Resin-Coated Bead Core Assembly for Faster Tire Production
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Solution Overview
Problem
The existing method for producing bead cores of various shapes using resin-coated bead wire is time-consuming, resulting in poor productivity.
Innovation Solution
A production method involving the formation of multiple annular bodies by winding bead wires coated with resin material and joining them in an axial direction, allowing for efficient production of bead cores with excellent shape moldability and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bead core is produced by winding a resin-coated bead wire in an axial direction and stage direction sequentially, then the bead core can be formed with the desired shape, but the production time becomes excessively long, resulting in poor productivity
Solution Approach 1:
The bead core production process is segmented into two independent stages: (1) forming annular bodies by winding bead wire in the stage direction only, and (2) joining multiple annular bodies in the axial direction. This segmentation allows parallel production of multiple annular bodies simultaneously, dramatically improving productivity while maintaining shape flexibility through selective joining of different annular bodies.
2Shape
If the bead wire is wound in multiple stages in the radial direction, then the bead core achieves the required structural complexity and shape, but the manufacturing process becomes excessively time-consuming
Solution Approach 1:
Annular bodies with complex radial structures are prepared in advance as pre-formed components. These pre-formed annular bodies are then simply joined in the axial direction to create the final bead core. This preliminary action eliminates the need for time-consuming multi-stage winding during final production, reducing manufacturing cycle time while preserving structural complexity.
Solution Approach 2:
The invention shifts the complexity from the radial winding process to the axial joining process. Instead of achieving structural complexity through time-consuming multi-stage radial winding, the complexity is achieved by joining multiple annular bodies (each with simple radial structure) in the axial dimension, dramatically reducing manufacturing time.
Data Source
Figure 1A~1I
Figure 2
Figure 3A~3F
AI summary
A production method for a bead core of the present disclosure includes a forming step of forming a plurality of one or more types of annular bodies, each of which is formed by winding a strip member two or more turns, the strip member being comprised of one or more bead wires coated with a resin material, and a joining step of joining the plurality of one or more types of annular bodies to one another in an axial direction of the annular body. A bead core of the present disclosure is formed by joining one or more types of a plurality of annular bodies in an axial direction of the annular body, each of the annular bodies being formed by winding a strip member two or more turns, the strip member being comprised of one or more bead wires coated with a resin material. A pneumatic tire of the present disclosure includes a pair of bead portions, and the above-described bead core in the bead portion.