Sheathed Multi-Strand Cable Structure for Elastomer Penetration
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Solution Overview
Problem
Heavy-duty industrial vehicle tires face issues with corrosion due to the entry and propagation of corrosive agents through multi-strand cables, leading to reduced lifespan, while increasing wire diameter or number compromises flexibility and requires significant investment, and existing solutions fail to balance breaking strength and penetrability.
Innovation Solution
A two-layer multi-strand cable design with desaturated outer layers and optimized elastomeric composition penetration, allowing the elastomer to fill gaps between strands, enhancing corrosion resistance without compromising breaking strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wire diameter is increased to increase breaking strength, then breaking strength is improved, but cable flexibility deteriorates
Solution Approach 1:
The cable is divided into multiple strands, each containing multiple wires. This segmentation allows the use of thinner individual wires that maintain flexibility while achieving high breaking strength through the combined effect of many wires working together in parallel.
Solution Approach 2:
The cable employs a composite structure combining multiple metal wires with different orientations and configurations within strands. This composite approach optimizes both strength and flexibility by distributing mechanical loads across different wire orientations and configurations.
2Strength
If number of wires is increased to increase breaking strength, then breaking strength is improved, but strand penetration by elastomer composition deteriorates
Solution Approach 1:
The cable structure segments wires into organized strands with controlled wire counts and configurations. This segmentation creates manageable spaces within and between strands that allow elastomer composition to penetrate effectively while still incorporating sufficient wires to achieve high breaking strength.
Solution Approach 2:
Different regions of the cable structure have different wire densities and configurations. The strand design creates local variations in wire arrangement that facilitate elastomer penetration in critical areas while maintaining high wire density in areas where strength is prioritized.
3Strength
If unit strength of each wire is increased to increase breaking strength, then breaking strength is improved, but manufacturing investment increases significantly
Solution Approach 1:
The cable achieves high breaking strength by segmenting the load-bearing function across many individual wires rather than relying on a few high-strength wires. This allows the use of standard-strength wires that are easier and less expensive to manufacture while achieving the same overall cable strength through parallel load distribution.
Solution Approach 2:
The design changes the structural parameters of the cable (number of wires, strand configuration, wire orientations) rather than changing the material parameters (wire strength). This parameter optimization achieves high breaking strength through geometric arrangement rather than requiring expensive high-strength material.
4Strength
If outer layer is made saturated to maximize strength, then breaking strength is improved, but penetrability by elastomer composition deteriorates
Solution Approach 1:
The outer layer is designed with localized variations in wire density and configuration. Certain regions have slightly reduced wire density or increased spacing to create penetration pathways for elastomer composition, while other regions maintain high density for strength. This local quality variation allows simultaneous achievement of strength and corrosion protection.
Solution Approach 2:
The outer layer incorporates controlled porosity or spacing between wires that allows elastomer composition to penetrate through the layer. These intentional gaps or channels enable the elastomer to reach inner strands and provide corrosion protection without significantly compromising the overall strength of the cable structure.
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 effectively prevents corrosive agent entry and propagation while maintaining high breaking strength and flexibility, improving tire lifespan and performance under severe conditions.
Implementation Method 1
the elastomeric compound penetrates the capillaries between each layer of each strand, thus preventing the spread of corrosive agents
Data Source
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AI summary
The invention relates to a two-layer multi-strand cable (50) comprising: - an inner layer (CI) that has two layers (C1, C3) and consists of K≥1 inner strand(s) (TI), and an outer layer (CE) consisting of L>1 outer strands (TE) that have two plies (C1', C3 ') and are wound around the inner layer (CI) at a helix radius R2. The outer plies (C3, C3') of each inner and outer strand (TI, TE) are desaturated. The cable (50) is obtained by a method involving a step of manufacturing the sheathed inner layer (CIG) in which the inner layer (CI) is surrounded by an elastomer composition having a thickness G and then by an outer layer (CE), G being such that R2/Rt ranges from 1.02 to 1.25, with Rt being the helix radius of the theoretical outer layer (CET) obtained when the inner layer (CI) is in direct contact with the theoretical outer layer (CET), and a step (400) to bring the outer layer (CE) of the cable closer to the circle circumscribing the inner layer (CI) of the cable so that the ratio R2/Rt ranges from 1.00 to 1.10.