Tyre cord and tyre

Abstract: A tyre cord and a tyre, wherein the tyre cord comprises three inner steel monofilaments (FC) having a smaller diameter (dc) and seven outer steel monofilaments (FB) having a larger diameter (db), both the diameters (dc) and (db) being in the range of 0.15 to 0.28 mm, the inner and outer steel monofilaments being twisted in the same direction but at different pitches, and an average gap of at least 0.03 mm is provided between the adjacent outer steel monofilaments. The tyre may incorporate the cords as for example carcass cords, belt cords or the like.

Description: The present invention relates to a pneumatic tyre including a cord for use as a reinforcement, e.g. carcass cords, belt cords or the like. In heavy duty tyres for trucks and buses, i.e. for commercial vehicles, and particularly for use as tread reinforcements thereof, steel cords having a 1X12 structure as shown in Fig.6, a 3+6 structure as shown in Fig.5 or a 3+9 structure as shown in Fig.4 are usually used. In the 3+6 structure three inner filaments (FC) are twisted in one direction, and six outer filaments (FB) are twisted in the reverse direction to the twisting direction of the three inner filaments (FC). That is, if the outer filaments (FB) are in the S-direction, thus the inner filaments (FC) are in the Z-direction, or vice versa. In the 1X12 structure, however, penetration of topping rubber into the cord is not good, and a separation failure from the rubber is liable to occur. In the 3+9 structure, also penetration of the topping rubber into the cord is not good, and the adhesion of the cord with its topping rubber is poor. In the 3+6 structure, if the strength required for heavy duty use is provided, the cord diameter is inevitably large, and the tyre weight thus is also inevitably increased. Further, in the 3+9 structure and the 3+6 structure, when the steel cord is used as tension-resistant members, (e.g. as belt cords) and the tyre is subjected to a severe service condition, such as high pressure, heavy load and high speed, the steel filaments are liable to be fretted, and the cord may finally be broken. A pneumatic tyre with the features as mentioned in the precharacterizing part of claim 1 is known from FR-A-2 487 866. It is an object of the present invention to provide a light tyre cord, which is improved in penetration of its topping rubber, and in which the filaments are prevented form being fretted in heavy use. It is another object of the present invention to provide a tyre which is provided with such improved cords as its reinforcements, e.g. as belt cords, carcass cords or the like. According to one aspect of the present invention a pneumatic tyre comprises a tread portion, a pair of axially spaced bead portions with a bead core therein, a pair of sidewall portions extending between the tread edges and the bead portions, a carcass comprising one ply of steel cords extending between the bead portions and turned up around the bead cores to have a high-ply-turnup structure, each said ply of cords comprising cords comprising three inner steel monofilaments having a first diameter and being twisted together to form a core, and seven outer steel monofilaments having a second diameter and being twisted around the core, the direction of the twist of the inner steel monofilaments being the same as that of the outer steel monofilaments, the pitch of the twist of the inner steel monofilaments being differed from that of the outer steel monofilaments, said second diameter being larger than said first diameter, characterised by said first diameter and said second diameter being in the range of 0.15 to 0.23mm, the adjacent outer steel monofilaments being provided therebetween with a gap whose average is 0.03mm to 0,7mm, with a cord count such that the total of the areas of the cords is not more than 80% of the whole area of the ply when viewed normally to a plane in which the cords are arranged and coated with a topping rubber having a complex elastic modulus E* in the range of 70 to 150kfg/cm 2 when measured at a temperature of 70 degrees C and 10 Hz sine wage with 2% amplitude. Embodiments of the present invention will now be described by way of example and in conjunction with the accompanying drawings in which: Fig.1 is a cross sectional view of a cord according to the present invention; Fig.2 is a cross sectional view of another cord according to the present invention; Fig.3 is a cross sectional view of a tyre according to the present invention; and Figs.4, 5 and 6 are cross sectional views each showing a steel cord of the prior art. In Fig.1, a steel cord 1 comprises three inner steel monofilaments FC defining a central core C and seven outer steel monofilaments FB defining a sheath B around the core C. The inner and outer monofilaments FC and FB are made of a carbon steel whose carbon content is 0.67 to 0.75 % and formed by wire drawing. The diameter dc of the inner monofilaments FC and the diameter db of the outer monofilaments FB are in the range of 0.15 to 0.28 mm. If the diameter is less than 0.15 mm, the cord strength decreases. If the diameter is more than 0.28 mm, the rigidity of the ply made of such a cord becomes large, and the workability becomes poor, and further the durability against repeated bending deformation decreases. The diameter db of the outer monofilaments FB is larger than the diameter dc of the inner monofilaments FC, so that the percentage of the total cross sectional area of the inner and outer monofilaments to the apparent cross sectional area of the cord increases and the cord strength is maximised. As a result the diameter of the cord is decreased to decrease the thickness of the ply and thereby to decrease the cord weight. The three inner monofilaments FC are twisted together in a first direction. The seven outer monofilaments FB are twisted around the inner monofilaments FC in the same direction as the first twisting direction of the inner monofilaments FC. That is, when the inner monofilaments FC are in S-direction, the outer monofilaments FB are in the same S-direction (to give S/S), or vice versa (Z/Z). Therefore, the inner monofilaments and the outer monofilaments are prevented from being fretted over and against each other. The twist pitch of the inner monofilaments FC is however, different to the twist pitch of the outer monofilaments FB. In this embodiment, the twist pitch of the inner monofilaments FC is in the range of 5.0 to 6.0 mm. The twist pitch of the outer monofilaments FB is in the range of 12.0 to 14.0 mm. The twist pitch of the outer monofilaments FB is two or more times that of the inner monofilaments FC. That is, the outer pitch is larger than the inner pitch in this embodiment. However, this relationship may be reversed. Further, between the adjacent outer monofilaments FB, a gap (g) whose average is not less than 0.03 mm is provided, whereby the rubber penetration into the cord is improved. If the average gap is less than 0.03 mm, the penetration of the topping rubber into the inner monofilaments FC becomes insufficient, and as a result the adhesion becomes poor, and corrosion resistance decreases. The average gap (g) is set to be not more than 1.0 mm, and more preferably to be not more than 0.7 mm so as to provide a structural or geometrical stability for the cord. Fig.2 shows a modification of the cord 1 shown in Fig.1, wherein at least one, in this embodiment only one wrapping filament FR is wound around the seven outer monofilaments FB in the reversed twist direction to the twisting direction of the inner and outer monofilaments. For the wrapping filament FR, steel or organic fibre materials can be used. Fig.3 shows a tyre 2, in which the above-explained cords 1 are used as reinforcements. The tyre 2 comprises a tread portion 3, a pair of axially spaced bead portions 5 each with a bead core 5A therein, a pair of sidewalls 4 extending between the tread edges and the bead portions 5, a carcass 6 extending between the bead portions 5 and turned up around the bead cores 5A, belts 7 and 8 disposed radially outside the carcass 6 and inside a rubber tread. In this embodiment, the carcass 6 comprises one ply of the steel cords 1. The breaker belt 7 comprises two plies of the steel cords 1. In the layers of fabric of the carcass 6 and the breaker belt 7, the topping rubber has a complex elastic modulus E* in the range of 70 to 150 kgf/sq.cm where the complex elastic modulus E* is measured by a visco-elasticity spectrometer of Iwamoto Seisakusyo manufacture under the following conditions: 10 Hz sine wave with 2% amplitude, and a temperature of 70 degrees C. If the modulus is out of the above-mentioned range, the flow of rubber during tyre vulcanisation becomes insufficient. Preferably, the cord count for the cords 1 in each ply is such that the total of the areas of the cords is not more than 80 % of the whole area of the ply when viewed normally to the plane in which the cords are arranged. If the total is more than 80%, it becomes difficult to make the ply and its workability decreases. Incidentally, in order to promote the penetration of the topping rubber, the inner pressure applied to the tyre during tyre vulcanisation is preferably set at more than 20.0 kgf/sq.cm. The cord 1 according to the invention can be used in a bead reinforcing layer 9 which is disposed in each bead portion 5 along the outer surface of the carcass 6. Further, the cord 1 according to the invention is preferably used in a so called high-ply-turn-up (HPTU) structure because the ply can be decreased in thickness and weight. Test tyres of 7.50R16, 10.00R20 and 11R22.5 in size (i.e.commercial vehicle tyres for trucks or buses) having the structure shown in Fig.3 were made, using example cords of the invention and prior art cords as carcass cords (Table 1), breaker belt cords (Table 2) and bead reinforcing layer cords (Table 3). Then, the following tests were made. The test results are shown in Table 1, Table 2 and Table 3. A) Air transmission The cord was taken out of the tyre together with its surrounding topping rubber, and the cord was cut into a length of 60 mm. Then, the volume of its air which was flowed out from one end of the cord in one minute when the other end has air at 2 kgf/sq.cm pressure applied to it was measured. The results are indicated by an index based on that when the Ref.1 (carcass), Ref.11 (belt) and Ref.21 (bead reinforcing layer) are set at 100. The smaller the value, the better the rubber penetration. B) Corrosion Resistance After the tyre had been run for a full initial tread life, five cords were taken from each tyre at different axial positions, and the cords were inspected for corrosion at intervals of 2 to 4 cm. The corrosion, if existed, was evaluated into ten ranks, and the results are indicated by an index based on those of Ref.1, Ref.11 and Ref.21 being 100. The larger the index, the larger the corrosion. The initial tread life was taken to be when the depth of the main circumferential groove had decreased to 40%. C) Fretting At the same time and in the same way as the corrosion resistance test, the cord was inspected for fretting. The fretting, if existed, was evaluated into ten ranks, and the results are indicated by an index set for Ref.1, Ref.11 and Ref.21 being 100. The larger the index, the larger the damage. As explained above, with the tyre cord according to the present invention, the penetration of topping rubber is improved, and the filaments are prevented from being fretted each other. Further, the cord diameter can be reduced. Therefore, the cord, when used as tyre reinforcements such as carcass cords, belt cords, bead reinforcing cords or the like, can improve the tyre durability and reduce tyre weight. Carcass cord Tyre Ex.1 Ex.2 Ex.3 Ref.1 Ref.2 Size 11R22.5 750R16 10.00R20 225/90R17.5 11R22.5 Cord Structure 3+7 3+7 3+7+1 3+9+1 1X12+1 Fig.1 Fig.1 Fig.2 Fig.4 Fig.6 Twist direction S/S S/S S/S S/S S/Z Twist pitch (mm) 6.0/14.0 5.0/12.0 5.0/12.0/3.5 6.0/12.0/3.5 12.0/3.5 Filament dia. (mm) Inner 0.20 0.17 0.17 0.22 0.22 Outer 0.23 0.20 0.20 0.22 0.22 Wrapping -- -- 0.15 0.15 0.15 Cord weight (g/m) 3.1 2.3 2.5 3.8 3.8 Test Results Air transmission 0.5 0.3 0.3 100 20 Corrosion 40 35 35 100 65 Fretting 100 88 113 100 125 Belt cord Tyre Ex.11 Ex.12 Ref.11 Size 11R22.5 7.50R16 10.00R20 Cord Structure 3+7 3+7 3+6 Fig.1 Fig.1 Fig.5 Twist direction S/S S/S S/S Twist pitch (mm) 6.0/14.0 5.0/12.0 9.5/17.5 Filament dia. (mm) Inner 0.20 0.17 0.20 Outer 0.23 0.20 0.35 Cord weight (g/m) 3.1 2.3 5.3 Test Results Air transmission 50 25 100 Corrosion resistance 85 65 100 Fretting 35 40 100 Bead reinforcing cord Tyre Ex.21 Ex.22 Ref.21 Size 11R22.5 10.00R20 10.00R20 Cord Structure 3+7 3+7+1 1X12+1 Fig.1 Fig.2 Fig.6 Twist direction S/S S/S/Z S/S Twist pitch (mm) 6.0/14.0 5.0/12.0/3.5 12.0/3.5 Filaments dia. (mm) Inner 0.20 0.17 0.22 Outer 0.23 0.20 0.22 Wrapping -- 0.15 0.15 Cord weight (g/m) 3.1 2.5 3.8 Test Results Air transmission 5 3 100 Corrosion resistance 55 50 100 Fretting 70 80 100

Claims: A pneumatic tyre comprising a tread portion (3), a pair of axially spaced bead portions (5) with a bead core (5A) therein, a pair of sidewall portions (4) extending between the tread edges and the bead portions, a carcass (6) comprising one ply of steel cords (1) extending between the bead portions (5) and turned up around the bead cores (5A) to have a high-ply-turnup structure, each said ply of cords comprising cords comprising three inner steel monofilaments having a first diameter (dc) and being twisted together to form a core, and seven outer steel monofilaments having a second diameter (db) and being twisted around the core, the direction of the twist of the inner steel monofilaments being the same as that of the outer steel monofilaments, the pitch of the twist of the inner steel monofilaments being differed from that of the outer steel monofilaments, said second diameter (db) being larger than said first diameter (dc), characterised by said first diameter (dc) and said second diameter (db) being in the range of 0.15 to 0.23mm, the adjacent outer steel monofilaments being provided therebetween with a gap whose average is 0.03mm to 0.7mm, with a cord count such that the total of the areas of the cords is not more than 80% of the whole area of the ply when viewed normally to a plane in which the cords are arranged and coated with a topping rubber having a complex elastic modulus E* in the range of 70 to 150kgf/cm 2 when measured at a temperature of 70 degrees C and 10 Hz sine wave with 2% amplitude. A tyre according to claim 1, in which each said steel cord further comprises at least one outermost monofilament being wound around the twisted seven outer monofilaments. A tyre according to claim 1 or 2, in which said tread portions is provided with a belt (7) disposed radially outside the carcass (6) and inside a rubber tread, said belt (7) comprising one ply of steel cords (1) having the same construction as the steel cords of the carcass ply, the steel cords in the belt ply are coated with a topping rubber having a complex elastic modulus E* in the range of 70 to 150kgf/cm 2 when measured at a temperature of 70 degrees C and 10 Hz sine wave with 2% amplitude, the cord count for the steel cords in the belt ply is such that the total of the areas of the cords is not more than 80% of the whole area of the ply when viewed normally to a plane in which the cords are arranged. A tyre according to claim 1, 2 or 3, in which each said bead portion (5) is provided therein with a bead reinforcing layer (9) extending along the outer surface of the carcass (6), the bead reinforcing layer (9) is composed of steel cords having the same construction as the steel cords of the carcass ply.

Inventors: SAKON YUTAKA AKASHIHAUSU -, SAKON, YUTAKA, AKASHIHAUSU, SAKON, YUTAKA, AKASHIHAUSU 2-910
Applicants: SUMITOMO RUBBER IND, SUMITOMO RUBBER INDUSTRIES LTD.
Application year: 1993
Main classification: B60C9
IPC codes: D07B1, B60C9