Patent Application
20100300592
The present invention relates to a steel cord for a tire suitable as a carcass cord and a bead-reinforcing cord, and to a pneumatic tire using the steel cord.
In a heavy-load tire, a steel cord is frequently used in a carcass forming a tire framework and/or in a bead-reinforcing layer that reinforces a bead section to improve bead durability. As the steel cord, to obtain high tensile strength of a cord per a diameter of the cord and excellent fatigue endurance, there is widely employed a double layer-stranding structure of 3+9 and 1+6, or a triple layer-stranding structure of 3+9+15 and 1+6+12 in which strands having the same diameter are most closely or densely arranged.
However, such a densest layer stranding structure, the number of gaps between strands in a sheath is small and rubber penetrability into a cord is poor. Therefore, rust is generated in the strand due to moisture from a damaged portion of a tire generated during running, and there is a tendency that cord strength is deteriorated. Hence, it is proposed to improve the rubber penetrability in the densest layer stranding structure by thickening a core strand as compared with a sheath strand, or to improve the rubber penetrability by stranding up with sheaths while twisting the cords using a corrugation-patterning strand as the core strand, thereby bringing a pattern into a three-dimensional pattern as shown in patent document 1. See Japanese Patent Application Publication No. 2002-161487.
According to the former proposal, however, it is necessary to prepare strands having different diameters and it is not economical, and if the core strand is thickened, tensile strength per area of cross section of the strand tends to be lowered, and this adversely affects weight-reduction. According to the latter proposal, since the strength is deteriorated due to the patterning processing, it is necessary to increase the number of cord-hammering times, and this also adversely affects weight-reduction.
On the other hand, steel cords of triple layer-stranding structure are frequently used in a carcass cord and/or a bead-reinforcing cord of a tire for a truck/bus and a dump truck that requires especially high strength. In the case of the triple layer-stranding structure, however, there is a problem that strands fret between inner and outer sheaths, and the strength is deteriorated by tire running.
Hence, in the steel cord of the triple layer-stranding structure, it is an object of the present invention to provide a steel cord for a tire and a pneumatic tire using the steel cord in which fretting between strands is reduced, deterioration in cord strength caused by running is suppressed, rubber penetrability is improved and tire durability can be enhanced.
An invention of claim 1 provides a steel cord for a tire comprising a cord main portion of a triple layer-stranding structure including: a core formed from one core strand, an inner sheath formed from N (2 to 5) inner sheath strands stranded with a stranding pitch Pi around the core; and outer sheath formed from M (6 to 11) outer sheath strands stranded with a stranding pitch Po around the inner sheath; wherein
diameters da of the core strand, the inner sheath strand and the outer sheath strand are equal to each other, the diameter da is in a range of 0.15 to 0.25 mm,
stranding directions of the inner sheath and the outer sheath are equal to each other,
the stranding pitch Pi of the inner sheath is greater than 25 times of the diameter da and smaller than 100 times of the diameter da, and the stranding pitch Po of the outer sheath is greater than the stranding pitch Pi, greater than 42 times of the diameter da and smaller than 167 times of the diameter da,
a difference (M−N) between the number N of the inner sheath strands and the number M of the outer sheath strands is in a range of 4 to 6, and a difference (|Ai−Ao|) between a stranding angle Ai of the inner sheath strand and a stranding angle Ao of the outer sheath strand is greater than 1° and smaller than 3°.
An invention of claim 2 provides a pneumatic tire wherein the steel cord for a tire according to claim 1 is used for a carcass cord or a bead-reinforcing cord.
According to the present invention, since the core is formed of one strand, rubber penetrability failure into the core can be avoided. Since the inner sheath is formed of 2 to 5 strands and the outer sheath is formed of 6 to 11 strands, sufficient gaps can be secured between the strands in each sheath without subjecting the strand to the patterning processing although the diameters of the strands are the same, the rubber penetrability can be improved, and deterioration in cord strength caused by rust can be suppressed. Since the diameters of the strands are the same, deterioration in tensile strength caused by thickening the core strand and deterioration in strength caused by the patterning processing can be prevented.
Since the stranding directions of the inner sheath and the outer sheath are the same, contact areas of the strands between the sheaths are increased, and a contact pressure per unit area between strands can be reduced. Especially in this invention, the difference (|Ai−Ao|) between the stranding angle Ai of the strand of the inner sheath and the stranding angle Ao of the strand of the outer sheath is set greater than 1° and smaller than 3°. With this, the contact pressure can largely be reduced. Generation of fretting can be suppressed at a high level, the rubber penetrability is improved and the tire durability can be enhanced.
An exemplary example of the present invention will be described with an illustrated example.
Referring to
The carcass 6 is formed from one or more, (one in this example) carcass plies 6A in which carcass cords are aligned at an angle for example of 70 to 90° relative to the circumferential direction of a tire. The carcass ply 6A is continuously provided with ply turnup portions 6b that are turned up axially outwardly from axially inward around the bead core 5 on both sides of the ply main portions 6a astride between the bead cores 5. A bead apex rubber 8 having a triangular cross section extending from the bead core 5 radially outwardly is disposed between the ply main portion 6a and the turnup portion 6b, thereby reinforcing from the bead section 4 to the side wall portion 3.
The belt layer 7 is formed from two or more (usually three or more in the case of a heavy-load tire) belt plies using the belt cord. In this example, the belt layer 7 includes four belt plies, i.e., a first belt ply 7A in which belt cords are aligned at an angle of 60±15° relative to the circumferential direction of the tire and which is located on a radially innermost side, and second to fourth belt plies 7B to 7D in which belt cords are aligned at a small angle of 10 to 35° relative to the circumferential direction of the tire. These belt plies 7A to 7D are disposed such that belt cords intersect with each other between the plies at least one location. With this, the belt rigidity is enhanced, and substantially the entire width of the tread portion 2 is strongly reinforced with hoop effect.
The bead-reinforcing layer 9 is formed from one or more (one in this example) bead-reinforcing plies 9A in which bead-reinforcing cords are aligned at an angle of 10 to 50° relative to the circumferential direction of the tire. In this example, the bead-reinforcing layer 9 has a U-shaped cross section in which an inner portion 9i rising along an axial inner side of the ply main portion 6a and an outer portion 9o rising along an axial outer side of the ply turnup portion 6b are connected to each other. In this example, the inner portion 9i and the outer portion 9o are terminated radially inwardly than the ply turnup portion 6b. The bead-reinforcing layer 9 can enhance the rigidity of the bead section 4, moderate a compression stress applied to the ply turnup portion 6b when a load is applied and a tensile stress applied to the ply main portion 6a, and enhance the bead durability.
In the pneumatic tire 1 of the exemplary example, a steel cord 15 of a structure shown in
The steel cord 15 includes a cord main portion 19 of a triple layer-stranding structure. The cord main portion 19 includes a core 16 formed from one core strand f1, an inner sheath 17 formed from N (2 to 5) inner sheath strands f2 stranded around the core 16 with a stranding pitch Pi, and an outer sheath 18 formed from M (6 to 11) outer sheath strands f3 stranded around the inner sheath 17 with a stranding pitch Po. In this example, one wrapping wire 20 is spirally wound around an outer side of the cord main portion 19.
More specifically, diameters da of the core strand f1, the inner sheath strand f2 and the outer sheath strand f3 are equal to each other, and the diameter da is set in a range of 0.15 to 0.25 mm. The core strand f1, the inner sheath strand f2 and the outer sheath strand f3 are collectively called strands fin some cases.
If a strand f is thick, a tensile strength per area of cross section tends to reduce, and a surface distortion on an outer side of bending increases relative to large bending deformation. Therefore, diameters of the strands f are set equal to each other so that concentration of loads and distortions on partial thick strands f can be suppressed, a stress load is balanced and strong utilizing ratio is enhanced, and thus this is advantageous in terms of cord durability. It is unnecessary to prepare strands having different diameters, this is economical and the stranding operability of cord can be enhanced. If a diameter da of the strand f is less than 0.15 mm, this diameter da is too thin when the strand f is used as the carcass cord 6C or the bead-reinforcing cord 9C, cut-resistance is inferior and it becomes difficult to obtain sufficient cord strength. If the diameter da exceeds 0.25 mm on the other hand, surface distortion relative to the large bending deformation becomes large, the strand is prone to be ruptured or damaged, and durability is deteriorated.
According to the cord main portion 19, since the core 16 is formed from one strand f1, penetrability failure of rubber into the core 16 can be avoided. Since the inner sheath 17 is formed from N (2 to 5) strands f2 and the outer sheath 18 is formed from M (6 to 11) strands f3, sufficient gaps can be secured between the strands in each sheath even though the diameters of the strands f are equal to each other, the rubber penetrability is enhanced, and reduction in cord strength caused by rust can be suppressed. Further, since patterning processing on the strand is unnecessary, reduction in cord strength caused by the patterning processing can also be prevented.
At that time, it is necessary that a difference (M−N) between the number N of the inner sheath strand f2 and the number M of the outer sheath strands f3 is in a range of 4 to 6. If the difference (M−N) is less than 4, there is a problem that the gap between the outer sheath strands f3 is too wide and a shape of the cord becomes unstable. If the difference (M−N) exceeds 6 on the other hand, the gap between the outer sheath strands f3 is eliminated. To appropriately maintain the gaps between the outer sheath strands f3 and to stabilize the shape of the cord, the number N is preferably in a range of 3 to 5, and more preferably in a range of 4 to 5.
In the cord main portion 19, stranding directions of the inner sheath 17 and the outer sheath 18 are the same, the stranding pitch Pi of the inner sheath 17 is greater than 25 times of the diameter da and smaller than 100 times of the diameter da, and the stranding pitch Po of the outer sheath 18 is greater than the stranding pitch Pi, greater than 42 times of the diameter da and smaller than 167 times of the diameter da. If the stranding directions of the sheaths 17 and 18 are equal to each other, contact areas of the strands between the sheaths can be increased, and a contact pressure per unit area between the strands f can be reduced. By limiting the stranding pitches Pi and Po to the above-described ranges, there is an effect that fatigue endurance and strength of the cord can be secured. If the stranding pitch Pi is not more than 25 times of the diameter da of the strand f, there is a problem that the cord strength is deteriorated, and if the stranding pitch Pi exceeds 100 times, there is a problem that the fatigue endurance of the cord is deteriorated. If the stranding pitch Po is not more than 42 times of the diameter da of the strand f, there is a problem that the cord strength is deteriorated, and if the stranding pitch Po exceeds 167 times, there is a problem that the fatigue endurance of the cord is deteriorated.
According to the cord main portion 19 of the exemplary example, a difference (|Ai−Ao|) between a stranding angle Ai of the strand f2 of the inner sheath 17 and a stranding angle Ao of the strand f3 of the outer sheath 18 is limited to a value greater than 1° and smaller than 3°. As shown in
tan Ai=π×Di/Pi
tan Ao=π×Do/Po
By limiting the difference (|Ai−Ao|) of the stranding angles to the above-described range, the contact pressure between the strands f2 and f3 can largely be reduced, and generation of fretting can be suppressed at a high level. If the difference (|Ai−Ao|) is 3° or greater, a sufficient fretting suppressing effect can not be expected even if the stranding directions of the sheaths 17 and 18 are the same. If the difference (|Ai−Ao|) is 1° or less, the outer sheath strand f3 drops between the inner sheath strands f2, the rubber penetrability is deteriorated, and it becomes difficult to secure stable rubber penetrability. At the portion where the outer sheath strand f3 drops, bending rigidity of the cord is locally varied, and this portion may become a starting point of a new damage.
When the steel cord 15 is used as the bead-reinforcing cord 9C, it is preferable that one wrapping wire 20 is spirally wound around an outer side of the cord main portion 19 to gather the strands f of the cord main portion 19. This is because that large bending deformation is repeatedly applied to the bead section 4 when the tire runs, and if there is no wrapping wire 20, the strands f come apart at the time of bending deformation, a local abnormal compression is input to the strands f, and the strands f buckle and this leads to a tendency in the strands to rupture before the strands are ruptured by fretting. To prevent this, in the bead-reinforcing cord 9C, the strands f of the cord main portion 19 are gathered using the wrapping wire 20. At that time, a diameter dr of the wrapping wire 20 is smaller than the diameter da of the strand f, and a winding pitch Pr thereof is set to a small value as small as 15 to 30% of the stranding pitch Po. If the winding pitch Pr is less than 15% of the stranding pitch Po, there is a tendency that the rubber penetrability is deteriorated, and if the winding pitch Pr exceeds 30%, the gathering performance of the strands f is insufficient.
The winding direction of the wrapping wire 20 is the same as the stranding directions of the sheaths 17 and 18. With this, a contact pressure between the wrapping wire 20 and the outer sheath strand f3 is reduced, and fretting to the outer sheath strand f3 is reduced.
The strand f and the wrapping wire 20 are not especially limited, but hard-drawn wire of carbon content of 0.65 to 0.88 wt % can suitably be employed.
Next, in this example, a steel cord 21 having a structure shown in
In the pneumatic tire 1, the steel cord 15 of the present invention can be employed for the bead-reinforcing cord 9C, and a conventional steel cord or organic fiber cord can also be employed for the carcass cord 6C. On the contrary, the conventional steel cord can be employed for the bead-reinforcing cord 9C, and the steel cord 21 of the present invention can be employed for the carcass cord 6C.
The especially preferable exemplary example of the invention has been described in detail above, the invention is not limited to the exemplary example and the invention can variously be modified and carried out.
To confirm the effects of the present invention, heavy-load tires A (tire size: 11R22.5) using bead-reinforcing cords having the structure shown in
(1) Rubber Penetrability:
The bead-reinforcing cords and the carcass cords were detached from the tires in a state where topping rubbers attached, rubbers were removed from the surfaces of cords having rubber as much as possible and then, the cords were disassembled. Each cord was observed over 10 cm in its length direction, and a length of a portion thereof where rubber was completely charged between the strands was measured. A ratio of the portion where rubber was completely charged to the length of 10 cm was defined as permeability of rubber. The above measurement was carried out for ten cords, and its average was defined as a measured value of the cord.
(2) Generation of Rust after Running:
After tires were made to run about 200,000 km, the tires were disassembled, and generation states of rust of the bead-reinforcing cords and the carcass cords were observed. Evaluations are indicated by means of indices, and as a numeric value is smaller, generation of rust is smaller and a result is more excellent.
(3) Strength Retaining Ratio after Running:
After tires were made to run about 200,000 km, the tires were disassembled, and the bead-reinforcing cords and the carcass cords were taken out. Strengths of the cords are indicated by means of indices in which strengths of cords (cord strengths) before running are defined as 100. The greater a numeric value is, the more excellent a result is.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-306157 | Nov 2007 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2008/067425 | 9/23/2008 | WO | 00 | 5/26/2010 |
