Metallic cord and pneumatic tire

Abstract

A steel cord is formed by compactly twisting steel filaments together, the steel filaments including a plurality of zigzag filaments and optionally a nonzigzag filament, the zigzag filament being zigzaged two-dimensionally and made up of straight segments each extending between the zigzag peak points, the nonzigzag filament being straight. In case the cord is composed of only the zigzag filaments, the zigzag filaments include at least two kinds of zigzag filaments having different zigzag pitch lengths. In case the cord is composed of both the zigzag filaments and nonzigzag filaments, some of the zigzag and nonzigzag filaments are first loosely twisted together into a bunch, and then a plurality of bunches are twisted together into the cord. In any case, the zigzag pitch length and zigzag wave height of each zigzag filament are substantially constant along the length thereof. A Tire comprises a reinforcing layer such as a tread reinforcing belt layer, carcass, bead reinforcing layer and the like made of the above-mentioned steel cords.

Description

[0002] The present invention relates to a metallic cord for reinforcing rubber articles such as pneumatic tires in which penetration of rubber into the cord is improved.

[0003] Many rubber articles such as pneumatic tires and the like are generally reinforced with steel cords.

[0004] As shown in FIG. 15, a conventional steel cord is formed by compactly twisting straight steel filaments together. This type of steel cords however have a defect such that closed space not filled with rubber is formed among the filaments and steel filaments are liable to rust and adhesion between the cords and rubber becomes insufficient. As a result, the cord strength greatly decreases and the cord is broken finally.

[0005] Recently, in order to improve the penetration of rubber into cords to solve the above-mentioned problems, there have been proposed a steel cord (b) in which straight filaments (f) are loosely twisted as shown in FIG. 16, and a steel cord (c) in which spiral filaments (f1) and straight filaments (f2) are twisted as shown in FIG. 17.

[0006] Such cords however, necessitate a relatively large cord diameter in order to secure stable rubber penetration. Further, such cords tend to show a large initial elongation. As a result, it is difficult to use the cords in order to reinforce a carcass and beads of pneumatic tires.

[0007] It is therefore, an object of the present invention to provide a steel cord in which the rubber penetration is improved without increasing the cord diameter and initial elongation.

[0008] According to the present invention, a steel cord is formed by compactly twisting steel filaments together, the steel filaments including a plurality of zigzag filaments and optionally a nonzigzag filament, the zigzag filament being zigzaged two-dimensionally and made up of straight segments each extending between the zigzag peak points, the nonzigzag filament being straight. In case the cord is composed of only the zigzag filaments, the zigzag filaments include at least two kinds of zigzag filaments having different zigzag pitch lengths. And at least two kinds of zigzag filaments are first loosely twisted together into a bunch, and then a plurality of bunches are twisted together into the cord. In case the cord is composed of both the zigzag filaments and nonzigzag filaments, some of the zigzag and nonzigzag filaments are first loosely twisted together into a bunch, and then a plurality of bunches are twisted together into the cord. In any case, the zigzag pitch length and zigzag wave height of each zigzag filament are substantially constant along the length thereof.

[0009] A tire comprises a reinforcing layer such as a tread reinforcing belt layer, carcass, bead reinforcing layer and the like made of the above-mentioned steel cords.

[0010] Embodiments of the present invention will now be described in detail in conjunction with the accompanying drawings.

[0011] FIG. 1(A) and FIG. 1(B) show zigzag filaments having different zigzag pitch lengths.

[0012] FIG. 2 is a schematic view for explaining a method of making a cord (Embodiment 1) according to the present invention.

[0013] FIG. 3(A) to FIG. 5(B) are cross sectional views each showing a combination of the number of filaments and the number of filament bunches in Embodiment 1.

[0014] FIG. 6(A) and FIG. 6(B) are cross sectional views each showing a cord (Embodiment 1) according to the present invention.

[0015] FIG. 7 is a graph showing a cord strength reduction and rubber penetration as a function of dXh/Pw value.

[0016] FIG. 8 is a schematic view for explaining a method of making a cord (Embodiment 2) according to the present invention.

[0017] FIG. 9(A) to FIG. 10(D) are cross sectional views each showing a cord (Embodiment 2) according to the present invention.

[0018] FIG. 11(A) and FIG. 11(B) are cross sectional views each showing a cord (Embodiment 3) according to the present invention.

[0019] FIG. 12 is a cross sectional view showing a cord (Embodiment 4) according to the present invention.

[0020] FIG. 13 is a cross sectional view showing a tire according to the present invention.

[0021] FIG. 14 is a diagram for explaining a coincidence of the zigzag phases of zigzag filaments.

[0022] FIG. 15 is a cross sectional view of a conventional compact cord.

[0023] FIG. 16 is a cross sectional view of an open cord.

[0024] FIG. 17 is a cross sectional view of a cord comprising spiral filaments.

[0025] In the drawings, steel cords 1 according to the present invention are each formed by compactly twisting steel filaments 2 together.

[0026] The steel filaments 2 include a plurality of zigzag filaments 2A and optionally a nonzigzag filament 2B.

[0027] The zigzag filament 2A is, before twisted, zigzaged two-dimensionally or in a plane, and it is made up of straight segments 3 each extending between the zigzag peak points U and D (peak U, dip D) as shown in FIG. 1(A) and FIG. 1(B). The distance between the zigzag peak points (D and D) or (U and U) measured in the longitudinal direction of the filament defines a zigzag pitch length Pw. The distance between the adjacent peak points U and D measured normally to the longitudinal direction of the filament defines a zigzag wave height h.

[0028] On the other hand, the nonzigzag filament 2B is straight before twisted.

[0029] Preferably, the steel filaments 2 is made of a high carbon steel including 0.65 to 0.88 wt % of carbon. And the steel filaments are plated with a metal or coated with resin to improve the corrosion resistance and adhesion to rubber. If the carbon content is less than 0.65 wt %, the strength of the filament becomes insufficient. If the carbon content is more than 0.88 wt %, the strength of the filament is greatly decreased when bent zigzag.

[0030] When the cord 1 is composed of only the zigzag filaments 2A, the zigzag filaments 2A should include at least two kinds of zigzag filaments 2A1-2An having different zigzag pitch lengths Pw in order to avoid the coincidence of the zigzag phases as shown in FIG. 14 which lowers the rubber penetration.

[0031] When the cord 1 is composed of both the zigzag filaments 2A and nonzigzag filaments 2B, some of the zigzag and nonzigzag filaments are first loosely twisted together into a bunch, and then a plurality of bunches are twisted together (last-twist) into the cord, whereby concentration of a cord load on the nonzigzag filaments 2B can be mitigated. Further, it becomes possible to form spaces between the filaments between the bunches and to avoid the coincidence of the zigzag phases, which further improve the rubber penetration. During last-twisting, it is preferable to twist every bunch itself. (hereinafter, bunch-twist)

[0032] In any case, the zigzag pitch lengths Pw and zigzag wave height h of each zigzag filament 2A are substantially constant along the length thereof. If a zigzag filament has a variable zigzag pitch and a variable zigzag wave height, the strength of the cord has a tendency to decrease.

* Cord Embodiment 1

[0033] This embodiment is designed for a belt reinforcing a tread portion of a pneumatic radial tire, which can be suitably used as a substitute for a conventional steel cord of a 3+9+15 construction widely used in heavy duty radial tires for trucks, buses and the like.

[0034] The cord 1 in this embodiment is composed of 8 to 10 zigzag filaments 2A having a diameter d of from 0.30 to 0.45 mm.

[0035] The zigzag filaments 2A include at least two kinds of zigzag filaments 2A1-2An having different zigzag pitch lengths Pw1-Pwn.

[0036] As shown in FIG. 2, the cord 1 is formed by twisting bunches 4 of filaments 2A together at a twist pitch Pc of 10 to 40 mm (last twist).

[0037] Each bunch 4 is formed by twisting together two or three zigzag filaments 2A including at least two kinds of zigzag filaments 2A1 and 2An at a twist pitch Pf of 3 to 20 times the pitch Pc of the last twist.

[0038] In each zigzag filament 2A, the filament diameter d, zigzag pitch lengths Pw and zigzag wave height h are set to satisfy the following conditions: Pw is 5.0 to 30.0 times d; h is 0.2 to 3.0 times d; and d×h/Pw is 0.014 to 0.028 preferably 0.020 to 0.025.

[0039] FIG. 3(A) to FIG. 5(B) show preferable combinations of the number of bunches 4 and the number of filaments 2A.

[0040] In FIG. 3(A), the cord is composed of four bunches 4A of one zigzag filament 2A1 and one zigzag filament 2An.

[0041] In FIG. 3(B), the cord is composed of two bunches 4B of one zigzag filament 2A1 and two zigzag filaments 2An and one bunch 4A of one zigzag filament 2A1 and one zigzag filament 2An.

[0042] In FIG. 4(A), the cord is composed of one bunch 4B of one zigzag filament 2A1 and two zigzag filaments 2An and three bunches 4A of one zigzag filament 2A1 and one zigzag filament 2An.

[0043] In FIG. 4(B), the cord is composed of three bunches 4B of one zigzag filament 2A1 and two zigzag filaments 2An.

[0044] In FIG. 5(A), the cord is composed of five bunches 4A of one zigzag filament 2A1 and one zigzag filament 2An.

[0045] In FIG. 5(B), the cord is composed of two bunches 4B of one zigzag filament 2A1 and two zigzag filaments 2An and two bunches 4A of one zigzag filament 2A1 and one zigzag filament 2An.

[0046] Further, FIG. 6(A) shows a cross sectional view of a cord composed of six zigzag filament 2A1 and three zigzag filaments 2An.

[0047] FIG. 6(B) shows a cross sectional view of a cord composed of five zigzag filament 2A1 and three zigzag filaments 2An.

[0048] In the above-mentioned examples shown in FIG. 3(A) to FIG. 5(B), the type (B) is more preferable than the type (A) because two or more bunches 4B of three filaments are included therein.

[0049] In the illustrated examples, the direction of twisting the filaments is the same as the direction of twisting the bunches. However, it is also possible to twist in the reverse direction. Further, all the filaments 2A are the same diameter d, but, they may have two or more different diameters. With respect to the zigzag pitch length Pw and zigzag wave height h, the zigzag filament 2An is larger than the zigzag filaments 2A1.

[0050] If the diameter d is less than 0.30 mm, it becomes difficult to obtain a rigidity required for a belt layer of the heavy duty tires, and the zigzag shape is apt to return to a straight shape during twisting, and the rubber penetration decreases. If the diameter d is more than 0.45 mm, the strength of the filament tends to decrease when shaped into a zigzag, and a suppleness required during making tires is lost.

[0051] If the twist pitch Pf is less than 3 times the last twist pitch Pc, the spaces formed between the filaments becomes narrow and the rubber penetration decreases. If the twist pitch Pf is more than 20 times the last twist pitch Pc, the zigzag phases are liable to coincide with each other and the rubber penetration decreases.

[0052] It is not necessary for improving the rubber penetration to shorten the twist pitch, and a relatively long pitch 10 to 40 mm can be employed. Thus, the production efficiency of the cord can be improved.

[0053] If the zigzag pitch length Pw is less than 5.0 times the diameter d, the strength of the filament tends to decrease when shaped into a zigzag. If more than 30 times, the rubber penetration decreases.

[0054] If the zigzag wave height h is less than 0.2 times the diameter d, it becomes difficult to increase the rubber penetration. If more than 3.0 times, the strength of the filament tends to decrease when shaped into a zigzag.

[0055] FIG. 7 shows the cord strength reduction (%) and rubber penetration (%) as a function of the dXh/Pw value. As can be seen therefrom, by setting dXh/Pw in the range of 0.014 to 0.028 more preferably 0.020 to 0.025, both the rubber penetration and cord strength are improved.

* Comparison Tests

[0056] Various experimental steel cords were made, and test tires having a belt layer made of the experimental cords were also made, and the following comparison tests were conducted. The results of the tests are shown in Table 1.

* Cord Strength Reduction

[0057] In this test, a reduction (%) in the strength of an object cord (Ex.) from a conventional compact cord (Ref.) was obtained, wherein the object cord and the compact cord were the same with respect to the material, number of filaments and last-twist pitch, but the compact cord is composed of nonzigzag filaments only.

* Bending Rigidity

[0058] The bending rigidity of each cord was measured with a TABER “V-5 Rigidity Tester” (USA).

* Rubber Penetration

[0059] The cord was took out from the tire together with the surrounding topping rubber, and the topping rubber was carefully removed from the surface of the cord. Then, adjacent two filaments were took out therefrom along 10 cm long using a knife, and the length of a part surrounded by the two took-out filaments and the remaining filaments into which the rubber completely penetrated was measured to obtain the percentage of this length to the total length of 10 cm as the rubber penetration %.

* Rust and Reserved Strength

[0060] The tire was disassembled after running about 200,000 km, and the steel cords were checked for rust. The results are indicated by an index based on the conventional cord being 100. The smaller the index, the smaller the rust.

[0061] Further, the steel cords were took out and the cord strength was measured. The results are indicated in percentage to the original strength.

TABLE 1
	Ref.	Ref.	Ref.	Ref.	Ref.	Ref.	Ref.	Ref.
	A1	A2	A3	A4	A5	A6	A7	A8
Filament diameter (mm)	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38
Number of filaments	9	9	9	9	9	9	9	9
Zigzag filament	0	5	0	9	9	9	9	9
Straight filament	9	4	0	0	0	0	0	0
Spiral filament	0	0	9	0	0	0	0	0
Wave height h (mm)	—	0.28	0.45	0.4	0.50/0.40	0.35/0.28	0.35/0.28	0.35/0.30
Wave pitch Pw (mm)	—	5	5	5	6.30/5.00	6.30/5.00	6.30/5.00	1.50/1.30
dXh/Pw	—	0.021	0.034	0.03	0.030/0.030	0.021/0.021	0.021/0.021	0.089/0.088
Number of respective	—	5	9	9	3/6	3/6	3/6	3/6
filaments
Structure*1		(5.0*2 + 0*1)*2 +	—	—	(6.3*1 +	(6.3*1 +	(6.3*1 +	(1.5*1 +
		(5.0*1 + 0*2)*1			5.0*1)*3	5.0*2)*3	1.3*2)*3	1.3*2)*3
Last twist pitch (mm)	18	18	18	18	18	8	50	18
Bunch Twist	yes	yes	yes	yes	yes	yes	yes	yes
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82
Cord characteristics
Diameter (mm)	1.4	1.42	1.53	1.43	1.45	1.46	1.42	1.44
Strength (N/sq.mm)	3013	2630	2980	2561	2570	2953	2970	2420
Strength reduction (%)	0	12.7	2.3	15	14.7	2	1.4	19.7
Elongation @ 50 N (%)	0.052	0.057	0.293	0.057	0.059	0.132	0.049	0.173
Cord bending rigidity	260	257	249	254	252	256	256	256
(N cm)
Tire performance
Rubber penetration (%)	0	69	83	72	90	95	89	95
Rust (index)	100	49	32	43	12	10	25	10
Reserved strength (%)	86	91	92	93	98	98	94	98
	Ref.	Ref.	Ref.	Ex.	Ex.	Ex.	Ex.	Ex.
	A9	A10	A11	A1	A2	A3	A4	A5
Filament diameter (mm)	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38
Number of filaments	9	9	9	9	9	9	9	9
Zigzag filament	9	9	9	9	9	9	9	9
Straight filament	0	0	0	0	0	0	0	0
Spiral filament	0	0	0	0	0	0	0	0
Wave height h (mm)	0.35/0.30	0.06/0.05	1.40/1.20	0.35/0.28	0.35/0.28	0.35/0.28	0.35/0.28	0.35/0.28
Wave pitch Pw (mm)	13.0/12.0	6.30/5.00	6.30/5.40	6.30/5.00	6.30/5.00	6.30/5.00	6.30/5.00	6.30/5.00
dXh/Pw	0.010/0.010	0.004/0.004	0.084/0.084	0.021/0.021	0.021/0.021	0.021/0.021	0.021/0.021	0.021/0.021
Number of respective	3/6	3/6	3/6	3/6	3/6	3/6	3/6	3/6
filaments
Structure*1	(13.0*1 +	(6.3*1 +	(6.3*1 +	(6.3*1 +	(6.3*1 +	(6.3*1 +	(6.3*1 +	(6.3*1 +
	12.0*2)*3	5.0*2)*3	5.4*2)*3	5.0*2)*3	5.0*2)*3	5.0*2)*3	5.0*2)*3	5.0*2)*3
Last twist pitch (mm)	18	18	18	18	35	12	18	18
Bunch Twist	yes	yes	yes	yes	yes	yes	yes	yes
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.65	0.88
Cord characteristics
Diameter (mm)	1.43	1.41	1.44	1.43	1.41	1.45	1.43	1.43
Strength (N/sq.mm)	2965	2970	2530	2953	2967	2938	2658	3148
Strength reduction (%)	1.6	1.4	16	2	1.5	2.4	1.3	2.4
Elongation @ 50 N (%)	0.054	0.053	0.199	0.057	0.054	0.071	0.057	0.055
Cord bending rigidity	256	256	256	256	258	242	255	256
(N cm)
Tire performance
Rubber penetration (%)	55	43	95	95	93	96	95	95
Rust (index)	54	62	10	10	16	9	10	11
Reserved strength (%)	89	88	98	98	97	98	99	99
	Ex.	Ex.	Ref.	Ref.	Ref.	Ex.	Ref.	Ex.
	A6	A7	A12	A13	A14	A8	A15	A9
Filament diameter (mm)	0.38	0.38	0.25	0.50	0.30	0.30	0.45	0.45
Number of filaments	9	9	9	9	9	9	9	9
Zigzag filament	9	9	9	9	0	9	0	9
Straight filament	0	0	0	0	9	0	9	0
Spiral filament	0	0	0	0	0	0	0	0
Wave height h (mm)	0.42/0.35	0.60/0.51	0.35/0.28	0.35/0.28	—	0.37/0.24	—	0.37/0.29
Wave pitch Pw (mm)	8.00/6.30	11.00/9.60	6.30/5.00	6.30/5.00	—	5.00/3.30	—	8.00/6.30
dXh/Pw	0.020/0.021	0.021/0.020	0.021/0.021	0.021/0.021	—	0.022/0.022	—	0.021/0.021
Number of respective	3/6	3/6	3/6	3/6	—	3/6	—	3/6
filaments
Structure*1	(8.0*1 +	(11.0*1 +	(6.3*1 +	(6.3*1 +	—	(5.0*1 +	—	(8.0*1 +
	6.3*2)*3	9.6*2)*3	5.0*2)*2	5.0*2)*2		3.3*2)*3		6.3*2)*3
Last twist pitch (mm)	18	18	18	18	18	18	18	18
Bunch Twist	yes	yes	yes	yes	yes	yes	yes	yes
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82
Cord characteristics
Diameter (mm)	1.45	1.43	0.94	1.88	1.1	1.12	1.68	1.7
Strength (N/sq.mm)	2968	2972	2993	2552	3032	2975	2972	2772
Strength reduction (%)	1.5	1.4	1.8	14.3	0	2.2	0	6.7
Elongation @ 50 N (%)	0.059	0.064	0.057	0.038	0.078	0.081	0.041	0.044
Cord bending rigidity	252	256	47	749	101	98	500	496
(N cm)
Tire performance
Rubber penetration (%)	93	95	83	95	0	94	0	95
Rust (index)	14	11	34	10	100	13	100	11
Reserved strength (%)	98	99	91	98	86	97	86	97
	Ref.	Ex.	Ref.	Ex.	Ex.	Ex.
	A16	A10	A17	A11	A12	A13
Filament diameter (mm)	0.38	0.38	0.38	0.38	0.38	0.30
Number of filaments	8	8	10	10	9	9
Zigzag filament	0	8	0	10	9	9
Straight filament	8	0	10	0	0	0
Spiral filament	0	0	0	0	0	0
Wave height h (mm)	—	0.35/0.28	—	0.35/0.28	0.35/0.28	0.37/0.24
Wave pitch Pw (mm)	—	6.30/5.00	—	6.30/5.00	6.30/5.00	5.00/3.30
dXh/Pw	—	0.021/0.021	—	0.021/0.021	0.021/0.021	0.022/0.022
Number of respective	—	3/5	—	4/6	3/6	3/6
filaments
Structure*1	—	(6.3*1 +	—	(6.3*1 +	(6.3*1 +	(5.0*1 +
		5.0*2)*2		5.0*2)*2	5.0*2)*3	3.3*2)*3
		(6.3*1 +		(6.3*1 +
		5.0*1)*1		5.0*1)*2
Last twist pitch (mm)	18	18	18	18	18	18
Bunch Twist	yes	yes	yes	yes	no	no
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82
Cord characteristics
Diameter (mm)	1.31	1.33	1.53	1.59	1.48	1.17
Strength (N/sq.mm)	3013	2943	3013	2953	2926	2941
Strength reduction (%)	0	2.3	0	2	2.9	3
Elongation @ 50 N (%)	0.057	0.06	0.05	0.055	0.069	0.089
Cord bending rigidity	229	225	285	281	232	96
(N cm)
Tire performance
Rubber penetration (%)	0	95	0	96	92	91
Rust (index)	100	9	100	10	16	17
Reserved strength (%)	86	97	86	97	96	96

[0062] *1) For example, (5.0*2+0*1)*2+(5.0*1+0*2)*1 means two bunches of two zigzag filaments whose Pw=5.0 and one straight filament (Pw=0) and one bunch of one zigzag filament whose Pw=5.0 and two straight filaments (Pw=0). (6.3*1+5.0*1)*3 means three bunches of one zigzag filament whose Pw=6.3 and one zigzag filament whose Pw=5.0.

[0063] All the cords had a twist pitch Pf of 10 times the last twist pitch Pc. The direction of twisting filaments into a bunch was the same as the last twist. Ref.A1, A14, A15, A16 A17 were conventional cords composed of compactly twisted straight filaments. Ref.A3 was composed of only spiral filaments. Ref.A4 was composed of one kind of zigzag filaments twisted together without forming any bunch.

* Cord Embodiment 2

[0064] This embodiment is again designed for a belt reinforcing a tread portion of a pneumatic radial tire, which can be suitably used as a substitute for a conventional steel cord of a 3+6 or 2+7 construction widely used in heavy duty radial tires for trucks, buses and the like.

[0065] The cord in this embodiment is composed of a number (n) of steel filaments 2 having a diameter d of 0.25 to 0.45 mm, wherein the number n is 5 or 6.

[0066] The steel filaments 2 include at least two but at most (n−3) of zigzag filaments 2A and the remaining two or three nonzigzag filaments 2B.

[0067] All the zigzag filaments 2A are the substantially same zigzag pitch length Pw and same zigzag wave height h.

[0068] Further, in the illustrated examples, all the steel filaments are the same diameter d.

[0069] When a steel filament having a relatively large diameter such as this embodiment is shaped into a zigzag, the strength of the filament tends to decrease. Thus, in this embodiment, in order to provide a strong cord, some of the zigzag filaments are replaced by straight filaments.

[0070] The cord 1 is formed by twisting together:

[0071] (A) a plurality of bunches 4 of filaments or

[0072] (B) a nonzigzag filaments 2B and a plurality of bunches 4 of filaments as shown in FIG. 8.

[0073] In either case (A) or (B), each bunches 4 is formed by twisting together one zigzag filament 2A and one or two nonzigzag filaments 2B at a twisting pitch Pf of 3 to 20 times the last-twisting pitch Pc. The last-twisting pitch Pc is in the range of from 10 to 25 mm. The direction of twisting the filaments into a bunch is the same as the last-twisting direction, but it may be reversed.

[0074] In this embodiment, also the diameter d, zigzag pitch lengths Pw and zigzag wave height h in each zigzag filament 2A satisfy the following conditions: Pw is 5.0 to 30.0 times d, preferably 10.0 to 25.0 times d; h is 0.2 to 3.0 times d, preferably 0.5 to 2.0 times d; and dXh/Pw is 0.014 to 0.028, preferably 0.020 to 0.025.

[0075] FIG. 9(A) shows a cord formed by last-twisting one nonzigzag filament 2B and two bunches 4C of one zigzag filament 2A and one nonzigzag filament 2B.

[0076] FIG. 9(B) shows a cord formed by last twisting one bunch 4C of one zigzag filament 2A and one nonzigzag filament 2B and one bunch 4D of one zigzag filament 2A and two nonzigzag filaments 2B.

[0077] FIG. 10(A) shows a cord formed by last twisting three bunches 4C.

[0078] FIG. 10(B) shows a cord formed by last twisting two bunches 4D.

[0079] FIG. 10(C) shows a cord formed by last twisting two bunches 4C and two nonzigzag filaments 2B.

[0080] FIG. 10(D) shows a cord formed by last twisting one bunch 4C, one bunch 4D and one nonzigzag filament 2B.

[0081] In each of the example cords, all the filaments are the same diameter, but may have two or more different diameters.

[0082] If the diameter d is less than 0.25 mm, it becomes difficult to obtain a rigidity required for a belt layer of the heavy duty tires, and the zigzag shape is apt to return to a straight shape during twisting, and the rubber penetration decreases. If the diameter d is more than 0.45 mm, the strength of the filament tends to decrease when shaped into a zigzag, and a suppleness required during making tires is lost.

[0083] If the twist pitch Pf is less than 3 times the last twist pitch Pc, the spaces formed between the filaments becomes narrow and the rubber penetration decreases. If the twist pitch Pf is more than 20 times the last twist pitch Pc, the zigzag phases are liable to coincide with each other and the rubber penetration decreases.

[0084] It is not necessary for improving the rubber penetration to shorten the twist pitch, and a relatively long pitch 10 to 25 mm can be employed. Thus, the production efficiency of the cord can be improved.

[0085] If the zigzag pitch length Pw is less than 5.0 times the diameter d, the strength of the filament tends to decrease when shaped into a zigzag. If more than 30 times, the rubber penetration decreases.

[0086] If the zigzag wave height h is less than 0.2 times the diameter d, it becomes difficult to increase the rubber penetration. If more than 3.0 times, the strength of the filament tends to decrease when shaped into a zigzag.

* Comparison Tests

[0087] Various experimental steel cords were made, and test tires having a belt layer made of the experimental cords were also made, and the following comparison tests were conducted. The results of the tests are shown in Table 2.

* Cord Strength Reduction Test

[0088] Same as above

* Bending Rigidity Test

[0089] Same as above

* Rubber Penetration Test

[0090] Same as above

* Rust and Reserved Strength Test

[0091] Same as above

TABLE 2
	Ref.	Ref	Ref.	Ref.	Ref.	Ref.	Ex.	Ex.	Ex.	Ex.	Ex.	Ex.	Ex.	Ex.	Ex.	Ref.	Ref.	Ref.	Ref.	Ex.
	B1	B2	B3	B4	B5	B6	B1	B2	B3	B4	B5	B6	B7	B8	B9	B7	B8	B9	B10	B10
Filament diameter (mm)	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.38	0.25	0.25
Number of filaments	5	5	5	5	5	5	5	5	5	5	5	5	5	5	5	5	5	5	5	5
Zigzag filament	0	0	0	1	2	2	2	2	2	2	2	2	2	2	2	2	2	2	0	2
Straight filament	5	3	5	4	3	3	3	3	3	3	3	3	3	3	3	3	3	3	5	3
Spiral filament	0	2	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0
Wave height h (mm)	—	0.25	—	0.25	0.4	0.25/0.34	0.25	0.25	0.25	0.25	0.41	0.5	0.25	0.35	0.19	0.05	1.5	0.85	—	0.26
Wave pitch Pw (mm)	—	5	—	5	5	5.00/6.30	5	5	5	5	8	9.6	5	5	5	0.95	28	16	—	3.3
dXh/Pw	—	0.019	—	0.019	0.03	0.019/0.019	0.019	0.019	0.019	0.019	0.02	0.02	0.02	0.027	0.014	0.02	0.02	0.02	—	0.02
Last twist pitch (mm)	18	18	18	18	18	18	18	18	15	25	18	18	18	18	18	18	18	18	18	18
Bunch Twist	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.65	0.82	0.82	0.82	0.82	0.88	0.82	0.82	0.82	0.82	0.82	0.82	0.82
Cord characteristics
Diameter (mm)	1.13	1.25	1.32	1.14	1.17	1.15	1.15	1.15	1.18	1.14	1.18	1.21	1.15	1.16	1.14	1.21	1.15	1.14	0.76	0.78
Strength (N/sq.mm)	3015	2973	2954	2984	2563	2683	2946	2651	2887	3004	3005	2966	3241	2849	2999	2966	2983	2999	3045	2899
Strength reduction (%)	0	1.4	2	1	15	11	2.3	1.8	4.2	0.4	0.3	1.6	2.7	5.6	0.5	0.5	8.7	6.5	0	4.8
Elongation @ 50 N (%)	0.065	0.132	0.283	0.073	0.123	0.091	0.094	0.095	0.101	0.09	0.121	0.131	0.094	0.103	0.087	0.131	0.094	0.087	0.113	0.128
Bending rigidity (N cm)	151	143	137	149	141	143	145	146	142	149	143	142	147	140	148	142	147	148	28	27
Tire performance
Rubber penetration (%)	0	87	94	75	85	98	98	98	99	97	98	98 99	94	90	45	56	67	0	93
Rust (index)	100	21	13	37	25	6	5	6	2	10	6	6	2	12	16	43	37	31	100	12
Reserved strenght (%)	88	94	96	93	93	97	98	97	99	97	97	97	99	97	94	91	93	96	87	97
	Ex. B11	Ref. B11	Ex. B12	Ex. B13	Ref. B12	Ref. B13	Ref. B14	Ex. B14	Ex. B15	Ref. B15	Ex. B16	Ref. B16	Ex. B17	Ex. B18	Ex. B19
Filament diameter (mm)	0.25	0.45	0.45	0.45	0.17	0.5	0.32	0.32	0.32	0.25	0.25	0.45	0.45	0.38	0.32
Number of filaments	5	5	5	5	5	5	6	6	6	6	6	6	6	6	6
Zigzag filament	2	0	2	2	2	2	0	2	3	0	2	0	2	2	2
Straight filament	3	5	3	3	3	3	6	4	3	6	4	6	4	4	4
Spiral filament	0	0	0	0	0	0	0	0	0	0	0	0	0	0	0
Wave height h (mm)	0.52	—	0.24	0.57	0.39	0.2	—	0.35	0.35	—	0.32	—	0.38	0.25	0.35
Wave pitch Pw (mm)	6.3	—	5	12.8	3.3	5	—	5	5	—	5	—	8	5	5
dXh/Pw	0.021	—	0.022	0.02	0.02	0.02	—	0.022	0.022	—	0.021	—	0.021	0.019	0.022
Last twist pitch (mm)	18	25	25	25	18	25	18	18	18	18	18	25	25	18	18
Bunch Twist	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	yes	no	no
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82
Cord characteristics
Diameter (mm)	0.8	1.36	1.38	1.42	0.53	1.51	0.97	1	1.08	0.78	0.81	1.41	1.43	1.2	1.1
Strength (N/sq.mm)	2999	2969	2903	2932	2780	2630	3038	2971	2942	3043	2896	2972	2831	2878	2913
Strength reduction (%)	1.5	0	2.2	1.2	8.7	10.2	0	2.2	3.2	0	4.8	0	4.7	4.5	4.1
Elongation @ 50 N (%)	0.136	0.059	0.071	0.089	0.132	0.065	0.075	0.098	0.119	0.107	0.125	0.056	0.072	0.125	0.137
Bending rigidity (N cm)	25	277	275	272	6	418	91	89	85	33	31	334	332	141	82
Tire performance
Rubber penetration (%)	94	0	99	95	82	89	0	99	98	0	98	0	97	93	92
Rust (index)	15	100	6	11	25	17	100	3	6	100	7	100	12	14	15
Reserved strenght (%)	96	89	99	97	92	91	88	98	98	87	98	89	96	95	94

[0092] Ex.B1 to Ex.B9 had a cord structure shown in FIG. 9(A). Ex.B14 to 17 had a cord construction shown in FIG. 10(B).

[0093] The direction of twisting filaments into a bunch was the same as the last twist. (S direction) The twist pitch Pf was 10 times the last twist pitch Pc.

[0094] Ref.B1, B10, B11, B14, B15 and B16 were conventional comapct cords composed of straight filaments. Ref.B3 was an open cord composed of loosely twisted nonzigzag filaments. Ref.B6 had two kinds of zigzag filaments.

* Cord Embodiment 3

[0095] This embodiment is designed as a carcass cord for reinforcing a carcass of a pneumatic radial tire, which can be suitably used as a substitute for a conventional steel cord of a 3+9 or 3+9+15 construction widely used in heavy duty radial tires for trucks, buses and the like.

[0096] The cord 1 in this embodiment is composed of 8 to 12 zigzag filaments 2A. All the filaments are the same diameter d of 0.15 to 0.30 mm.

[0097] The zigzag filaments 2A include at least two kinds of zigzag filaments 2A1-2An having different zigzag pitch lengths Pw1-Pwn. The number (n) of the kinds is preferably two. The number of zigzag filaments in each kind is at least two, preferably at least three.

[0098] The cord 1 is formed by twisting all the zigzag filaments 2A together at a twist pitch of 10 to 25 mm (last twist). During twisting the zigzag filaments 2A, the relative positions thereof are changed repeatedly along the length so that a central filament (core filament) is not formed by a specific filament, and all the zigzag filaments 2A are the substantially same length when measured along the zigzag of each filament. More specifically, the “changing of the relative positions” means that any one of the filaments may be positioned in the center of the cord in a place but in another place positioned on the outside. For example, two of the filaments are interlaced at predetermined intervals along the cord length, wherein the two interlaced filaments are changed or replaced in a predetermined regular or irregular order. As the zigzag filaments 2A are interlaced, a problem of loosening of the filaments can be solved.

[0099] If there is a large difference in the filament lengths, some filaments tends to break out during rubberizing the cords.

[0100] In each zigzag filament 2A, the filament diameter d, zigzag pitch lengths Pw and zigzag wave height h are set to satisfy the following conditions: Pw is 10.0 to 35.0 times, preferably 15.0 to 30.0 times d; and h is 0.5 to 4.0 times, preferably 1.0 to 3.0 times d.

[0101] Further, a zigzag filament 2A1 having a minimum zigzag pitch Pw1 and the remaining zigzag filament 2An having a larger zigzag pitch Pwn satisfy the following condition: hn/Pwn is 0.75 to 1.25 times h1/Pw1, wherein: h1 is the zigzag wave height of the zigzag filament 2A1; and hn is the zigzag wave height of the zigzag filament 2An. However, if there are plural zigzag filaments having the same minimum zigzag pitch lengths Pw1 but different heights, the minimum height is used as h1.

[0102] FIG. 11(A) shows a cord composed of six zigzag filaments 2A1 having a small zigzag pitch Pw1 and three zigzag filaments 2An having a larger zigzag pitch Pwn, which are twisted together by changing the relative positions.

[0103] FIG. 22(B) shows a cord composed of five zigzag filaments 2A1 having a small zigzag pitch Pw1 and three zigzag filaments 2An having a larger zigzag pitch Pwn, which are twisted together by changing the relative positions.

[0104] If the diameter d is less than 0.15 mm, the zigzag shape is apt to return to a straight shape during twisting, and the rubber penetration decreases. If the diameter d is more than 0.30 mm, it is difficult to provide a suppleness required in a tire carcass, and the fatigue resistance of the cord is lowered.

[0105] If the twist pitch is less than 10 mm, the initial elongation of the cord is too large for the carcass of a pneumatic tire, and thus it becomes difficult to keep a stable tire shape. If the twist pitch is more than 25 mm, the filaments are liable to loosen at cut ends, and thus tire durability is liable to decrease.

[0106] If the zigzag pitch length Pw is less than 10.0 times the diameter d, the strength of the filament tends to decrease when shaped into a zigzag. If more than 35.0 times, the rubber penetration decreases.

[0107] If the zigzag wave height h is less than 0.5 times the diameter d, it becomes difficult to increase the rubber penetration. If more than 4.0 times, the strength of the filament tends to decrease when shaped into a zigzag.

[0108] If hn/Pwn is less than 0.75 times h1/Pw1 or more than 1.25 times h1/Pw1, it becomes difficult to equalize the filament lengths, and thus the cord load is liable to concentrate on a particular filament, and as a result the cord strength is liable to decrease.

* Comparison Tests

[0109] Various experimental steel cords were made, and test tires having a carcass made of the experimental cords were also made, and the following comparison tests were conducted. The results of the tests are shown in Table 3.

* Cord Strength Reduction Test

[0110] Same as above

* Bending Rigidity Test

[0111] Same as above

* Rubber Penetration Test

[0112] Same as above

* Rust and Reserved Strength Test

[0113] Same as above

* Filament Breaking-Out

[0114] During rubberizing a carcass ply for a heavy duty tire, the cords were investigated if the filaments broke out from the cord.

[0115] Cord-cut-end looseness

[0116] In this test, the degree of looseness at cut ends of the cord was evaluated.

TABLE 3
	Ref. C1	Ref. C2	Ref. C3	Ref. C4	Ref. C5	Ref. C6	Ref. C7	Ref. C8
Filament diameter (mm)	0.20	0.20	0.20	0.20	0.20	0.20	0.20	0.20
Number of filaments	9	9	9	9	9	9	9	9
Zigzag filament	0	5	0	9	9	9	9	9
Straight filament	9	4	0	0	0	0	0	0
Spiral filament	0	0	9	0	0	0	0	0
Wave height h (mm)	—	0.45	0.65	0.45	0.45/0.45	0.45/0.30	0.45/0.30	0.08/0.05
Wave pitch Pw (mm)	—	5.00	5.00	5.00	5.00/3.00	1.80/1.20	12.0/8.0	5.00/3.30
h/PwX100	—	9.0	13.0	9.0	9.0/15.0	25.0/25.0	3.8/3.8	1.6/1.5
Number of respective filaments	—	5	9	9	3/6	3/6	3/6	3/6
filament length (cm/100 cm cord)	105.0	106.7	109.3	106.7	106.7/109.7	117.4/117.4	105.3/105.3	105.1/105.0
Last twist pitch (mm)	17.0	17.0	17.0	17.0	17.0	17.0	17.0	17.0
Filament twist	yes	yes	yes	yes	yes	yes	yes	yes
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82
Cord characteristics
Diameter (mm)	0.71	0.73	0.85	0.78	0.77	0.75	0.75	0.75
Strength (N/sq.mm)	3052	2750	2785	3015	2880	2723	3018	3027
Strength reduction (%)	0.0	9.9	8.7	1.2	5.6	10.8	1.1	0.8
Elongation @ 50 N (%)	0.107	0.112	0.265	0.118	0.125	0.153	0.127	0.118
Bending rigidity (N · cm)	22	22	20	21	22	22	22	22
Tire performance
Rubber penetration (%)	0	76	73	75	95	91	64	53
Rust (index)	100	45	47	46	10	20	57	68
Reserved strength (%)	88	94	92	96	99	97	91	90
Breaking-out	none	some	none	none	few	none	none	none
Cut-end loose	none	none	none	none	none	none	none	none
	Ref. C9	Ex. C1	Ref. C10	Ref. C11	Ex. C2	Ex. C3	Ex. C4	Ex. C5
Filament diameter (mm)	0.20	0.20	0.20	0.20	0.20	0.20	0.20	0.20
Number of filaments	9	9	9	9	9	9	9	9
Zigzag filament	9	9	9	9	9	9	9	9
Straight filament	0	0	0	0	0	0	0	0
Spiral filament	0	0	0	0	0	0	0	0
Wave height h (mm)	1.40/1.00	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30
Wave pitch Pw (mm)	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30
h/PwX100	28.0/30.3	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1
Number of respective filaments	3/6	3/6	3/6	3/6	3/6	3/6	3/6	3/6
filament length (cm/100 cm cord)	120.3/122.8	106.7/106.7	105.6/105.6	107.8/107.8	106.7/106.7	107.2/107.2	105.6/105.6	106.7/106.7
Last twist pitch (mm)	17.0	17.0	28.0	8.0	23.0	10.0	17.0	17.0
Filament twist	yes	yes	yes	yes	yes	yes	yes	yes
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.65	0.88
Cord characteristics
Diameter (mm)	0.75	0.75	0.75	0.77	0.75	0.77	0.75	0.76
Strength (N/sq.mm)	2675	3010	3026	2890	3020	2975	2900	3250
Strength reduction (%)	12.3	1.4	0.9	5.3	1.0	2.5	1.2	1.7
Elongation @ 50 N (%)	0.232	0.122	0.118	0.215	0.121	0.157	0.132	0.137
Bending rigidity (N · cm)	22	22	23	20	23	20	22	22
Tire performance
Rubber penetration (%)	90	95	92	96	92	96	95	95
Rust (index)	23	11	14	8	14	8	10	10
Reserved strength (%)	97	98	98	99	98	99	98	99
Breaking-out	none	none	none	none	none	none	none	none
Cut-end loose	none	none	some	none	few	none	none	none
	Ex. C6	Ex. C7	Ex. C8	Ref. C12	Ref. C13	Ref. C14	Ex. C9	Ref. C15
Filament diameter (mm)	0.20	0.20	0.20	0.125	0.35	0.15	0.15	0.30
Number of filaments	9	9	9	9	9	9	9	9
Zigzag filament	9	9	9	9	9	0	9	0
Straight filament	0	0	0	0	0	9	0	9
Spiral filament	0	0	0	0	0	0	0	0
Wave height h (mm)	0.60/0.48	0.45/0.30	0.55/0.41/	0.55/0.37	0.41/0.29	—	0.45/0.32	—
			0.29
Wave pitch Pw (mm)	6.30/5.00	5.00/3.30	6.30/4.70/	4.70/3.30	4.70/3.30	—	4.70/3.30	—
			3.30
h/PwX100	9.5/9.6	9.0/9.1	8.7/8.7/8.8	11.7/11.2	8.7/8.8	—	9.6/9.7	—
Number of respective filaments	3/6	6/3	3/3/3	3/6	3/6	—	3/6	—
filament length (cm/100 cm cord)	106.7/	106.7/	106.4/	108.0/	106.7/	104.7	107.0/	105.4
	106.9	106.7	106.7/	107.6	106.6		106.9
			106.6
Last twist pitch (mm)	17.0	17.0	17.0	17.0	17.0	17.0	17.0	17.0
Filament twist	yes	yes	yes	yes	yes	yes	yes	yes
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82
Cord characteristics
Diameter (mm)	0.80	0.78	0.77	0.44	1.24	0.71	0.55	1.09
Strength (N/sq.mm)	2985	3015	3009	3014	2735	3108	3092	3035
Strength reduction (%)	2.2	1.2	1.4	1.0	8.5	0.0	0.5	0.0
Elongation @ 50 N (%)	0.183	0.120	0.123	0.182	0.098	0.115	0.153	0.089
Bending rigidity (N · cm)	19	22	21	3	185	7	6	101
Tire performance
Rubber penetration (%)	96	94	97	77	89	0	93	0
Rust (index)	9	13	9	42	17	100	12	100
Reserved strength (%)	95	97	98	91	84	82	97	87
Breaking-out	none	none	none	none	none	none	none	none
Cut-end loose	none	none	none	none	none	none	none	none
	Ex. C10	Ref. C18	Ex. C11	Ref. C17	Ex. C12	Ref. C18	Ex. C13	Ex. C14
Filament diameter (mm)	0.30	0.20	0.20	0.23	0.23	0.20	0.20	0.23
Number of filaments	9	8	8	12	12	9	9	12
Zigzag filament	9	0	8	0	12	9	9	12
Straight filament	0	8	0	12	0	0	0	0
Spiral filament	0	0	0	0	0	0	0	0
Wave height h (mm)	0.64/0.51	—	0.45/0.30	—	0.45/0.30	0.45/0.45	0.45/0.30	0.45/0.30
Wave pitch Pw (mm)	8.00/6.30	—	5.00/3.30	—	5.00/3.30	5.00/3.00	5.00/3.30	5.00/3.30
h/PwX100	8.0/8.1	—	9.0/9.1	—	9.0/9.1	9.0/15.0	9.0/9.1	9.0/9.1
Number of respective filaments	3/6	—	3/5	—	4/8	3/6	3/6	4/8
filament length (cm/100 cm cord)	106.3/	104.9	106.7/	105.2	106.7/	106.7/	106.7/	106.7/
	106.2		106.7		106.7	109.7	106.7	106.7
Last twist pitch (mm)	17.0	17.0	17.0	17.0	17.0	17.0	17.0	17.0
Filament twist	yes	yes	yes	yes	yes	yes	no	no
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.82	0.82
Cord characteristics
Diameter (mm)	1.15	0.69	0.74	1.02	1.06	0.77	0.80	1.10
Strength (N/sq.mm)	2892	3052	3013	3048	3006	2880	2976	2960
Strength reduction (%)	5.2	0.0	1.3	0.0	1.4	5.6	2.5	2.9
Elongation @ 50 N (%)	0.099	0.110	0.145	0.097	0.148	0.183	0.147	0.198
Bending rigidity (N · cm)	97	18	19	48	47	22	19	45
Tire performance
Rubber penetration (%)	96	0	95	0	90	95	90	91
Rust (index)	7	100	10	100	15	10	15	14
Reserved strength (%)	97	86	98	90	98	99	95	98
Breaking-out	none	none	none	none	none	some	none	none
Cut-end loose	none	none	none	none	none	none	few	few

[0117] Ref.C1, C14, C15, C16 and C17 were conventional compact cords composed of straight filaments twisted together without changing the relative positions. Ref.C2 and C4 were composed of one kind of zigzag filaments.

* Cord Embodiment 4

[0118] This embodiment is designed as a cord of a bead reinforcing layer for reinforcing bead portions of a pneumatic radial tire, which can be suitably used as a substitute for a conventional steel cord of a 3+9 or 3+9+15 construction widely used in heavy duty radial tires for trucks, buses and the like.

[0119] The cord in this embodiment is composed of nine zigzag filaments 2A having the same diameter d of 0.17 to 0.25 mm.

[0120] The zigzag filaments 2A include at least two kinds of zigzag filaments 2A1-2An having different zigzag pitch lengths Pw1-Pwn. The number (n) of the kinds is preferably two. The number of zigzag filaments in each kind is at least two, preferably at least three.

[0121] In each zigzag filament 2A, the filament diameter d, zigzag pitch lengths Pw and zigzag wave height h are set to satisfy the following conditions: Pw is 10.0 to 35.0 times d; and h is 0.5 to 4.0 times d.

[0122] Further, a zigzag filament 2A1 having a minimum zigzag pitch Pw1 and the remaining zigzag filament 2An having a larger zigzag pitch Pwn satisfy the following condition: hn/Pwn is 0.75 to 1.25 times h1/Pw1, wherein h1 is the zigzag wave height of the zigzag filament 2A1, and hn is the zigzag wave height of the zigzag filament 2An. However, if there are zigzag filaments having the same minimum zigzag pitch lengths Pw1 but different heights, the minimum height is used as h1.

[0123] The cord is formed by twisting all the zigzag filaments 2A together at a twist pitch of 10 to 20 mm (last twist). As explained in the formed Embodiment 3, during twisting the zigzag filaments 2A, the relative positions thereof are changed so that a central filament or core is not formed by a specific filament, and all the zigzag filaments 2A are the substantially same length when measured along the zigzag of each filament.

[0124] In this embodiment, further, a wrapping wire is wound around the resultant bunch 4 of the twisted filaments 2A. Preferably, the wrapping wire 5 is a single filament made of a high carbon steel including 0.65 to 0.88 wt % of carbon. The diameter of the wrapping wire is 0.13 to 0.17 mm. The winding direction is reverse to the twisting direction, and the winding pitch is 3.0 to 7.0 mm.

[0125] If the winding pitch is less than 3.0 mm, the production efficiency is greatly decreased. If the winding pitch is more than 7 mm and/or the diameter of the wrapping wire is less than 0.13 mm, the cord-shape-retaining function decreases to decrease the dimensional accuracy of a rubber reinforcing layer. If the diameter of the wrapping wire is more than 0.17 mm, as the cord diameter and weight increase, it is not preferable. If the carbon content of the steel wire 5 is lower than 0.65 wt %, the strength tends to decrease. If the carbon content is higher than 0.88 wt %, the wire becomes too hard and the bending strength decreases.

[0126] FIG. 12 shows a cord composed of six zigzag filaments 2A1 having a small zigzag pitch Pw1 and three zigzag filaments 2An having a larger zigzag pitch Pwn.

[0127] If the filament diameter d is less than 0.17 mm, it becomes difficult to obtain a rigidity required for a bead reinforcing layer of the heavy duty tires, and as a result, tire durability decreases. Further, the zigzag shape is apt to return to a straight shape during twisting, and the rubber penetration decreases. If the diameter d is more than 0.25 mm, it is difficult to provide a bead reinforcing layer with a suppleness required during applying to the bead portion.

[0128] If the twist pitch is less than 10 mm, the initial elongation of the cord is too large for the bead reinforcing layer of a pneumatic tire, and thus the reinforcing effect becomes insufficient. If the twist pitch is more than 20 mm, the filaments are liable to loosen at cut ends, and thus tire durability is liable to decrease.

[0129] If the zigzag wave height h is less than 0.5 times the diameter d, it becomes difficult to increase the rubber penetration. If more than 4.0 times, the strength of the filament tends to decrease when shaped into a zigzag.

[0130] If the zigzag pitch length Pw is less than 10.0 times the diameter d, the strength of the filament tends to decrease when shaped into a zigzag. If more than 35.0 times, the rubber penetration decreases.

[0131] If hn/Pwn is less than 0.75 times h1/Pw1 or more than 1.25 times h1/Pw1, it becomes difficult to equalize the filament lengths, and thus the cord load is liable to concentrate on a particular filament, and as a result the cord strength is liable to decrease.

* Comparison Tests

[0132] Various experimental steel cords were made, and test tires having a bead reinforcing layer of the experimental cords were also made, and the following comparison tests were conducted. The results of the tests are shown in Table 4.

* Cord Strength Reduction Test

[0133] Same as above

* Bending Rigidity Test

[0134] Same as above

* Rubber Penetration Test

[0135] Same as above

* Rust and Reserved Strength Test

[0136] Same as above

* Filament Breaking-Out

[0137] Same as above

* Cord-Cut-End Looseness

[0138] Same as above

* Shape Retention Test

[0139] The cord of 1,000 mm long was coiled into a loop of 200 mm diameter. The loop was collapsed gradually in fifteen seconds as follows: the loop was put on a horizontal plane; and one of two oppositely opposed points was fixed, and the other is pressed towards the fixed point so that the two points contact each other. The collapsed state was maintained for ten seconds. Then, the pressing force was decreased gradually in fifteen seconds to allow the loop to return to its original shape. And the distance L between the two points was measured to obtain the shape retention rate E=(L/200)×100. The shape retention rate E of each cord was divided by that of Ex.D1 and converted into the reciprocal number and further multiplied by 100. The larger the value, the better the shape retention.

* Cord Pull-Out Resistance Test

[0140] From the tire, a specimen of the bead cord reinforcing layer was cut out, and a force required to pull a cord 15 mm out of the specimen was measured.

*TABLE 4
	Ref. D1	Ref. D2	Ref. D3	Ref. D4	Ref. D5	Ref. D6	Ref. D7
Cord structure (Ref.) or	1 ×12 ×.22 +	3 × .22 +	1 × 9 ×	1 × 9 ×	1 × 9 ×	1 × 9 ×	1 × 9 ×
Filament diameter (Ex.)	1 × .15	9 × .20 +	.20 + 1 × .15	.20 + 1 × .15	.20 + 1 × .15	.20 + 1 × .15	.20 + 1 × .15
		1 × .15
Number of zigzag filaments	0	0	0	5	9	9	9
Wave height h (mm)	—	—	—	0.45	0.45	0.45/0.45	0.45/0.30
Wave pitch Pw (mm)	—	—	—	5.00	5.00	5.00/3.00	5.00/3.30
h/PwX100	—	—	—	9.0	9.0	9.0/15.0	9.0/9.1
number of respective filaments	—	—	—	9	9	3/6	3/6
Filament length (cm)	105.5	105.3	105.0	zigzag	106.7	106.7/109.7	106.7/106.7
per 100 cm long cor				106.7
				straight
				105.0
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82	0.82
Last twist pitch (mm)	15.0	15.0	17.0	17.0	17.0	17.0	17.0
Filament Twist	yes	yes	yes	yes	yes	yes	yes
Wrapping wire dia. (mm)	0.15	0.15	0.15	0.15	0.15	0.15	0.15
Wrapping wire winding pitch (mm)	3.5	3.5	5.0	5.0	5.0	5.0	9.0
Cord characteristic
Diameter (mm)	1.18	1.09	1.10	1.12	1.12	1.17	1.13
Strength (N/sq.mm)	2916	2935	3035	2635	2927	2735	2925
Strength reduction (%)	—	—	0.0	13.2	3.6	9.9	3.6
Elongation @ 50 N (%)	0.089	0.090	0.119	0.120	0.148	0.137	0.123
Bending rigidity (N cm)	51	41	33	32	30	31	32
Shape retention (index)	98	99	98	96	99	95	85
Tire performance
Rubber penetration (%)	0	6	0	68	78	91	91
Pullin-out force (N/15 mm)	5	78	128	136	152	173:cord cut	178:cord cut
Rust (index)	100	87	95	50	42	21	20
Reserved strength (%)	89	92	90	92	93	96	97
Filament break-out	none	none	none	some	none	some	none
Cut-end loose	none	none	none	none	none	none	none
	Ref. D8	Ref. D9	Ref. D10	Ref. D11	Ref. D12	Ref. D13
Cord structure (Ref.) or	1 × 9 ×	1 × 9 ×	1 × 9 ×	1 × 9 ×	1 × 9 ×	1 × 9 ×
Filament diameter (Ex.)	.15 + 1 × .15	.30 + 1 × .15	.20 + 1 × .15	.20 + 1 × .15	.20 + 1 × .15	.20 + 1 × .15
Number of zigzag filaments	9	9	9	9	9	9
Wave height h (mm)	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30	0.08/0.05	1.40/1.00
Wave pitch Pw (mm)	5.00/3.30	5.00/3.30	1.80/1.20	12.0/8.0	5.00/3.30	5.0/3.30
h/PwX100	9.0/9.1	9.0/9.1	25.0/25.0	3.8/3.8	1.6/1.5	28.0/30.3
number of respective filaments	3/6	3/6	3/6	3/6	3/6	3/6
Filament length (cm)	106.7/106.7	106.7/106.7	117.4/117.4	105.3/105.3	105.1/105.0	120.3/122.8
per 100 cm long cor
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82
Last twist pitch (mm)	17.0	17.0	17.0	17.0	17.0	17.0
Filament Twist	yes	yes	yes	yes	yes	yes
Wrapping wire dia. (mm)	0.15	0.15	0.15	0.15	0.15	0.15
Wrapping wire winding pitch (mm)	5.0	5.0	5.0	9.0	5.0	5.0
Cord characteristic
Diameter (mm)	0.85	1.75	1.17	1.13	1.13	1.17
Strength (N/sq.mm)	2955	2873	2732	2925	2945	2673
Strength reduction (%)	2.3	5.3	10.0	3.6	3.0	11.9
Elongation @ 50 N (%)	0.143	0.104	0.217	0.115	0.117	0.247
Bending rigidity (N cm)	9	32	31	32	31	32
Shape retention (index)	102	94	96	98	99	94
Tire performance
Rubber penetration (%)	85	91	92	63	58	90
Pullin-out force (N/15 mm)	143	172:cord cut	135	170:cord cut	132	171:cord cut
Rust (index)	28	20	17	54	64	12
Reserved strength (%)	92	97	92	91	90	97
Filament break-out	none	none	none	none	none	none
Cut-end loose	none	none	none	none	none	none
	Ref. D14	Ref. D15	Ref. D16	Ref. D17	Ex. D1	Ex. D2	Ex. D3
Cord structure (Ref.) or	1 × 9 × .20 +	1 × 9 ×	1 × 9 ×	1 × 9 ×	0.20	0.20	0.20
Fillament diameter (Ex.)	1 × .10	.20 + 1 × .22	.20 + 1 × .15	.20 + 1 × .15
Number of zigzag filaments	9	9	9	9	9	9	9
Wave height h (mm)	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30
Wave pitch Pw (mm)	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30
h/PwX100	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1
number of respective filaments	3/6	3/6	3/6	3/6	106.7/106.7	106.7/106.7	106.7/106.7
Filament length (cm)	106.7/106.7	106.7/106.7	105.6/105.6	107.8/107.8	3/6	3/6	3/6
per 100 cm long cor
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.65	0.88
Last twist pitch (mm)	17.0	17.0	28.0	8.0	17.0	17.0	17.0
Filament Twist	yes	yes	yes	yes	yes	yes	yes
Wrapping wire dia. (mm)	0.15	0.15	0.15	0.15	0.15	0.15	0.15
Wrapping wire winding pitch (mm)	5.0	5.0	5.0	5.0	5.0	5.0	5.0
Cord characteristic
Diameter (mm)	1.13	1.28	1.13	1.15	1.13	1.13	1.14
Strength (N/sq.mm)	2925	2931	3007	2873	2970	2840	3012
Strength reduction (%)	3.6	3.4	1.2	5.3	2.1	1.3	2.8
Elongation @ 50 N (%)	0.129	0.121	0.117	0.208	0.123	0.132	0.130
Bending rigidity (N cm)	30	35	33	30	32	32	33
Shape retention (index)	82	102	92	98	100	100	100
Tire performance
Rubber penetration (%)	92	91	88	96	91	95	95
Pullin-out force (N/15 mm)	155:cord cut	165:cord cut	163:cord cut	178:cord cut	178:cord cut	170:cord cut	182:cord cut
Rust (index)	23	20	28	8	12	9	9
Reserved strength (%)	93	89	95	96	97	98	99
Filament break-out	none	none	none	none	none	none	none
Cut-end loose	none	none	occurred	none	none	none	none
	Ex. D4	Ex. D5	Ex. D6	Ex. D7	Ex. D8	Ex. D9
Cord structure (Ref.) or	0.20	0.20	0.18	0.25	0.25	0.20
Fillament diameter (Ex.)
Number of zigzag filaments	9	9	9	9	9	9
Wave height h (mm)	0.45/0.30	0.45/0.30	0.45/0.30	0.45/0.30	0.69/0.55	0.45/0.30
Wave pitch Pw (mm)	5.00/3.30	5.00/3.30	5.00/3.30	5.00/3.30	8.00/6.30	5.00/3.30
h/PwX100	9.0/9.1	9.0/9.1	9.0/9.1	9.0/9.1	8.6/8.7	9.0/9.1
number of respective filaments	106.7/106.7	106.7/106.7	106.5/106.5	107.0/106.9	106.6/106.4	106.7/106.7
Filament length (cm)	3/6	3/6	3/6	3/6	3/6	3/6
per 100 cm long cor
Carbon content (%)	0.82	0.82	0.82	0.82	0.82	0.82
Last twist pitch (mm)	10.0	20.0	15.0	17.0	17.0	17.0
Filament Twist	yes	yes	yes	yes	yes	no
Wrapping wire dia. (mm)	0.15	0.15	0.13	0.17	0.17	0.15
Wrapping wire winding pitch (mm)	5.0	5.0	3.0	7.0	7.0	5.0
Cord characteristic
Diameter (mm)	1.17	1.11	1.01	1.41	1.45	1.19
Strength (N/sq.mm)	2963	3003	3009	2967	2931	2928
Strength reduction (%)	2.4	1.1	0.9	2.2	3.4	3.5
Elongation @ 50 N (%)	0.142	0.128	0.152	0.115	0.123	0.152
Bending rigidity (N cm)	30	34	24	59	57	29
Shape retention (index)	101	97	101	98	97	93
Tire performance
Rubber penetration (%)	97	91	95	95	91	91
Pullin-out force (N/15 mm)	178:cord cut	180:cord cut	143:cord cut	280:cord cut	270:cord cut	172:cord cut
Rust (index)	7	13	6	6	13	15
Reserved strength (%)	98	97	95	98	97	96
Filament break-out	none	none	none	none	none	none
Cut-end loose	none	slight	none	none	none	slight

[0141] Ref.D1 and D3 were conventional compact cords composed of nonzigzag filaments. Ref.D2 had a layered structure having a specific core filament. Ref.D4 was formed by twisting one kind of zigzag filaments and nonzigzag filaments together. Ref.D5 was formed by twisting one kind of zigzag filaments together.

[0142] In the cord pull-out resistance test, the filaments of every Example cord were broken without some of them coming out, which shows that the adhesion to the rubber was excellent.

[0143] In the cord-cut-end looseness test, Ex.D5 and D9 caused slight looseness by which no problem would be causes with tire making processes.

* Tire Embodiment

[0144] Next, a pneumatic tire according to the present invention is described according to FIG. 13.

[0145] In FIG. 13, a pneumatic tire T is a radial tire for heavy duty vehicles such as trucks, buses and the like.

[0146] The tire T comprises a tread portion 12, a pair of axially spaced bead portions 13 with a bead core 15 therein, a pair of sidewall portions 13 extending between the tread edges and the bead portions 14, a carcass C extending between the bead portions 14, and a belt 17 disposed radially outside the carcass C in the tread portion 12.

[0147] The carcass C comprises at least one ply of radially arranged cords extending between the bead portions through the tread portion and the sidewall portions, and turned up around the bead cores 15 to form two turned up portion and one main portion therebetween. For the carcass cords, the above-mentioned Embodiment 3 is used.

[0148] Between the turned up portion and main portion in each bead portion 14 is provided with a rubber bead apex 16.

[0149] The belt 17 comprises at least two plies of parallel cords, wherein the cords of one ply cross the cords of the other ply. For the belt cords, the above-mentioned Embodiment 1 or 2 is used.

[0150] Each bead portion 14 is provided with a bead reinforcing layer G. The layer G is composed of a single ply of parallel cords. For the bead reinforcing cords, the above-mentioned Embodiment 4 is used. In FIG. 13, the layer G extends along the axially outside of the carcass ply turned up portion.

Claims

1. A steel cord formed by twisting a plurality of bunches of zigzag filaments together at a twisting pitch (Pc), each said bunch formed by twisting zigzag filaments together at a twisting pitch (Pf), each said zigzag filament being zigzaged two-dimensionally or in a plane by a zigzag pitch length (Pw) and a zigzag wave height (h) and being made up of straight segments each extending between zigzag peak points, said zigzag filaments including at least two kinds of zigzag filaments having different zigzag pitch lengths (Pw), the zigzag pitch length (Pw) and zigzag wave height (h) of each said zigzag filament being constant along the longitudinal direction thereof, each said bunch made up of at least two kinds of zigzag filaments, the number of the filaments in each bunch being 2 or 3, the total number of the filaments being 8 to 10, said zigzag filaments having a diameter (d) of 0.30 to 0.45 mm, the twisting pitch (Pc) being 10 to 40 mm, the twisting pitch (Pf) being 3 to 20 times the twisting pitch (Pc), the zigzag pitch length (Pw) being 5.0 to 30.0 times the diameter (d), the zigzag wave height (h) being 0.2 to 3.0 times the diameter (d), the product of the diameter (d) and height (h) being in 0.014 to 0.028 times the pitch length (Pw).

2. The steel cord according to claim 1, which includes two bunches of three zigzag filaments.

3. A steel cord formed by twisting (A) a plurality of bunches of filaments or (B) a plurality of bunches of filaments and a nonzigzag filament together at a twisting pitch (Pc), each said bunch formed by twisting one zigzag filament and one or two nonzigzag filaments together at a twisting pitch (Pf), each said zigzag filament being zigzaged two-dimensionally or in a plane by a zigzag pitch length (Pw) and a zigzag wave height (h) and being made up of straight segments each extending between zigzag peak points, all the zigzag filaments being substantially the same zigzag pitch length (Pw) and the same zigzag wave height (h), the number n of all the filaments being 5 or 6, the number of zigzag filaments being at least 2 but at most (n−3), all the filaments having a diameter (d) of 0.25 to 0.45 mm, the twist pitch Pc being 10 to 25 mm, the twist pitch (Pf) being 3 to 20 times the twist pitch (Pc), the zigzag pitch length (Pw) being 5.0 to 30.0 times the diameter (d), the zigzag wave height (h) being 0.2 to 3.0 times the diameter (d), the product of the diameter (d) and height (h) being in 0.014 to 0.028 times the pitch length (Pw)

4. A steel cord formed by twisting zigzag filaments together at a twisting pitch (Pc), each said zigzag filament being zigzaged two-dimensionally or in a plane by a zigzag pitch length (Pw) and a zigzag wave height (h) and being made up of straight segments each extending between zigzag peak points, said zigzag filaments including at least two kinds of zigzag filaments having different zigzag pitch lengths (Pw), the zigzag pitch length (Pw) and zigzag wave height (h) of each said zigzag filament being constant along the longitudinal direction thereof, the filaments being twisted together by changing their relative positions so that a central core is not formed by a specific filament and the lengths of all the filaments are substantially equal to each other, the number of all the filaments being 8 to 12, all the filaments having the same diameter (d) of 0.15 to 0.30 mm, the twist pitch (Pc) being 10 to 25 mm, the zigzag pitch length (Pw) being 10.0 to 35.0 times the diameter (d), the zigzag wave height (h) being 0.5 to 4.0 times the diameter (d), in each filament, the quotient (h/Pw) of the zigzag pitch length (Pw) and zigzag wave height (h) being 0.75 to 1.25 times h1/Pw1, wherein Pw1 is the minimum zigzag pitch and h1 is the zigzag wave height of the filament having said minimum zigzag pitch.

5. A steel cord composed of a filament bunch and a wrapping wire, said filament bunch being formed by twisting zigzag filaments, each said zigzag filament being zigzaged two-dimensionally or in a plane by a zigzag pitch length (Pw) and a zigzag wave height (h) and being made up of straight segments each extending between zigzag peak points, said zigzag filaments including at least two kinds of zigzag filaments having different zigzag pitch lengths (Pw), the zigzag pitch length (Pw) and zigzag wave height (h) of each said zigzag filament being constant along the longitudinal direction thereof, the filaments being twisted together by changing their relative positions so that a central core is not formed by a specific filament and the lengths of all the filaments are substantially equal to each other, the number of all the filaments being 9, all the filaments having a diameter (d) of 0.17 to 0.25 mm, the twist pitch (Pc) being 10 to 20 mm, the zigzag pitch length (Pw) being 10.0 to 35.0 times the diameter (d), the zigzag wave height (h) being 0.5 to 4.0 times the diameter (d), in each filament, the quotient (h/Pw) of the zigzag pitch length (Pw) and zigzag wave height (h) being 0.75 to 1.25 times h1/Pw1, wherein Pw1 is the minimum zigzag pitch and h1 is the zigzag wave height of the filament having said minimum zigzag pitch said wrapping wire having a diameter of 0.13 to 0.17 mm, and wound around the filament bunch at a pitch of 3.0 to 7.0 mm in the reverse direction to the direction of twisting the filaments.

6. A pneumatic tire comprising a reinforcing layer embedded in rubber, the reinforcing layer made of steel cords according to any one of claims 1 to 5.

7. A heavy duty tire comprising a belt layer made of the steel cords according to claim 1 or 2 or 3.

8. A heavy duty tire having a carcass made of the steel cords according to claim 4

9. A heavy duty tire having a bead reinforcing layer made of the steel cords according to claim 5.