Pneumatic tires

Abstract: A pneumatic tire comprises a carcass (2) toroidally extending between a pair of bead portions and a belt (3) arranged outside the carcass in a radial direction of the tire and composed of at least one belt layer (3a,3b), in which the belt layer is made from a plurality of steel cords (5), each cord being formed by twisting 2 to 4 filament bundles (7) each consisting of two steel filaments (6) parallel with each other so as to have a structure that major axes of the filament bundles constituting the cord are set toward substantially the same direction. In the belt layer, the major axes of the filament bundles (7) in the cords (5) constituting the belt layer (3a,3b) are arranged substantially in a row in a widthwise direction of the belt (3).

Description: This invention relates to a pneumatic tire having an improved steering ability without sacrificing durability. As a factor lowering the durability of a pneumatic tire, it is known that separation failure occurs when water enters from the outside of the tire through cut failure or the like into a belt arranged inside of the tire to cause corrosion of cords arranged in the belt and then the corrosion region is widened to cause peeling between cord and rubber. In order to avoid the occurence of separation failure, it is effective to arrange that rubber is sufficiently penetrated into the inside of the cord so as not to form a space propagating water between filaments constituting the cord, or a so-called rubber penetration structure. Such a rubber penetration structure is attained by loosely twisting the filaments to make the space between the filaments constituting the cord large and hence easily allow rubber to penetrate thereinto, and is particuarly suitable for single twisted cord of 1x3 or 1x5 structure. On the other hand, cords having the rubber penetration structure have a large space between the filaments constituting the cord, so that they have small modulus of elasticity as compared with the conventionally known cords having no space between the filaments. Therefore, when cords having the rubber penetration structure are applied to a belt in a tire, the tensile rigidity of the belt is naturally lowered to bring about deterioration of the steering stability of the tire. Moreover, it is possible to ensure the tensile rigidity of the belt by increasing the end count of the cords in the belt, which results in an increase of the tire weight and narrows the distance between adjacent cords in the belt. Consequently, rubber separation starting from a cord end located at the end portion of the belt in the widthwise direction is easily propagated to another cord adjacent thereto to bring about the occurrence of so-called belt end separation. Document EP-A-0146046 discloses a steel cord for pneumatic tires comprising 2 filament bundles, each consisting of two steel-filaments parallel with each other so as to have a structure that major axes of the filament bundles constituting the cord are set toward the same direction. It is, therefore, an object of the present invention to provide a pneumatic tire having an improved steering stability without lowering the durability of the tire due to the occurrence of separation failure in the belt and its surrounding area. According to the invention, there is provided a pneumatic tire comprising a carcass toroidally extending between a pair of bead portions and a belt arranged outside the carcass in a radial direction of the tire and composed of at least one belt layer, in which said belt layer is constituted by arranging a plurality of steel cords, each cord being formed by twisting 2 to 4 filament bundles each consisting of two steel filaments parallel with each other so as to have a structure that major axes of the filament bundles constituting the cord are set toward substantially the same direction, in such a manner that the major axes of the filament bundles in the cords constituting the belt layer are arranged substantially in the same direction in a widthwise direction of the belt, and such that the crossing angle defined between the directions of the major axes of the filament bundles is not more than 50°. The invention will be further described with reference to the accompanying drawings, wherein: Fig. 1 is a diagrammatic sectional view of an embodiment of a pneumatic tire according to the invention; Fig. 2a is a plan view of a first embodiment of a steel cord used in a tire according to the invention; Figs. 2b to 2d are diagrammatic sectional views taken along lines I-I, II-II and III-III in Fig. 2a, respectively; Fig. 3 is a partial and diagrammatic sectional view of a first embodiment of a belt used in a tire according to the invention using the steel cords shown in Fig. 2a; Figs. 4a to 4c are diagrammatic sectional views of a second embodiment of a steel cord used in a tire according to the invention; Fig. 5 is a partial and diagrammatic sectional view of a second embodiment of a belt used in a tire according to the invention using the steel cords shown in Fig. 4; Fig. 6 is a diagrammatic sectional view of a second embodiment of a steel cord used in a tire according to the invention; Fig. 7 is a diagrammatic sectional view of a third embodiment of a steel cord used in a tire according to the invention; Figs. 8a and 8b are diagrammatic sectional views illustrating the twisted states of filament bundles taken at certain positions in a longitudinal direction of the cord shown in Fig. 7, respectively; Fig. 9 is a diagrammatic sectional view of a modified embodiment of the steel cord shown in Fig. 7; Fig. 10 is a schematic and partially plan view of a wavy-formed filament used in a filament bundle constituting the cord shown in Fig. 9; Fig. 11 is a graph showing a stress-strain curve of the cord; Figs. 12a and 12b are schematic views illustrating changes of cord size in the twisting of two filament bundles for the formation of the cord used in a tire according to the invention; and Figs. 13 to 17 are diagrammatic sectional views of various comparative embodiments of steel cord, respectively. In Fig. 1 is shown an embodiment of the pneumatic tire according to the invention. This pneumatic tire comprises a carcass 2 toroidally extending between a pair of bead cores 1, a belt 3 superimposed about a crown portion of the carcass 2 in a radial direction of the tire and comprised of, for example, two belt layers 3a, 3b, and a tread 4 arranged outside the belt 3 in the radial direction of the tire, in which steel cords 5 as shown in Fig. 2a are included in the belt 3 in a given arrangement. The steel cord 5 shown in Fig. 2a is formed by twisting two filament bundles 7 each consisting of two steel filaments 6 parallel with each other so as to have a structure that major axes of the filament bundles 7 constituting the cord 5 are set toward the same direction as shown in Figs. 2b to 2d. When the steel cords 5 are applied to the belt layer 3a, 3b constituting the belt 3, as shown in Fig. 3, they are arranged in such a manner that the major axes of the filament bundles 7 in the cords 5 constituting the belt layers 3a, 3b are arranged substantially in a row in the widthwise direction of the belt 3. Moreover, the cord 5 shown in Fig. 2a has an arrangement that all major axes of the filament bundles 7 are set toward the same direction as seen from Figs. 2b to 2d. In the invention, however, it is not necessary to completely match the directions of the major axes of the filament bundles 7 with each other. In the latter case, as the sections of the cord corresponding to the same positions in the longitudinal direction of the cord as shown in Fig. 2a are shown in Figs. 4a to 4c, it is acceptable that a crossing angle  defined between a direction x of a major axis of a filament bundle 7 constituting the cord and a direction y of a major axis of another filament bundle 7 constituting the same cord is deviated from 90°, or the crossing angle  is specifically not more than 50°. This is applicable even in cords consisting of 3-4 filament bundles as shown in Figs. 6-9. In any case, the crossing angle  defined between the directions of the major axes of the filament bundles is not more than 50°. When the steel cords 5 having the structure as shown in Fig. 4 are applied to the belt layer 3a, 3b constituting the belt 3, as shown in Fig. 5, either major axis direction x or major axis direction y or both of the filament bundles 7 constituting the cord 5 may be arranged at an inclination angle of not more than 50° with respect to the widthwise direction z of the belt. Moreover, the directions x 1 , x 2 , x 3 and/or the directions y 1 , y 2 , y 3 in the adjoining cords are not necessarily required to be in line with each other. This is also applicable in the steel cords consisting of 3-4 filament bundles as shown in Figs. 6-9. Steel cords 5 shown in Figs. 6 and 7 are formed by twisting three or four filament bundles 7 each consisting of two steel filaments 6 parallel with each other so as to have a structure that major axes of these filament bundles constituting the cord are set toward the same direction likewise the case of Fig. 2. These steel cords 5 are applied to the belt of the tire in such a manner that the major axes of the filament bundles 7 in the cords constituting the belt layer are arranged substantially in a row in the widthwise direction of the belt. In the invention, the belt of the tire is reinforced with the steel cords each formed by twisting 2-4 filament bundles each consisting of 2 steel filaments parallel with each other so as to have a structure that the major axes of the filament bundles constituting the cord are set toward substantially the same direction, whereby the bending rigidity in the direction of the major axis is increased and the bending rigidity in the direction of the minor axis is decreased to give an anisotropy of the rigidity to the cord. Since the bending rigidity in the direction of the major axis is high in the steel cord formed by twisting the 2-4 filament bundles so as to set the major axes of the filament bundles toward the same direction, when in-plane bending deformation is applied to the belt during cornering, the rigid feeling of the tire is enhanced to improve the steering stability of the vehicle. When the steel cords are applied to the belt, it is important that the major axes of the filament bundles in the cords constituting the belt are arranged substantially in a row in the widthwise direction of the belt. This is because, if the major axis of the filament bundle constituting the cord is existent in a direction crossing the widthwise direction of the belt, strain concentrates in such a filament bundle due to out-of-plane bending deformation caused in a direction perpendicular to the surface of the belt such as buckling deformation or the like created in a ground contact region of the tire during the cornering of the vehicle and hence the local strain increases in the cord to result in cord breakage as such a phenomenon is repeated every cornering takes place. According to the invention, the local concentration of strain due to the out-of-plane bending deformation can be avoided by arranging the major axes of the filament bundles in the cords constituting the belt substantially in a row in the widthwise direction of the belt, whereby the durability of the cord and hence the tire durability can be improved. Further, the constitutional element of the steel cord according to the invention is not a monofilament but is a filament bundle consisting of two steel filaments, so that even when the steel cord is particularly comprised of three or four filament bundles, a closed space inevitably formed between the filaments is not continuous in the longitudinal direction of the cord as compared with the case of the conventional single-twisted cord and hence the rubber penetration structure can easily be attained. That is, when the steel cord 5 shown in Fig. 6 is formed by twisting three filament bundles 7, a shadowed steel filament 6 forming a closed space at a position of Fig. 8a locates outward at a position of Fig. 8b separated from the position of Fig. 8a in the longitudinal direction of the cord and hence the closed space is not formed at the position of Fig. 8b. As a result, the closed space is not continuous in the longitudinal direction of the cord and hence the space for penetrating rubber inside the cord is always formed. When the number of steel filaments in the filament bundle is 3 or more, a spiral orbit of the filament bundle in the cord spreads in the widthwise direction of the belt, so that it is undesirably caused that strain locally concentrates in the filament bundle through the in-plane bending deformation of the belt or the bending deformation along the plane thereof. Also, when tension is applied to the cord, the parallel arrangement of the filaments in the filament bundle is apt to be broken, which results in the lowering of the rigidity in the cord. The reason why the steel cord is constructed with 2-4 filament bundles is due to the fact that when the cord consists of a single filament bundle, it is necessary to increase the end count for ensuring the belt rigidity and hence the control of the aforementioned belt end separation is obstructed and also the steel filaments in the filament bundle are easily scattered to lower the operability in the production of the tire, while when the cord is comprised of 5 or more filament bundles, the total number of the steel filaments in the cord becomes large and hence the penetration of rubber into the inside of the cord is difficult and the belt rigidity is too high to degrade the ride comfortability. When 2-4 filament bundles are twisted under the above arrangement, it is preferable that a ratio P/d of twisting pitch of the filament bundle (P, mm) to filament diameter (d, mm) is not less than 50. When the ratio P/d is less than 50, the twisting angle becomes larger to decrease the modulus of elasticity of the cord and hence the tensile rigidity of the belt is lowered to degrade the steering stability of the tire. In order to further promote the penetration of rubber into the inside of the cord, it is effective that at least one steel filament 6a constituting the filament bundle is subjected to wavy forming to positively ensure the space between the filaments in the filament bundle as shown in Fig. 9. Moreover, the wave shape applied to the filament preferably has a wave height (H) of H≦3d and a wave length (W L ) of W L ≧10d when the filament diameter is d as shown in Fig. 10. When H>3d, the wave shape formed becomes larger and hence the fatigue property and rigidity of the cord lower. On the other hand, when W L <10d, the forming pitch of the wave shape becomes small and hence the fatigue property and strength of the cord lower. In the steel cord formed by twisting 2-4 filament bundles so as to have a structure that major axes of the filament bundles constituting the cord are set toward substantially the same direction, it is preferable that a difference E D between strain at a tensile stress of 23.5 kgf/mm 2 and strain at a tensile stress of 1.2 kgf/mm 2 is within a range of 0.11-0.25% when a tensile stress applied to the cord as a reinforcing member for the tire is a range of 1.2-23.5 kgf/mm 2 during the usual running of the vehicle. That is, when E D is within a range of 0.11-0.25%, there is obtained a stress-strain curve as shown by a solid line in Fig. 11. When this stress-strain curve is compared with a stress-strain curve of the conventional 1x5 twisting structure as shown by dotted lines in Fig. 11, the rising of gradient in the stress-strain curve becomes faster and hence the initial modulus of the cord is high and the belt rigidity is enhanced by these cords and the dimensional stability of the tire is improved. When the value of E D (E 2 - E 1 in Fig. 11) exceeds 0.25%, the closing space between the filament bundles through twisting is created to facilitate the stretching of the cord and hence the belt rigidity lowers, while a value of E D of less than 0.11% is physically impossible. Moreover, the steel cords having E D of 0.11-0.25% may be produced by a method of subjecting the filament bundle to forming, a method of twisting the filament bundles under tension, or the like. When the two filament bundles are twisted so as to have a structure that major axes of the filament bundles are set toward substantially the same direction, the size of the resulting cord variously changes in the longitudinal direction of the cord. When the average size of the cord becomes greatest at A-plane as shown in Fig. 12a, maximum value A max and minimum value A min are alternately shown at an appearing pitch L in the longitudinal direction of the cord, while when the average size of the cord becomes smallest at B-plane as shown in Fig. 12b, maximum value B max and minimum value B min are alternately shown at the appearing pitch L in the longitudinal direction of the cord, and also the relations between A max and B min and between A min and B max may appear at the respective positions in the longitudinal direction. In these relations, the cord preferably satisfies the following equations (1)-(3): 1.5≦A max /A min ≦2.5 1.5≦B max /B min ≦2.5 3.0≦A max /B min ≦5.0 When the value of A max /A min or B max /B min is less than 1.5, the side face of the cord is not waved and hence rubber cracking is easily propagated along the cord to obstruct the resistance to separation failure. When the value of A max /A min or B max /B min exceeds 2.5, the waving degree in the side face of the cord is too large and hence the cords of the adjoining belt layers are rubbed to lower the fatigue property of the cord and also the closing space in the cord through twisting is created and it may be difficult to control the value of E D to not more than the upper limit. On the other hand, when the value of A max /B min is less than 3.0, the flatness degree of the cord becomes small and it is difficult to ensure the in-plane rigidity when such cords are used in the belt layer of the tire, while when the value of A max /B min exceeds 5.0, the flatness degree of the cord becomes inversely large and hence the cords of the adjoining belt layers are rubbed to lower the fatigue property of the cord. Further, it is preferable that the cord having the structure shown in Fig. 12 satisfies the following relations (4) and (5) with respect to the appearing pitch L: 5≦L/A min ≦ 20 15≦L/B min ≦40 When the value of L/A min is less than 5 or the value of L/B min is less than 15, the appearing pitch L becomes too short to make the deformation degree of the cord large and hence degrade the fatigue property, and also the cord is easily stretched by the shortening of the appearing pitch to hardly ensure the belt rigidity. On the other hand, when the value of L/A min exceeds 20 or the value of L/B min exceeds 40, the waved pitch of the side face of the cord becomes longer and hence rubber cracking is easily propagated along the cord to degrade the resistance to separation failure. Moreover, the steel cords are applied to the belt in the tire by covering with a coating rubber. In this case, the coating rubber preferably has a 100% modulus of not less than 40 kgf/mm 2 in order to sufficiently develop the performances of the cord to enhance the belt rigidity and improve the steering stability of the tire. The following examples are given in illustration of the invention and are not intended as limitations thereof. Steel cords having structures as shown in Figs. 2, 4, 6, 9 and 13-17 are produced by using steel filaments having various diameters according to a specification as shown in Table 1. Then, a tire having a structure shown in Fig. 1 and having a tire size of 185/70R14 is prepared by using each kind of these steel cords in a belt at an end count shown in Table 1. Moreover, the belt 3 consists of a first belt layer 3a arranged on the carcass 2 and containing steel cords inclined at a cord angle of 22° upward to the left with respect to an equatorial plane of the tire and a second belt layer 3b arranged thereon and containing steel cords inclined at a cord angle of 22° upward to the right with respect to the equatorial plane. Each of the thus obtained tires is mounted onto a standard rim and inflated under a standard internal pressure, which is mounted onto a passenger car and run on a paved road over a distance of 50,000 km. Thereafter, the belt is taken out from the tire to measure the number of cords broken, crack length at the belt end, and corrosion length of the cord from cut failure. Furthermore, the steering stability and ride comfortability are evaluated by feelings of three professional drivers after running over 50,000 km. The feeling evaluation is carried out by a ten point process and an average value is calculated from the evaluation points of the drivers. The results are also shown in Table 1. According to the invention, the steering stability can be improved during the running of the tire while maintaining a high durability, whereby higher performance of the tire can be attained.

Claims: A pneumatic tire comprising a carcass (2) toroidally extending between a pair of bead portions and a belt (3) arranged outside the carcass in a radial direction of the tire and composed of at least one belt layer (3a,3b), in which said belt layer is constituted by arranging a plurality of steel cords (5), each cord being formed by twisting 2 to 4 filament bundles (7) each consisting of two steel filaments (6) parallel with each other so as to have a structure that major axes of the filament bundles constituting the cord are set toward substantially the same direction, in such a manner that the major axes (x, y) of the filament bundles (7) in the cords (5) constituting the belt layer (3a,3b) are arranged substantially in the same direction in a widthwise direction of the belt (3), and such that the crossing angle () defined between the directions of the major axes (x, y) of the filament bundles (7) is not more than 50°. A pneumatic tire as claimed in claim 1, characterized in that said steel cord has a ratio of twisting pitch (P) of the filament bundle to filament diameter (d) of not less than 50. A pneumatic tire as claimed in claim 1 or 2, characterized in that at least one steel filament (6a) constituting said filament bundle is a wavy steel filament having a wave height (H) of H≦3d and a wave length (W L ) of W L ≧10d when the filament diameter is d. A pneumatic tire as claimed in any of claims 1 to 3, characterized in that said steel cord is such that a difference between strain at a tensile stress of 23.5 kgf/mm 2 and strain at a tensile stress of 1.2 kgf/mm 2 is within a range of 0.11-0.25% when a tensile stress applied to the cord as a reinforcing member for the tire is a range of 1.2-23.5 kgf/mm 2 during the running of the tire. A pneumatic tire as claimed in any of claims 1 to 4, characterized in that said steel cord are covered with a coating rubber having a 100% modulus of not less than 40 kgf/mm 2 .

Inventors: YANAGISAWA MANABU, YANAGISAWA, MANABU
Applicants: BRIDGESTONE CORP, BRIDGESTONE CORPORATION
Application year: 1996
Main classification: B60C9
IPC codes: B60C9