Flat Wire Cable Bead for Tire Strength and Stress Reduction
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Solution Overview
Problem
The existing cable beads have large arrangement gaps and circular cross sections, leading to low effective strength and stress concentration, which shortens the service life due to point contacts between outer winding wires.
Innovation Solution
A cable bead design with a core wire and outer winding wires having flat surfaces with specific major and minor axes orientations, reducing gaps and stress concentration through surface contact and optimized winding directions, enhancing cross-sectional strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circular cross section outer winding wires are used, then the bead structure is simple to manufacture, but the arrangement gaps between wires are large and effective strength is low
Solution Approach 1:
The patent changes the outer winding wire cross-section from a symmetric circular shape to an asymmetric flat shape with a specific aspect ratio (0.6-0.8). This asymmetric flat configuration allows wires to pack more efficiently, reducing arrangement gaps between adjacent wires while maintaining manufacturing feasibility through standardized wire drawing processes.
2Ease of manufacture
If circular cross section outer winding wires are used, then manufacturing is easier, but point contact between adjacent layers causes stress concentration
Solution Approach 1:
The flat cross-sectional shape with aspect ratio 0.6-0.8 creates line contact between adjacent wire layers instead of point contact. This geometric modification distributes stress along a line rather than concentrating it at a point, significantly improving reliability and service life while remaining compatible with standard wire manufacturing processes.
3Strength
If flat surface outer winding wires with optimized orientation are used, then cross section strength is improved and gaps are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent specifies a precise aspect ratio parameter (0.6-0.8) for the flat wire cross-section, which optimizes both strength and packing efficiency. This parameter control, combined with standardized manufacturing processes, achieves the desired performance without requiring excessive manufacturing precision, balancing performance improvement with manufacturing feasibility.
Data Source
AI summary
Disclosed are a cable bead and a tire. The cable bead includes a core wire located at the middle position of the bead and at least one layer of outer winding wires wound around the core wire, each layer of outer winding wires being evenly wounded along the circumferential direction of the core wire, where the cross section of the outer winding wires is a flat surface having a major axis and a minor axis; the major axis is perpendicular to the radial direction of the cross section of the bead, and the minor axis is parallel to the radial direction of the cross section of the bead; the outer winding wires are in surface contact with the core wire; and when there are at least two layers of outer winding wires, a line contact is formed between the layers of outer winding wires.