CN109957865B - 钢帘线 - Google Patents
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Abstract
本发明涉及用于橡胶加固的钢帘线。钢帘线包括芯股和绞捻在芯股周围的至少三个外股,芯股包括至少一根第一芯单丝和绞捻在第一芯单丝周围的多根第一外单丝,每个外股包括多根第二钢单丝,多根第一外单丝中的至少一根第一外单丝在被绞捻到芯股中之前被预成型,并且第二钢单丝中的至少一根第二钢单丝在被绞捻以形成每个外股之前是直的。钢帘线在芯单丝迁移方面具有改善的性能。
Description
技术领域
本发明涉及用于橡胶加固的钢帘线。本发明还涉及由钢帘线加固的轮胎。
背景技术
用于加固诸如非公路用轮胎的重载轮胎的钢丝帘线需要具有高强度,因此,钢帘线具有包括多单丝的多个股以达到高强度,并且这种钢帘线是所谓的OTR帘线。
通常OTR帘线具有多股构造,并且这使得钢帘线具有高强度和高断裂负载。
在重载轮胎的使用或行驶期间,OTR帘线经受非常重的负载,该负载给OTR帘线的芯股中的芯单丝带来强力,并且有时候该强力使得芯单丝从橡胶层迁移出来并且然后暴露于空气(所谓的芯单丝迁移),并且这使得钢帘线强度变差并且导致腐蚀问题,因为芯单丝迁移导致水分渗入到橡胶层中并且腐蚀钢帘线。
JP2006022413公开了具有芯股和多个鞘股的钢帘线,在芯股中,芯单丝比鞘单丝粗并且芯单丝是波状预成型的。通过这样做,芯单丝的迁移被改善。
发明内容
本发明的一个目的是提供更好性能的钢帘线。
本发明的另一目的是提供由钢帘线加固的轮胎。
根据第一目的,提供用于橡胶加固的钢帘线,钢帘线包括芯股和绞捻在芯股周围的至少三个外股,芯股包括至少一根第一芯单丝和绞捻在至少一根第一芯单丝周围的多根第一外单丝,每个外股包括多根第二钢单丝,第一外单丝中的至少一根外单丝在被绞捻到芯股中之前被预成型,并且第二钢单丝中的至少一根钢单丝在被绞捻以形成每个外股之前是直的。
通过给第一外单丝中的至少一根外单丝提供性能,由于第一芯单丝的锚固力显著增强,第一芯单丝的迁移减少。
优选地,全部第一外单丝在被绞捻到芯股中之前被预成型。这带来第一芯单丝的更高锚固力,并且此后在将钢帘线嵌入轮胎的橡胶层时减少芯单丝迁移的风险。
优选地,至少一根第一芯单丝在被绞捻到芯股中之前被预成型。
优选地,全部第二钢单丝在被绞捻以形成外股之前是直的。
“直的”是指最终钢帘线中的钢单丝是以下的单丝:该单丝经历仅由绞捻过程引起的形变,该绞捻过程以直单丝为开始,并且以沿螺旋路径或沿彼此施加的多个螺旋路径的单丝结束。“直的”不是指钢单丝在最终钢帘线中是完全的直线。在从最终钢帘线被解捻时,“直的”第二钢单丝具有沿其长度的螺旋路径,这是由于绞捻过程而没有任何其他附加的弹性形变。
“预成型的”是指钢单丝,即第一外单丝,是在最终钢帘线中的以下单丝:该单丝不仅经历了由绞捻过程引起的形变,此外还经历一些附加的弹性形变,使得该单丝从直单丝的路径偏离。附加的弹性形变可以是单卷曲形变、如WO99/28547描述的在两个不同平面中的双卷曲形变、如CN1133075描述的多边形形变以及其他已知的形变类型。在从最终钢帘线被解捻时,除了沿单丝长度的螺旋路径外,最终钢帘线中的“预成型的”单丝还具有由于附加弹性形变的小的波形。芯股中的第一芯单丝是例外,因为其在芯中而不经受绞捻过程,换言之,预成型的第一芯单丝沿其长度仅具有小的波形而无螺旋路径。
在从钢帘线解捻预成型的第一外单丝时,预成型的第一外单丝包括沿其长度的连续波形A和连续波形B。波形A和波形B都是由预成型形变和绞捻过程的组合效应引起,除绞捻过程外,波形A主要由预成型形变引起,而波形B除预成型形变外主要由绞捻过程引起。优选地,波形A具有范围从1.05×d1mm至4×d1mm的波形高度,d1是第一外单丝的直径,波形B具有范围从0.5×D1mm至1.5×D1mm的波形高度,D1是第一外单丝的包络圆的直径,这里,包络圆是覆盖钢帘线的一个横截面处的全部第一外单丝的最小圆。更优选地,波形A具有范围从1.05×d1mm至3.5×d1mm的波形高度,并且波形B具有范围从0.7×D1mm至1.2×D1mm的波形高度。如果波形高度过大,则钢帘线强度将过低;如果波形高度过小,则第一芯单丝的锚固力将过小。
在从钢帘线解捻预成型的第一芯单丝时,预成型的第一芯单丝包括连续波形C,该连续波形C是沿单丝长度的预成型形变的结果。优选地,波形C具有范围从1.05×d2mm至4×d2mm的波形高度,d2是第一芯单丝的直径。更优选地,波形C具有范围从1.05×d2mm至3.5×d2mm的波形高度。
波形高度通过轮廓投影来测量。单丝被从钢帘线解捻并且被切成具有100mm至150mm的长度,以作为波形高度测量的样品,并且在测量前应当确保待投影的样品平面具有最大波形高度。在样品或单丝被投影时,通过以下来测量波形高度:首先在两个相邻波峰之间画一条线,并且然后测量从两个相邻波峰之间的波谷到该线的最短距离。该最短距离是包括钢单丝直径的波形高度。
缠绕单丝被缠绕在外股周围以固定钢帘线的形状。
包括芯股和外股的股可以具有两层构造或三层构造。两层构造包括第一芯单丝所在的芯层和第一外单丝所在的外层,而三层构造包括芯层、外层和中间层。在多于两层的情况下,中间层中的单丝也被定义为第一外单丝,并且优选地在被绞捻到芯股中之前被预成型。
钢帘线可以具有任何已知的构造,例如7×7+1、7×(1+6+12)+1、(1+6)+6×(3+9+15)或(1+6+12)+6×(3+9+15)。
根据本发明的第二目的,提供一种非公路用轮胎,该轮胎包括多个带束层和胎体,其中带束层由钢帘线加固,钢帘线中的至少一个钢帘线包括芯股和被绞捻在芯股周围的至少三个外股,芯股包括至少一根第一芯单丝和被绞捻在至少一根第一芯单丝周围的多根第一外单丝,每个外股包括多根第二钢单丝,第一外单丝中的至少一根第一外单丝在被绞捻到芯股中之前被预成型,并且第二钢单丝中的至少一根第二钢单丝在被绞捻以形成每个外股之前是直的。
非公路用轮胎具有降低的芯单丝迁移的风险,并且由此具有更好的质量和更长的寿命。
附图说明
图1示出了具有7×7+1构造的钢帘线。
图2示出了从钢帘线被解捻的预成型钢单丝和直钢单丝。
具体实施方式
用于钢帘线的钢单丝由盘条制成。
首先通过机械除鳞和/或通过在H2SO4或HCl溶液中的化学酸洗来清洗盘条,以除去存在于表面的氧化物。然后将盘条在水中漂洗并且干燥。然后使干燥的盘条经受第一系列的干拉操作,以便将直径减小到第一中间直径。
在该第一中间直径时,例如,在大约3.0mm至3.5mm时,使干拉钢丝经受被称为铅淬火的第一中间加热处理。铅淬火是指首先奥氏体化至约1000℃的温度,然后在约600℃至650℃的温度下从奥氏体转变为珠光体。然后,钢丝准备好进行进一步的机械形变。
然后,在直径减小步骤的第二步骤中,钢丝被从第一中间直径进一步干拉至第二中间直径。第二直径的范围通常从1.0mm至2.5mm。
在该第二中间直径时,使钢丝经受第二铅淬火处理,即,在约1000℃的温度下再次奥氏体化,然后在约600℃至650℃的温度下淬火以允许转变为珠光体。
如果在第一干拉步骤和第二干拉步骤中的总减小量不太大,则可以进行从盘条到第二中间直径的直接拉拔操作。
在该第二铅淬火处理后,钢丝通常被提供有黄铜涂层:铜被镀在钢丝上,并且锌被镀在铜上。热扩散处理被应用以形成黄铜涂层。备选地,钢丝可以被提供有三元合金涂层,该三元合金涂层包括铜、锌以及钴、钛、镍、铁或其他已知金属中的第三合金。
然后,经黄铜涂覆的钢丝或经三元合金涂覆的钢丝被借助湿拉机而经受最终系列的横截面减小。最终产品是具有以下的钢丝:碳含量高于0.60%重量,例如高于0.70%重量、或高于0.80%重量、或甚至高于0.90%重量;拉伸强度通常高于2000MPa,例如高于3800-2000dMpa、或高于4100-2000d MPa或高于4400-2000d MPa(d是钢丝的直径)并且适用于弹性体产品的加固。
适用于轮胎加固的钢丝通常具有范围从0.05mm至0.60mm的最终直径,例如从0.10mm到0.40mm的最终直径。单丝直径的示例是0.10mm、0.12mm、0.15mm、0.175mm、0.18mm、0.20mm、0.22mm、0.245mm、0.28mm、0.30mm、0.32mm、0.35mm、0.38mm、0.40mm。
在制备钢单丝后,将位于芯股的外层中的至少一根钢单丝、优选地芯股的外层中的全部钢单丝经受预成型过程,并且全部钢单丝继而经受绞捻过程以形成钢帘线。
预成型过程是单卷曲、在两个不同的平面中的双卷曲、或多边形预成型。优选地,预成型过程是单卷曲,因为单卷曲给钢单丝带来较小的强度损失。
图1图示了第一实施例。钢帘线100具有7×7+1的构造,第一芯单丝105和第一外单丝110在绞捻过程前被预成型,并且每个外股具有单丝115和单丝120,单丝120在外股的芯中,单丝115和单丝120在绞捻过程前是直的,单丝125被缠绕在外股周围。图2示出了单丝105、110、115和120的不同波形形态。波形C是单丝105的波形形态,波形C仅由预成形形变引起。波形A是单丝110的较小波形形态,除绞捻过程外,波形A主要由预成型形变引起。波形B是单丝110的较大波形形态,除预成形形变外,波形B主要由绞捻过程引起。单丝115和单丝120的波形形态仅由绞捻过程引起,单丝115的波形形态和单丝120的波形形态具有不同的波形高度,因为单丝115和单丝120具有不同的绞捻过程。如图2所示,波形高度通过以下而被测量:在单丝通过轮廓投影而被投影时,首先在两个相邻波峰之间画一条线,并且继而测量从波谷到该线的最短距离(参见波形A、波形B和波形C的示例)。该最短距离是包括钢单丝直径的波形高度。
进行了比较测试。表1总结了结果。
表1
芯单丝锚固力通过具有以下步骤的方法来测试:首先,制作橡胶化的样品,该样品嵌有被平行布置的4根钢帘线,两根相邻钢帘线之间从一根钢帘线的中心到另一根钢帘线的中心测量的距离是5mm,橡胶化的样品具有220×25×15mm(长×宽×高)的尺寸;其次,选择橡胶化的样品的一端,除去所选端的橡胶化合物并且将钢帘线留在其中,并且确保剩余的橡胶化的样品具有1英寸的长度;第三,从所选端的钢帘线解开外股和第一外单丝,以暴露第一芯单丝;第四,从橡胶化的样品拉出第一芯单丝中的一根并且记录所需的力。所记录的力是芯单丝锚固力。
从上表中,清楚的是:与参考相比,本发明的钢帘线在芯单丝锚固力方面具有相当高的提高。预成型第一外单丝的锚固力比仅预成型第一芯单丝的锚固力高10倍。提高的锚固力降低了芯单丝迁移的风险。
第二实施例是7×(1+6+12)钢帘线。钢帘线的每股具有三层构造:芯、中间层和外层。中间层和外层中的单丝在绞捻过程前被预成型,并且钢帘线的剩余单丝在绞捻过程前是直的。预成型的第一外单丝包括沿其长度的连续波形A和连续波形B,波形A具有0.290mm的波形高度,并且波形B具有0.558mm的波形高度。
Claims (10)
1.一种用于橡胶加固的钢帘线,所述钢帘线包括芯股和绞捻在所述芯股周围的至少三个外股,所述芯股包括至少一根第一芯单丝和绞捻在所述至少一根第一芯单丝周围的多根第一外单丝,每个所述外股包括多根第二钢单丝,其特征在于,所述多根第一外单丝中的至少一根第一外单丝在被绞捻到所述芯股中之前被预成型,并且所述多根第二钢单丝中的至少一根第二钢单丝在被绞捻以形成每个所述外股之前是直的。
2.根据权利要求1所述的钢帘线,其特征在于,所述多根第一外单丝中的全部第一外单丝在被绞捻到所述芯股中之前被预成型。
3.根据权利要求1或2所述的钢帘线,其特征在于,所述至少一根第一芯单丝在被绞捻到所述芯股中之前被预成型。
4.根据权利要求1或2所述的钢帘线,其特征在于,所述多根第二钢单丝中的全部第二钢单丝在被绞捻以形成所述外股之前是直的。
5.根据权利要求1或2所述的钢帘线,其特征在于,对所述第一芯单丝或所述第一外单丝的所述预成型是单卷曲、在两个不同平面上的双卷曲、或多边形预成型。
6.根据权利要求1或2所述的钢帘线,其特征在于,预成型的所述第一外单丝包括沿所述第一外单丝的长度的连续的波形A和连续的波形B,所述波形A的波形高度和所述波形B的波形高度不同,所述波形A具有范围从1.05×d1mm至4×d1mm的波形高度,d1是所述第一外单丝的直径,所述波形B具有范围从0.5×D1mm至1.5×D1mm的波形高度,D1是所述第一外单丝的包络圆的直径。
7.根据权利要求6所述的钢帘线,其特征在于,所述波形A具有范围从1.05×d1mm至3.5×d1mm的波形高度,所述波形B具有范围从0.7×D1mm至1.2×D1mm的波形高度。
8.根据权利要求3所述的钢帘线,其特征在于,预成型的所述第一芯单丝包括沿所述第一芯单丝的长度的连续的波形C,所述波形C具有范围从1.05×d2mm至4×d2mm的波形高度,d2是所述第一芯单丝的直径。
9.根据权利要求8所述的钢帘线,其特征在于,所述波形C具有范围从1.05×d2mm至3.5×d2mm的波形高度。
10.一种非公路用轮胎,包括多个带束层和胎体,其特征在于,所述带束层由根据权利要求1至9中任一项所述的钢帘线加固。
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