Multi-Strand Tire Cord Structure for Elastomer Penetration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heavy industrial vehicle tires are prone to perforations on uneven surfaces, allowing corrosive agents to enter and oxidize the metal reinforcing elements, significantly reducing their lifespan, and increasing the cord diameter or number of cords to enhance breaking force compromises flexibility and penetrability.
Innovation Solution
A two-layer multi-strand cable with a desaturated outer layer, characterized by a specific pitch ratio and inter-strand distance, allowing elastomer composition to penetrate and form a protective matrix, reducing corrosion while maintaining mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cord diameter is increased to enhance breaking force, then the breaking force is improved, but the flexibility of the cord decreases
Solution Approach 1:
The cord is segmented into multiple strands (e.g., 7 strands) instead of using a single thick cord. Each strand contains multiple wires (e.g., 19 wires per strand), creating a hierarchical segmented structure that maintains flexibility while achieving high breaking force through the combined strength of numerous smaller elements.
Solution Approach 2:
The cord uses a composite structure combining metal wires with elastomeric composition. The metal wires provide tensile strength while the elastomeric material provides flexibility and corrosion protection, creating a composite that achieves both high breaking force and maintained flexibility.
2Strength
If the number of cords is increased to enhance breaking force, then the breaking force is improved, but the penetrability of the strands by elastomer composition decreases
Solution Approach 1:
The cord structure is segmented into strands with controlled wire arrangements that create inter-wire spaces. This segmentation allows elastomer composition to penetrate between wires during manufacturing while still achieving high breaking force through the combined strength of multiple cords and wires.
Solution Approach 2:
The strand structure incorporates controlled porosity through the arrangement of wires with different diameters and winding patterns, creating channels and spaces that allow elastomer composition to penetrate and impregnate the strand structure during manufacturing, while maintaining structural integrity for high breaking force.
3Strength
If the unit strength of each cord is increased to enhance breaking force, then the breaking force is improved, but significant investment in cord manufacturing facilities is required
Solution Approach 1:
Instead of manufacturing fewer high-strength cords requiring advanced facilities, the solution segments the structure into many standard-strength wires and strands that can be manufactured using conventional equipment. The cumulative strength of numerous standard components achieves the required breaking force without requiring significant investment in specialized manufacturing facilities.
Solution Approach 2:
The invention changes the parameters from few high-strength cords to many standard-strength wires, adjusting the quantity and arrangement parameters rather than increasing individual wire strength parameters. This approach achieves the same breaking force using standard manufacturing capabilities.
4Strength
If a saturated outer layer is used in the cable, then the breaking force is maximized, but the penetrability by elastomer composition decreases
Solution Approach 1:
The cable employs local quality variation where the outer layer has a specific loose arrangement with controlled inter-strand distances (e.g., at least 30 μm) that differs from the inner layers. This local structural characteristic in the outer layer enables elastomer penetration while the overall cable structure maintains high breaking force through the combined strength of all layers.
Solution Approach 2:
The cable uses a composite structure where the outer layer serves dual functions: providing mechanical strength as part of the overall cable strength while simultaneously serving as a penetrable barrier that allows elastomer composition to reach inner strands, achieving both strength and corrosion protection functions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cable design enhances penetrability and accessibility of the internal strands by the elastomer composition, limiting corrosive agent entry and propagation, while maintaining breaking force and flexibility.
Implementation Method 1
the elastomeric composition penetrates the capillaries present between each layer of each strand
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The disclosed cord (50) comprises: - K > 1 inner strands (TI) comprising an inner layer (C1) and an outer layer (C3); - L > 1 outer strands (TE) comprising an inner layer (C1') consisting of Q'=1 inner wire (F1'), an intermediate layer (C2') consisting of M' intermediate wires (F2') wound around the inner layer (C1') at a pitch p2', and an outer layer (C3') consisting of N' outer wires (F3') wound around the intermediate layer (C2') at a pitch p3'; the average inter-strand distance E separating two adjacent outer strands is at least 30 μm; the intermediate layer (C2') of each outer strand (TE) is desaturated; the outer layer (C3') of each outer strand (TE) is desaturated; and 0.36 ≤ (p3'-p2')/p3' ≤ 0.57.