Beadlock assembly

A method for producing a beadlock assembly, said method comprising:

• (a) fabricating a beadlock case, comprising:
• (i) producing a beadlock tread, comprising:
• (A) providing a first synthetic material of a given width and a given length and a given strength, wherein the given length is longer than the given width, wherein the first synthetic material comprises a first terminal end and a second terminal end;
• (B) joining the first terminal end of the first synthetic material and the second terminal end of the first synthetic material such that a pre-determined distance exists between said first and second terminal ends of the first synthetic material, wherein a tread overlap, comprising a double layer of the first synthetic material, is defined by the pre-determined distance and the given width, wherein joining the first terminal end and the second terminal end of the first synthetic material forms an annular shape of the beadlock tread having a first circumferential edge and a second circumferential edge;
• and
• (C) stitching the tread overlap with a double-W stitching pattern to bind together the double layer of the first synthetic material, wherein the double-W stitching pattern comprises a first set of stitches forming multiple W-shaped patterns and a second set of stitches forming multiple W-shaped patterns rotated 180 degrees relative to the first set of stitches, wherein the first set of stitches and the second set of stitches overlap;
• (ii) stitching a first beadlock sidewall and a second beadlock sidewall circumferentially to opposite sides of an inside of the beadlock tread, wherein the first beadlock sidewall and the second beadlock sidewall are composed of a PVC material,
• wherein the first beadlock sidewall is a first annular PVC material stitched to the first circumferential edge of the beadlock tread, wherein the second beadlock sidewall is a second annular PVC material stitched to the second circumferential edge of the beadlock tread, wherein the first beadlock sidewall and the second beadlock sidewall are equal in size and shape;
• (iii) forming a first beadlock bead by folding a second synthetic material over a circumferential edge of the first beadlock sidewall, and stitching the second synthetic material to the circumferential edge of the first beadlock sidewall, wherein said stitching is disposed within a given distance from an edge of the first beadlock bead;
• and
• (iv) forming a second beadlock bead by folding a third synthetic material over a circumferential edge of the second beadlock sidewall, and stitching the third synthetic material to the circumferential edge of the second beadlock sidewall, wherein said stitching is disposed within the given distance from an edge of the second beadlock bead;
• (b) placing an inner tube, having an inner tube valve stem, within the beadlock case;
• and
• (c) providing a bead lock air channel;
• wherein the bead lock assembly is inserted into a tire that comprises two inner circumferential tire beads, a tire valve stem, and a main air chamber, wherein the beadlock case is positioned within the tire such that the beadlock case encircles a rim on which the tire is mounted, wherein the beadlock assembly contacts the tire at one of the inner circumferential tire beads and the second beadlock bead contacts the tire at the other circumferential tire bead,
• wherein the main air chamber is an air tight space between the tire, when inflated, and the rim, wherein the bead lock air channel joins the main air chamber to the tire valve stem, wherein the tire valve stem allows air to enter and exit the main air chamber through the bead lock air channel,
• wherein the inner tube valve stem is mounted on the rim and allows air to enter and exit the inner tube, wherein when the inner tube (134) disposed within the beadlock assembly (100) is inflated from the inner tube valve stem (106), the beadlock assembly (100) exerts a force on the two inner circumferential tire beads such that the tire (102) stays mounted on the rim (104) even when the inflation pressure of the tire (102) is not sufficient to lock the tire (102) to the rim.