[0001] This invention relates to cords adapted for the reinforcement of pneumatic tires
and more particularly to cords for use as reinforcing elements for the carcass and
the belt structure of pneumatic radial tires, especially pneumatic radial truck tires.
[0002] Pneumatic vehicle tires are generally reinforced with steel cords having substantailly
round cross-sections. A plurality of single filaments or strands are twisted together
to form such a cord. By substantially round cross-sections is meant cross-sections
where the enveloping curve is approximatively a circle.
[0003] Flat wires for the reinforcement of pneumatic tires have an improved lateral stiffness,
require a thinner rubber ply, have a better compression performance and a greater
elongation at break than cords having substantially round cross-sections ; however
the latter have a better tensile strength and better fatigue performance than flat
wires.
[0004] Attempts have previously been made to combine the properties of the above-mentioned
structures with two or three single filaments or strands, lying in one plane in contact
with each other, forming the core and being wound around by a plurality of single
wires (DE-A-2.941.541). These cords have a poor twisting stability and the breadth-to-thickness
ration of the core of these cords is limited to a maximum of 3. The twisting stability
can be improved by using only strands for the core and by laying the strands of the
core in alternating directions (FR-A-2.472.040), but this complicates the construction,
does not provide complete twisting stability and does not allow breadth to thickness
ratios greater than 3.
[0005] It is an object of the invention to avoid the drawbacks of the prior art and to provide
a cord structure that combines the advantages of flat wire with the advantages of
steel cords having substantially round cross-sections.
[0006] Thus according to one feature the invention provides a cord, with an elongated cross-section,
adapted for the reinforcement of plies in a pneumatic tire, comprising a layer of
steel filaments that are wound around a core, the core having a tensile strength of
at least 1800 N/mm² and an elongation at rupture of at least 2 per cent, characterized
in that the core is an untwisted monofilament which has an elongated cross-section,
preferably a substantially rectangular cross-section, and a breadth-to-thickness ratio
of at least 2.
[0007] By an elongated cross-section is meant a cross-section that is not round and where
the longest axis is at least 1.5 times the length of the shortest axis.
[0008] By plies in a pneumatic tire is meant the carcass and the belt reinforcement structure.
[0009] By a layer of steel filaments around a core is meant a plurality of filaments disposed
side by side so as to form around said core a sheath of a thickness equal to the diameter
of a filament.
[0010] By a substantially rectangular cross-section is meant a cross-section with two rectilinear
parallel long sides. The extremities of these long sides are connected to each other
by two short sides, which are not necessarily rectilinear. Rectangular cross-sections
with rounded edges are also substantailly rectangular cross-sections.
[0011] The longest cross-sectional dimension (for a rectilinear cross-section), the maximum
distance between the two short sides, measured along a line parallel to the long sides,
is called the breadth, the minimum cross-sectional dimension (for a rectilinear cross-section
the distance between the two long sides) is called the thickness.
[0012] The breadth-to-thickness ratio of the monofilament core is greater than 2, and, by
preference, lies between 4 and 10. A minimum breadth-to-thickness ratio is necessary
to keep the cord in place during its manufacturing process. The maximum ratio 10 is
determined by stability considerations.
[0013] The monofilament core has an elongation at rupture of at least 2 per cent, and, by
preference, lies between 2.5 and 3.3 per cent. A core with an elongation at rupture
of less than 2 per cent is too crisp. The monofilament core has a tensile strength
of at least 1800 N/mm² in order to give the whole cord a sufficient strength.
[0014] The monofilament core can be preferably made of steel.
[0015] "A cord adapted for the reinforcement in a pneumatic tire" means that the steel filaments
of the layer conveniently have a carbon content between 0.70 and 0.90 per cent by
weight, a tensile strength between 2700 N/mm² and 3500 N/mm² or even more, by preference
between 2900 and 3400 N/mm², and a coating that favours the adhesion to rubber, for
example brass. Said steel filaments can have by preference a round cross-section with
a diameter suitably between 0.12 and 0.40 mm, by preference between 0.175 and 0.300
mm, but they can also have a substantially rectangular cross-section with a breadth-to-thickness
ratio between 1.3 and 4. If said steel filaments have a substantially rectangular
cross-section, then the long sides of the cross-section of the steel filaments will
lie parallel to the nearest touching line of the cross-section of the core.
[0016] The pitch of the steel filaments is expressed as p, the axial distance required to
make a 360 degree revolution of a steel filament of the layer. If the steel filaments
are wound in the S-direction p is positive, if the steel filaments are wound in the
Z-direction p is negative.
[0017] The layer of steel filaments may be surrounded by a second layer of steel filaments.
The pitch of the steel filaments in the second layer may be the same as, or different
from, the pitch of the first layer.
[0018] A steel filament can be wrapped helicoidally around the layer (or outer layer where
there is more than one layer) of steel filaments with a pitch q different from the
pitch of the steel filaments in the layer (or outer layer).
[0019] The wrapped helicoid filament is not necessarily a round steel filament with a high
carbon content, but can also be a filament with a carbon content of e.g. less than
0.20 per cent by weight, or a filament with a flat or oval shape.
[0020] The invention provides a "hybrid" structure : elements having different cross-sections
are combined. The core has an elongated and substantially rectangular cross-section.
The steel filaments have a round cross-section or a substantially rectangular cross-section
with a breadth-to-thickness ratio which is smaller than the breadth-to-thickness ratio
of the core. The fatigue resistance of the steel filaments is greater than that of
the core ; however, in a cord adapted for the reinforcement of a pneumatic tire the
core requires less fatigue resistance than the layers. Thus the fatigue performance
of the entire cord is not weakened by the comparatively small fatigue resistance of
the core.
[0021] The steel filaments in the layer or in the layers around the core have, by preference,
line contacts with the adjoining filaments. This has the advantage that loads are
spread over all the filaments.
[0022] The distance from the steel filaments in the layer or in the layers to the central
long axis of the structure is small in comparison with the distance from the steel
filaments to the center in steel cords having a substantially round cross-section
and having the same cross-section surface as the cord of the invention. This results
in smaller tensile and compressive tensions in the filaments of the layer of the cord
according to the invention.
[0023] The proposed structure is also flexible to deformations perpendicular to the plane
of the core. This means that the stiffness in the plane perpendicular to the plane
of the core is small. Due to the elongated and preferably substantially rectangular
cross-section of the core, the stiffness in the plane of the core, however, is great.
Consequently the cord accor ding to the invention
has a stiffness which is advantageous for its use in pneumatic radial tires.
[0024] The cords according to the invention may be used in the carcass or in the belt structure
of pneumatic radial tires, and are particularly useful for use in truck tires. In
both applications the long side of the cross-section of the cord is parallel to the
surface of the tire.
[0025] Referring to the accompanying drawings,
Figure 1 and Figure 2 illustrate the cross-sections of two steel cords according to
the invention ;
Figure 3 is a side view of a cord according to the invention;
Figure 4 illustrates apparatus for making a cord according to the invention ;
Figure 5 illustrates the cross-section of a forming die on the plane V-V of Figure
4 ;
Figure 6 illustrates the cross-section of straightener pulleys on the plane VI-VI
of Figure 4.
[0026] Figure 1 illustrates a cross-section of a cord according to the invention. The monofilament
core (1) is made of steel. It has a breadth X of 1 mm and a thickness Y of 0.25 mm.
The breadth-to-thickness ratio X/Y is 4. Twelve steel filaments (2) with a diameter
of 0.25 mm are wound with pitch p of 18 mm in the S-direction around the monofilament
core (1). A steel filament (3) with an original diameter of 0.15 mm is wrapped around
the layer of steel filaments (2) in the Z-direction with a pitch q of -3.5 mm. The
above structure can be notated as :
[1x0.25] + 12x0.25 + 1x0.15 ; = /18 S / 3.5 Z
where the dimensions of the monofilament core are given inside the rectangular brackets.
The "="-sign corresponds to the monofilament core and means that the monofilament
core is not twisted.
[0027] Figure 2 corresponds to :
[1.3x0.22] + 14x0.25 + 1x0.15 ; = /18 S / 3.5 Z.
Other examples are ;
[1.1x0.22] + 14x0.22 + 1x0.15 ; = /16 S / 3.5 Z.
[1.25x0.25] + 14x0.25 + 1x0.15 ; = /18 S / 3.5 Z.
The last example has particularly good rubber penetration.
[0028] Figure 4 illustrates apparatus for manufacturing a cord according to the invention.
[0029] The steel filaments (2) are wound around the monofilament core (1) by a tubular stranding
machine (4) at the forming die (5). A steel filament (3) is wrapped around the cord
at (6). The cord then passes through a pair of grooved rollers (7), and, eventually,
through a straightener (8), before it is wound up on a drum (9).
[0030] The monofilament core (1) of the cord is supplied by a spool (41) with a horizontal
axle. The steel filaments (2) of the layer have a round cross-section or, at least,
have a breadth-to-thickness ratio that is lower than the breadth-to-thickness ration
of the monofilament core. Consequently the steel filaments (2) need not be delivered
from spools with horizontal axles. The delivering spools (42) of the steel filaments
(2) may have vertical axles. The forming die (5) must have a profile that is adapted
to the profile of the cross-section of the steel cord to be formed. Figurae 5 illustrates
the cross-section of the forming die (5). The grooves of the rollers (7) and of the
rollers (81) of the straightener (8) also have an adapted profile as illustrated in
Figure 6.
[0031] The cord according to the invention is pressed together in the rollers (7). If the
cord is provided with a filament (3) made of low carbon steel, the rollers (7) subject
the filament (3) to plastic deformation, as can be seen on Figures 1 and 2. A straightener
(8) can be used to diminish the torsion of the steel cord. Such a straightener is
disclosed in GB patent 2.092.629.
[0032] Normally such a straightener has two sets of rollers situated in considerably different
planes. This is the case with cables having substantially round cross-sections. Because
of the elongated cross-section of the cord according to the invention only one set
of rollers is used. The rollers are so situated that their profile is parallel to
the long central axis
of the cord according to the invention.It can be easily understood that the greater
the breadth-to-thickness ratio of the cord the more easily the cord can be kept in
a horizontal plane and the more easily torsions can be avoided.
[0033] The performance of the steel cord according to Figure 1 has been examined and compared
to the performance of existing steel cords for truck tire reinforcement. The structure
[1.00x0.25] + 12x0.25 + 1x0.15 = /18 S / 3.5 Z (I) was compared to the following structures
:
1. (3 + 9 + 15) x 0.22 + 1x0.15 ; 6.3S/12.5S/18Z/3.5S
2. compact cord 27x0.22 + 1x0.15 25S/3.5Z
3. compact cord 12x0.25 + 1x0.15 12.5S/5Z
4. 7x4x0.175 + 11x0.15 10S/20Z/3.5S
Tensile test
[0034] The tensile strength is the breaking load of a filament per unit of unstrained cross-sectional
area expressed in Newtons per square millimetre. The elongation at rupture is the
increase in length, which results from subjecting the cord to the breaking force in
a tensile test and is expressed as a percentage of the initial length of the cord
measured under a defined pre-tension.
Compression test
[0035] To measure the compression performance of a cord, the cord is embedded in the center
of a rubber cylinder with a diameter of 30 mm and a height of 48.25 mm and submitted
to an axial compression force. A force versus deformation diagram is recorded. The
compression modulus is defined as the secant modulus at a specified axial stress and
can be derived from the diagram. The compression stress is obtained by the equation
where P
rubber = 0.4825 w
k V
r (N)
S
k = compression stress (N/mm²)
P
tot = total compressive load of the sample at deformation w
k (N)
V
r = rubber spring constant (N/mm)
S
eff = cross-sectional area of the cord without the wrapped steel filament (mm²)
w
k = deformation at instability or at maximum load sustained by the cord (%)
Impact test
[0036] A transverse impact test method for (steel) cord was developed to determine the resistance
to cutting with a view to their use as tire belt reinforcement (puncture resistance).
The test consists in a modified "charpy test" adapted with a sharp knife. The sample
is a rubber cylinder with a 3 mm diameter, reinforced in the center with a steel cord.
The total amount of absorbed energy is measured and is expressed in energy per unit
cross-sectional area (Joule/mm²).
[0037] A more complete description of these tests can be found in the paper of Bourgois
L., "Survey of Mechanical Properties of Steel Cord and related Test Methods", Tire
Reinforcement and Tire Performance, ASTM STP694, (R.A. Fleming and D.I. Livingstone,
Eds., American Society for Testing and Materials, 1979, pp.19-46.
[0038] The results obtained in each test for the cord according to the invention and the
four comparison cords are summarized in Table 1 :
[0039] As can be seen from Table 1 the tensile strength of the cord according to the invention
is lower than the tensile strength of existing steel cords 1 - 4 with substantially
round cross-sections but greater than the tensile strength of flat wires with substantially
rectangular cross-section, the tensile strength of flat steel wires lying usually
between 1800 N/mm² and 2400 N/mm².
[0040] The elongation at rupture of the cord according to the invention is equal or greater
than the elongation at rupture of steel cords 1 to 4.
[0041] The cord according to the invention has better compression performance than the steel
cords 1 to 4, as can be seen from the higher compression modulus and compression stress.
[0042] The cord according to the invention is compara
ble with the existing steel cords 1-4 regarding impact properties, in spite of a lower
tensile strength.
[0043] It is clear that the invention is not limited to specific examples as herein described
and illustrated, but extends to all structures and materials of steel cords in which
the teaching of the present invention is used.
1. A cord, with an elongated cross-section, adapted for the reinforcement of plies
in a pneumatic tire, comprising a layer of steel filaments that are wound around a
core, the core having a tensile strength of at least 1800 N/mm² and an elongation
at rupture of at least 2 per cent, characterized in that the core is an untwisted
monofilament which has an elongated cross-section and a breadth-to-thickness ratio
of at least 2.
2. A cord according to claim 1, characterized in that the core has a substantially
rectangular cross-section.
3. A cord according to claim 1 or 2, characterized by an elongation at rupture between
2.5 and 3.3 per cent.
4. A cord according to claim 1 to 3, characterized by a breadth-to-thickness ratio
between 4 and 10.
5. A cord according to claims 1 to 4, characterized in that the monofilament core
is made of steel.
6. A cord according to any of claims 1 to 5, characterized in that the filaments in
the layer around the core have a round cross-section.
7. A cord according to any of claims 1 to 5, characterized in that the filaments in
the layer around the core have a substantially rectangular cross-section with a breadth-to-thickness
ratio between 1.3 and 4.
8. A cord according to any of claims 1 to 7, characterized in that the layer of steel
filaments is surrounded by a second layer of steel filaments.
9. A cord according to any of claims 1 to 7, characterized in that a steel filament
is wrapped helicoidally around the layer (or outer layer when there is more than one
layer) of steel filaments with a pitch different from the pitch of the steel filaments
in the layer (or outer layer).
10. A cord according to claim 9, characterized in that the helicoid steel filament
that is wrapped around the layer (or outer layer) has a carbon content of less than
0.20 per cent by weight.