallel wires coated with a resilient elastomeric material around a mandrel to form the tire bead. The key innovation is using a tape with interconnected parallel wires instead of individual wires. The interconnected wires allow the tape to be more pliable, enabling the same cross-sectional shapes as with individual wires. This allows faster winding since the tape can be positioned more easily compared to feeding and aligning individual wires. The interconnected wires also prevent loose wire ends from misaligning during winding.

Source

A method to manufacture tire carcass reinforcements from a single filament wrapped around the bead wire, that allows mechanization of the process for improved efficiency. The method involves using a ring with hooks around it that holds the filament, a reel housing with guide rails, and a bead wire. The filament is wound onto the reel, passed through the bead wire, and then wrapped around the ring with hooks to create the carcass shape. This allows the carcass to be formed in a controlled and repeatable way by moving the ring and reel along the bead wire and ring hooks.

Source

A method for producing tire carcasses using a single filament wrapped around the bead wire. The method involves holding a ring with hooks around it a predetermined distance from the bead wire. A reel of filament is mounted in a housing with a guide path perpendicular to the bead wire. The path runs around the bead wire, crosses the ring, and back to the reel. This allows the filament to be fed continuously around the bead wire and loops on the ring to create the carcass. The ring hooks secure the filament segments and provide pretension. The method enables simple, flexible production of customizable carcasses using a single filament.

Source

A method and device for producing a toroidal tire carcass with beads connected by a reticulated structure. The method involves forming a toroidal frame with the beads, then winding cords outside the frame in a U shape and connecting them to form loops that enclose the beads. The frame and knotting device rotate relative to each other to create the toroidal reticulated structure. This allows efficient production of the toroidal tire carcass shape with bead loops.

Source

A simple, low-cost method to produce toroidal radial tire carcasses with two annular beads connected by a reticulated structure of elongated reinforcing elements. The method involves winding a continuous cord around a toroidal frame with removable outer annular element, rotating the frame while winding, and having the cord extend outside the frame and through the openings. This allows the cord to spiral between the beads and outer annular element to form the reticulated structure.

Source

A device for applying sinuous threads to a support like a tire reinforcement ply that improves precision and reduces complexity compared to existing methods. The device has a thread feeder that moves the thread in a sinuous pattern as it is applied to the support. This avoids the need for separate winding and unwinding steps that can cause thread misalignment. The device also has a support clamp to securely hold the material being threaded. This prevents slippage and helps maintain consistent thread spacing. The sinuous threading motion is controlled by a displacement ratio between the thread feeder and support clamp. By minimizing variation in this ratio, the threads are applied with consistent sinuous shape and spacing. This improves ply uniformity and quality compared to methods with variable thread spacing.

Source

A method for making the bead filler component in a pneumatic tire that improves upon previous techniques. The method involves helically winding flat strips of polymeric material around the outer side of the tire bead to create a triangular shape that tapers radially outward. This replaces cutting and winding triangular extrusions to fill the triangular space between the bead and sidewall. The helical winding provides a more efficient and compact way to reinforce the bead area.

Source

A method to construct a reinforced bead for a hollow flexible article like a tire that provides a smooth and consistent bead shape without overlaps. The method involves wrapping successive layers around a mandrel - an initial flat strip of uncured polymer material, followed by spaced-apart windings of inextensible material. The windings are tensioned so the polymer fills the spaces between them. This builds the required thickness and shape of the bead, with the windings embedded in the polymer. The result is a reinforced bead with a smooth cross-section and no overlap joints.

Source

Apparatus for manufacturing tire reinforcements from a single thread that improves efficiency and reduces thread breakage compared to prior art designs. The apparatus has a presentation head with an endless flexible strand carrying the presentation head. The strand has guide wheels perpendicular to the crown axis near the retaining hooks. This allows the thread to be presented to the hooks in a plane parallel to the crown axis, reducing thread kinking and breakage compared to vertical presentation.

Source

Reducing the size of the bead "turn ups" in pneumatic tires by using a specialized tire building former and a unique winding method. The method involves winding the tire cord around supports instead of directly onto the bead wire. This creates hooped support elements at the edges of the cord ply. When the cord is rubberized and shaped, the supports are incorporated into the bead wire assemblies. This anchors the cord loops to the bead instead of wrapping around it, significantly reducing the bead turn ups. The specialized tire building former has rotating discs to support the tire components during winding and can move to wind the inner liner. This allows the cord to be wound onto the supports instead of directly onto the bead wire.

Source