Two-Layer Metal Cable With Elastomeric Sheath For Tire Reinforcement
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Solution Overview
Problem
Current metal cables used in tire reinforcement face challenges such as reduced endurance due to corrosion, high manufacturing costs, and difficulty in achieving both high strength and penetrability, particularly in heavy-duty tires that require resistance to compressive fatigue and cleavage.
Innovation Solution
A two-layer metal cable design with an internal layer of M+1 internal metal wires surrounded by an elastomeric composition and an external layer of N external metal wires, where N is greater than Nmax, allowing for increased breaking strength and improved wire efficiency through the use of a sheath that relieves contact pressures and enhances wire participation in the breaking force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If M+N construction cables are used with a core of M wires surrounded by N wires, then the cable structure provides good mechanical strength, but the channel in the center of N core wires remains empty after impregnation and promotes corrosion propagation through wicking effect
Solution Approach 1:
An elastomeric composition is introduced as an intermediary material between the inner and outer wire layers. This composition fills the central channel that would otherwise remain empty and promote corrosion, while also providing cushioning between the wire layers to improve mechanical performance and reduce contact pressures.
2Ease of manufacture
If the outer layer is relatively desaturated due to large diameter of inner layer, then penetrability by calendering rubber is improved, but the number of outer wires N is limited by maximum Nmax
Solution Approach 1:
The invention transitions from a direct wire-to-wire contact structure to a structure with an intermediate elastomeric layer, adding a dimensional element between the inner and outer wire layers. This allows the outer layer to be saturated (N=Nmax) while maintaining good penetrability, as the elastomeric composition facilitates rubber impregnation without compromising the mechanical strength provided by the additional outer wires.
3Strength
If N is increased beyond Nmax to improve breaking strength, then more outer wires provide higher strength, but contact pressures between wires increase reducing wire efficiency
Solution Approach 1:
The elastomeric composition is placed beforehand between the inner and outer wire layers to provide cushioning. This cushioning effect reduces contact pressures between adjacent outer wires, allowing the outer layer to be saturated with N=Nmax wires while maintaining wire efficiency and preventing excessive stress concentration that would reduce overall cable strength.
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 significantly improves breaking strength and endurance while maintaining a compact external diameter, addressing the limitations of existing cables by enhancing resistance to fatigue and corrosion, and optimizing manufacturing efficiency.
Implementation Method 1
an internal layer of M+1 internal metal wires surrounded by an elastomeric composition
Data Source
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AI summary
The invention relates to a two-layer cable (50) comprising: - an inner layer (C1) consisting of M>1 inner metal wires (F1); - a cable outer layer (C3) consisting of N outer metal wires (F3) wound around the inner layer (C1) of the cable. 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 the N outer metal wires to form the outer layer (C3), with N being strictly greater than Nmax, which is the maximum number of outer metal wires (F3) that can be arranged on the theoretical outer layer (C3T) obtained when the inner layer (C1) is in direct contact with the theoretical outer layer (C3T).