Two-Layer Multi-Strand Cable for Flexible Tire Apex Plies
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Solution Overview
Problem
Existing cables for tire apex plies are too rigid, leading to increased sensitivity to aggression and reduced endurance performance, particularly in applications with installation angles less than 10°, necessitating a balance between flexibility and tensile strength.
Innovation Solution
A two-layer multi-strand cable design with specific layer configurations and structural elongation, comprising inner and outer layers of helically wound strands with varying diameters and pitches, ensuring flexibility and sufficient breaking strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a cable has a large cross-section to carry high currents, then the current carrying capacity is improved, but the cable becomes increasingly inflexible and difficult to handle
Solution Approach 1:
The cable is divided into multiple individual strands (at least 5 strands) instead of a single solid conductor. Each strand can flex independently, allowing the cable to bend and flex while maintaining sufficient cross-sectional area for high current carrying capacity. The strands are twisted together to form the composite cable structure.
Solution Approach 2:
The cable structure transitions from a single-dimensional solid conductor to a multi-dimensional composite structure with strands arranged in multiple layers. At least two strands are positioned in an inner layer and at least two strands in an outer layer, creating a spatial arrangement that enhances flexibility while maintaining current carrying capacity.
2Quantity of substance
If a cable has a large cross-section to carry high currents, then the current carrying capacity is improved, but the cable becomes increasingly prone to corrosion
Solution Approach 1:
The cable employs a composite structure with at least two different metal materials used for the strands. This allows combining materials with different properties - such as copper for electrical conductivity and corrosion resistance, or aluminum for lightweight and corrosion resistance - to achieve both high current carrying capacity and improved corrosion resistance.
3Quantity of substance
If a cable has a large cross-section to carry high currents, then the current carrying capacity is improved, but the cable becomes increasingly difficult to bend
Solution Approach 1:
The cable is divided into multiple individual strands (at least 5 strands) instead of a single solid conductor. Each strand can flex independently, allowing the cable to bend and flex while maintaining sufficient cross-sectional area for high current carrying capacity. The strands are twisted together to form the composite cable structure.
Solution Approach 2:
The cable structure transitions from a single-dimensional solid conductor to a multi-dimensional composite structure with strands arranged in multiple layers. At least two strands are positioned in an inner layer and at least two strands in an outer layer, creating a spatial arrangement that enhances flexibility while maintaining current carrying capacity.
Data Source
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AI summary
The invention relates to a multi-strand cable (50) with two multi-strand layers, the cable (50) comprising: - an inner layer (CI) of the cable, made up of X = 3 or 4 multi-strands (M1) comprising K = 2, 3 or 4 strands (T1) helically wound around an axis (B), each strand (T1) being a strand with at least two layers (C1, C3); and - an outer layer (CE) of the cable, made up of Y > 1 multi-strands (M2) wound around the inner layer (CI) of the cable, each multi-strand (M2) comprising L = 2, 3 or 4 strands (T2) helically wound around an axis (A'), each strand (T2) being a strand with at least two layers (C1'; C3'), with the multi-strands of the inner layer (M1) and of the outer layer (M2) being helically wound around a main axis (A). The cable (50) has a structural elongation As such that As ≥ 1.0%.