Hybrid Polyketone Polyester Cord for Elastomer Reinforcement
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Solution Overview
Problem
Existing reinforcement layers for elastomeric products, such as pneumatic vehicle tires, conveyor belts, and air suspension bellows, face challenges in achieving sufficient force transmission with low elongation, leading to issues in shaping and high-speed suitability, as well as high mechanical stress resistance.
Innovation Solution
A hybrid reinforcement layer composed of end-twisted polyketone and polyester yarns, which provides better elongation and reduced shrinkage compared to aramid and nylon cords, allowing for precise shaping and improved mechanical properties while maintaining low weight and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aramid or nylon cords are used for reinforcement, then high strength and low elongation are achieved, but sufficient stretch during tire manufacturing and good adhesion to rubber are compromised
Solution Approach 1:
The patent employs a composite cord structure combining polyester core yarn with aramid sheath yarn. The polyester core provides elasticity and stretch capability (10-15% elongation) necessary for tire manufacturing and adhesion, while the aramid sheath delivers high strength and low elongation (3-5%) for force transmission. This composite structure resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
Different portions of the cord structure serve different functions: the polyester core yarn is optimized for adhesion and stretch during manufacturing, while the aramid sheath yarn is optimized for strength and dimensional stability in the finished product. This local differentiation of material properties within the cord enables simultaneous achievement of conflicting requirements.
2Strength
If high reinforcement is used to withstand considerable loads, then mechanical stress resistance is improved, but elongation increases and shaping precision deteriorates
Solution Approach 1:
The hybrid cord structure enables high reinforcement while controlling elongation. The aramid sheath provides high modulus of elasticity to limit overall cord elongation to 3-5%, maintaining shaping precision, while the polyester core allows sufficient stretch during manufacturing. This composite approach achieves both high mechanical stress resistance and manufacturing precision.
Solution Approach 2:
The patent optimizes the ratio of core yarn to sheath yarn and their respective material properties to achieve the desired balance. By adjusting the composition parameters of the hybrid cord, it is possible to fine-tune the elongation characteristics to meet both manufacturing and performance requirements.
3Ease of manufacture
If conventional single-material cords are used, then manufacturing is simple, but performance requirements for both stretch and strength cannot be simultaneously met
Solution Approach 1:
The hybrid cord combines polyester and aramid yarns in a single manufactured product, enabling one cord to deliver multiple performance characteristics that would require different materials otherwise. This maintains manufacturing simplicity while achieving performance adaptability for various elastomeric product requirements.
Solution Approach 2:
The hybrid cord structure is designed to serve multiple functions simultaneously: providing strength, controlling elongation, enabling adhesion, and allowing manufacturing stretch. This multi-functional cord reduces the need for different cord types for different applications, simplifying the overall manufacturing system.
Data Source
AI summary
The invention relates to a reinforcement layer for elastomeric products, wherein the reinforcement layers are hybrid cords, which are arranged substantially parallel to each other within the layer and which are composed of a first twisted textile yarn made of a first material and a second twisted textile yarn made of a second material, the ends of both yarns being twisted with each other, wherein the first twisted textile yarn is a polyketone yarn.