Bead Winding in Tire Manufacturing

A method and mechanical drum for building tires that allows simultaneous attachment of bead filler and sidewalls to improve tire building efficiency. The method involves rolling the bead filler and sidewall at the same time using separate mechanisms attached to the tire drum. A lead screw moves the turn-up mechanism to roll the sidewall while the attaching mechanism rolls the bead filler. This allows overlapping the processes to shorten tire building time compared to sequential attachment.

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Tire bead manufacturing device that improves tire durability by stacking coated wires with polygonal cross sections in close contact. The device has a wire coater to form coated wires with compounded rubber, and a wire winder with segments having grooves. An adhesion unit allows the coated wires to closely stack in the grooves. This reduces gaps between wires in the tire bead, preventing splitting and cracks.

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Spiral winding machine for making tire beads with adjustable winding direction to allow customization of bead strength for different tire applications. The machine has two groups of winding mechanisms with adjustable rotation direction. Each group has vertical wire cores surrounded by windable wire reels. The reels have detachable outer rings that can be swapped between groups. This allows winding steel wire around the cores in different directions. A transmission mechanism connects the winding rings and a drive mechanism turns both rings simultaneously. An adjustment mechanism allows reversing the rotation of one ring. This provides flexibility to adjust the winding direction for optimal bead strength based on tire requirements.

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A method for preparing lightweight cable-type tire beads with improved performance by optimizing the winding process to reduce weight without sacrificing strength. The method involves adjusting the yield ratio of the metal outer winding wire and the diameter of the self-forming ring for the non-metallic outer winding wire. This compensates for the reduced stiffness caused by the lighter non-metallic outer winding wire. It allows using lower weight materials while maintaining comparable strength and formability to conventional cable beads.

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A structural cable bead for tires with improved rubber penetration, corrosion resistance, and wear life compared to conventional cable beads. The novel bead has at least one layer of non-metallic winding wire with a different diameter than the metallic winding wires. This allows better rubber penetration between the winding layers, reducing friction and corrosion compared to tightly compacted metallic winding. The non-metallic winding also improves flexibility and reduces weight compared to metallic winding alone.

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Method to manufacture cable-type tire beads for passenger cars that improves tire durability and prevents air leakage between the tire and rim. The method involves regulating the elongation of the steel wire in the tire bead core through heat treatment during manufacturing. This prevents excessive stretching of the bead when mounted on the wheel rim, ensuring tight fit and preventing air leakage. The heat treatment involves annealing the steel wire at specific temperatures and times to control elongation within a range of 1.5-5%. This prevents excessive stretching of the bead when mounted on the wheel rim, ensuring tight fit and preventing air leakage.

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Method for manufacturing cable-type beads for passenger car tires that can be predicted to prevent unexpected failures. The method involves controlling the yield ratio of the outer winding wire during bead production. The yield ratio is kept between 70% and 90%. This allows the bead to deform more before breaking, providing warning signs and delaying failure compared to higher yield ratios. By adjusting the pressing force on the outer winding during bead straightening, the yield ratio can be targeted.

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High-speed radial tire bead wire winding device that improves wire winding stability for radial tire production. The device has a rotating disk with winding plates that can move towards or away from the disk axis. The plates have moving mechanisms to adjust their position. A wire blocking mechanism with a movable tube moves towards and away from the disk and axis. The tube corresponds to each plate and guide rods connect them. This allows controlling wire tension during winding for improved fatigue resistance in radial tires.

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Bead wire winding mechanism for bead forming equipment in tire manufacturing that prevents wire scatter and bead misalignment during winding. The mechanism has synchronized moving forming heads and clamping device to keep wire centered as it winds around spokes. The heads have slotted arches to accommodate the wire and spokes. A clamping device on one head grabs the wire end and holds it while the heads move opposite directions. This prevents wire separation and ensures consistent bead wire positioning.

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Cable bead for tires with improved strength and manufacturing efficiency. The cable bead has an annular core made by winding round steel wire without twisting, and side wires spirally wound around the core. The annular core shape provides better bead-rim contact due to uniform deformation. The side wires follow the core curvature. This integrates the core and side wires into a single cable bead, eliminating separate core welding steps. The cable bead can be manufactured at lower cost and higher speed compared to conventional stranded cable beads.

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Tension control system for a bead ring winding machine used in tire production. The system aims to improve consistency and quality of bead rings by controlling the tension of the steel wire during winding. It uses a tension detection device to measure wire tension before winding, and a tension adjustment mechanism in the wire storage device to change wire tension. This allows precise tension control of the wire as it is wound into the bead ring, mitigating deformation issues caused by tension variations during winding.

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Method for manufacturing bead wires for tires that reduces length and simplifies assembly by folding the excess braided wire after winding. After braiding the wire around a looped core to form the bead wire, an extra-long section protrudes. This section is then plastically deformed to create a bend that deflects it outward from the braided toroid. This folds and shortens the excess wire while keeping the main toroid shape. The folded section now protrudes partially, making it easier to handle and join compared to the elastic winding section.

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Bead wire for tires that reduces weight, improves flexibility and durability compared to traditional bead wires. The bead wire has a polyhedron shape formed by topping a twisted wire part with rubber. This provides a specific cross-sectional shape to the bead wire instead of the traditional round wire. The polyhedron shape reduces weight, maintains rigidity and flexibility, and allows combining multiple polyhedrons to expand cross-sectional area. The unique bead wire design improves tire bead installation and retention.

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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.

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A tire design with improved durability and reduced stresses in the bead area. The tire has a unique bead construction that aims to mitigate cyclic stresses and deformations in the bead structures. The bead has a folding part of the carcass reinforcement and a protrusion that extends inward. A wire reinforcement contacts the carcass ply at the inner bead and the folding part. This prevents cyclic bending and stresses at the folding end. A filler between the carcass and folding part reduces deformations. The seating portion contacts the rim to prevent cyclic displacement. The protrusion prevents cyclic bending at the inner bead.

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A cable bead for tires with improved strength and durability compared to conventional beads. The bead has a core wire surrounded by at least one layer of outer winding wires. The outer winding wires have a unique cross section shape, with a major axis perpendicular to the radial direction and a minor axis parallel to the radial direction. The minor axis axes all converge at a point. This shape eliminates large gaps between wires and prevents point contact between adjacent layers. The wires contact the core wire and line contact between layers.

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Anti-broken tire bead structure to prevent wire separation in tires. It has a bead wire, rubber sealing sleeve, curved rubber blocks, apex, and carcass cord layer. The rubber sealing sleeve around the bead wire is slotted and the curved rubber blocks fit inside the slots. This adds thickness to the friction protection layer between the bead wire and carcass cord. It reduces wire-wire contact and friction compared to just an apex. The blocks are inserted and sealed using a processing device with steps like wire fixing, slotting, block pushing, apex gluing, and cord wrapping.

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Bead wire array former for tires that allows easy and precise arrangement of bead wires in tires to improve tire performance and durability. The bead wire array former has a rotating body controlled by a sensor-based system that winds bead wires into the tire carcass. The rotating body has fixed central fastening parts and variable frame members that form U-shaped grooves. When winding the bead wires, they are guided into the U-shaped grooves on the outer surfaces of the fixed central parts. This provides a simple way to change the bead wire arrangement structure by varying the frame members. The U-shaped grooves also have features like recesses or pyramids between the bead fillers to improve binding force and prevent separation.

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Bead core manufacturing apparatus for stable production of bead cores used in tires. The apparatus has a winding mechanism to form bead cores by winding a rubber-coated wire. It measures the winding diameter and adjusts the wire tension based on that measurement. This prevents variation in bead core outer diameter caused by tension changes during winding. It also has an option to adjust wire temperature based on extruded rubber temperature to prevent sticking issues.

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Tire bead winding molding process using a specialized machine that allows automated, synchronized flattening and rolling of the steel wire reinforcement around the tire bead. The machine has a rotating platform with a flattening rod, a locking mechanism, and a leveling mechanism. The locking mechanism secures the wire belt during winding, while the leveling mechanism positions and rolls the belt. This prevents manual support, synchronizes flattening, and avoids irregular bead shapes.

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A device for manufacturing bead cores of pneumatic tires that prevents the bead wire from bouncing during winding and protruding at the ends. The device has a rotating support to wind the bead wire onto an expandable/contractible diameter body. A clamping device grips the bead core widthwise to include the winding end of the bead wire. This crimps the wire end to the core instead of allowing it to extend. This prevents the wire from twisting during winding and keeps the end from protruding in the finished bead core.

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Bead member for pneumatic tires that prevents protrusion of the end wires while improving adhesion to the bead filler. The bead core is made by winding a bead wire coated with a low tackiness rubber. The end portions of the wound wire are then wrapped with a higher tackiness rubber tape to prevent wire popping. The higher tackiness of the tape improves adhesion between the bead core and filler compared to the low tackiness of the wire coating. The tape length is 10-50 mm around the wire ends.

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Bead member for tires with improved bead core adhesion and reduced wire popping. The bead member has an annular bead core made by winding a topped bead wire from start to end. Only the start and end regions are heated to fuse the topping rubber. This fixes the wires and prevents popping. The rest of the bead core remains unheated to maintain tack and adhesion. A thin tackier tape covers the fused regions.

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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.

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Rubber extrusion die for tire bead wire coating that reduces post-processing defects like growth and surface defects by allowing more relaxation of elastic deformation. The die has a longer blowing zone length compared to standard dies for specific wire speeds and rubber compounds. This increases the residence time of the rubber in a deformed state, preventing elastic post-processing effects. The die length can be adjusted based on wire speed, rubber properties, and temperature to optimize coating quality.

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Heavy load tire with improved bead separation resistance and manufacturing method to achieve it. The tire has a bead core made of multiple wound bead wires and a rubber sheet wrapped around the bead wire ends. This wrapping is done on the bead wire ends closest to each other in the tire circumferential direction. The wrapped rubber helps prevent bead separation during heavy load and high speed operation. The wrapping is done before vulcanization to secure the rubber in place.

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Pneumatic tire design to prevent bead core collapse during vulcanization while reducing weight. The tire has a bead core made by winding bead wires around it multiple times. The carcass layer wraps the bead core and bridges over it. The carcass layer is rewound and sealed around the bead core to create a closed region. This prevents core collapse during vulcanization. The carcass cord heat shrinkage is 0.1-1.5%. A rim cushion rubber covers the rewinding portion of the carcass. The rubber occupancy in the closed region is 15%.

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A method of manufacturing beads for tires with improved handling properties by preventing overlapping of the rubber coating when stacked. The method involves winding a coated wire around a bead drum in a specific sequence. After each m rotations, the wire is dried or hardened for n rotations before continuing winding. This prevents adjacent turns from overlapping as they wind, preventing peeling and tearing issues when the beads are stacked. The drying/hardening can be done using heat, light, or electron beams.

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A bead core design for pneumatic tires that improves steering stability without compromising tire uniformity. The bead core is made by winding non-circular wires multiple times in radial stages to form rows. The wires are coated in resin between them. This non-circular, multi-row winding with resin interstices provides better shape retention compared to circular winding. The resin overlaps and joins between wires. This allows reducing weight by having constant overlapping thickness regions. The non-circular winding and resin joinings improve bead core shape versus circular winding. The resulting bead core can be used in tires without affecting tire roundness.

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Bead core design for pneumatic tires that improves durability in the bead portion. The bead core has an annular body made by winding and stacking strip members coated with a resin around the bead wires. The interface between the steps of the stacked strips is non-linear, with a central apex and curved ends. This configuration reduces peeling and delamination compared to straight step interfaces. The curved shape allows better adhesion between the steps and prevents separation.

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Pneumatic radial tire with improved bead core shape to prevent floating of the wire ends and defects like poor bead core shaping. The tire has a bead core made by winding at least one bead wire in an annular shape around the tire inner diameter. The wire ends overlap at least twice in the overlapping region. A string-shaped binding member made of heat-shrinkable organic fibers is tied around the overlapped wire ends. This restrains the wire ends and prevents them from floating during tire manufacturing. The heat-shrinkable fibers contract during vulcanization to tighten the binding member and improve bead core shape.

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Pneumatic tire design with improved durability of the carcass layer at the bead portion. The tire has a bead core made by bundling metal wire surrounding parts in a specific arrangement. The bead core has central layers at the tire center, an outer layer on one side, and an inner layer on the other side. The number of surrounding metal wires in the central layer is the same maximum value. The outer and inner layers have decreasing numbers of surrounding wires as they move away from the center. This disperses stress on the carcass layer at the bead to improve durability.

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Pneumatic tire design to efficiently suppress bead toe lift while maintaining core collapse resistance. The tire has a hexagonal wire arrangement in the bead core, where the innermost wire winding is tightly packed. The hexagon shape has blunt internal angles. The distance from the innermost apex to the center of gravity follows a relationship of 0.75 * Nmax <= d <= 1.30 * Nmax, where Nmax is the maximum wire packing. The outermost apex distance from the center is 1.05 * B / A, where B and A are width and height measurements. This arrangement suppresses toe lift without excess winding or material.

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A tire bead wire ring structure that reduces stress concentrations and puncture risks compared to conventional bead rings. The wire ring has multiple layers of wire loops with progressively increasing numbers of loops per layer. The outermost layer has 6 loops per layer, reducing to 1 loop per layer at the center. This gradual increase in loops per layer reduces the force concentration at the inner rim of the tire where it contacts the carcass ply, preventing cutting and puncturing. The wire loops are wound onto a U-shaped winding disk to create the circular bead ring.

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Method to manufacture tire core members with reduced unwinding during molding. The core member has an inclined bottom surface. The winding process involves alternating between an ascending winding where the bead wire is wound from inside to outside, and an inward winding where the bead wire is wound from outside to inside. In the downward winding step, the tension applied to the bead wire is lower than in the upward winding step. This reduces unwinding during molding of the core member.

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A technique for forming a bead core of a tire by accurately winding a steel wire around a target position in a groove of a rotating bead former to reduce unwinding and prevent bead core collapse. The bottom surface of the groove at the steel wire supply position is tilted to be horizontal using a tilting mechanism. This prevents downward forces acting on the wire when winding, allowing easier winding to the target position and preventing bead core collapse. The tilting is done in a range of 0-45 degrees in increments of 1 degree.

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A pneumatic tire with a bead core that has an unusual winding pattern for the bead wire. Instead of starting the wire winding at the center of the bead, it starts inside the tire in both radial and width directions. The wire is then wound around to form the bead core with the end on the outer side of the center. This unconventional winding order is aimed at improving tire bead strength and durability, potentially reducing bead failures.

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Pneumatic tire design to improve bead durability and productivity in manufacturing. The tire has a bead core formed by winding bead wires around the tire inner surface. To improve durability, the tire design aims to prevent collapse of the winding shape and avoid matching end points of adjacent wires. To prevent collapse, the meridional cross-sectional area at the butt joint is kept in a range of 90-115% of the other wire sections. This maintains the winding shape. To avoid matching end points, the butt joint is placed a constant distance from the wire end, outside a range of 0-270 degrees in circumferential direction. This prevents end point alignment. By controlling wire size (1.2-2.0mm diameter) and strength (2.2kN or more) the bead wire durability is improved.

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Pneumatic tire with improved bead core design for better grip, ride comfort, and steering stability. The tire has a carcass extending from the tread through sidewalls to the bead, with annular bead cores inside. The bead core wire is wound around itself multiple times in the radial direction, with the number of windings greater than 1.5 times the number of axial wire rows. This stacked winding configuration provides higher force when inflated and loaded, improving bead core grip, while maintaining flexibility for ride comfort.

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Method for manufacturing a pneumatic tire with a tapered bead core. The process involves winding the bead wire around a tilting disk-shaped former. The former has a groove on the outer edge that the wire is fed into. The wire is initially placed on the bottom of the groove. The groove position is then moved relative to the wire feed point while rotating the former. This spirally winds the wire inside the groove. The angle between the wire feed direction and the groove bottom is 80-100 degrees. This allows the wire to be accurately wound onto the tilting former. The former tilt is adjusted to match the wire feed angle to achieve the tapered bead core.

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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.

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Pneumatic tire design with improved safety and durability of the bead area. The tire has a carcass extending between the tread, sidewall, and bead. The end of the carcass is wound between multiple layers of bead wires instead of turning it up. This provides better support and rigidity at the bead. The bead wires are wrapped around the carcass end to secure it. Alternatively, the carcass can be wound around the bead wires from the inside or outside. The tire can have multiple carcass plies. The bead wires can also be wound multiple times.

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An improved folding tire structure with a stronger bead for better durability and longer life compared to conventional folding tires. The bead is made of a set of loops formed by combining multiple soft bead rings. The loops are twisted with a straight steel wire and spiral wound flexible wire. This creates gaps between the wires. The twisted wires have copper-zinc plating and rubber coating. This provides a uniform adhesion between the bead loops and surrounding tire layers like the carcass ply and rim, preventing separation and damage. The improved bead structure maintains a tight, stable state during folding, storage, and riding to enhance tire durability and life.

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Pneumatic tire with improved uniformity by optimizing the shape of the bead core. The bead core is made of a wire wound body around the tire's rotation axis. It has a first portion with constant radius layers and a second portion with varying radius layers. This configuration aligns the winding center close to the center of gravity, reducing misalignment and improving tire uniformity compared to gradually increasing radius winding.

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A device for winding bead wire onto a wheel rim to form an inclined bead core without causing irregular winding. The device has a rotating body with an inclined winding unit on its outer surface. A transverse roller aligns the wire windings in contact with the winding unit. The roller shaft is parallel to the winding unit's incline. This forces the roller to laterally displace along the incline while winding. This supports the wire with pressure to form a stable, inclined bead core without irregular winding.

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A bead wire winding machine for efficiently winding bead wire around a wire holder to make tire beads. The machine improves on existing designs by providing a better wire holder for winding consistency and quality. The wire holder, which is a mandrel-like structure, has a shape that matches the cross-section of the tire bead. This ensures the wound wire closely conforms to the shape of the tire bead, eliminating gaps or voids that can weaken the bead. The customized wire holder also allows for optimized winding tension and spacing between windings for improved strength and uniformity.

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A bead wire winding device for making uniform and stable bead cores for vehicle tires without irregular winding. The device has a rotating body with an annular winding unit having aligned coils of wire in mounting grooves. There are also sections without grooves to cover gaps between grooves. This prevents wires from moving between grooves and collapsing on the innermost coil, ensuring consistent winding without wrinkles or sloping. The groove width is optimized to prevent wire shifting while allowing accurate wire alignment.

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A bead design for tires that prevents cracking and delamination of the bead area during tire usage. The bead has a unique winding pattern with specific layer configurations. It consists of a hexagonal core surrounded by layers winding outward. The outermost layer has M1 windings extending outward, the next layer has M3 windings, and the innermost layer has M4 windings. This winding sequence prevents crack propagation into the bead seat. The bead also has a basic hexagonal core with N layers. The tire bead design aims to reduce cracking and delamination issues in the bead area by preventing crack propagation into the rim seat.

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Pneumatic tire with a narrow winding region in the bead core to prevent cord slippage and loosening. The tire has a bead core made by winding a bead wire multiple times around in an annular shape. A cord is then wound in the region from the end of the bead wire winding to a specific position in the opposite direction. This narrow winding region prevents the bead wire end from jumping outward and also keeps the cord from slipping and loosening.

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Steel radial tire bead design to improve tire rigidity and reduce bead deformation under high load conditions. The bead consists of a carcass, hard apex, soft apex, wire cloth, bead reinforcement strip, and nylon cord wrapping. The wire cloth is a double layer structure with an outer #1 wire cloth wrapped by #2 wire cloth. This double layer wire cloth improves tire rigidity and flex resistance at the bead area. The bead reinforcement strip is also made of two layers to enhance stiffness and reduce bead deformation.

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