Patent Publication Number: US-2017361664-A1

Title: Metallic bead structure

Description:
BACKGROUND 
     In the manufacture of a rubber article, including for example a vehicle tire, a bead structure may be integrated into the article to create a stiffened portion of the article for interface with another element, including for example a vehicle wheel. Additionally, a bead structure may act to anchor reinforcing elements, including for example one or more body plies. 
     A bead structure may traditionally include a bead bundle, including for example one or more metal bead wires oriented adjacent one another. A bead structure may traditionally include a rubber bead filler, configured to fill a void created adjacent the bead bundle following turnup of one or more body plies about the bead bundle. Traditionally, the bead bundle and bead filler are separate components that must be assembled together during the manufacture of the rubber article. 
     Traditionally, the bead filler and bead bundle are solid elements. As a result, these elements may be heavier than a similarly-shaped hollow element Likewise, these solid bead filler and/or bead bundle elements may not permit introduction or translation of other materials within the interior of the bead filler and/or bead bundle elements. 
     What is needed is a metallic bead structure that may be at least partially hollow to allow for introduction of other materials therein and/or which is lighter than traditional bead elements. 
     SUMMARY 
     In one embodiment, a bead structure for use in a vehicle tire is provided, the bead structure comprising: a wall defining a cavity, wherein the wall includes at least one of a substantially teardrop-shaped cross-section and a substantially triangular cross section; and a bead filler portion; wherein the bead structure is formed into an annulus. 
     In another embodiment, a bead structure for use in a vehicle tire is provided, the bead structure comprising: a wall defining a cavity, wherein the wall includes at least one of a substantially teardrop-shaped cross-section and a substantially triangular cross section; and a bead filler portion; and a bead bundle portion. 
     In another embodiment, a bead structure for use in a vehicle tire is provided, the bead structure comprising: a wall defining a cavity, wherein the wall includes at least one of a substantially teardrop-shaped cross-section and a substantially triangular cross section; and a bead filler portion; and a bead wire bundle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying figures, which are incorporated in and constitute a part of the specification, illustrate various example systems and apparatuses, and are used merely to illustrate various example embodiments. In the figures, like elements bear like reference numerals. 
         FIG. 1A  illustrates a sectional view of an example embodiment of a bead structure  100 . 
         FIG. 1B  illustrates a sectional view of an example embodiment of bead structure  100  including balancing elements  110 . 
         FIG. 2  illustrates a sectional view of an example embodiment of a tire  220  including a bead structure  200 . 
         FIG. 3A  illustrates a sectional view of an example embodiment of a bead structure  300 . 
         FIG. 3B  illustrates a sectional view of an example embodiment of bead structure  300  including balancing elements  310 . 
         FIG. 4  illustrates a sectional view of an example embodiment of a tire  420  including a bead structure  400 . 
         FIG. 5A  illustrates a sectional view of an example embodiment of a bead structure  500  including an over-molded bead filler  506 . 
         FIG. 5B  illustrates a sectional view of an example embodiment of bead structure  500  including an over-molded bead filler  506  and balancing elements  510 . 
         FIG. 6A  illustrates a sectional view of an example embodiment of an over-molded bead structure  600 . 
         FIG. 6B  illustrates a sectional view of an example embodiment of over-molded bead structure  600  including balancing elements  610 . 
         FIG. 7A  illustrates a sectional view of an example embodiment of a bead structure  700  including a cut-out  718 . 
         FIG. 7B  illustrates a sectional view of an example embodiment of bead structure  700  including a cut-out  718 , at least partially engaged by body plies  728 A and  728 B. 
         FIG. 7C  illustrates a sectional view of an example embodiment of bead structure  700  including a cut-out  718 , at least partially engaged by body plies  728 A and  728 B, and including balancing elements  710 . 
         FIG. 8A  illustrates a sectional view of an example embodiment of a bead structure  800  including a cut-out  818 . 
         FIG. 8B  illustrates a sectional view of an example embodiment of bead structure  800  including a cut-out  818 , at least partially engaged by body plies  828 A and  828 B. 
         FIG. 8C  illustrates a sectional view of an example embodiment of bead structure  800  including a cut-out  818 , at least partially engaged by body plies  828 A and  828 B, and including balancing elements  810 . 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1A  illustrates a sectional view of an example embodiment of a bead structure  100 . Bead structure  100  may include a wall  102 . Wall  102  may define a cavity  104 . Bead structure  100  may include a bead filler portion  106 . Bead structure  100  may include a bead bundle portion  108 . 
     Bead structure  100  may be a bead structure for molding within a rubber article (not shown). Bead structure  100  may be a bead structure for molding within a vehicle tire (not shown). Bead structure  100  may be a bead structure for molding within a pneumatic vehicle tire. Bead structure  100  may be a bead structure for molding within a non-pneumatic vehicle tire. Bead structure  100  may provide structural integrity to an interface between a vehicle tire and a vehicle wheel. Bead structure  100  may provide an anchor point for reinforcement within a vehicle tire, including such reinforcement as one or more body ply. 
     Bead structure  100  may be substantially annular in shape. Bead structure  100  may be oriented within a vehicle tire and may extend along the circumference of the vehicle tire. A vehicle tire may include a plurality of bead structures  100 . A vehicle tire may include at least two bead structures  100 . A vehicle tire may include two bead structures  100 - a  first bead structure  100  oriented on an inboard side of the tire, and a second bead structure  100  oriented on an outboard side of the tire. 
     Wall  102  may be a relatively thin sheet of material, relative to the width (axially) and/or height (radially, as designated by R) of bead structure  100 . Wall  102  may have a thickness/gauge of between about 0.5 mm and about 10.0 mm. Wall  102  may have a thickness/gauge of between about 0.7 mm and about 6.0 mm. Wall  102  may have a thickness/gauge of about 1.0 mm. Wall  102  may have a thickness/gauge of about 2.0 mm. Wall  102  may have a thickness/gauge of about 3.0 mm. Wall  102  may have a thickness/gauge of about 4.0 mm. Wall  102  may have a substantially constant thickness. Wall  102  may have a varied thickness, such that certain portions of wall  102  are selectively thicker or thinner than other portions. 
     Wall  102  may include any of a variety of materials, including for example a metal, an alloy, a polymer, a composite, and the like. Wall  102  may include a metal such as steel. Wall  102  may include a metal such as stainless steel. Wall  102  may include an alloy such as aluminum. Wall  102  may include an alloy such as titanium. Wall  102  may comprise a metallic structure. 
     Wall  102  may be formed into a substantially teardrop-shaped cross-section. Wall  102  may be formed into a substantially triangular cross-section. Wall  102  may be formed into at least one of a substantially teardrop-shaped cross-section and a substantially triangular cross-section. Wall  102  may be formed with any of a variety of cross-sections, including for example a rectangular cross-section, a square cross-section, an oval-shaped cross-section, a circular cross-section, and the like. Wall  102  may be formed using roll forming processes. Wall  102  may have a cross-section similar to that of a traditional wire bead bundle and traditional bead filler following curing of the same within a vehicle tire. 
     Wall  102  may be a strip of flat sheet metal roll formed into a tube. Wall  102  may be a strip of flat sheet metal roll formed into a tube, and then formed into a hoop. The hoop may include any diameter as required to meet tire specifications. The hoop may include two distinct ends. The ends may be attached to one another so as to form a continuous hoop or ring of material. The ends may be attached to one another through any of a variety of mechanisms, including for example welding, an adhesive, an epoxy, a fastener, and the like. 
     Wall  102  may be formed from a section of billet material. Wall  102  may be formed about a mandrel. Wall  102  may be formed through any of a variety of methods to prepare a tube and/or ring-shaped tube. 
     Cavity  104  may be a substantially hollow cavity defined by wall  102 . Cavity  104  may contain only air, by virtue of exposure to air during manufacturing. Cavity  104  may be at least partially filled with a material. Cavity  104  may be at least partially filled with a material configured to adjust the strength of bead structure  100 . Cavity  104  may be completely filled with a material configured to adjust the strength of bead structure  100 . Cavity  104  may be at least partially filled with a material configured to adjust the properties of bead structure  100 . Cavity  104  may be completely filled with a material configured to adjust the properties of bead structure  100 . 
     Cavity  104  may be at least partially filled with any of a variety of materials, including for example: a foam, a rubber, a polymer, a metal, a liquid, a pressurized gas, and the like. The material may include a foam, for example a closed cell foam, an open cell foam, a foam rubber, and the like. The material may include a polymer, for example a solid polymer, a polymer having a webbing structure, a ground polymer, a flake polymer, and the like. The material may include a metal, for example a solid metal, a metal having a webbing structure, a ground metal, a flake metal, and the like. The material may include a liquid, for example a liquid having a high density such as mercury, a liquid having a density similar to water, an oil, and the like. 
     Cavity  104  may be at least partially filled with elements configured to adjust the balance of a vehicle tire incorporating bead structure  100 . For example, cavity  104  may be at least partially filled with one or more dynamic balancing elements (not shown). The dynamic balancing elements may comprise spheres configured to travel within a ring-shaped bead structure  100  and maintain position via centrifugal force where it is necessary to improve dynamic properties of a tire. The dynamic balancing elements may include a liquid configured to travel within a ring-shaped bead structure  100 . The dynamic balancing elements may include a powdered material configured to travel within a ring-shaped bead structure  100 . 
     Bead structure  100  may include a single cavity  104  extending about the circumference of bead structure  100 . Alternatively, bead structure  100  may include a plurality of cavities  104  extending in parallel about the circumference of bead structure  100 . Alternatively, bead structure  100  may include a plurality of chambers within cavity  104  as it extends about the circumference of bead structure  100 , such that cavity  104  is broken by dividers into a series of cavities  104  that extend around the circumference of bead structure  100 . Alternatively, bead structure  100  may include any combination of the cavity arrangements disclosed above. 
     Bead structure  100  may include bead filler portion  106  and bead bundle portion  108 . Thus, bead structure  100  may replace a traditional two-piece bead filler and bead bundle assembly. Alternatively, bead structure  100  may include a substantially hollow bead filler portion  106  while including a traditional bead bundle of any variety (see  FIGS. 3A-3B ). Alternatively, bead structure  100  may include a traditional bead filler portion (not shown) while including a substantially hollow bead bundle. 
     Wall  102  may include an exterior surface comprising a texture to improve bonding between a rubber of a tire and bead structure  100 . Wall  102  may include an exterior surface comprising an adhesive to improve bonding between a rubber of a tire and bead structure  100 . Wall  102  may include an exterior surface comprising a coating to improve bonding between a rubber of a tire and bead structure  100 . 
     Wall  102  may include an exterior surface comprising a texture to improve bonding between a body ply of a tire and bead structure  100 . Wall  102  may include an exterior surface comprising a ribbed texture to improve bonding between a body ply of a tire and bead structure  100 . Wall  102  may include an exterior surface comprising a knurled texture to improve bonding between a body ply of a tire and bead structure  100 . Wall  102  may include an exterior surface comprising an adhesive to improve bonding between a body ply of a tire and bead structure  100 . Wall  102  may include an exterior surface comprising a coating to improve bonding between a body ply of a tire and bead structure  100 . 
       FIG. 1B  illustrates a sectional view of an example embodiment of bead structure  100  including balancing elements  110 . As discussed above, balancing elements  110  may include any of a variety of materials, material types, material sizes, material shapes, and the like. Balancing elements  110  may comprise a plurality of spherical elements configured to travel about the circumference of a ring-shaped bead structure  100 . 
       FIG. 2  illustrates a sectional view of an example embodiment of a tire  220  including a bead structure  200 . 
     Bead structure  200  may include a wall  202 . Wall  202  may define a cavity  204 . Bead structure  200  may include a bead filler portion  206 . Bead structure  200  may include a bead bundle portion  208 . 
     Tire  220  may include a tread portion  222 . Tire  220  may include at least one sidewall  224 . Tire  220  may include at least one bead portion  226 . Bead structure  200  may be oriented in at least one bead portion  226 . 
     Tire  220  may include at least one reinforcement element. The at least one reinforcement element may be at least one body ply  228 . Tire  220  may include a plurality of body plies  228 . Body ply  228  may extend about at least a portion of bead structure  200 . Body ply  228  may include a turnup end  230  representing that portion at which body ply  228  terminates after extending about at least a portion of bead structure  200 . Turnup end  230  may be oriented radially outwardly of bead structure  200 . Turnup end  230  may be oriented radially inwardly of at least a portion of bead structure  200 . 
     Bead filler potion  206  may act to at least partially fill the void created radially outward of bead bundle portion  208 , between turnup end  230  and the remainder of body ply  228 . 
     Tire  220  may be substantially annular in shape, and bead structure  200  may extend along the circumference of tire  220 . 
       FIG. 3A  illustrates a sectional view of an example embodiment of a bead structure  300 . Bead structure  300  may include a wall  302 . Wall  302  may define a cavity  304 . Bead structure  300  may include a bead filler portion  306 . Bead structure  300  may include a bead wire bundle  312 . 
     Bead structure  300  may be substantially similar to bead structure  100  described above with respect to  FIGS. 1A-1B . 
     Wall  302  may define cavity  304 , which may define bead filler portion  306 . Bead filler portion  306  may be oriented radially outward of bead wire bundle  312 . Bead filler portion  306  may be oriented adjacent to bead wire bundle  312 . Bead wire bundle  312  may include a plurality of bead wires oriented adjacent one another. Bead wire bundle  312  may include a traditional bead wire bundle. Bead wire bundle  312  may alternatively include any traditional bead reinforcement used in a vehicle tire. 
     Use of bead wire bundle  312  in combination with bead filler portion  306  may permit flexion in a tire to permit easier mounting of the tire upon a vehicle wheel. This combination may include any of the benefits described above pertaining to weight savings, utilization of cavity  304 , strength modification, property modification, and the like. 
     Bead filler portion  306  may be connected to bead wire bundle  312 . Bead filler portion  306  may be operatively connected to bead wire bundle  312 . Bead filler portion  306  may be adhered to bead wire bundle  312 . Bead filler portion  306  may be bonded to bead wire bundle  312 . Bead wire bundle  312  may be coated with a material, which is configured to bond with and/or crosslink with a material coating bead filler portion  306 . Bead filler portion  306  may include a concave portion configured to at least partially accept and/or nest with at least a portion of bead wire bundle  312 . 
       FIG. 3B  illustrates a sectional view of an example embodiment of bead structure  300  including balancing elements  310 . Balancing elements  310  may be substantially similar to balancing elements  110  described above with respect to  FIGS. 1A-1B . 
       FIG. 4  illustrates a sectional view of an example embodiment of a tire  420  including a bead structure  400 . 
     Bead structure  400  may include a wall  402 . Wall  402  may define a cavity  404 . Bead structure  400  may include a bead filler portion  406 . Bead structure  400  may include a bead wire bundle  412 . 
     Tire  420  may include a tread portion  422 . Tire  420  may include at least one sidewall  424 . Tire  420  may include at least one bead portion  426 . Bead structure  400  may be oriented in at least one bead portion  426 . 
     Tire  420  may include at least one reinforcement element. The at least one reinforcement element may be at least one body ply  428 . Tire  420  may include a plurality of body plies  428 . Body ply  428  may extend about at least a portion of bead structure  400 . Body ply  428  may include a turnup end  430  representing that portion at which body ply  428  terminates after extending about at least a portion of bead structure  400 . 
     Tire  420  and the orientation of bead structure  400  therein may be substantially similar to tire  220  and bead structure  200  described above with respect to  FIG. 2 . 
       FIG. 5A  illustrates a sectional view of an example embodiment of a bead structure  500 . Bead structure  500  may include a wall  502 . Wall  502  may define a cavity  504 . Bead structure  500  may include a bead filler portion  506 . Bead structure  500  may include a bead wire bundle  512 . 
     Bead structure  500  may be substantially similar to bead structure  300  described above with respect to  FIGS. 3A-3B . 
     Bead filler portion  506  may include a bead filler over-mold  514 . Bead filler over-mold  514  may comprise a layer of material at least partially surrounding bead filler portion  506 . At least a portion of bead filler portion  506  may be at least partially surrounded by bead filler over-mold  514 . Bead filler over-mold  514  may comprise a layer of material completely surrounding bead filler portion  506 . Bead filler over-mold  514  may comprise a layer of any of a variety of materials, including for example a polymer, a rubber, a coating, an adhesive, and the like. Bead filler over-mold  514  may be configured to aid in bonding between bead filler portion  506  and a rubber of the tire. Bead filler over-mold  514  may be configured to aid in bonding between bead filler portion  506  and a body ply. Bead filler over-mold  514  may be configured to aid in bonding between bead filler portion  506  and bead wire bundle  512 . 
       FIG. 5B  illustrates a sectional view of an example embodiment of bead structure  500  including balancing elements  510 . Balancing elements  510  may be substantially similar to balancing elements  110  described above with respect to  FIGS. 1A-1B . 
       FIG. 6A  illustrates a sectional view of an example embodiment of a bead structure  600 . Bead structure  600  may include a wall  602 . Wall  602  may define a cavity  604 . Bead structure  600  may include a bead filler portion  606 . Bead structure  600  may include a bead wire bundle  612 . 
     Bead structure  600  may be substantially similar to bead structure  300  described above with respect to  FIGS. 3A-3B . 
     Bead structure  600  may include a bead structure over-mold  616 . Bead structure over-mold  616  may comprise a layer of material at least partially surrounding bead structure  600 . At least a portion of bead structure  600  may be at least partially surrounded by bead structure over-mold  616 . Bead structure over-mold  616  may comprise a layer of material completely surrounding bead structure  600 . Bead structure over-mold  616  may comprise a layer of any of a variety of materials, including for example a polymer, a rubber, a coating, an adhesive, and the like. Bead structure over-mold  616  may be configured to aid in bonding between bead structure  600  and a rubber of the tire. Bead structure over-mold  616  may be configured to aid in bonding between bead structure  600  and a body ply. Bead structure over-mold  616  may be configured to aid in bonding between bead filler portion  606  and bead wire bundle  612 . 
       FIG. 6B  illustrates a sectional view of an example embodiment of bead structure  600  including balancing elements  610 . Balancing elements  610  may be substantially similar to balancing elements  110  described above with respect to  FIGS. 1A-1B . 
       FIG. 7A  illustrates a sectional view of an example embodiment of a bead structure  700 . Bead structure  700  may include a wall  702 . Wall  702  may define a cavity  704 . Bead structure  700  may include a bead filler portion  706 . Bead structure  700  may include a bead bundle portion  708 . Bead structure  700  may include a cut-out  718 . Wall  702  may include cut-out  718 . 
     Cut-out  718  may be a notch, groove, indentation, or the like in an axially-outer portion of wall  702 . Cut-out  718  may be configured to permit an end of a body ply turnup to be oriented within cut-out  718 . Cut-out  718  may accept an end of a first body ply turnup so as to allow a second body ply turnup to be oriented thereover without creating a step at the end of the first body ply turnup. Elimination of this step may at least partially eliminate a stress riser in the second body ply. Cut-out  718  may be circumferential, and may extend about the entire circumference of a ring-shaped bead structure  700 . 
       FIG. 7B  illustrates a sectional view of an example embodiment of a bead structure  700  including a first body ply  728 A and a second body ply  728 B. 
     First body ply  728 A may extend at least partially about bead structure  700 . A turnup end of first body ply  728 A may be oriented at least partially within cut-out  718 . 
     A turnup end of second body ply  728 B may extend at least partially about bead structure  700 . A turnup end of second body ply  728 B may extend radially past cut-out  718  and the turnup end of first body ply  728 A. 
       FIG. 7C  illustrates a sectional view of bead structure  700  including balancing elements  710 . 
       FIG. 8A  illustrates a sectional view of an example embodiment of a bead structure  800 . Bead structure  800  may include a wall  802 . Wall  802  may define a cavity  804 . Bead structure  800  may include a bead filler portion  806 . Bead structure  800  may include a bead wire bundle  812 . Bead structure  800  may include a cut-out  818 . Wall  802  may include cut-out  818 . 
       FIG. 8B  illustrates bead structure  800  including a first body ply  828 A and a second body ply  828 B. 
     First body ply  828 A may extend at least partially about bead structure  800 . A turnup end of first body ply  828 A may be oriented at least partially within cut-out  818 . 
     A turnup end of second body ply  828 B may extend at least partially about bead structure  800 . A turnup end of second body ply  828 B may extend radially past cut-out  818  and the turnup end of first body ply  828 A. 
       FIG. 8C  illustrates a sectional view of bead structure  800  including balancing elements  810 . 
     To the extent that the term “includes” or “including” is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term “comprising” as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term “or” is employed (e.g., A or B) it is intended to mean “A or B or both.” When the applicants intend to indicate “only A or B but not both” then the term “only A or B but not both” will be employed. Thus, use of the term “or” herein is the inclusive, and not the exclusive use. See Bryan A. Garner, A Dictionary of Modern Legal Usage 624 (2d. Ed. 1995). Also, to the extent that the terms “in” or “into” are used in the specification or the claims, it is intended to additionally mean “on” or “onto.” To the extent that the term “substantially” is used in the specification or the claims, it is intended to take into consideration the degree of precision available or prudent in manufacturing. To the extent that the term “selectively” is used in the specification or the claims, it is intended to refer to a condition of a component wherein a user of the apparatus may activate or deactivate the feature or function of the component as is necessary or desired in use of the apparatus. To the extent that the term “operatively connected” is used in the specification or the claims, it is intended to mean that the identified components are connected in a way to perform a designated function. As used in the specification and the claims, the singular forms “a,” “an,” and “the” include the plural. Finally, where the term “about” is used in conjunction with a number, it is intended to include ±10% of the number. In other words, “about 10” may mean from 9 to 11. 
     As stated above, while the present application has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art, having the benefit of the present application. Therefore, the application, in its broader aspects, is not limited to the specific details, illustrative examples shown, or any apparatus referred to. Departures may be made from such details, examples, and apparatuses without departing from the spirit or scope of the general inventive concept.