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 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 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 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 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.