Double-Layer Multi-Strand Tire Cable for Bending Endurance

The cable is divided into multiple thin wires (12-16 outer wires per strand) arranged in layers rather than using a single thick cord. This segmentation allows the cable to maintain high breaking strength through the collective strength of many wires while preserving flexibility because each individual wire remains thin and adaptable. The multi-strand construction with 6-8 strands further segments the structure, enabling the cable to bend more easily while distributing mechanical loads across numerous wire-cable interfaces.

The cable employs a nested hierarchical structure where multiple thin wires are bundled into strands, and multiple strands are bundled into the final cable. Each strand contains an inner layer of wires and an outer layer of wires, with the outer wires nested around the inner wires. This nested arrangement allows the cable to achieve the breaking strength of a thick cord while maintaining the flexibility of thin wires, as each nested layer can independently deform during bending.

The cable structure implements local quality variations with different wire diameters in different layers. The outer layer wires have a diameter of 0.23 mm while inner layer wires have a diameter of 0.26 mm. This local differentiation optimizes both strength and penetrability: the thinner outer wires provide good elastomeric compound penetrability for corrosion protection, while the thicker inner wires contribute to breaking strength. The multi-layer arrangement creates local channels that facilitate compound penetration while maintaining overall structural integrity.

The cable transitions from a single-dimension thick cord to a multi-dimensional multi-layer structure. By arranging wires in concentric layers (inner layer and outer layer within each strand) and organizing strands in multiple layers around the cable axis, the structure creates three-dimensional pathways for elastomeric compound penetration. This dimensional transformation allows the compound to access all wire surfaces through inter-wire spaces in multiple layers, achieving thorough penetrability while maintaining high breaking strength through the distributed wire architecture.

Instead of manufacturing fewer high-strength cords requiring specialized expensive equipment, the invention segments the strength requirement across many standard-gauge wires (12-16 per strand). Each wire can be manufactured using conventional, less expensive drawing and twisting equipment. The cumulative strength of these numerous wires, organized into 6-8 strands, achieves the required breaking strength without necessitating significant investment in specialized high-strength cord manufacturing facilities.

The invention changes the structural parameters from few high-strength cords to many standard-strength wires arranged in multi-layer strands. By adjusting the number of wires per strand (12-16), the number of strands (6-8), and the wire diameters (0.23 mm outer, 0.26 mm inner), the design achieves the required breaking strength through parameter optimization rather than requiring exceptional unit-strength wires that would demand expensive manufacturing equipment.