Compact Steel Cord Structure for Rubber Penetration and Corrosion Resistance
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Solution Overview
Problem
Existing compact steel cords face instability due to sliding between layers, which prevents rubber penetration and reduces corrosion resistance by allowing water vapor to penetrate internal voids.
Innovation Solution
A compact steel cord structure with a core-filament steel wire surrounded by four middle-layer and eight outer-layer steel wires, featuring gaps between the outer-layer wires that allow rubber penetration while maintaining stability, with specific diameter ratios and tensile strength relationships to enhance corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the steel cord structure is made compact by narrowing gaps between monofilaments to prevent sliding, then the stability of the steel cord structure is improved, but rubber penetration is prevented and water vapor can penetrate along internal voids reducing corrosion resistance
Solution Approach 1:
The patent applies the porous materials principle by intentionally designing gaps between outer-layer steel wires that allow rubber penetration while maintaining structural stability. The gaps serve as controlled porous pathways for rubber to reach inner layers, preventing water vapor penetration and improving corrosion resistance without compromising structural integrity
Solution Approach 2:
The patent applies local quality by creating different structural characteristics in different regions: the inner layers maintain tight packing for stability, while the outer layer intentionally includes gaps for rubber penetration. This localized differentiation allows simultaneous achievement of structural stability and corrosion protection
2Reliability
If gaps are reserved between outer-layer steel wires to allow rubber penetration, then corrosion resistance is improved, but the structural stability may be compromised due to potential sliding between layers
Solution Approach 1:
The controlled porous structure with gaps between outer-layer wires allows rubber penetration while the overall twisted cord structure maintains stability. The gaps are strategically positioned and sized to enable corrosion protection without causing layer sliding
Solution Approach 2:
The patent applies preliminary action by pre-designing the gap structure and wire arrangement before the steel cord is used in tires. The gaps are intentionally created during manufacturing to facilitate future rubber penetration and corrosion protection, while the twisted structure is pre-configured to prevent sliding
3Manufacturing precision
If a compact structure is created to prevent steel wire sliding, then manufacturing stability is improved, but rubber coating performance deteriorates due to inability of rubber to penetrate into the steel cord
Solution Approach 1:
The patent uses porous materials principle by creating a controlled gap structure that facilitates rubber penetration during the coating process. The gaps allow rubber to access inner layers, improving coating uniformity and performance while maintaining manufacturing stability through the twisted cord structure
Solution Approach 2:
Local quality is applied by creating regions of different density: tight packing in inner layers for manufacturing stability, and intentional gaps in outer layers for rubber coating penetration. This spatial differentiation enables both manufacturing precision and coating quality
Data Source
AI summary
A compact steel cord is provided. The cord includes a core-filament I steel wire with a diameter of d0, and four middle-layer M steel wires with a diameter of d1 and eight outer-layer O steel wires with a diameter of d2 that are twisted around the core-filament I steel wire in the same lay direction and the same lay length. Gaps L are reserved between the outer-layer O steel wires, an average width of the gaps L is not smaller than 0.02 mm, and the total size of the gaps L is larger than d0 and smaller than d1. The steel cord of a stable structure can be obtained by controlling the proportion of the sizes of all layers of monofilaments, the rubber coating performance of a tire cord can also be improved, the corrosion resistance, fatigue resistance, impact resistance and adhesion retention of a tire are improved.