Aviation Tire Bead Core Locking Insert
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Solution Overview
Problem
The manufacturing process of tires with multiple bead cores and carcass plies is inefficient and ergonomically challenging due to the need for manual pullout and wrapping of carcass plies, which requires significant physical effort and increases production time and cost, especially in high-load applications like aviation where the tire must pass the double overload test.
Innovation Solution
Incorporating a bead core locking insert that is separate from the carcass plies and located adjacent to the bead cores, which eliminates the need for manual manipulation of the innermost ply by overlapping with the turn down band and extending radially to create a splice, thereby locking the bead cores together without the pullout step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual pullout and wrapping of carcass plies is performed, then the tire structure is secured, but production time and labor cost increase significantly
Solution Approach 1:
A bead core locking insert is introduced as an intermediary component between the bead cores and carcass plies. This insert includes a locking mechanism that secures the bead cores together without requiring manual manipulation of the carcass plies, thereby maintaining structural security while eliminating the time-consuming pullout and wrapping steps
Solution Approach 2:
The tire construction is segmented into distinct functional components: bead cores, locking insert, and carcass plies. The locking insert is divided into separate sections including a first section engaging with the first bead core and a second section engaging with the second bead core, allowing independent assembly of each component without requiring complex manual operations
2Reliability
If manual pullout and wrapping of carcass plies is performed, then the tire structure is secured, but ergonomic challenges and physical effort increase
Solution Approach 1:
The locking insert serves as a mediator that eliminates the need for workers to manually pullout and wrap heavy carcass plies around bead cores. The insert includes automated or semi-automated locking mechanisms that secure the bead cores through simple positioning operations, dramatically reducing physical effort and ergonomic risks
Solution Approach 2:
The locking insert is designed to self-lock the bead cores together through its geometric configuration and material properties. The insert automatically engages with the bead cores upon positioning, eliminating the need for manual manipulation and reducing ergonomic challenges associated with handling heavy tire components
3Strength
If multiple bead cores with wrapped plies are used, then heavy load capacity is achieved, but manufacturing complexity increases
Solution Approach 1:
The locking insert simplifies the manufacturing of multi-bead-core tires by providing a standardized intermediate component that connects multiple bead cores. Instead of manually wrapping plies around each bead core individually, the insert can be positioned to engage multiple cores simultaneously, reducing manufacturing complexity while maintaining the heavy load capacity provided by the multiple bead core structure
Solution Approach 2:
The locking insert is pre-configured with locking mechanisms and engagement features before assembly. This preliminary preparation allows for faster and simpler assembly of the multi-bead-core structure, as the insert is already shaped and positioned to automatically engage with the bead cores and secure them together without complex manual operations
Data Source
AI summary
This invention relates generally to tires having multiple carcasses that wrap around multiple bead cores on a single side of the tire, and, more specifically, to a tire that has a bead core locking insert that eliminates a pullout step for one of the carcass plies or bands during fabrication, This step includes wrapping one of the plies or bands completely around said multiple bead cores that are found on a single side of the tire. In certain embodiments, the tire is an aviation tire that has bands of multiple plies that are wrapped about multiple bead cores found on each side of the tire. The bead core locking insert is found below the multiple bead cores found on each side of the tire and is adjacent to the bands that wrap around the inside and outside head cores, thereby locking these beads and associated bands together.