BACKGROUND OF THE INVENTIO

Field of the Invention

{0001] This invention relates generally to tires having multiple carcass plies that wrap around multiple bead cores on a single side of the tire, arid, more specifically,, to a tire that has a bead core locking insert thai eliminates, a pull-out step for one of the carcass piles 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 m aviation tire thai 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 plies or bands, that wrap around the inside and outside bead cores, thereby locking these beads and associated plies or bands together.

.Description, of the Related Art

[0002] Those skilled in the art are familiar with tires having multiple beads and carcass piles that are wrapped around those multiple beads, These tires often have bias pl carcass constructions and are intended to carry very heavy loads although radial ply constructions _, are also known, Typical applications for such tires include mining, off road, earth .moving, freight hauling, and aviation environments where the tires can be subjected to high stresses due to the high loads they must endure, whether these loads be transitor o shock loads versus steady state loads, or somewhere in between, or combination thereof. For example, the loads experienced by aircraft tires can range from 1 ,200 to 78,800 pounds per tire.

{0003] Looking at Figure 1, an example of an aircraft tire 100 having multiple carcass plies wrapped around multiple beads is ..shown that is currently on the market and that, is a f 144.5x16.5-21 sized tire. The tire 100 defines circumferential X, axial Y and radial Z directions and has a tread portion 102, sldewall portions 104A, 04B and bead areas 106 A, 106B which are used to secure the tire to a wheel or rim (not shown) when the tire is inflated according to means commonly known in the art, which causes the toe portion 110 of the bead area 106, which i located toward the interior of the tire near the inner liner 10.8, to press

3 - down on the Wheel -or rim seat (not shown), t hereby supporting the sidewall 104 of the tire and preventing it from rotating. At the s me time, the heel portion 112 of the bead area 106, ^• which. Is found toward the exterior of the tire next to the sidewall 104, helps to limit the movement of the sidewal l axially along the wheel or rim seat that typically has a flange (not shown) against which the heal 112 presses. The tread- .182 has circumferential grooves 114 that help the tire maintain traction in wet conditions, as these grooves allow for the displacement of water, thereby decreasing the likelihood -of hydroplaning. More specifically, this tire has bias ply construction for its carcass plies which are grouped in bands- 116 that are each wrapped around a different bead core 118. As shown, there are three bead cores 118 on each side of fire in the respective bead areas 106 that are each wrapped by a bead, core wrap 120, which is -.constructed in a manner -commonly known in the art. Overall, the construction of the tire is essentiall symmetrical about the equatorial plane E.

[0004] Turning to Figure 2, an enlarged front view of the left bead area 106A found ^■ on. the tire .100 in Figure 1 can be seen. Again, there are three bead cores 118 and associated bead core wraps 120 that, are arranged side by side in the axial Y direction of the tire, The first or leftmost bead core USA has a first set or band 11. A of carcass plies thai extends from the -summit or tread portion J 02 of the tire 100 and that are wrapped around it and its wrap 120A, bead filler 119A and associated, flipper (not .shown for simplicity) -in a clockwise fashion. The second or middle bead core 118B has a second set or band Π6Β of carcass piles that extends from the. summit or tread portion 102 of the tire .100 -and that are wrapped around it, its bead Oiler 1I.9B, its wrap 120B, and associated flipper (hot shown for simplicity) in a clockwise fashion hile the third or rightmost bead core 118C also has a third- set or band 116-C. of carcass plies that extends from the summit or tread portion 102 of the tire. 100 and that are wrapped around it.: its bead filler 1.19C, its wrap 120C, and associated flipper (not shown -for simplicity) in a -clockwise fashion. These same bands 116 extend from this bead 106A area through the summit or tread portion 102 of the tire. 100 to another, set of bead cores 118 found in the rightmost, bead area. 1.06B and are- wrapped around them in a counterclockwise fashion (best seen in Figure 1 and 3).

[0005] In this tire, the first, band 1J6A comprises two individual carcass layers or plies while the second band 116B and third band 1.16C each comprise four individual carcass layers or plies. The- cords of the piles are made from nylon and are embedded in an ^• elastomer!© mix and are angled from 40 to 72 degrees from the circumferential X direction or equatorial plane E of the tire 100, with the angle .going from positive to negative. -from one ply to the other ply. Other configurations and materials are also used. For .example, the cords can be made from nylon, rayon, cotton or any other suitable material

[00061 it should be noted that there are examples of such tires -where the wrapping of the bands of plies are in the opposite direction just described and/or where more than one band is wrapped around the same bead core, Also, as is the ease here, there may be a fourth band 122 that extends from the summit or tread portion, along the outside or exterior portion of the sidewali 10 A nearest the exterior of the tire and continues underneath all the cores USA, 11-8B, U8C and bands 116 thai have been wrapped around them. This is called the turn down band .122 and in this ease .it comprises two separate carcass layers with cords made from nylon, that are- embedded in an ei-astomeric mix and are .angled from 40 to 72 degrees from the circumferential direction X o equatorial plane R of the tire in like fashion to the other plies that have been already described. Other configurations and materials are known.

10007] Finally, a fifth band 1 4 is utilized that extends from the summit or tread portion, along, the interior portion ^' of the s ^' idewail 1Θ4Α of the tire adjacent the inner liner 108 and extends underneath all four of the previous bands 11 ,. 122. and underneath -all the bead cores 118A, Π8Β, 118C. The Fifth and fourth bands 124, 122 overlap over the entire distance in the axial. Y direction found beneath the cores 118 A, ί X8B. 11SC so that once the tire is cured and the plies, have -all cured, together and adhered to each other, these cores are. effectively locked to together, allowing the plies to perform their function and create an effective spine for the tire to transmit the heavy loads exerted on it from the summit of the tire through the carcass plies to the bead- cores and from there to the wheel or rim as is necessary. For this tire, the fifth band 124 .comprises two separate carcass layers with cords made from nylon that are embedded in an elastomeric mix and are angled from 40 to 72 degrees from the circumferential X direction or equatorial plane E of the tire in like ma ner as described above for the other plies. Other configurations and materials are known.

[0008] Beneath and to the sides of the fourth and fifth bands 122, 124, one can see first and second chafer strips 126A, F28A (sometimes referred to as finishing strips) that are found in the bead area 106 that partially surround the multi-bead assembly and therefo separate the bands found! within this assembly from, the wheel or rim during use and are intended to protect the same from damage that can happen should movement -occur between the bead portions and the wheel. These components are routinely found in tires of all sorts including those using only a single bead core per bead area. In addition, these strips may have butyl or some, other chemical property similar to the inne liner in them that helps to retain air so that the tire Is less prone to deflation over time. The chafer strips are typically square woven, monofilament, calendered fabric and are not intended to provide any structural benefit to the tire. As a result, they do not lock the bead cores together. Although there can be a single chafer strip, most tires including tills one have two chaffer strips in each bead area found on each side of the tire as shown by Figures 2 and 3.

[000-9] Focusing now on Figure 3;, a -schematic view -of the construction of the right bead area 106B of Figure 1 is shown for enhanced clarity, The fourth or rightmost bead core Π8.0 has the first set or band 116 A of carcass plies thai extends from the summit or tread portion of the tire and that are wrapped around it in a counterclockwise fashion. The fifth or middl bead eore USE has the second set or band 116B of carcass plies: that extends from the summit or tread portion of the tire and that are wrapped around it in a counterclockwise fashion ^' while the sixth or leftmost bead core 1Ϊ8Ε also .has a _. third set o band 1 _. J6C- of carcass plies thai: extends from the summit or tread portion of the tire and that are wrapped around it in a counterclockwise fashion. Note other components- such as bead filters, and flippers are also present but not shown for simplicity,

{0010] Put into other words, the bead cores have carcass plies, which extend from one bead portion to the other bead portion through the sidewalls and summit or tread portion of the tire, wrapped around each of them, in the following manner in both bead portions. The carcasses plies approach the bead core from the interior side of the tire, whieh is the side of the tire that, is nearest the inner liner, and. extend generally radially downward. The then, continue underneath the bead cores in the axial Y direction and exit along the exterior surface of the bead cores, so called since this surface faces toward the exterior of the tire. From there, they extend in a general upward radial Z direction. This is typically done sy mmetrica! iy about the -equatorial plane E of the tire so the Wrapping is consistent on both sides of the tire. However, there are examples where the wrapping is done in the opposite direction or in both directions.

[0011] The fourth band or turn down band 122 extends from the summit or tread portion, along the outside portion of the side wall that is nearest, the exterior of the tire- and. continues underneath, all the- cores USD, 118E, 118F and bands 116 that have been wrapped around them. The fifth band 124 extends from the summit along tiie interior portion of the sidewalS of the tire adjacent the inner liner and extends underneath all four of the previous bands 116 and underneath all the bead cores 118D, 118E, 118F in this bead area 106B. The fifth and fourth bands 122, 124 overlap over the entire distance in the axiai Y direction found

... .. beneath the cores so that once the tire is cured and the bands have ail -cured together and adhered to each other, these, cores 118¾ 1 X8E, 11.8F are effectively locked to together as previously described. -Beneath and to the sides of the fourth and fifth bands* one can see third and fourth: chafer strips: 1.26B, 128B thai are found In the bead area that partially surround the multi-bead assembly and therefor separate the bands found within this assembly from the wheel or rim during, use as. described above for the first bead area.

[0012] As is often the case with tires, the fourth though six head cores 1181), USE, 11.8F and third and fourth chaffer strips 126B, 128B found in the second bead area 106B have the same material properties and construction and are configured symmetrically about the equatorial plane E as compared to their counterparts found ½ the first bead area 106A. Specifically, the first bead core 1 8 A matches up with the fourth head cove USD, the second bead core 118B matches up with the fifth bead core 1 _. 18E, the third bead core 118C matches: up with the sixth bead core 118F, the first chaffer strip 126 A matches up with the third chaffer strip 126B and the second chaffer stri 128A matches up with the fourth chaffer strip 128B, ete The places where these ^' tire: components terminate are also in approximately the. equivafentp!ace from one side of the tire to the other, maintaining the symmetry of the tire about the equatorial plane E. The terminations for the plies that wrap around the bead cores is. usually a suitable -distance above the topmost extent of the bead filler, allowing the- turned, up portion of one of. the plies to adhere: to its main portion found en the other side of the bead core and bead filler. In some cases, asymmetrical designs are employed,

[0013] However, in _. order to show manufacturing and/or design variability, it should be noted thai the schematic of Figure. 3 shows the pulloui band 124 extending up radially Z past the third bead core USD w ile it does riot do this in Figure 1, This can represent a design choice or -manufacturing tolerances as plies often, move during the manuiacturing process, which is described in more detail below, such that the position a ply- is originally laid may- not be its final position. For example, a ply may he originally laid with the upward extension past the third bead core shown in Figure 3 but may move during the molding and/or laying down step of the manufacturing process, resulting in the position: shown in Figure 2 where this extension that terminates radially upward past the third bead, core does hot exist.

[0014] The methods of manufacturing tires with multiple bead cores are wel l known in the art and these processes and the equipment used, in these processes are described by U.S. Pat, Nos. 4,44.5,962; 2,926.721 and 2,95-1 ,526, During the .manufacturing process of these tires, a liner- is first -wrapped about the building- drum, then successive-separate plies are then wrapped about the drum, the bead core is then, positioned appropriately on the drum, finally a - turns up of the piles about the bead core is then effected. Additional plies are wrapped about the drum and a second bead core is placed against the first set of plies and first bead core, after which a turn up of the additional plies is accomplished, This process can be repeated as necessary depending on how many sets of bead cores and associated wrapped plies are desired. Then the sklewalls, shoulder rubber, finishing strips and tread can be added,

fOOiS] Onee the green tire has been created, the tire drum is collapsed and the green tire is then placed into a molding- apparatus that changes the configuration of ihe green tire from a flat cylindrical band to a toroidal shape. It is in this vulcanizing process that the beads cores, plies and rubber material physically are moved in. configuration to the toroidal form -such as -shown by- Figure 1, Also, it is at- this point that the various bands of carcass layers or plies adhere to each other,, locking the bead cores together thereby creating a reinforced structure able- to carry heavier loads than, tires that have only a single bead core in each bead area on each side o f the tire.

(0016] During the manufacturing process of the tire already described, the firs band laid clown sequentially on the building drum is the structural fifth band 124 mentioned above that eventually is used to help lock all the bead cores together. Initially, the -outer portions of this band are wrapped underneath the building drum so that the other bead cores and plies can be applied o top of it without haying the extra, length at either end of this band Interfering with the laying of the other components. It is therefore necessary later to manually pullout this band on the tire building drum once all the bead cores and associated piles have been laid and turned up so that it can be -wrapped around ail of the bead cores and satisfy its locking function.

[0017] Figure 4 illustrates this pullout and wrap around ste necessary during this manufacturing process. As can be imagined due to the sticky nature of the carcass plies, sucb a manual pullout requires an extreme amount of physical effort and repetitive motion as this step Is performed repeatedly around the circumference of the building drum _. 132 which is periodically indexed so- this fifth band 124 can be positioned, correctly about the entire circumference of the green tire intermediate 1.30. The operators are required to bend over to reach within the building drum while doing ^' this, which can cause them to have poor pasture and the amount -of pinch- force necessary to accomplish, this can be as high as 80- lbs of pinch force. Hence, this tire design and associated building- process pose ergonomic challenges during the. tire building process as well as Inefficiency that increase the time necessary to make such a tire, which raises the cost of the the, ·

[0018] For many aircraft tire -applications,, a puliout ply and a turn down ply are required in order to lock the multiple bead cores and associated wrapped around plie together. Both are required for sonic tires that are subjected to very -high loads, such as when an aircraft is taking off or landing for -instance, that a tire not having the turn down band will fail. As a result, this -construction has been considered -necessary for many commercial and military aircraft applications while the problems it presents have not been solved for several decades. In less-demanding applications, the pull out band has not been necessary.

[0019] When developing a tire for some of these demanding aviation applications, it is typical to use a double overload test to determine if a tire can withstand approximately twice its rated load should one tire of a pair of tires located on the fending gear fail. Thai is to say, .the surviving tire must carry the .load safel until the plane can stop. Many tires intended for these harsh conditions must pass this test. This lest, can be performed using equipment known in the art. For commercial aircraft manufacturers who- required such testing, this can involve a single test -cycle where the lire is- subjected to a rationalized Load Speed Time curve at 1.87 times the rated load. To date, no design variations that lack the puliout of the. innermost ply and that have been subjected to this test and have passed.

|0020] Accordingly, it is desirable to find a construction for a tire that has multiple, bead cores and multiple carcass plies wrapped around the multiple bead cores that also has a way to lock said beads, together in a cost efficient manner that does not require manual manipulation of a carcass ply and in a sufficiently durable manner so that it can support the heavy loads that the tire is required to handle In the field. For tires in the aviation sector, it is desirable if the new construction can pass the dynamometer double overload test reliably and consistently when required.

SUMMARY OF THE INVENTION

{0021] A tire according to a first embodiment of the present invention defines circumferential,, axial and radial directions and has bead portions that have one or more (multiple) bead cores. The tire further comprises one or more carcass plies wherein the first bead core has a carcass ply wrapped around it and the second bead core has a second carcass ply wrapped around it The tire also has a bead, core locking insert that is separate from any carcass ply and that is located adjacent said bead cores and any carcass ply that is wrapped around said bead cores.

[0022] In some ^' embodiments, the ply that is wrapped around a bead core is a bias ply. in other cases, the carcass ply that is ^' Wrapped around the first bead core is a first carcass ply and the carcass ply ^' that is wrapped around the second bead core is a second carcass ply that is separate from the first carcass ply.

[0623] In still other embodiments,, the tire further comprises an outermost carcass ply that does not wrap-around a bead core and that -extends from the sidewall next to the bead core that is located nearest the exterior of the t ire and extends axial !y underneath one or more of the bead cores. The outermost ply then terminates near one or more of the bead cores and the bead core locking insert is- found radially below and adjacent to the innermost bead core and the termination of the outermost -ply. In some cases, the outermost carcass pty terminates adjacent the bead core that is located nearest the interior of the tire. In such a case, the tire may further comprise an innermost carcass ply that does not wrap around a bead core and that also terminates in the bead portion proximate- tire termination of the outermost carcass ply. The bead core locking insert is found adjacent said terminations of tire innermost and outermost carcass plies in such a case. In- fact, the- bead core -locking insert may extend underneath all the bead cores in the axial direction and my further extend radially upward along the interior side of the innermost carcass ply, creating a splice therewith, and radially along the exterio side of the outermost carcass ply,

10624] In .some embodiments, the tire- further comprises an inner liner that is relatively air impermeable and that is interposed between the bead core locking insert and the outermost carcass ply,

[0025} In other designs, the carcass plies have cores that are angled at + -40 to 72 degrees from the circumferential direction. In still other eases, the bead core locking- insert also has at least one bias ply layer with cords that- are arranged .at +/- 40 to 72 degrees from the circumferential, direction,

[0026] In some applications, the tire is -an aircraft tire. Often, there- is a plurality of carcass plies that: are wrapped around the first bead core and another- plurality of carcass plies that are wrapped around the second head core.

[0027] Oftentimes, a tire according to an embodiment of the present invention is symmetrically configured: about its equatorial plane. A ply that wraps around a bead core found in a bead portion will extend radially downward along th interior side of the bead core, continue: axiaily underneath the bead core, and then will .return upward along the exterior side of the bead core,

[0028 J The foregoing and .other objects, features and advantage ^' s of the invention will be apparent from the following more detailed descriptions of particular embodiments of the invention, as illustrated in the accompanying drawing wherein like reference numbers represent like parts of the invention. As used herein, reference numbers in the JflO's ^' refer to a tire known already in the art and reference numbers in the 200's: refer to a tire having features according to an -embodiment of the present invention,

DETAl LED: DESCRIPTION OF THE DRAWINGS

{0029] FIG, 1 is a perspective- sectional view of an existing aviation tire that has .multiple bead cores, and multiple- bands of carcass plies wrapped around the bead cores;

[0030] FIG, 2 is an enlarged front sectional view of the left bead area of the tire of

Fig. 1;

[0031] FIG..3 is a schematic of the omponents found in the right bead area of FIG, I for enhanced clarity;

[0032] FIG. 4 depicts the manual, pullout of the innermost band of carcass plies during the manufacture- of the ^' tire of FIG. I;

[0033] FIG. S. is an enlarged front sectional view of the left bead area of a tire constructed with a bead locking insert according to one embodiment of the present invention; and

[0.034] FiG. 6 shows the cosnponents in schematic format for enhanced clarity found in the right bead area of a tire having the left head portion shown in FIG. 5 assuming that the tire is constructed in a symmetrical manner about its equatorial plane.

DEFINITIONS.

[003:5] The longitudinal or circumferential direction, X, is the direction, of the tire along which it roils or rotates and that is perpendicular to the _. axis of rotation of the tire.

[0036] The axial, direction, Y, is the direction of the tire along the width -of its tread that is substantially parallel t the axis of rotation of the tire.

0037] The radial direction, Z, is the direction of a tire as -viewed from its side that is parallel to the radial direction of ^' lhe generally annular shape of the tire and is perpendicular to the latera I direction thereof. {00381 The equatorial plane, E, is a plane that cuts the tire in half and is perpendicular to the axis of rotation or is parallel to the radial direction of the tire.

DETAILED DESCRIPTION OF PARTICULAR EMBODIMENTS

[0039] Embodiments of the present invention include the use of a bead core locking insert -hat is found andemeath the bead cores found in the bead portion of a tire and near the carcass plies that wrap around the multiple bead cores. Often, there wiH. be at least two or sometimes four other carcass plies or band(s) of carcass layers or plies: that extends from either the interior -portion and/or exterior portion of the sidewail -and that extend underneath arid /or adjacent one or more of the multiple bead cores without wrapping around the individual bead cores, in such a case, the bead core locking insert will be found .underneath, overlapping and/or adjacent to an additional carcass ply that does not wrap around an individual bead core.

[0040] -Focusing on Figure 5, it shows, a front sectional view of a portion of a tire similar to that -shown in Figure 1 but that uses a bead core locking insert according to a .firs embodiment of the present invention. This tire would have similar functions and components as described above for -the tire shown in Figure 1 including having, multiple carcass- piles wrapped around multiple bead cores that have associated bead core wraps. This is also m H44,5x1 ,5-21 sized tire but this size can be changed depending on the application. The tire, defines circumferential X, axial Y and radial Z directions and has a tread portion (not shown), sidewail portions 2Q4A, 2-Q4B and left and right bead areas 206A, 206B which are used to secure the tire to a wheel or rim (not shown) when, the ire is inflated according to means commonly known in the art, which causes the toe portion 210 of the bead area 206.. which is located toward the interior of the tire near the inner liner 208. to press down on the wheel or rim seat (not shown), thereby preventing the tire from rotating, At the- same time, the heel, portion 212 of the Bead area 206, which is found toward the exterior of the tire next to the side-wall 204, limits the m vement of the tire axiaily along the wfeei or rim seat thai typically has a flange (not shown) against which the hen! presses,

[0041 ] The tread has circumferential grooves (not shown) that help the tire maintain traction in wet conditions as these grooves allow for the displacement of water, thereby decreasing the likelihood of hydroplaning. Focusing on the carcasses, this tire has bias ply construction for its carcass plies, which are grouped in bands that are each wrapped around a. di ferent bead core. There are three bead cores on each side of tire in the respective bead areas, Overall, the construction of the tire is essentially symmetrical about the equatorial plane (not shown).

[0042] The first or leftmost bead core 218A has a first set: or band 216 A of carcass plies that extends from the summit or tread portion of the tire and that are wrapped around it,, its bead filler 219A, its associated wrap 220A, and flipper (not shown for simplicity) in a clockwise fashion. The second or middle ^' bead core 21 S has a second set or band 216B of. carcass plies that extends from the ^■ summit or tread portion of the tire and that are wrapped around it, its associated wrap 22ΘΒ, bead filler 219B, and flipper (not shown for simplicity) in a clockwise fashion while the third or rightmost head core 218C also has a third set or band 216 of carcass plies that extends from the summit or tread portion of the tire and that are wrapped around it, its associated wrap 220C, head filler 21 _. 9C, and flipper (not shown for simplicity) in a clockwise fashion. These same bands extend from this bead area 206A through the summit or tread portion of the tire to another set of bead cores found in the rightmost bead area 206B and are wrapped around them in a counterclockwise fashion,

[0043] In this tire, the first band comprises- two individual carcass layers while the second band and third band each, comprise- four individual carcass layers. The cords of the plies are made from nylon and are embedded --in an el¾stomerie mix and are angled from 40 to 72 degrees from the circumferential direction or equatorial plane of the tire. Other configurations- and materials could be used. For example, the cords can be made from nylon, rayon, cotton or any other suitable material and the angles could be varied. Also, the - number of plies can be altered depending on the application, It is also, contemplated that other embodiments of the resent invention include tires where the wrapping -of the. bands of carcasses are in the opposite direction, just described and/or where more than one band or carcass ply is wrapped around the same bead core,

[0044] Additionally, there is a fourth hand or turn down band 222 that extends from the outside portion of the sidewall 204 nearest the- exterior of the tire and continues underneath all the bead cores and bands that have been wrapped around them in the first head area 2Θ6Α and terminates before extending radially upward. The turn down band and in this embodiment -com rises two separate carcass layers or plies with cords made from nylon that are embedded- in an elastomeric mix and. are angled from 40 to 72 degrees from the circumferential, direction or equatorial plane of the tire, Other configurations and materials could be used as just described for the first, through third bands of carcass plies, [00.45] Finally, a -fifth band 224 is found that extends from the interior portion of the -sidewall 20 A of the tire adjacent the inner liner 208 and that terminates near the third, bead core 218C short: of going underneath this bead core. This- .termination substantially coincides with the termination of the turn down band 222 just described. This is different than the previous construction, shown by Figure 2 where this band 224 was pulled ^. out. during the manufacturing process so that it extended underneath all the bead cores. Hence, there is no overlap between the. fifth and fourth bands 222, 224 as was previously done in order to lock the bead cores together. For this embodiment, the fifth band 224 comprises two separate carcass, layers or piles with cords made from nylon that are embedded in an efastomeric mix and are angled 40 to 72 degrees from the circunife.rent.ial direction or equatorial plane -of the tire. Other configurations and materials as described, above could also be employed.

[0046] Instead of pulling out the fifth band 224 of carcass pises, a bead core locking insert 240A is provided that is located underneath these bead cores and that overlaps the fourth band or turn down band 222 and overlaps with this band over the entire distance in the axial Y direction found beneath these cores. The bead core locking insert 240 A also extends past the fifth, band 224 or the band that would have been pulled out band in the prior art so that there is a splice or overlap O in this, region, which is toward the interior of the tire, and serves to lock the fourth and fifth bands together, which in turn lock the bead cores together as will be. described in further detail later. It should be noted that the place where the fourth and fifth bauds terminate can be adjusted so that the bead core locking insert does not have to extend past the heel and toe areas of the bead portion.

(6047] This splice O is present In the bead portion of the tire around the entire circumference of the tire and for this embodiment is 20 mm long but may be varied depending on design and manufacturing considerations mentioned previously and in some cases this splice may not be necessary at ail in either the green tire intermediate or cured tire, or ma be arranged such that the inner liner is present in the splice between the bead core locking insert and the fifth band. The bead core locking insert 240 for this embodiment comprises two layers of bias ply tissue. The cords in these plies are arranged at an angle ^' ranging from 40° to 72° with respect to the circumferential X direction of the tire. The first layer of the bead core locking insert that is adjacent the fifth or pullout band has the same angle orientation as the cords found in fifth band.. The second layer of the bead core locking insert lias the same angle value but an. opposite angle orientation compared to the first layer, However, these angles of the cords of either tissue may be varied depending on design and manufacturing considerations, Lastly, chafer strips 226A, 228A are provided with like .constructions .and materials as described above For the finishing strips used for the existing tire 100 shown by Figure 1,

[0048] Once the tire Is cured and the bead core locking Insert and the bands have adhered to each other, these bead cores are effectively locked to together, -allowing the carcass plies to perform their function and create an effective spine for the. tire to transmit the Heavy loads exerted on it from the summit, of the. tire, through the carcass plies to the- bead cores and from there to the wheel or rim as is necessary. This has been substantiated by test, data which will be revealed below. This can now be successfully accomplished without the use of a pullout step during the manufacturing of the tire: as the bead. core, locking insert can be applied after the bead cores and associated wrapped plies ^' have already been created on the buildin drum and the fifth band i no longe too long, creating an obstacle during the beginning phase of the fabrication of ^" the tire as was .the case previously. Consequently, the use of the bead core locking ^' insert has succeeded where previous attempts to eliminate the pullout ste have failed,

[0049] Finally, Figure 6 shows a -schematic view of the Construction of ^" the right bead area 2Θ6Β assuming that the- tire having the left bead area 206A shown in Figure 5 is substantially symmetrically configured .about its equatorial plane. The fourth or rightmost head core 218D has the first set or band 2.16 A of carcass plies that extends from the summit or tread portion of the tire and that are wrapped around it i a counterclockwise fashion, The fifth or middle bead core 218E has- the- -second -set or band 216B- of carcass plies that, extends from the summit or .tread portion, of the .tire and that are wrapped around ^' it in a counterclockwise fashion -while the sixth or leftmost bead core 218F also has the third set or band 216C of carcass plies that extends from the summit or tread portion of the tire and that are wrapped around it in a counterclockwise Fashion. _. Other components such as bead fillers and flippers are omitted from this figur for enhanced clarity .

[0050] The fourth hand or turn down band 222 extends from the summit or tread portion, along the outside portio of the sidewall that is nearest the exterior of the tire and continues underneath all the cores and bands that have been wrapped around the . Finally, a fifth band 22 is found thai extends from the summit or tread portion, along the ^' interior portion. -of the sidewall of the tire adjacent the inner liner and that terminates near the sixth bead core 218F shor of going underneath this bead core. This too is different than the previous construction shown by Figure; 2 where this band was pulled out during the manufacturing process so that it extended underneath all the bead cores. Hence, there- is no overlap between the fifth and fourth bands as was previousl done in order to lock the bead cores together. For this embodiment, the fifth band comprises two separate carcass layers with cords, made from, nylon that are -embedded in an elastomerlc mis ^' and: are- angled from 4.0 to 72 degrees from the circumferential direction or equatorial plane of the tire. Other configurations and ..materials as described above could also he- employed.

[0051] A second bead core locking insert 24GB i provided that is located underneath the bead cores and that overlaps tire fourth band or pulldown band and overlaps with this band over the entire distance in the axial direction found beneath the cores. The bead locking insert also extends past the fifth .band or the band that would have been pulled out in the- prior art so that there, is a splice or overlap O hi this region, which, is toward the interior, of the tire, and serves to lock the fourth and fifth bands- together, whic in turn lock the bead cores together, This splice is present in the second bead portion of the ti e around the entire circumference of the tire. The second bead core locking insert is constructed: in like manner as described above for the first bead, core locking insert. Lastly, third and fourth chafer strips 226B, 228B are provided with like constructions and materials as described above for the chafer strips used in the left bead portion .206 A of the tire. Also, the bead cores found in the right bead area 206B are similarly constructed and placed in mirrored configuration about the equatorial plane of the tire to those found in the left bead area 2Ό6Α in like manner as was described above for the tire shown in Figure 1. The places where these ^' tire components terminate are also in approximately the equ ivalent place from one side of the tire to the other, maintaining the -symmetry of the tire about the equatorial plane. Although, it is contemplated that -asymmetrical designs could he employed -in other embodiments of the present invention.

[0052] As can be seen in Figure 5. the- splice region between the pu!lout or innermost band of carcass plies and the bead core locking: insert is located near the interior of the tire where the inner liner stops. As a result, the bead core locking insert may have some of the material used in the inner liner present in this splice o overlap region, including, butyl or some other material -properties or constituents that decrease the air permeability of the head core: locking insert locally in this .area- in order to reduce the air leakage of the tire. Bead core locking inserts having and not having inner liner material hi them or where the inner liner does extend past the splice region have been tested with positive results as shown below for passing the double overload test so both are contemplated to be within the scope of the present in vention.

[0053] Fialhennore, the bead core locking insert could, be constructed from a single layer of bias ply tissue or square woven tissue similar to the material used in the- bead wraps as well. Similarly, the angle -of the- reinforcements found i the bead core locking Insert could be varied and not match the angle used In the carcass plies to which it is adjacent, in some, cases, the bead core locking insert would not have to overlap the with a carcass ply, such as the innermost ply, but could be located near such a piy close enough where a locking effect can still be accomplished. For example, both the- bead core locking Insert and the plies that were previously pulled out In the prior art could terminate- in the toe of the tire with no overlap. Similarly, the bead core locking insert could be radially above the fourth or turn down band such that the turn down band is- turned on top of the bead core locking insert In addition, the presence or absence of other standard tire components such as bead flippers, bead core wraps, etc. may be adjusted depending on the tire application and still be .used with the present invention.

[0054] Testin of several embodiments of the present invention using the double overload test has yielded the following results as shown in Table 1.

Table 1 - Test Results for Various Designs

and 2 B (taxi) cycles at rated load

I L (double overloa ^' take οΠ) at 5.87 x rated

load

^' Dead Core Locking Insert- w/o Static test consisting of: Sizing:

splice between if and the jlft Finding Outside Diameter and Section SW avg

Width sizing at rated pressure 16,00

and determining the Burst pressure OD ~ 44.38 at

rated pressure and the

Burst - 897 psi

All values within required limits

Embodiments- ith and without the splice and with and without the Inne liner being interposed between the bead core locking- insert and the fifth, band were successful Particularly surprising, no splice is necessary in order for the dimensional and pressure requirements to be met when pressuring the tire to failure. Also, while only embodiments having a fourth and fifth band of carcass plies have been tested, the inventors believe that a fifth or innermost carcass ply or band of plies that do not wrap around a bead core may not be necessary to be used with the present invention as the innermost, carcass ply or hand of carcass plies may be sufficient to. aid in. the bead core locking function in addition to the bead core locking insert since no splice is necessary. Likewise, it may be possible, tor applications that are outside of aviation sector to omit the use of a fourth carcass ply or band of plies and use only the bead core locking insert,

[0855] As can be- seen, embodiments of the present invention, help tires to lake severed loads without, necessitating the use of a pullout of the innermost ban of carcass plies, in addition, the bead core locking insert could be used with an innermost ply or band alone, a turn, down ply o band alone, or both simultaneously. In some eases, the bead core locking insert could be used with multiple bead cores having one or .more bands or individual plies wrapped around them without the use of the innermost or pullout band/ply or turn- down band/ply. In aircraft tire applications, it is contemplated, that there will almost always be a turn down band present while the fifth band may or may not be present depending o the ti e application. [0O56J While this invention has been described with reference to p rticular embodiments thereof, it shall be understood that such description is fay way of illustration and not by way of limitation. For example, the present invention could be used on tires that use a cas'cass structure having radial plies alone or some combination of radial and bias: plies. Similarly, this: Invention -can be applied to tires used In a: host of applications other than aviation that require the tire to withstand extreme loads -and that use multiple beads and associated wrapped carcass plies to support the load including those whore only two bead- cores are found in a bead portion using, bead core locking insert and those applications where more than three bead core are used. Furthermore, particular dimensions and materials have been given but it Is well within the purview of one skilled in the art to make -adjustments to these parameters and still practice the spirit of the present invention, Accordingly, the scop and content of the invention are to be defined only by the terms of the appended claims.