Classifications

• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B1/00—Constructional features of ropes or cables
  • D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B1/00—Constructional features of ropes or cables
  • D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
  • D07B1/0606—Reinforcing cords for rubber or plastic articles
  • D07B1/062—Reinforcing cords for rubber or plastic articles the reinforcing cords being characterised by the strand configuration
  • D07B1/0633—Reinforcing cords for rubber or plastic articles the reinforcing cords being characterised by the strand configuration having a multiple-layer configuration
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B1/00—Constructional features of ropes or cables
  • D07B1/16—Ropes or cables with an enveloping sheathing or inlays of rubber or plastics
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B7/00—Details of, or auxiliary devices incorporated in, rope- or cable-making machines; Auxiliary apparatus associated with such machines
  • D07B7/02—Machine details; Auxiliary devices
  • D07B7/14—Machine details; Auxiliary devices for coating or wrapping ropes, cables, or component strands thereof
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B7/00—Details of, or auxiliary devices incorporated in, rope- or cable-making machines; Auxiliary apparatus associated with such machines
  • D07B7/02—Machine details; Auxiliary devices
  • D07B7/14—Machine details; Auxiliary devices for coating or wrapping ropes, cables, or component strands thereof
  • D07B7/145—Coating or filling-up interstices
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  • D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
  • D07B1/0606—Reinforcing cords for rubber or plastic articles
  • D07B1/0613—Reinforcing cords for rubber or plastic articles the reinforcing cords being characterised by the rope configuration
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B1/00—Constructional features of ropes or cables
  • D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
  • D07B1/0606—Reinforcing cords for rubber or plastic articles
  • D07B1/0646—Reinforcing cords for rubber or plastic articles comprising longitudinally preformed wires
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B1/00—Constructional features of ropes or cables
  • D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
  • D07B1/0606—Reinforcing cords for rubber or plastic articles
  • D07B1/0646—Reinforcing cords for rubber or plastic articles comprising longitudinally preformed wires
  • D07B1/0653—Reinforcing cords for rubber or plastic articles comprising longitudinally preformed wires in the core
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2001—Wires or filaments
  • D07B2201/201—Wires or filaments characterised by a coating
  • D07B2201/2011—Wires or filaments characterised by a coating comprising metals
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2023—Strands with core
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2024—Strands twisted
  • D07B2201/2025—Strands twisted characterised by a value or range of the pitch parameter given
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2024—Strands twisted
  • D07B2201/2027—Compact winding
  • D07B2201/2028—Compact winding having the same lay direction and lay pitch
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2024—Strands twisted
  • D07B2201/2029—Open winding
  • D07B2201/2031—Different twist pitch
  • D07B2201/2032—Different twist pitch compared with the core
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  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2038—Strands characterised by the number of wires or filaments
  • D07B2201/204—Strands characterised by the number of wires or filaments nine or more wires or filaments respectively forming multiple layers
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  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2015—Strands
  • D07B2201/2046—Strands comprising fillers
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2047—Cores
  • D07B2201/2052—Cores characterised by their structure
  • D07B2201/2059—Cores characterised by their structure comprising wires
  • D07B2201/2061—Cores characterised by their structure comprising wires resulting in a twisted structure
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  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2047—Cores
  • D07B2201/2052—Cores characterised by their structure
  • D07B2201/2059—Cores characterised by their structure comprising wires
  • D07B2201/2062—Cores characterised by their structure comprising wires comprising fillers
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2201/00—Ropes or cables
  • D07B2201/20—Rope or cable components
  • D07B2201/2095—Auxiliary components, e.g. electric conductors or light guides
  • D07B2201/2097—Binding wires
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2205/00—Rope or cable materials
  • D07B2205/20—Organic high polymers
  • D07B2205/2039—Polyesters
  • D07B2205/2042—High performance polyesters, e.g. Vectran
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  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
  • D07B2205/3025—Steel
  • D07B2205/3046—Steel characterised by the carbon content
  • D07B2205/305—Steel characterised by the carbon content having a low carbon content, e.g. below 0,5 percent respectively NT wires
• • D—TEXTILES; PAPER
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
  • D07B2205/3025—Steel
  • D07B2205/3046—Steel characterised by the carbon content
  • D07B2205/3053—Steel characterised by the carbon content having a medium carbon content, e.g. greater than 0,5 percent and lower than 0.8 percent respectively HT wires
• • D—TEXTILES; PAPER
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  • D07B2205/00—Rope or cable materials
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  • D07B2205/3021—Metals
  • D07B2205/306—Aluminium (Al)
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  • D07B2205/3067—Copper (Cu)
• • D—TEXTILES; PAPER
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  • D07B2205/3085—Alloys, i.e. non ferrous
• • D—TEXTILES; PAPER
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  • D07B2205/00—Rope or cable materials
  • D07B2205/30—Inorganic materials
  • D07B2205/3021—Metals
  • D07B2205/3085—Alloys, i.e. non ferrous
  • D07B2205/3089—Brass, i.e. copper (Cu) and zinc (Zn) alloys
• • D—TEXTILES; PAPER
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  • D07B—ROPES OR CABLES IN GENERAL
  • D07B2207/00—Rope or cable making machines
  • D07B2207/40—Machine components
  • D07B2207/4072—Means for mechanically reducing serpentining or mechanically killing of rope
• • D—TEXTILES; PAPER
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  • D07B2401/00—Aspects related to the problem to be solved or advantage
  • D07B2401/20—Aspects related to the problem to be solved or advantage related to ropes or cables
  • D07B2401/202—Environmental resistance
  • D07B2401/2025—Environmental resistance avoiding corrosion
• • D—TEXTILES; PAPER
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  • D07B2501/00—Application field
  • D07B2501/20—Application field related to ropes or cables
  • D07B2501/2046—Tyre cords

Definitions

• the present invention relates to three-layered metal cables, which can be used in particular for reinforcing rubber articles such as tires for industrial vehicles.
• This invention is more specifically related to three-layer metal cables of specific construction 2 + M + N, and their use in carcass reinforcement, also called “carcasses”, tires for industrial vehicles.
• a radial tire comprises in known manner a tread, two inextensible beads, two flanks connecting the beads to the tread and a belt circumferentially disposed between the carcass reinforcement and the tread.
• This carcass reinforcement is constituted in known manner by at least one ply (or “layer”) of rubber reinforced by reinforcement elements (“reinforcements”) such as cords or monofilaments, generally of the metal type in the case of pneumatic tires for industrial vehicles.
• reinforcement elements such as cords or monofilaments
• steel cords consisting of a central layer and one or more layers are generally used. concentric threads disposed around this central layer.
• the most widely used three-layer cables are essentially L + M + N construction cables, formed of a central layer of L-wire (s) surrounded by at least one layer of M-wire itself surrounded by a layer external of N son.
• 2 + M + N consist of a central layer of 2 son surrounded by an intermediate layer of M son itself surrounded by an outer layer of N son, the assembly may be optionally shrunk by an outer wire wrapped coil in a helix around the outer layer.
• these layered cables are subjected to considerable stresses during the rolling of the tires, in particular to repeated flexures or variations of curvature inducing at the level of the strands of friction, in particular as a result of the contacts between adjacent layers, and therefore of wear, as well as fatigue; they must therefore have a high resistance to phenomena known as "fatigue-fretting".
• this material penetrates the best in all spaces between the son constituting the cables. Indeed, if this penetration is insufficient, then empty channels are formed along the cables, and corrosive agents such as water or even oxygen in the air, which can penetrate the tires, for example as a result of cuts, they run along these empty channels into the carcass of the tire.
• corrosive agents such as water or even oxygen in the air, which can penetrate the tires, for example as a result of cuts, they run along these empty channels into the carcass of the tire.
• the presence of this moisture plays an important role in causing corrosion and accelerating the degradation processes above (phenomena known as "fatigue-corrosion”), compared to use in a dry atmosphere.
• the application WO 2005/071157 proposed cables with three layers of L + M + N construction, with L varying from 1 to 4, M from 3 to 12 and N from 8 to 20, in particular of construction 1 + M + N, one of the essential characteristics is that a sheath made of a rubber composition covers at least the intermediate layer consisting of M son, the central layer of L son can be itself covered or no rubber. Thanks to this specific architecture, not only an excellent penetrability by the rubber is obtained, limiting the corrosion problems, but also the fatigue-fretting endurance properties are significantly improved compared to the cables of the prior art. The longevity of tires for industrial vehicles and that of their carcass reinforcement are thus very significantly improved.
• these three-layer cables are obtained in several steps which have the disadvantage of being discontinuous, firstly by making an intermediate cable L + M, then by sheathing via an extrusion head of this intermediate cable, finally by a final operation of wiring the remaining N son around the core (L + M) and sheathed, for forming the outer layer.
• L + M intermediate cable
• a plastic interlayer film during intermediate operations of winding and unwinding. All these successive manipulations are penalizing from the industrial and antinomic point of view of the search for high production rates.
• a first object of the invention is a three-layer metal cable (C1, C2, C3) of construction 2 + M + N, gummed in situ, comprising a first layer or central layer (Cl) consisting of two wires of diameter di helically wound in a pitch p b first layer around which are helically wound in a pitch p 2 , in a second layer or intermediate layer (C2), M son of diameter d 2 , second layer around which are helically wound in a pitch p 3 , in a third or outer layer (C3), N son of diameter d 3 , said cable being characterized in that it has the following characteristics (di, d 2 , d 3 , pi , p 2 and p 3 being expressed in mm): - AT - ;
• a rubber composition called “filling rubber” is present in each of the capillaries delimited on the one hand by the two son of the first layer (C1) and the M son of the second layer (C2), on the other hand by the M son of the second layer (C2) and the N son of the third layer (C3);
• the rate of filling rubber in the cable is between 10 and 50 mg per gram of cable.
• This three-layer cable of the invention compared to the three-layer gummed in situ cables of the prior art, has the notable advantage of having a reduced amount of filling rubber, which guarantees a better compactness, this eraser being further distributed uniformly inside the cable, inside each of its capillaries, thus conferring on it optimal impermeability along its axis.
• the invention also relates to the use of such a cable for the reinforcement of articles or semi-finished products of rubber, for example webs, pipes, belts, conveyor belts, tires.
• the cable of the invention is particularly intended to be used as reinforcing element of a tire carcass reinforcement of industrial vehicles (ie, carrying heavy loads) chosen from vans and vehicles called "heavy vehicles" it is - ie metro vehicles, buses, road transport vehicles such as trucks, tractors, trailers, or off-the-road vehicles, agricultural or civil engineering machinery, and any other type of transport or handling vehicle.
• the invention further relates to these articles or semi-finished rubber products themselves when reinforced with a cable according to the invention, in particular tires for industrial vehicles such as vans or heavy vehicles.
• the invention also relates to a method of manufacturing the cable of the invention, said method comprising at least the following steps: a first assembly step by twisting the two wires of the central layer for forming into a first point called "first assembly point" of the first layer or central layer (Cl);
• FIGS. 1 to 4 relating to these examples which schematize, respectively: in cross-section, a construction cable 2 + 8 + 14 according to the invention, gummed in situ, of the type with cylindrical layers (Figure 1);
• FIG 3 An example of a twisting and in situ scrubbing installation that can be used for manufacturing cables in accordance with the invention (FIG 3);
• the modulus measurements are carried out in tension, unless otherwise indicated according to the ASTM D 412 standard of 1998 (test piece “C”): one measures in second elongation (that is to say after a cycle of accommodation) the secant modulus "true” (that is to say, brought back to the real section of the specimen) at 10% elongation, denoted ElO and expressed in MPa (normal conditions of temperature and hygrometry according to ASTM D 1349 of 1999).
• Air permeability test This test makes it possible to determine the longitudinal air permeability of the cables tested, by measuring the volume of air passing through a specimen under constant pressure for a given time.
• the principle of such a test is to demonstrate the effectiveness of the treatment of a cable to make it impermeable to air; it has been described for example in ASTM D2692-98.
• the test is here carried out either on cables extracted from tires or rubber sheets which they reinforce, thus already coated from the outside by rubber in the fired state, or on raw manufacturing cables, which have been coated and subsequent cooking.
• the raw cables must be, before the test, coated from the outside with a so-called coating gum.
• a series of 10 cables arranged in parallel is placed between two skims (two rectangles of 80 x 200 mm) of a rubber composition in the raw state, each skim having a thickness 3.5 mm; the whole is then locked in a mold, each of the cables being kept under a sufficient tension (for example 2 daN) to ensure its straightness during the establishment in the mold, using clamping modules; then the vulcanization (baking) is carried out for 40 minutes at a temperature of 140 ° C. and at a pressure of 15 bar (rectangular piston of 80 ⁇ 200 mm). After which, the assembly is demolded and cut 10 pieces of cables thus coated, in the form of parallelepipeds of appropriate dimensions (for example 7x7x20 or 7x7x30 mm), for characterization.
• appropriate dimensions for example 7x7x20 or 7x7x30 mm
• a conventional rubber composition for tires based on natural rubber (peptized) and carbon black N330 (65 phr), comprising the following usual additives: sulfur (7 phr), sulfenamide accelerator, is used as a coating rubber. (1 phr), ZnO (8 phr), stearic acid (0.7 phr), antioxidant (1.5 phr), cobalt naphthenate (1.5 phr) (phr parts per hundred parts of elastomer) ; the ElO module of the coating gum is approximately 10 MPa.
• the test is carried out over a predetermined length (for example 3 cm or even 2 cm) of cable, thus coated by its surrounding rubber composition (or coating gum) in the state baked, as follows: air is sent to the cable inlet, at a pressure of 1 bar, and the volume of air at the outlet is measured, using a flow meter (calibrated by example of 0 to 500 cm 3 / min).
• a flow meter calibrbrated by example of 0 to 500 cm 3 / min.
• the cable sample is locked in a compressed seal (eg a dense foam or rubber seal) in such a way that only the amount of air passing through the cable from one end to the other, along its longitudinal axis, is taken into account by the measure; the tightness of the seal itself is checked beforehand with the aid of a solid rubber specimen, that is to say without cable.
• a compressed seal eg a dense foam or rubber seal
• the average air flow measured (average of the 10 specimens) is even lower than the longitudinal imperviousness of the cable is high. As the measurement is made with an accuracy of ⁇ 0.2 cm 3 / min, the measured values less than or equal to 0.2 cm 3 / min are considered as zero; they correspond to a cable that can be described as airtight (totally airtight) along its axis (ie, in its longitudinal direction). 1-3. Filling rate
• the amount of filling compound is measured by difference between the weight of the initial cable (thus erased in situ) and the weight of the cable (and therefore that of its threads) whose filling rubber has been eliminated by a suitable electrolytic treatment.
• a sample of cable (length 1 m), wound on itself to reduce its bulk, constitutes the cathode of an electrolyzer (connected to the negative terminal of a generator), while the anode (connected to the positive terminal ) consists of a platinum wire.
• the electrolyte consists of an aqueous solution (demineralized water) comprising 1 mole per liter of sodium carbonate.
• the sample immersed completely in the electrolyte, is energized for 15 min under a current of 300 mA.
• the cable is then removed from the bath, rinsed thoroughly with water. This treatment allows the rubber to be easily detached from the cable (if it is not the case, we continue the electrolysis for a few minutes).
• the eraser is carefully removed, for example by simply wiping with an absorbent cloth, while detaching one by one the son of the cable.
• the threads are again rinsed with water and then immersed in a beaker containing a mixture of deionized water (50%) and ethanol (50%); the beaker is immersed in an ultrasonic tank for 10 minutes. The threads thus devoid of any trace of gum are removed from the beaker, dried under a stream of nitrogen or air, and finally weighed.
• the filling rate in the cable expressed in mg (milligram) of filling rubber per g (gram) of initial cable, is calculated and averaged over 10 measurements (i.e. total cable meters).
• any range of values designated by the expression "between a and b" represents the range of values from more than a to less than b (i.e. terminals a and b excluded) while any range of values designated by the term “from a to b” means the range from a to b (i.e., including the strict limits a and b).
• the metal cable of the invention thus comprises three concentric layers: a first layer or central layer (Cl) consisting of two di diameter wires pieced together in a pitch pi;
• a second layer (C2) having M son of diameter d 2 helically assembled, in a pitch p 2 , around the first layer;
• C3 having N diameter d 3 diameter wires helically assembled, at a pitch p 3 , around the second layer.
• the first and second assembled layers (C1 + C2) constitute what is usually called the cable core, which supports the outermost layer (C3).
• This cable of the invention also has the following characteristics (di, d 2 , d 3 , p 1 , p 2 and p 3 being expressed in mm): ;
• a rubber composition called “filling rubber” is present in each of the capillaries delimited on the one hand by the two son of the first layer (C1) and the M son of the second layer (C2), on the other hand by the M son of the second layer (C2) and the N son of the third layer (C3); -
• the rate of filling rubber in the cable (CI) is between 10 and 50 mg per gram of cable.
• This cable of the invention can be qualified cable gummed in situ, that is to say, it is erased from the inside, during its manufacture itself (so in the raw state of manufacture), by the rubber filling.
• each of the capillaries or interstices (the two interchangeable terms denoting voids, free spaces in the absence of filling rubber) located between, delimited by, both the two son of the first layer (Cl) and the M yarns of the second layer (C2), and both the M yarns of the second layer (C2) and the N yarns of the third layer (C3), are filled at least in part, continuously or not along the axis of the cable, by the filling rubber.
• each capillary or interstice described above comprises at least one rubber stopper; in other words and preferentially, there is at least one rubber stopper every 3 cm, preferably every 2 cm of cable, which obstructs each capillary or interstice of the cable in such a way that, in the air permeability test (According to paragraph 1-2), this cable of the invention has an average air flow rate of less than 2 cm / min, more preferably less than or equal to 0.2 cm / min.
• Another essential feature of the cable of the invention is that its level of filling rubber is between 10 and 50 mg of gum per g of cable. Below the minimum indicated, it is not possible to guarantee that, on any cable length of 3 cm, preferably 2 cm, the filling rubber is present, at least in part, in each of the interstices or capillaries of the cable to preferentially form at least one plug, while beyond the maximum indicated, it is exposed to the various problems described above due to the overflow of the filling rubber at the periphery of the cable. For all these reasons, it is preferred that the level of filling rubber is between 15 and 45 mg, more preferably between 15 and 40 mg of filling gum per g of cable.
• each capillary comprises at least one plug (or internal partition) of filling rubber on this given length, so that said cable (once coated from the outside by a polymer such as rubber) is tight or almost airtight in its longitudinal direction.
• an "airtight" cable in the longitudinal direction is characterized by an average air flow rate of not more than 0.2 cm 3 / min while a cable called “almost airtight" in the longitudinal direction is characterized by an average air flow less than 2 cm 3 / min, preferably less than 1 cm 3 / min.
• the diameters of the son of the layers C1, C2 and C3, these son have a diameter identical or not from one layer to another, check the following relations (di, d 2 , d 3 being expressed in mm): ;
• the p 2 and p 3 are equal, the pitch pi may be identical to or different from p 2 .
• pi p 2 ⁇ p 3 or pi ⁇ p 2 ⁇ p 3 .
• the following characteristics are verified:
• the pitch "p" represents the length, measured parallel to the axis of the cable, at the end of which a wire having this pitch performs a complete revolution about said axis of the cable.
• the three steps pi, p 2 and p 3 are not identical. This is particularly the case for example for cables with cylindrical type of layers such as shown schematically in Figure 1, in which the three layers C1, C2 and C3 preferentially have the additional feature of being wound in the same direction of twist (S / S / S or Z / Z / Z).
• the third or outer layer C3 has the preferred characteristic of being a saturated layer, that is to say that, by definition, there is not enough room in this layer to add at least one (N max + l) th wire d 3 diameter, N max representing the maximum number of windable son in a layer around the second layer C2.
• This construction has the significant advantage of further limiting the risk of overfilling gum filling at its periphery and offer, for a given diameter of the cable, a higher strength.
• the invention also applies to cases where the outer layer (C3) is an unsaturated layer.
• the number N of wires can vary to a very large extent according to the particular embodiment of the invention, it being understood that the maximum number N max of wires N will be increased if their diameter d 3 is reduced compared to the diameter d 2 son of the second layer, in order to preferentially keep the outer layer in a saturated state.
• the second layer (C2) has 6 to 10 wires and the third layer (C3) comprises 12 to 16 wires.
• the second layer (C2) comprises 7 or 8 wires (ie M equal to 7 or 8) and the third layer (C3) comprises 13 or 14 wires (ie N equal to 13 or 14) .
• the cable of the invention has particularly preferred constructions 2 + 7 + 13 and 2 + 8 + 14.
• the cable of the invention can be of two types, namely of the compact type or the type with cylindrical layers.
• the three layers C1, C2 and C3 are wound in the same direction of torsion, that is to say either in the S direction ("S / S / S” layout), or in the Z direction ("S" arrangement). Z / Z / Z "). Coiling in the same direction of these layers advantageously allows to minimize the friction between these two layers and therefore the wear of the son that constitute them.
• the construction of the cable of the invention advantageously allows the removal of the wire hoop, thanks to a better penetration of the rubber in its structure and self-frettage resulting therefrom.
• wire rope is meant by definition in the present application a cable formed of son constituted mainly (that is to say for more than 50% in number of these son) or integrally (for 100% son) a metallic material.
• the wire or wires of the central layer (C1), the wires of the second layer (C2) and the wires of the third layer (C3) are preferably in steel, more preferably carbon steel.
• steel more preferably carbon steel.
• other steels for example a stainless steel, or other alloys.
• carbon steel its carbon content (% by weight of steel) is preferably between 0.4% and 1.2%, especially between 0.5% and 1.1%; these levels represent a good compromise between the mechanical properties required for the tire and the feasibility of the wires.
• a carbon content of between 0.5% and 0.6% makes such steels ultimately less expensive because easier to draw.
• Another advantageous embodiment of the invention may also consist, depending on the applications concerned, of using steels with a low carbon content, for example between 0.2% and 0.5%, in particular because of a cost lower and easier to draw.
• the metal or steel used, whether in particular carbon steel or stainless steel, may itself be coated with a metal layer improving, for example, the properties of implementation of the wire rope and / or its constituent elements, or the properties of use of the cable and / or the tire themselves, such as adhesion properties, corrosion resistance or resistance to aging.
• the steel used is covered with a layer of brass (Zn-Cu alloy) or zinc; it is recalled that during the wire manufacturing process, the coating of brass or zinc facilitates the drawing of the wire, as well as the bonding of the wire with the rubber.
• the son could be covered with a thin metal layer other than brass or zinc, for example having the function of improving the resistance to corrosion of these son and / or their adhesion to rubber, for example a thin layer of Co, Ni, Al, an alloy of two or more compounds Cu, Zn, Al, Ni, Co, Sn.
• the cables of the invention are preferably carbon steel and have a tensile strength (Rm) preferably greater than 2500 MPa, more preferably greater than 3000 MPa.
• the total elongation at break (At) of the cable, the sum of its structural, elastic and plastic elongations, is preferably greater than 2.0%, more preferably at least 2.5%.
• the elastomer (or indistinctly "rubber”, both of which are considered synonymous) of the filling rubber is preferably a diene elastomer, that is to say by definition an elastomer derived at least in part (ie a homopolymer or a copolymer) of monomer (s) diene (s) (ie, monomer (s) carrier (s) of two carbon-carbon double bonds, conjugated or not).
• the diene elastomer is more preferentially selected from the group consisting of polybutadienes (BR), natural rubber (NR), synthetic polyisoprenes (IR), various butadiene copolymers, the various isoprene copolymers, and mixtures of these elastomers.
• Such copolymers are more preferably selected from the group consisting of butadiene-styrene copolymers
• SBR styrene
• BIR isoprene-butadiene copolymers
• SIR isoprene-styrene copolymers
• SBIR isoprene copolymers -butadiene-styrene
• a preferred embodiment consists in using an "isoprene" elastomer, that is to say a homopolymer or copolymer of isoprene, in other words a diene elastomer chosen from the group consisting of natural rubber (NR).
• the isoprene elastomer is preferably natural rubber or synthetic polyisoprene of the cis-1,4 type.
• polyisoprenes having a content (mol%) of cis-1,4 bonds greater than 90%, more preferably still greater than 98%, are preferably used.
• the isoprene elastomer may also be associated with another diene elastomer such as, for example, an SBR and / or BR elastomer.
• the filling rubber may contain one or more elastomer (s), especially diene (s), the latter or they may be used (s) in combination with any type of polymer other than elastomer.
• the filling rubber is preferably of the crosslinkable type, that is to say that it comprises by definition a crosslinking system adapted to allow the crosslinking of the composition during its baking (i.e., its hardening and not its melting); thus, in such a case, this rubber composition can be described as infusible, since it can not be melted by heating at any temperature.
• the system for crosslinking the rubber sheath is a so-called vulcanization system, that is to say based on sulfur (or a sulfur-donor agent). ) and at least one vulcanization accelerator. To this basic vulcanization system may be added various known vulcanization activators.
• Sulfur is used at a preferential rate of between 0.5 and 10 phr, more preferably between 1 and 8 phr
• the vulcanization accelerator for example a sulphenamide
• pce is used at a preferential rate of between 0.5 and 10.
• the filling rubber may also comprise, in addition to said crosslinking system, all or part of the additives normally used in rubber matrices intended for the manufacture of tires, such as, for example, reinforcing fillers such as carbon black or inorganic fillers such as silica, coupling agents, anti-aging agents, antioxidants, plasticizing agents or extension oils, whether the latter are of aromatic or non-aromatic nature, especially very low or non-aromatic oils, for example of naphthenic or paraffinic type, high or preferably low viscosity, MES or TDAE oils, plasticizing resins with high Tg greater than 30 0 C, agents facilitating the implementation (processability) of compositions in the raw state , tackifying resins, anti-eversion agents, acceptors and methylene donors such as for example HMT (hexamethylenetetramine) or H3M (hexamethoxymethylmelamine), reinforcing resins (such as resorcinol or bismaleimide), known adhesion promoter
• the level of reinforcing filler for example carbon black or a reinforcing inorganic filler such as silica, is preferably greater than 50 phr, for example between 50 and 120 phr.
• carbon blacks for example, all carbon blacks are suitable, in particular blacks of the HAF, ISAF, SAF type conventionally used in tires (so-called pneumatic grade blacks). Among the latter, mention will be made more particularly of carbon blacks of (ASTM) grade 300, 600 or 700 (for example N326, N330, N347, N375, N683, N772).
• reinforcing inorganic fillers are especially suitable mineral fillers of the silica (SiO 2) type, in particular precipitated or fumed silica having a BET surface area of less than 450 m 2 / g, preferably from 30 to 400 m 2 / g.
• the formulation of the filling rubber can be chosen to be identical to the formulation of the rubber matrix that the cable of the invention is intended to reinforce; thus, there is no problem of compatibility between the respective materials of the filling rubber and said rubber matrix.
• the formulation of the filling gum may be chosen different from the formulation of the rubber matrix that the cable of the invention is intended to reinforce.
• the formulation of the filling gum may be adjusted by using a relatively high quantity of adhesion promoter, typically for example from 5 to 15 phr of a metal salt such as a salt of cobalt or nickel, and reducing advantageously the amount of said promoter (or even completely suppressing it) in the surrounding rubber matrix.
• adhesion promoter typically for example from 5 to 15 phr of a metal salt such as a salt of cobalt or nickel
• the filling rubber has, in the crosslinked state, a secant modulus in extension ElO (at 10% elongation) which is between 2 and 25 MPa, more preferably between 3 and 20 MPa, in particular included in a range of 3 to 15 MPa.
• the invention relates, of course, to the previously described cable both in the green state (its filling rubber then being uncrosslinked) and in the fired state (its filling rubber then being crosslinked or vulcanized).
• Figure 1 shows schematically, in section perpendicular to the axis of the cable (assumed rectilinear and at rest), an example of a preferred cable 2 + 8 + 14 according to the invention.
• This cable (denoted CI) is of the type with cylindrical layers, that is to say that its first, second and third layers (respectively C1, C2 and C3) are wound either in different steps or in different directions of torsion .
• This type of construction has the consequence that the wires (respectively 11, 12) of its second and third layers (C2, C3) form around the two wires (10) of the first layer (C1) two substantially cylindrical layers which each have a contour (E) (shown in dotted lines) which is substantially cylindrical, and non-polygonal (more precisely hexagonal) as in the case of so-called compact cables.
• FIG. 1 shows that the filling rubber (13), while spacing the wires very slightly, at least partially fills each of the capillaries or interstices (14) (for example, some of them being here symbolized by a triangle) delimited on the one hand by the two son (10) of the first layer (C1) and the M son (11) of the second layer (C2), on the other hand by the M son (11) of the second layer (C2) and the N wires (12) of the third layer (C3), these wires being taken at least in groups of 3 adjacent wires (3, 4, 5 or even 6 in the present case, depending on the examples of capillaries or interstices shown in Figure 1).
• the filling rubber extends in a continuous manner around the second layer (C2) that it covers.
• Figure 2 recalls the section of a cable 2 + 8 + 14 (C-2) conventional (ie, not gummed in situ) with three layers (C1, C2 and C3), also of the type with cylindrical layers (cylindrical contour E).
• the characteristic of this type of cable is that its various wires (10, 11, 12) form numerous channels or capillaries (14) which remain closed and empty and thus conducive, by "wicking" effect, to the propagation of corrosive media such as water.
• the cable of the invention could be provided with an outer hoop, constituted for example by a single wire, metallic or not, helically wound around the cable in a shorter pitch than that of the outer layer (C3), and a winding direction opposite or identical to that of this outer layer.
• the cable of the invention already self-shrinking, does not generally require the use of an external hoop wire, which advantageously solves the wear problems between the hoop and the wires. the outermost layer of the cable.
• a hoop wire in the general case where the son of the outer layer are carbon steel, then one can advantageously choose a stainless steel wire hoop to reduce the fretting wear of these son carbon steel in contact with the stainless steel hoop, as taught for example in the application WO-A-98/41682, the stainless steel wire may optionally be replaced, in an equivalent manner, by a composite yarn which only the skin is made of stainless steel and the carbon steel core, as described for example in the document EP-A-976 541. It is also possible to use a hoop consisting of a polyester or a thermotropic aromatic polyester-amide, such as described in WO-A-03/048447.
• the cable of the invention described above could be optionally gummed in situ with a filling rubber based on elastomers other than diene, especially thermoplastic elastomers (TPE) such as for example polyurethane elastomers.
• TPE thermoplastic elastomers
• TPU polyurethane elastomers
• TPU do not require a known manner of crosslinking or vulcanization but which have, at the operating temperature, properties similar to those of a vulcanized diene elastomer.
• the present invention is implemented with a filling rubber based on diene elastomers such as previously described, thanks in particular to a specific manufacturing process which is particularly suitable for such elastomers; this manufacturing process is described in detail below.
• the cable of the invention described above preferably gummed in situ by a diene elastomer, is capable of being manufactured according to a process preferably comprising the following steps, more preferably carried out online and continuously: a first assembly step by twisting the two wires of the central layer for forming into a first point called "first assembly point" of the first layer or central layer (Cl);
• the step of sheathing by the filling rubber is conducted on the single central layer (Cl), downstream of the first assembly point and upstream of the second assembly point, the filling rubber being delivered in a only once in sufficient quantity to obtain the cable according to the invention.
• a possible embodiment may consist in operating, downstream of the second assembly point, an additional step of sheathing the core strand (C1 + C2). However, it is preferred to use only one cladding step.
• An essential characteristic of the above method is to use a twisting step for both the assembly of the first layer (Cl) and the second layer (C2) around the central layer (Cl). .
• the assembly of the third layer (C3) around the second layer (C2) can be made by twisting or cabling. It is preferred to use a twisting operation as for the first two assembly operations (layers C1 and C2).
• the cable is then preferably manufactured in two discontinuous steps (twisting the first two layers, then subsequent wiring of the third layer); in this case it is preferred to use two cladding steps, a first cladding of the central layer (Cl), a second subsequent cladding on the core strand (C 1 + C2).
• the procedure is as follows.
• the two wires of the central layer are twisted together (direction S or Z) to form the first layer (Cl), in a manner known per se; the son are delivered by feeding means such as coils, a distribution grid, coupled or not to a connecting grain, intended to converge the two son into a common point of torsion (or first point of assembly ).
• the M son of the second layer (C2) are twisted together (direction S or Z) around the central layer (C1) for formation of the core strand (C1 + C2); as previously for the yarns of the central layer, the yarns of the second layer are delivered by feeding means such as reels, distribution grid, intended to converge around the central layer the M son in a torsion point common (or second assembly point).
• the core (C1 + C2) thus formed is then sheathed by the filling gum in the green state, provided by an extrusion screw at an appropriate temperature.
• the filling rubber can thus be delivered at a fixed point, unique and compact, by means of a single extrusion head.
• the extrusion head may comprise one or more dies, for example an upstream guide die and a downstream die calibration. It is possible to add continuous measurement and control means of the diameter of the cable connected to the extruder.
• the extrusion temperature of the filling rubber is between 50 ° C. and 120 ° C., more preferably between 50 ° C. and 100 ° C.
• the extrusion head thus defines a cladding zone having, for example, in the preferred case of a single cladding step conducted on the central layer (Cl), the shape of a cylinder of revolution whose diameter is preferably comprised between 0.15 mm and 1.2 mm, more preferably between 0.2 and 1.0 mm, and whose length is preferably between 4 and 10 mm.
• the amount of filling compound delivered by the extrusion head can be adjusted easily so that in the final cable this amount is between 10 and 50 mg per g of final cable, that is to say finished from manufacturing, gummed in situ. Below the indicated minimum, it is not possible to guarantee that the filling rubber is present in each of the capillaries or interstices of the cable, while beyond the maximum indicated, one can expose oneself to the various problems previously described due to the overflow of the filling rubber at the periphery of the cable, according to the particular conditions of implementation of the invention and the specific construction of the cables manufactured. For all these reasons, it is preferred that the amount of filling gum delivered be between 15 and 45 mg, more preferably between 15 and 40 mg per g of cable. Downstream of the second assembly point, the tension stress exerted on the core strand is preferably between 10 and 25% of its breaking force.
• the central layer of the cable at the outlet of the extrusion head is, at any point of its periphery, preferably covered with a minimum thickness of filling rubber that is greater than 20 microns, more preferably greater than 30 microns, in particular between 30 and 80 microns.
• the final assembly is carried out, always by twisting (direction S or Z), N son of the third layer or outer layer (C3) around the core strand (C1 + C2) thus sheathed.
• the cable of the invention is not yet finished: the capillaries or channels delimited by the M son of the second layer (C2) and the N son of the third layer (C3), are not still filled with filling rubber, in any case insufficiently to obtain a cable having an impervious to air that is optimal.
• the next important step is to pass the cable, thus provided with its filling rubber in the green state, through torsion balancing means to obtain a cable said to be balanced in torsion (ie that is, virtually without residual torsion);
• Torsional balancing here means, in a known manner, the cancellation of the residual torsional torques (or of the detorsional springback) exerted on each wire of the cable in the twisted state, in its respective layer.
• Torsion balancing tools are known to those skilled in the art of twisting; they may consist for example of "trainers” and / or “twisters” and / or “twister-trainers” consisting of either pulleys for twisters or small diameter rollers for trainers, pulleys or rollers through which circulates the cable in a single plane or preferably in at least two different planes.
• the dressing function provided by the use of a trainer tool, would also have the advantage that the contact of the rollers of the trainer with the son of the outer layer (C3) will exert an additional radial pressure on the filling rubber promoting again its optimal distribution in the capillaries present between the second layer (C2) and the third layer (C3) of the cable.
• the method described above exploits the twisting of the son and the radial pressure exerted on the latter at the final stage of manufacture of the cable, to radially distribute the filling rubber inside the cable, while by perfectly controlling the amount of filling compound provided.
• Those skilled in the art will in particular be able to adjust the arrangement, the diameter of the pulleys and / or rollers of the torsion-balancing means, in order to vary the intensity of the radial pressure acting on the various wires.
• the thickness of filling rubber between two adjacent wires of the cable, whatever they are (in particular between the two wires of the central layer C1), is greater than 1 ⁇ m, preferably between 1 and 10 ⁇ m.
• This cable can be wound on a receiving reel, for storage, before being treated, for example, through a calendering installation, for preparing a metal-rubber composite fabric that can be used as a tire carcass reinforcement, or else to be assembled as a multistrand cable.
• Another variant embodiment of the manufacturing method which has just been described may consist in operating the sheathing step on the central layer (Cl) itself, that is to say in upstream and no further downstream of the second assembly point.
• the filling gum in the raw state is then delivered at one time, in an amount sufficient to obtain a cable according to the invention.
• Another embodiment variant may also consist in operating two successive cladding steps, the first on the central layer (Cl), the second on the core strand (C1 + C2), the green filling gum being then delivered in two separate steps, in respective appropriate amounts.
• the method described above has the advantage of making possible the complete operation of twisting and scrubbing in line and continuously, regardless of the type of cable manufactured (cable with cylindrical layers as compact cable), all this at high speed.
• the above method can be implemented at a speed (running speed of the cable on the twisting-scrub line) greater than 50 m / min, preferably greater than 70 m / min, especially greater than 100 m / min.
• This method of course applies to the manufacture of compact type cables (for recall and by definition, those whose layers C1, C2 and C3 are wound at the same pitch and in the same direction) as the manufacture of cables of the type with cylindrical layers (for recall and by definition, those whose layers C1, C2 and C3 are wound either at different steps (whatever their torsion directions, identical or not), or in opposite directions (whatever their not, identical or different)).
• the method described above makes it possible, according to a particularly preferred embodiment, to manufacture cables which may be devoid of (or almost free of) filling rubber at their periphery; by such an expression, it is meant that no particle of filling compound is visible, with the naked eye, at the periphery of the cable, that is to say that the person skilled in the art does not make any difference at the output of the manufacturing process, with the naked eye and at a distance of three meters or more, between a cable reel according to the invention and a conventional cable reel not gummed in situ.
• An assembly and scrubbing device preferably used for the implementation of this method, is a device comprising upstream downstream, according to the direction of advancement of a cable being formed: feed means and first assembly means by twisting the two central son for forming the first layer (C1) at a point called first point of assembly,; supply means and second assembly means by twisting the M son of the second layer (C2) around the central layer (Cl), at a point called said second point of assembly, for forming an intermediate cable said "strand of soul" of C1 + C2 construction;
• torsion balancing means At the output of the third assembly means, torsion balancing means.
• FIG. 3 shows an example of a twisting assembly device (30) that can be used for the manufacture of a three-layer cable, of construction 2 + M + N, of the type with cylindrical layers, as illustrated, for example in Figure 1 commented previously.
• supply means (110) first deliver two wires (10) through a distribution grid (111) (axisymmetric splitter), coupled or not to an assembly line (112). ), beyond which converge the two son (10) into a first assembly point (113) for forming the first layer or central layer (Cl).
• Feeding means (114) then deliver, around the central layer (Cl), M son (11), for example through a distribution grid coupled to an assembly grain, beyond which converge the M (for example 8) son of the second layer at a second assembly point (115), for formation of the core strand (C1 + C2) of construction 2 + M (for example 2 + 8).
• the core strand (C1 + C2) thus formed then passes through a cladding zone (116) consisting for example of an extrusion head.
• the distance between the sheathing point (116) and the second convergence point (115) is for example between 1 and 5 meters.
• the device used must comprise at least two members (power supply). or reception) coupled turns, and not a single one as in the case of a cable of layers of the compact type. II-3.
• the cable of the invention is particularly intended for a tire carcass reinforcement for an industrial vehicle.
• FIG. 4 very schematically represents a radial section of a tire with a metal carcass reinforcement that may or may not conform to the invention, in this general representation.
• This tire 1 has a crown 2 reinforced by a crown reinforcement or belt 6, two sidewalls 3 and two beads 4, each of these beads 4 being reinforced with a rod 5.
• the crown 2 is surmounted by a tread not shown in this schematic figure.
• a carcass reinforcement 7 is wound around the two rods 5 in each bead 4, the upturn 8 of this armature 7 being for example disposed towards the outside of the tire 1 which is shown here mounted on its rim 9.
• the carcass reinforcement 7 is in known manner constituted by at least one sheet reinforced by so-called "radial” metal cables, that is to say that these cables are arranged substantially parallel to each other and extend from a bead to the other so as to form an angle between 80 ° and 90 ° with the median circumferential plane (plane perpendicular to the axis of rotation of the tire which is located midway between the two beads 4 and passes through the middle of the crown frame 6).
• the tire according to the invention is characterized in that its carcass reinforcement 7 comprises at least, as reinforcing element of at least one carcass ply, a metal cable according to the invention.
• this tire 1 further comprises, in a known manner, a layer of rubber or inner elastomer (commonly known as
• Inner liner which defines the radially inner face of the tire and which is intended to protect the carcass ply from the diffusion of air from the interior of the tire.
• the rubber composition used for the fabric of the carcass reinforcement ply has, in the vulcanized state (ie, after curing), a secant modulus in extension ElO which is between 2 and 25 MPa, more preferably between 3 and 20 MPa, especially in a range of 3 to 15 MPa.
• the carbon steel wires are prepared in a known manner, for example starting from machine wires (diameter 5 to 6 mm) which are first cold-rolled, by rolling and / or drawing, to a neighboring intermediate diameter. of 1 mm.
• the steel used is a known carbon steel (USA AISI 1069 standard) with a carbon content of 0.70%.
• the intermediate diameter son undergo a degreasing treatment and / or pickling, before further processing.
• Table 1 These wires are then assembled as 2 + 8 + 14 layered cables whose construction is in accordance with the representation of FIG. 1 and whose mechanical properties are given in table 2.
• Table 2 The example (CI) of this cable 2 + 8 + 14 prepared according to the process previously described, as shown diagrammatically in FIG. 1, is thus formed of 24 wires in total, two wires forming the central layer (Cl) and 22 wires. around, all of diameter 0.18 mm, which have been wound in three concentric layers at different steps (same direction of twist S) to obtain a cable with cylindrical layers.
• the degree of filling rubber, measured according to the method indicated previously in paragraph II-1 -C, is equal to about 32 mg per g of cable.
• This filling rubber is present in each of the capillaries of the cable, that is to say that it fills all or at least part of each of these capillaries so that it exists at least on any portion of cable of length equal to 3 cm (preferably even reduced to 2 cm), a rubber stopper in each capillary.
• the filling compound is a conventional rubber composition for a tire carcass reinforcement for industrial vehicles, having the same formulation as that of the carcass rubber ply that the C-I cable is intended to reinforce; this composition is based on natural rubber (peptized) and carbon black N330 (55 phr); it also comprises the following usual additives: sulfur (6 phr), sulfenamide accelerator (1 phr), ZnO (9 phr), stearic acid (0.7 phr), antioxidant (1.5 phr), cobalt naphthenate (1 phr) pce); the ElO modulus of the composition is about 6 MPa. This composition was extruded at a temperature of about 85 ° C through a single calibration die with a diameter of about 0.420 mm.
• the CI cables thus prepared were subjected to the air permeability test described in paragraph II-1-B, by measuring the volume of air (in cm 3 ) passing through the cables in 1 minute.
• these examples of cables prepared according to the process of the invention can be qualified as airtight along their longitudinal axis; they therefore have an optimal penetration rate by rubber.
• control gummed cables in situ of the same construction as the CI compact cables above, were prepared according to the method described in the aforementioned application WO 2005/071157, in several discontinuous steps, by sheathing via a head. extrusion of the intermediate core strand 2 + 8, then in a second step by wiring the remaining 15 son around the thus sheathed core, for formation of the outer layer. These control cables were then subjected to the air permeability test of section 1-2.
• the method of the invention allows the manufacture of 2 + M + N construction cables gummed in situ which, thanks to an optimal penetration rate by rubber, on the one hand have a high endurance in carcass reinforcement of pneumatic, on the other hand can be implemented effectively under industrial conditions, especially without the difficulties associated with overflowing of rubber during their manufacture.
• At least one (ie one or more) wire of the cable of the invention could be replaced by a preformed wire or deformed, or more generally by a wire of different section than the other son diameter di and / or d 2 and / or d 3 , for example to further improve the penetrability of the cable by rubber or any other material, the bulk diameter of this replacement wire may be smaller, equal to or greater than the diameter (di and / or d 2 and / or d 3 ) of the other constituent wires of the layer (C1 and / or C2 and / or C3) concerned.
• part of the son constituting the cable according to the invention could be replaced by son other than son steel, metal or not, including son mineral or organic material to high mechanical strength, for example monofilaments organic polymers liquid crystal.
• the invention also relates to any multi-strand steel cable ("multistrand rope") whose structure incorporates at least, as elementary strand, a layered cable according to the invention.
• multi-strand cables in accordance with the invention which can be used, for example, in tires for industrial vehicles of the civil engineering type, in particular in their carcass or crown reinforcement, mention may be made of two-layer multistrand cables (J + K) strands of general construction known per se, for example: (1 + 5) x (2 + M + N) formed in total of six elementary strands, one in the center and the other five wired around the center;
• each elementary strand (or at least, at least some of them) is constituted by a cable with three layers 2 + M + N, in particular 2 + 7 + 13 or 2 + 8 + 14, which is in accordance with the invention.
• Such multi-strand steel cables in particular of the type (1 + 5) (2 + 7 + 13), (1 + 6) (2 + 7 + 13), (2 + 7) (2 + 7 + 13) ), (2 + 7) (2 + 7 + 13), (3 + 8) (2 + 7 + 13), (3 + 9) (2 + 7 + 13), (4 + 9) (2 + 7) +13), (4 + 10) (2 + 7 + 13), (1 + 5X2 + 8 + 14), (1 + 6) (2 + 8 + 14), (2 + 7) (2 + 8 + 14), (2 + 8) (2 + 8 + 14), (3 + 8) (2 + 8 + 14), (3 + 8) (2 + 8 + 14), (3 + 9) (2 + 8 + 14), (4 + 9) (2+ 8 + 14), (4 + 9) (2+ 8 + 14) or (4 + 10) (2 + 8 + 14), could themselves be erased in situ during their manufacture, that is to say that in this case the central strand is itself, or the central strands, if they are several, are themselves sheathed with uncured rubber compound (this filling rubber being of identical or

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• 2010
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