Composite cord and method of making and support structure and tire containing same

A method of forming a composite hybrid cord, comprising the steps of:

• a) forming or providing a first bundle of synthetic filaments having a filament tenacity of from 10 to 40 grams per decitex;
• b) forming or providing a second bundle of synthetic filaments having a filament tenacity of from 10 to 40 grams per decitex;
• and wherein the yarns of the first and second bundles of synthetic filaments have an elongation at break ranging from 0.75% to 2.8% and wherein the ratio of the largest cross sectional dimension of the first bundle of synthetic filaments to the largest cross sectional dimension of the second bundle of synthetic filaments is from 1.5:1 to 20:1;
• c) helically winding a plurality of metal strands around the second bundle of synthetic filaments to form a cabled strand having a center of synthetic filaments wherein the metallic filaments of the cabled strands have an elongation at break that is no more than 24 percent different from the elongation at break of the synthetic filaments of the first and second bundles and
• d) helically winding a plurality of the cabled strands around the first bundle of synthetic filaments to form a composite hybrid cord having a core of synthetic filaments.