Hybrid Bead Wire with Textile Core for Mass Reduction
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Solution Overview
Problem
Conventional bead wires for tires, particularly those used in aircraft, are heavy due to their metal core, which affects their mechanical properties and mass efficiency.
Innovation Solution
A bead wire design featuring a core made of a multifilament textile fiber embedded in an organic matrix, combined with outer and intermediate metal wire layers, reducing mass by 10-40% while maintaining mechanical properties like force at break.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal core is used in the bead wire, then the force at break is high, but the mass increases
Solution Approach 1:
The bead wire employs a composite structure combining an organic matrix core with multiple metal wire layers. The core uses non-metallic materials (thermosetting resin, glass fibers, carbon fibers) to reduce mass, while the metal wire layers (steel or aluminum alloy) provide the necessary tensile strength and force at break. This composite approach resolves the contradiction by distributing structural functions across different material types.
Solution Approach 2:
Different portions of the bead wire have different material compositions optimized for their specific functions. The core provides structural support and shape with low-density organic materials, while the outer metal wire layers concentrated at critical stress points provide the high strength needed for force at break. This local differentiation of material properties allows mass reduction without compromising overall strength.
2Weight of moving object
If a multifilament textile fiber core is used, then the mass is reduced, but the structural complexity increases
Solution Approach 1:
The bead wire structure follows a nested configuration where the multifilament textile fiber core is embedded within an organic matrix, which is in turn surrounded by intermediate and outer metal wire layers. This nested arrangement consolidates multiple functional elements into a compact hierarchical structure, reducing overall complexity despite the use of advanced composite materials.
Solution Approach 2:
The combination of multifilament textile fibers (glass or carbon) embedded in thermosetting resin creates a unified composite core material that behaves as a single structural unit. This composite core, while materially complex, simplifies the overall design by eliminating the need for solid metal cores and providing inherent damping and fatigue resistance properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves a significant reduction in mass while maintaining or exceeding the force at break of traditional bead wires, with improved elastic deformation capabilities and reduced risk of plasticization.
Implementation Method 1
a core comprising at least one yarn of a multifilament textile fibre embedded in an organic matrix
Implementation Method 2
at least one outer layer comprising an outer-layer metal wire wound around the core, at least one intermediate layer comprising an intermediate-layer metal wire wound around the core
Data Source
AI summary
A bead wire for a tire includes a core, an outer layer, and at least one intermediate layer. The core includes at least one yarn of a multifilament textile fiber embedded in an organic matrix. The outer layer includes an outer-layer metal wire wound around the core. Each intermediate layer includes an intermediate-layer metal wire wound around the core. Each intermediate layer is disposed between the core and the outer layer.