WO2008088307A2

WO2008088307A2 - Device and method for manufacturing tire having improved bead portion

Info

Publication number: WO2008088307A2
Application number: PCT/US2006/048855
Authority: WO
Inventors: Christian Beccavin
Original assignee: Michelin Recherche Et Technique S.A.; Societe De Technologie Michelin
Priority date: 2006-12-22
Filing date: 2006-12-22
Publication date: 2008-07-24
Also published as: WO2008088307A3

Abstract

A device and method for the construction of a tire intermediate comprising a bead profile and a bead ply is provided. Sequentially configured forming stations (200, 300, 400, 500, 600, 700, 800) comprising multiple rollers of varying shapes are used to wrap the bead ply about the bead profile to create the tire intermediate. The tire intermediate may then be stored for later integration into a tire architecture or fed directly to a tire assembly drum as the tire is being constructed.

Description

TITLE

DEVICE AND METHOD FOR MANUFACTURING TIRE HAVING IMPROVED BEAD PORTION

TECHNICAL FIELD OF THE INVENTION

[0001] The present invention provides a novel device and method for the construction of a tire intermediate comprising a bead profile and a bead ply. Sequentially configured forming stations comprising multiple rollers of varying shapes are used to wrap the bead ply about the bead profile to create the tire intermediate. The tire intermediate may then be stored for later integration into a tire architecture or fed directly to a tire assembly drum as the tire is being constructed.

BACKGROUND OF THE INVENTION

[0002] U.S. Patent No. 5,971,047 describes an exemplary embodiment of a unique tire design in which a carcass layer is wrapped around a profile located adjacent to the bead core. More specifically, in the exemplary embodiment of Fig. 2 of such patent, a head portion is described in which the carcass completely surrounds a profile located adjacent to the bead core. The carcass wraps around the outside of the profile and then turns up around the bead core such that the tum-up end of the carcass is located radially above, and axially inside the bead core. Another variant that includes a wrapped profile is shown in Fig. 4, for example. [0003] Challenges are encountered when manufacturing a bead portion having a profile analogous to the profile described in U.S. Patent No. 5,971,047. Equipment and techniques have been proposed for accomplishing the step by which the carcass is wrapped around the profile and then turned up around the bead core. For example, U.S. Patent No. 6,250,356 describes such an assembly drum and method for tire manufacture. As shown in Figs. 6A through 6H of this patent, the wrapping of the carcass reinforcement ends about the bead profiles is a multi-step process. In general, each end of the carcass reinforcement is positioned over a support element having a bearing groove or depression in its radial outermost surface. Along each end, a profile is positioned over the carcass reinforcement. Lifting fingers, located along each side of the assembly drum, are actuated so as to lift the carcass reinforcement ends in a manner that begins the maneuver of wrapping the carcass around the profile. Guide wires, carrying the bead cores, are advanced axially inward along the drum to engage the ends of the carcass reinforcement and further turn the ends around the profiles. Then, the advancement of the guide wires is synchronized with the expansion of the drum so that along each side of the carcass reinforcement, the profile and bead are moved into a respective bearing groove in a manner that completes the wrapping of the carcass reinforcement end around the profile while also turning up the carcass reinforcement end around the bead core.

[0004] The present invention provides a novel device and method for the manufacture of a tire intermediate that may be used in the construction of an improved tire structure. Using the present invention to manufacture the tire intermediate, a manufacturer can avoid certain challenges, as referenced above, that are encountered in wrapping a carcass ply around a tire component while present on an assembly drum. More specifically, as will be described below, the present invention advantageously allows elimination of the steps associated with wrapping a ply about a bead profile while such are present on a tire assembly drum. Instead, the present invention provides for wrapping the ply in a process that occurs apart from the assembly drum as will now be described.

THE SUMMARY OF THE INVENTION

[0005] Objects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0006] In one exemplary embodiment of the present invention, a machine for manufacturing a tire intermediate that includes a bead profile and a bead ply is provided. The machine defines a longitudinal axis and comprises a plurality of forming stations positioned for sequential receipt and transport of a bead profile feed and a bead ply feed. Each forming station further comprises a drive roller configured for rotating so as to pull the bead profile feed and bead ply feed through the forming station. A tracking roller is positioned adjacent to the drive roller and is configured for pressing the bead profile feed, the bead ply feed, or both towards the drive roller. The drive and tracking rollers of the forming stations are profiled so as to sequentially apply and wrap the bead ply feed about the bead profile feed as such are pulled through the machine along the longitudinal direction.

[0007] The drive roller can be configured to be in mechanical communication with a motor that provides power for rotating each drive roller. The tracking roller may be constructed such that it is selectively movable relative to the drive roller. A motor can be provided that is in mechanical communication with the tracking roller and is configured for selectively moving the tracking roller towards the drive roller so as to selectively control the pressure applied to the bead ply feed and the bead profile feed. By way of example, the motor may comprise a pneumatic cylinder. One or more of the forming^" stations may be provided with a lateral roller that is positioned adjacent to the drive roller and the tracking roller, where the lateral roller has a profile configured for wrapping the bead ply feed about the bead profile feed. The lateral roller may be constructed so that it defines a rotational axis, has a first surface that is substantially parallel to the rotational axis of the lateral roller, and has a second surface proximate the first surface with the second surface being frustoconical in shape. By way of example, the second surface maybe at an angle of between about 25 degrees and about 50 degrees to the rotational axis of the lateral roller.

[0008] The drive roller can be configured to have a first surface that is substantially parallel to the rotational axis of the drive roller and a second surface that is proximate to the first surface and frustoconical in shape. By way of example, the second surface may be at an angle of between about 25 degrees and about 50 degrees to the rotational axis of the drive roller. The drive rollers may be provided with an abrasive surface for contacting the bead ply feed. In certain embodiments, a frame may be provided to which the tracking roller is pivotally attached.

[0009] The present invention also provides a method of manufacturing an intermediate component for a tire. One exemplary method of the present invention comprises the steps of providing a substantially unfolded bead ply feed and a bead profile feed, positioning the bead ply feed contiguous to the bead profile feed, pressing the bead profile feed and the bead ply feed together, turning the bead ply feed a predetermined amount about the bead profile feed while pulling the bead ply feed and the bead profile feed over a predetermined distance, and repeating the pressing and turning steps until the bead ply feed is wrapped around the bead profile feed.

[0010] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

[0012] Fig. IA provides a schematic view of multiple forming stations as may be used in an exemplary embodiment of the present invention. Multiple numbered arrows represent the cross-sectional view from which additional figures are provided. The bead profile feed and bead ply feed are not pictured.

[0013] Fig. IB provides another schematic view of the forming stations of Fig 1 as may be used in an exemplary embodiment of the present invention.

[0014] Figs. 2 through 8 provide partial perspective views of the forming stations of Figs. 1 and 2 as may be used in an exemplary embodiment of the present invention. In each of the figures, for purposes of clarity and illustration, a small gap is shown between the rollers and the bead profile. In actual use, the bead profile contacts the rollers more closely.

[0015] Figs. 9A and 9B provide cross-sectional views of a bead profile feed and a bead ply feed as may be used with the present invention. Fig. 9B illustrates the bead ply feed wrapped about the bead profile feed. It should be understood that other shapes of a bead ply feed and bead profile feed are within the scope of the present invention.

[0016] Fig. 10 provides a partial cross-sectional view of an exemplary embodiment of a tire having components which may be constructed using the device and method of the present invention. Arrow A in this figure points axially inward while arrow R points radially outward.

DETAILED DESCRIPTION

[0017] The present invention provides a novel device and method for the construction of a tire intermediate comprising a bead profile and a bead ply. Multiple forming stations comprising one or more rollers are used to sequentially wrap a feed of the bead ply about a feed of the bead profile so as to create the tire intermediate. The tire intermediate may then be stored for later tire construction or fed directly to a tire assembly drum as the tire is being constructed. Reference will now be made in detail to embodiments of the invention, one or more examples of which are illustrated in the figures. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a third embodiment. It is intended that the present invention include these and other modifications and variations. Repeat use of identical or similar reference characters throughout the present specification and appended drawings is intended to represent same or analogous features or elements of the invention.

[0018] By way of introduction to the invention, a general description of an exemplary tire having components that may be constructed using the present invention will be initially described. Accordingly, Fig. 10 illustrates ahead portion 100 and part of a sidewall portion 135 along one side of such an exemplary tire. This tire incorporates a tire intermediate 175 (Fig. 9B) that may be constructed using the present invention. More specifically, tire intermediate 175 comprises a bead ply 150 wrapped around a bead profile 145 using a novel device and method, examples of which will be discussed below. In the tire of Fig. 10, the bead profile 145 is located at a position that is both axially outward and radially inward of bead core 110 and appears partially shaped to the circumference of bead core 110. Bead ply 150 encompasses, or wraps around, profile 145, curves around core 110 and then extends radially outward into a pair of ends including bead ply outside end 155 and bead ply inside end 160. Bead ply 150 may be constructed of a variety of suitable materials including, by way of example, composites of rubber and cords made from polyester, nylon, or rayon. Bead profile 145 maybe constructed from any suitable rubber materials. For example, profile 145 maybe constructed from a material having a Modulus of Elasticity at ten percent unit strain with a value in the range of about 50 MPa to about 60 MPa.

[0019] This exemplary tire also includes a sidewall portion 135 constructed from a rubber material that typically covers the outer surface of the tire and protects the carcass layers and other reinforcing members from damage. Rim strip 140 makes up the outer component of bead portion 100 and provides a rubber material that is shaped in part for the receipt of a rim or wheel onto which the tire having bead portion 100 will be mounted. Rim strip 140 wraps around various bead components including bead core 110 and bead filler 130, to meet with an inner liner 125, which is constructed of an air impermeable material to retain air pressure within the tire. Bead portion 100 includes a carcass ply 165 having a carcass ply end 170 that is located at a position that is radially inward of bead core 110. Carcass ply 165 extends between axially spaced-apart bead portions 100 located on both sides of the tire and is positioned radially inward of the tread and any belts in the crown region and axially inward of sidewall portion 135 on both sides of the tire. A cradle strip 115 is positioned between bead core 110 and the portion of bead ply 150 that wraps around core 110. As such, cradle strip 115 provides protection of ply 150 from the inextensible components of core 110. [0020] As stated, the structure of bead portion 100 facilitates certain advantages in manufacturing. More specifically, the preparation offline, i.e. before positioning on the assembly drum, of an intermediate tire structure 175 comprising bead profile 145 and bead ply 150 allows a manufacturer to avoid undertaking the turning up of a carcass layer about a bead profile while on the tire assembly drum. As such, improvements in the per tire time on the assembly drum and the complexity of the manufacturing process on the assembly drum can be achieved.

[0021] As shown in Figs. 9A and 9B, the intermediate tire structure 175 used in bead portion 100 is constructed by wrapping bead ply 150 about bead profile 145. An exemplary embodiment of a machine according to the present invention that may be used for constructing such intermediate tire structure 175 is shown in Figs. IA and IB. This machine is comprised of a plurality of forming stations 200, 300, 400, 500, 600, 700, and S00; each of which will be individually described. In operation, an unfolded feed — i.e. a substantially flat and continuous length of material — of both a bead ply 150 and a bead profile 145 are fed to forming station 200. While being pulled sequentially through each of the forming stations 200, 300, 400, 500, 600, 700, and 800 in the longitudinal direction of the machine as shown by arrows A, the feeds of bead ply 150 and bead profile 145 are pressed together. Furthermore, as the feeds of bead ply 150 and bead profile 145 are pulled through such forming stations, the bead ply feed 150 is gradually or sequentially wrapped about the bead profile feed 145 due at least in part to the shape of the rollers used in each forming station as will be described below. Accordingly, while feeds of the bead ply 150 and bead profile 145 are fed to forming station 200 as separated components as shown in Fig. 9A₃ the feeds leave 006/048855

forming station 800 wrapped together to form intermediate tire structure 175 as shown in Fig. 9B. From forming station 800, the resulting intermediate tire structure 175 may be fed directly to a tire assembly drum for immediate integration into a tire architecture. Alternatively, intermediate tire structure 175 may be collected on, for example, a spool or reel for storage until being supplied to a tire assembly drum. Regardless, the process of wrapping bead ply 150 about bead profile 145 while on the assembly drum may be avoided using the present invention.

[0022] Forming station 200, illustrated in Figs IA, IB, and 2, includes a drive roller 212 and tracking roller 214. Drive roller 212 has a flat profile that is configured for receipt of bead ply 150 in a substantially unfolded state as shown in Fig. 2. Drive roller 212 is powered so as to cause roller 212 to rotate and thereby draw bead ply feed 150 and bead profile feed 145 in the direction shown by arrows A (Fig. IA or IB). Drive roller 212 rotates about an axis B-B that is fixed or non-movable relative to tracking roller 214. [00231 Conversely, tracking roller 214 is not directly powered for rotation. Instead, tracking roller 214 rotates about axle 216 as drive roller 212 powers bead ply feed 150 and bead profile feed 145 through forming station 200. In addition, tracking roller 214 is movable or adjustable relative to drive roller 212. For example, as shown in IA, tracking roller 214 is positioned by support arms 218 over drive roller 212. Support arms 218 rotate about pivot point 220 so as to provide for an adjustable movement of tracking roller 214 relative to drive roller 212. Although not required for the present invention, support arms 218 may be positioned by a motor, such as pneumatic cylinder 222, attached to support arms 218. A desired, pneumatic cylinder 222 may be used to urge tracking roller 214 towards drive roller 212 so as to increase the pressure applied to the feeds of bead profile 145, bead ply 150, or both. Alternatively, in certain embodiments of the present invention, pneumatic 2006/048855

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cylinder 220 is not used because the weight of tracking roller 214 provides a sufficient amount of pressure without assistance. Tracking roller 214 also includes a groove 224 that is contoured for the receipt of bead profile feed 145. A small gap between profile 145 and groove 224 is shown for purposes of clarity; in actual operation profile 145 fits more closely into groove 224.

[0024] Accordingly, forming station 200 receives feeds of bead profile 145 and bead ply 150 and presses the two together between drive roller 212 and tracking roller 214. The tackiness of bead profile 145 causes it to adhere to bead ply 150 so as to begin the process of wrapping ply 150 about profile 145. By way of example, the two feeds 145 and 150 might be supplied to forming station 200 from spools of the respective materials. After being pressed and pulled along by forming station 200, bead profile feed 145 and bead ply feed 150 are then fed to forming station 300.

[0025] Referring now to Figs. IA, IB, and 3, forming station 300 also includes a drive roller 312 and tracking roller 314. As with forming station 200, the drive roller 312 has a fixed position and includes a powered rotation for moving the feeds of bead profile 145 and bead ply 150 through the machine. Tracking roller 314 is movable in a manner similar to that described with tracking roller 214. Different from forming station 200, however, are the shapes of drive roller 312 and tracking roller 314. Drive roller 312, for example, has an overall shape created by two surfaces 326 and 328. First surface 326 is substantially parallel to the axis of rotation B-B of the drive roller 312. Second surface 328 is angled so as to provide a frustoconical profile. By way of example, in certain embodiments, second surface 328 is profiled to an angle of between about 25 degrees and about 45 degrees to the axis of rotation B-B, and in still other embodiments second surface 328 is profiled to an angle of about 30 degrees. As such, second surface 328 operates to wrap bead ply feed 150 at least partially about bead profile feed 145 as such are pulled through forming station 300. Tracking roller 314 also includes an overall shape, created in part from surfaces 330 and 332, that is configured for the receipt of the feed of bead profile 145. Accordingly, as previously described, tracking roller 314 applies pressure to ensure the adherence of bead profile 145 to bead ply 150 as ply 150 is wrapped and to assist with moving these materials through forming station 300 through the powered rotation of drive roller 312. With bead ply feed 150 wrapped at least partially about bead profile feed 145 as shown in Fig 2, the feeds are now supplied to forming station 400.

[0026] As shown in Figs. IA, IB, and 4, forming station 400 also includes a drive roller 412 and tracking roller 414. Drive roller 412 has an overall shape created by two surfaces 426 and 428. First surface 426 is substantially parallel to the axis of rotation B-B of the drive roller 412. Second surface 428 is angled so as to provide a frustoconical profile. By way of example, in certain embodiments, second surface 428 is profiled to an angle of between about 30 degrees and about 60 degrees to the axis of rotation B-B, and in still other embodiments second surface 428 is profiled to an angle of about 45 degrees. As such, second surface 428 operates to continue the wrapping of bead ply feed 150 about bead profile feed 145 as such are pulled through forming station 400. Tracking roller 414 also includes an overall shape, created in part from surfaces 430 and 432, that is configured for the receipt of the feed of bead profile 145. Drive roller 412 and tracking roller 414 are otherwise configured as previously described for forming station 300. Accordingly, forming station 400 uses tracking roller 414 to apply pressure to continue the adherence of bead profile 145 to bead ply 150, sequentially provides an additional step in wrapping bead ply 150 about bead profile 145, and pulls each of these materials through forming station 400 under the power of drive roller 412 as such materials are being fed to forming station 500. 48855

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[0027] Continuing with the description of an exemplary embodiment of the present invention, Figs. IA, IB and 5 illustrate forming station 500. Drive roller 512 is substantially flat and does not include the frustoconical shape of forming stations 300 and 400. Instead, to continue wrapping the feed of bead ply 150 about the feed of bead ply 145, a lateral roller 534 is positioned adjacent to drive roller 512 and tracking roller 514. Lateral roller 534 has an overall shape created in part by surfaces 536 and 538, and has an axis of rotation C-C that is perpendicular to the axis of rotation B-B of drive roller 512. First surface 536 is substantially parallel to the axis of rotation C-C of the lateral roller 534. Second surface 538 is angled so as to provide a frustoconical profile. By way of example, in certain embodiments second surface 538 is profiled to an angle of between about 5 degrees and about 45 degrees to the axis of rotation C-C of lateral roller 534, and in still other embodiments second surface 538 is profiled to an angle of about 10 degrees. With the help of these surfaces, lateral roller 534 facilitates the continued wrapping of bead ply feed 150 about bead profile feed 145 as such are pulled through forming station 500. [0028] The position of lateral roller 534 relative to rollers 512 and 514 is adjustable. As shown in Fig. IB, tracking roller 534 is positioned by support arms 544 adjacent to rollers 512 and 514. Support arms 544 rotate about pivot point 546 so as to provide for an adjustable movement of lateral roller 534 relative to rollers 512 and 514. Although not required for the present invention, support arms 544 may be positioned by a motor, such as pneumatic cylinder 548, attached to support arms 544. As desired, pneumatic cylinder 548 may be used to urge lateral roller 534 towards drive roller 512 so as to selectively increase the force applied to the feeds of bead profile 145 and bead ply 150.

[0029] Tracking roller 514 is provided with an overall shape, created in part from surfaces 530 and 532, that is configured for the receipt of the feed of bead profile 145. Accordingly, US2006/048855

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as previously described, tracking roller 514 applies pressure to ensure the adherence of bead profile 145 to bead ply 150 as bead ply 150 is wrapped and to assist with moving these materials through forming station 500 through the powered rotation of drive roller 512. Tracking roller 514 and drive roller 512 are otherwise configured as described with previous forming stations.

[0030] A pair of guides 540 and 542 are positioned between forming station 400 and forming station 500. The guides are configured so as to assist with supporting feeds 145 and 150 and to facilitate the wrapping of bead ply feed 150 about bead profile feed 145 as such travels from forming station 400 to forming station 500. Guides 540 and 542 may be constructed from metal rods or rails and positioned as shown.

[0031] Forming station 600 is shown in Figs. IA, IB, and 6 and is similar to forming station 500 but uses differently shaped rollers. Drive roller 612 is substantially flat. A lateral roller 634 is positioned adjacent to drive roller 612 and tracking roller 614. Lateral roller 634 has an overall shape created in part by surfaces 636 and 638, and has an axis of rotation C-C that is perpendicular to the axis of rotation B-B of drive roller 612. First surface 636 is substantially parallel to the axis of rotation C-C of the lateral roller 634. Second surface 638 is angled so as to provide a frustoconical profile. By way of example, in certain embodiments second surface 638 is profiled to an angle of between about 25 degrees and about 60 degrees to the axis of rotation C-C of lateral roller 634, and in still other embodiments second surface 638 is profiled to an angle of about 45 degrees. Lateral roller 634 facilitates the continued wrapping of bead ply feed 150 about bead profile feed 145 as such are pulled through forming station 600. As with lateral roller 534, the position of lateral roller 634 relative to rollers 612 and 614 is selectively adjustable using support arms 644 that rotate about pivot point 646 so as to provide for an adjustable movement of lateral roller 634. A motor, such as pneumatic cylinder 648 attached to support arms 644, may also be used to selectively position lateral roller 634.

[0032] The substantially flat surface of tracking roller 614 assists drive roller 612 as it powers the feed of bead profile 145 and bead ply 150 through forming station 600. Tracking roller 614 also applies pressure to ensure the adherence of bead profile 145 to bead ply 150 as bead ply 150 is wrapped. Tracking roller 614 and drive roller 612 are otherwise configured as described with previous forming stations. A guide 640 is positioned between forming station 500 and forming station 600. Guide 640 is configured to assist with supporting feeds 145 and 150 and to facilitate the wrapping of bead ply feed 150 about bead profile feed 145 as such travels from forming station 500 to forming station 600.

[0033] Referring now to Figs. IA, IB, and 7, forming station 700 also includes a drive roller 712 and tracking roller 714. As with forming station 200, the drive roller 712 has a fixed position and includes a powered rotation for moving the feeds of bead profile 145 and bead ply 150 through the machine. Tracking roller 714 is movable in a manner similar to that described with tracking roller 214. Drive roller 712 is relatively flat. Tracking roller 714 has an overall shape, created in part from surfaces 730 and 732, that is configured for the receipt of the feed of bead profile 145 and the feed of bead ply 150. Accordingly, as previously described, tracking roller 714 applies pressure to ensure the adherence of bead profile 145 to bead ply 150, to assist with wrapping ply 150, and to continue moving these materials through forming station 700 by the powered rotation of drive roller 712. Guide 740, located between forming station 600 and forming station 700, assists with suspending and properly orienting the bead ply feed 150 as it feeds to forming station 700. [0034] Finally, forming station 800 completes the process of wrapping the bead ply feed 150 about the bead profile feed 145. As shown in Figs. IA, IB, and 8, forming station 800 includes a relatively flat profiled drive roller 812. Tracking roller 814 includes a groove 824 for the receipt of the shape of ply 150 now completely wrapped about profile 145. As previously described, tracking roller 814 may be equipped with a pneumatic cylinder 822 so that the pressure applied by forming station 800 may be selectively controlled. Alternatively, the weight of tracking roller 814 alone may supply the desired pressure. As the feeds of these two materials 145 and 150 are pulled through forming station 800, the two are pressed together to complete the wrapping process and adhesion to one another. The resulting tire intermediate 175 (Fig. 9B) may be then fed directly to a tire assembly drum or stored for later use.

[0035] The drive rollers 212, 312, 412, 512, 612, 712 and 812 may mechanically connected by a chain or belt, for example, and driven in synchronization by a single motor. Alternatively, individual servos may be used to power each drive roller. In addition, to keep the feeds of bead profile 145 and bead ply 150 in tension between each of the forming stations, the diameter of one or more of the drive rollers 312, 412, 512, 612, 712 and 812 may be increased in sequence along the longitudinal direction A of the machine. For example, the diameter of drive roller 312 may be slightly larger than the diameter of drive roller 212, drive roller 512 may be slightly larger in diameter than 312, and so forth. In this manner, even though the drive rollers may be rotated at the same rotational speed, the feeds of material 145 and 150 will be maintained in tension due to the differences in diameter. By way of example, in one embodiment of the invention, the diameters of one or more drive rollers is increased by affixing a layer of abrasive material to the surface of the drive roller. Such not only increases the diameter of a drive roller but also increases the ability of a drive roller to pull the feed of the bead ply 150 through a forming station. [0036] It should be understood that the present invention includes various modifications US2006/048855

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that can be made to the exemplary embodiments described herein that come within the scope of the appended claims and their equivalents. By way of example only, the present invention has been described using an exemplary embodiment in which the relative positioning of the tracking roller was adjustable while the drive roller provided rotational power to pull materials 145 and 150 through a forming station. It should be understood that the tracking roller could also be powered as to provide the force for pulling the materials through the machine. Similarly, the tracking roller could have a fixed position while the drive roller has a position that is adjustable. Furthermore, the tracking roller and driver roller could be constructed in a fixed position, although this might limit the overall adjustability and flexibility of the machine. These and other variations and embodiments fall within the scope of the invention and claims that follow.

Claims

WHAT IS CLAIMED IS:

1. A machine for manufacturing a tire intermediate that includes a bead profile and a bead ply, the machine defining a longitudinal axis, the machine comprising: a plurality of forming stations positioned for sequential receipt and transport of a bead profile feed and a bead ply feed, wherein each said forming station comprises a drive roller configured for rotating so as to pull the bead profile feed and bead ply feed through said forming station; a tracking roller positioned adjacent to said drive roller and configured for pressing the bead profile feed, the bead ply feed, or both towards said drive roller; wherein said drive and said tracking rollers of said forming stations are profiled so as to sequentially apply and wrap the bead ply feed about the bead profile feed as such are pulled through the machine along the longitudinal direction.

2. The machine of claim 1 , wherein each said drive roller is in mechanical communication with a motor configured for rotating each said drive roller.

3. The machine of claim 1 , wherein said tracking roller is selectively movable relative to said drive roller, and further comprising a motor in mechanical communication with said tracking roller and configured for selectively moving said tracking roller towards said drive roller so as to selectively control the pressure applied to the bead ply feed and the bead profile feed.

4. The machine of claim 3, wherein said motor comprises a pneumatic cylinder. 55

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5. The machine of claim 1 , wherein at least one of said plurality of forming stations further comprises a lateral roller positioned adjacent to said drive roller and said tracking roller, said lateral roller having a profile configured for wrapping the bead ply feed about the bead profile feed.

6. The machine of claim 1, wherein said lateral roller defines a rotational axis and further comprises: a first surface that is substantially parallel to said rotational axis of said lateral roller, and a second surface proximate said first surface, wherein said second surface is frustoconical in shape.

7. The machine of claim 6, wherein said second surface is at an angle of between about 25 degrees and about 50 degrees to said rotational axis of said lateral roller.

8. The machine of claim 1, wherein at least one of said drive rollers define a rotational axis and further comprises a first surface that is substantially parallel to said rotational axis of said drive roller, and, a second surface proximate said first surface, wherein said second surface is frustoconical in shape.

9. The machine of claim S, wherein said second surface is at an angle of between about 5 degrees and about 60 degrees to said rotational axis of said drive roller.

10. The machine of claim 1, further comprising a frame to which said tracking roller is pivotally attached.

11. The machine of claim 1, wherein said drive roller of at least one of said forming stations further comprises an abrasive surface for contacting the bead ply feed.

12. A method of manufacturing an intermediate component for a tire, comprising: providing a substantially unfolded bead ply feed and a bead profile feed; positioning the bead ply feed contiguous to the bead profile feed; pressing the bead profile feed and the bead ply feed together; turning the bead ply feed a predetermined amount about the bead profile feed while pulling said bead ply feed and said bead profile feed over a predetermined distance, and repeating said pressing and said turning steps until said bead ply feed is wrapped around said bead profile feed.

13. A method of manufacturing an intermediate component for a tire as in claim 12, further comprising the step of applying an increasing tension to said bead ply feed and said bead profile during said repeating step.

14. A method of manufacturing an intermediate component for a tire as in claim 12, further comprising the step of rolling the intermediate component onto a spool.

15. A method of manufacturing an intermediate component for a tire as in claim 12, further comprising the step of supplying the intermediate component to a tire assembly drum.

16. A method of manufacturing an intermediate component for a tire as in claim 12, wherein said pressing step comprises receiving said bead profile feed and said bead ply feed onto a forming station comprising a drive roller and a tracking roller located proximate to said drive roller., wherein said drive roller and said tracking roller are configured for applying a pressure to said bead profile feed and said bead ply feed as such are moved between said drive roller and said tracking roller.

17. A method of manufacturing an intermediate component for a tire as in claim 16, wherein said drive roller comprises a frustoconical surface.

18. A method of manufacturing an intermediate component for a tire as in claim 16, wherein said tracking roller comprises a frustoconical surface.

19. A method of manufacturing an intermediate component for a tire as in claim 18, wherein said tracking roller defines a rotational axis, and wherein said firustoconical surface is at an angle of between about 25 degrees and about 50 degrees to said rotational axis of said tracking roller.

20. A method of manufacturing an intermediate component for a tire as in claim 16, further comprising the step of adjusting the amount of said pressure applied to said bead ply feed and said bead profile feed.