Double-Layer Multi-Strand Cord for Elastomer Penetration and Strength
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Solution Overview
Problem
Heavy-duty industrial vehicle tires face issues with tire lifespan reduction due to corrosive agents entering through tread perforations, which oxidize metallic reinforcement elements, and increasing wire diameter or number to enhance breaking strength leads to decreased flexibility and increased manufacturing costs.
Innovation Solution
A two-layer multi-strand cable with a desaturated outer layer design, allowing sufficient space between outer strands for elastomeric composition penetration, enhancing penetrability and reducing corrosive agent ingress while maintaining breaking strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wire diameter is increased to enhance breaking strength, then breaking strength is improved, but flexibility decreases
Solution Approach 1:
The cable is divided into multiple fine wires (7-15 wires per strand) arranged in hierarchical strands rather than using fewer thick wires. This segmentation allows the cable to achieve high breaking strength through the collective strength of many wires while maintaining flexibility due to the smaller individual wire diameters and the ability of strands to move relative to each other.
2Strength
If number of wires is increased to enhance breaking strength, then breaking strength is improved, but strand penetration by elastomer composition decreases
Solution Approach 1:
The cable structure implements local quality variations by creating desaturated zones between strands where elastomer composition can penetrate, while maintaining saturated compact structures within individual strands for strength. The inter-strand spaces are specifically designed to allow elastomer infiltration without compromising the internal wire structure that provides breaking strength.
3Strength
If outer layer is saturated to maximize breaking strength, then breaking strength is improved, but penetrability by elastomer composition decreases
Solution Approach 1:
The outer layer is designed with a porous or desaturated structure containing intentional voids and spaces between strands, allowing elastomer composition to penetrate through the cable structure. These spaces act as channels for elastomer infiltration while the overall cable structure maintains sufficient breaking strength through the arranged wire configuration.
4Strength
If wire diameter is increased beyond 0.50 mm to enhance breaking strength, then breaking strength is improved, but flexibility decreases and manufacturing complexity increases
Solution Approach 1:
Instead of using fewer large-diameter wires, the invention segments the load-bearing function across many small-diameter wires (0.15-0.50 mm) arranged in hierarchical strands. This segmentation simplifies manufacturing by using standard wire sizes while achieving equivalent or superior breaking strength, and improves flexibility through the finer wire structure.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The disclosed cord (50) comprises K > 1 helically wound inner strands (TI) and L > 1 outer strands (TE). Each outer strand (TE) comprises: an inner layer (C1') consisting of Q' = 2, 3 or 4 inner wires (F1'); an intermediate layer (C2') consisting of M' intermediate wires (F2') wound at a pitch p2'; an outer layer (C3') consisting of N' outer wires (F3') wound at a pitch p3'. The average inter-strand distance E between two adjacent outer strands is at least 30 µm. p1' is different from p2' and/or the direction of the inner layer (C1') of each outer strand (TE) is different from the direction of the intermediate layer (C2') of each outer strand (TE). The intermediate layer (C2') of each outer strand (TE) is desaturated, and the outer layer (C3') of each outer strand (TE) is desaturated. The following applies to steps p2' and p3': 0.33 ≤ (p3'-p2')/p3' ≤ 0.45 if Q'=2; 0.35 ≤ (p3'-p2')/p3' ≤ 0.42 if Q'=3; 0.28 ≤ (p3'-p2')/p3' ≤ 0.43 if Q'=4.