Abstract: A ply application station for applying a tire carcass cord ply to an annular surface includes a plurality of applicator heads disposed at respective spaced apart circumferential locations about the annular surface, each applicator head proximally positioned to a respective assigned region of the annular surface. The system coordinates the application of at least one ply cord by each head to the annular surface region assigned respectively to each head. The plurality of applicator heads operate independently within their respective assigned regions while the core annular surface is rotatably indexed in order to achieve a desired cord ply pattern.

Abstract: A cord tensioning mechanism for a tire cord applicator head includes a closed loop timing belt extending between spaced apart pulleys and a tension adjustment pulley pressuring the cord laterally against the timing belt sufficiently to place the cord into a desired tension.

Abstract: A tooling head for bi-directional tire cord application to an annular surface reciprocates in a forward and a reverse direction across the annular surface. The tooling head includes a housing; a nose block assembly coupled to the housing and reciprocating in an axial direction relative to the tooling head housing; a pair of cord engaging rollers mounted to a remote end of the nose block assembly and moving therewith in a forward and a reverse direction across the annular surface, the rollers positioning at least one cord against the annular surface in the forward and reverse directions; and a biasing element engaging against the nose block assembly for alternatively biasing the rollers against the annular surface.

Abstract: A tooling head for bi-directional tire cord application to an annular surface is mounted to reciprocally move in a forward and a reverse direction across the annular surface. The tooling head includes a plurality of rollers for positioning one or more cords on an elastomeric layer on the annular surface in the forward and reverse directions and a tilt mechanism for angular repositioning the rollers into alternative engagement with the annular surface in the forward and reverse directions.

Abstract: A synchronous drive system and method for tire cord application to an annular core surface includes an arm that moves laterally about a first axis in a forward and a reverse direction across the annular surface. A cord application head is coupled to the arm and positions one or more cords on an on the annular surface in the forward and reverse directions. First and second ring motors are coupled to synchronously move the arm and rotate the core. The cord application head may further reciprocate about a second axis of rotation.

Abstract: A cutting mechanism and method for a tooling head is provided, the tooling head including a housing; a cord line feeding passageway extending through the housing to an applicator end, and an applicator assembly at the applicator end for application of the cord line to an annular surface. The cutting mechanism provides a reciprocally moving plunger body housed within the tooling head; a reciprocating cutting member moving between a first position cutting the cord line and a second position in a non-cutting relationship with the cord line; a cutting member being coupled to the plunger body to translate reciprocal movement of the plunger body to reciprocal movement of the cutting member between the first and second positions. A stream of air may be directed into the cord line passageway proximate the cutting member to assist in threading a severed free end of the cord through the passageway to the applicator assembly.

Abstract: A cord ply construction for a tire is provided formed by a series of spaced single line cord paths, each extending along a path from an originating side of the tire across the crown region to an opposite terminal tire side, the cord paths each creating a loop at the terminal tire side and returning to the originating side and wherein the series of spaced single line cord paths combine to form a completed cord ply layer. Each cord path forms a cord angle that changes in magnitude from the originating side to the terminal tire side, the cord angle being at a highest magnitude at a tire tread centerline and decreasing toward the originating tire side.

Abstract: A method of simultaneously producing production runs of tires 200 on a multi-station sequential tire manufacturing system 10, the tires 200 being from a group of tire types of different build specifications in lot sizes of one or more tires is disclosed. The steps include: scheduling the production run by imputing tire build software, wherein the software program performs the steps of: selecting the tire building equipment and materials required for the respective tire types; calculating the corresponding number of cycles each piece of building equipment must perform to build a given lot; and automatically changing to a second build specification at a lot change by switching to the second build specification after the last tire 200 of the first build specification passes; repeating the automated changing to the next build specification at each station 11-16 and 71-74) as each last tire 200 of each prior lot passes until a final lot is produced.

Abstract: A method of manufacturing an annular toroidially-shaped cord reinforced ply for a tire is described. The method involves applying an elastomeric layer on a toroidal surface and placing and stitching one or more cords in continuous lengths onto the elastomeric layer in predetermined cord paths. The method further includes dispensing the one or more cords from spools and guiding the cord in a predetermined path as the cord is being dispensed. Preferably, each cord is held against the elastomeric layer after the cord is placed and stitched and then indexing the cord path to a next circumferential location forming a loop end by reversing the direction of the cord and releasing the held cord after the loop end is formed and the cord path direction is reversed. This method allows the step of forming loop ends to occur at more than one diameter on the toroidal surface.

Abstract: A method for applying a breaker or other reinforcement layer to a carcass strip by strip includes the steps of calculating an end gap based upon a nominal strip width, the size of the carcass, and the end count desired; calculating a distributed gap required to distribute the calculated end gap substantially equally between each strip; and applying the breaker strip by strip with each strip being separated from an adjacent strip by the distributed gap spacing.

Abstract: A method of building a tire carcass onto a toroidially expanded building drum core is disclosed which comprises: transferring a breaker and tread package to a mold; loading the tire carcass at diameter D1 into the mold; toroidally expanding the tire carcass to a second diameter D2 wherein the tire carcass and the breaker and tread package form an uncured tire assembly; curing the uncured tire assembly to form a cured tire in the mold; and removing the cured tire from the mold.

Abstract: A method of building and transferring a tread 12 or a tread belt reinforcing assembly 14 on a building drum 10 is disclosed. The steps include applying at least one uncured tread component 12, 14 onto a radially collapsible building drum 10, inserting the at least one uncured tread component 12 and the radially collapsible building drum 10 into an open segmented mold 2 wherein a plurality of mold tread forming segments 4 are radially expanded; contracting the plurality of mold tread forming segments 4 pressing into the at least one uncured tread component 12, 14; collapsing the building drum 10; and removing the building drum 10 thereby transferring the at least one uncured tread component 12, 14 into the mold.