Classifications

• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
  • D02G3/26—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre with characteristics dependent on the amount or direction of twist
  • D02G3/28—Doubled, plied, or cabled threads
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01H—SPINNING OR TWISTING
  • D01H1/00—Spinning or twisting machines in which the product is wound-up continuously
  • D01H1/02—Spinning or twisting machines in which the product is wound-up continuously ring type
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
  • D02G3/04—Blended or other yarns or threads containing components made from different materials
• • D—TEXTILES; PAPER
  • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
  • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
  • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
  • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
  • D02G3/48—Tyre cords
• • D—TEXTILES; PAPER
  • D07—ROPES; CABLES OTHER THAN ELECTRIC
  • D07B—ROPES OR CABLES IN GENERAL
  • D07B1/00—Constructional features of ropes or cables
  • D07B1/02—Ropes built-up from fibrous or filamentary material, e.g. of vegetable origin, of animal origin, regenerated cellulose, plastics
  • D07B1/025—Ropes built-up from fibrous or filamentary material, e.g. of vegetable origin, of animal origin, regenerated cellulose, plastics comprising high modulus, or high tenacity, polymer filaments or fibres, e.g. liquid-crystal polymers

Definitions

• This invention relates to producing twisted hybrid cords.
• Different types of materials for example one having a higher modulus and one having a lower modulus, are often used together in hybrid cords for applications such as tire reinforcement.
• hybrid cords can be made on cable corders, the cord behavior that can be achieved is limited to that of a balanced twist cord, that is, a cord where the high- modulus and low-modulus ply lengths are the same in which case there is only one response for any given twist level.
• a balanced twist cord that is, a cord where the high- modulus and low-modulus ply lengths are the same in which case there is only one response for any given twist level.
• an unbalanced hybrid is required, it is currently made on ring twisters. Cable corders provide a tremendous productivity advantage, so it would be desirable to make both balanced and unbalanced hybrids on such machines considering that the unbalanced hybrids are more common than perfectly balanced twist hybrids.
• Figure 1 depicts a prior art cable corder.
• Figure 2 depicts a front view of the inventive cable corder.
• Figure 3 depicts a side view of the inventive cable corder.
• Figure 4 is a graph showing load vs. elongation at break.
• the invention pertains to a hybrid cord comprising a plurality of plies, wherein at least two of the plies are of unequal ply length regardless of the twist of the plies and at least one of the plies has a length that is from 1 to 50 percent longer than the other plies.
• hybrid cord we mean a cord consisting of at least two plies in which at least one ply has a different modulus from the other plies.
• one ply can be para-aramid and the other ply can be nylon.
• the plies may also be of the same composition, but of different modulus.
• zero ply twist we mean the amount of twist that could be measured in a ply if it were removed from a cord without untwisting the cord.
• ply length we mean the length of the ply if it were removed from the cord without untwisting the cord.
• Fig. 1 shows generally at 10 a prior art regulator comprising pulleys 1 1 connected by axles 12. The diameters of the pulleys are all the same.
• Fig. 2 shows generally at 20 a regulator comprising pulleys 14a connected by axles 15 to pulleys 14b.
• the two pulleys 14a on side 1 are of a larger diameter than the pulleys 14b on side 2, thus the ply traveling through side 1 will enter the cord faster than the ply from side 2. This is because the pulleys on both sides are connected by a solid axle and must rotate at the same speed.
• the larger diameter is because the pulleys on both sides are connected by a solid axle and must rotate at the same speed.
• Fig. 3 is a side view of Fig. 2 and shows the path of a ply 13 around the larger diameter pulleys 14a.
• a second component ply follows a similar path around the smaller diameter pulleys 14b (not shown).
• this invention is to use a series of pulley sizes to create unbalanced hybrid cords.
• the high modulus ply By sending a high modulus ply over larger pulleys and a lower modulus ply over the smaller pulleys, the high modulus ply will be longer than the other ply in the cord structure.
• the ratio between pulley sizes will dictate the ratio between ply lengths. If the pulleys for the high modulus ply are 25% larger in diameter than the pulleys for the low modulus ply, the former will be roughly 25% longer than the latter.
• the quality of the cord can also be improved.
• the highly twisted low modulus ply provides a tremendous amount of residual torque in the cord. If the difference in length is achieved on a cable corder using different size pulleys, such residual torque in the low modulus ply will be minimized or absent. This will allow for more neutral cords and cords that should be easier to control in manufacturing.
• the hybrid cord can be made of a plurality of plies, wherein there is zero twist in the plies and at least one of the plies has a length that is from 1 to 50 percent longer than the other plies or 1 to 35 % longer or even 1 to 25% longer.
• the amount of differential length between the plies is selected to suit specific performance requirements.
• the hybrid cord has a linear density of from 500 to 5000 denier. In some other embodiments, the hybrid cord has a linear density of from 1000 to 3500 denier.
• the hybrid cord may be made from polymeric plies such as meta- aramid, para-aramid, polyazole, nylon, polyester, polyethylenenaphthalate (PEN), rayon, polypropylene, ultra-high-molecular weight polyethylene (UHMW-PE) or carbon.
• a suitable polyazole is polyoxadiazole such as is available under the tradename Arselon from OJSC Svetlogorsk Khimvolokno, Svetlogorsk, Ecuador.
• the hybrid cord may also be made from metallic plies.
• the hybrid cord may comprise a single ply of a high modulus material and a single ply of a low modulus material, such as at least one p- aramid ply and at least one nylon ply, wherein the shortest length ply is nylon.
• the hybrid cord may even comprise at least one p-aramid ply and at least one m-aramid ply wherein the shorter length ply is m-aramid.
• the plies comprise filamentary yarns that can be continuous, partly discontinuous or discontinuous such terms being well known in the textile art.
• An example of a partly discontinuous yarn is a stretch-broken yarn.
• An example of a discontinuous yarn is a staple-spun yarn.
• the p-aramid ply is from 2 to 7 percent longer than the m-aramid ply, preferably from 3 to 6 percent longer or more preferably from 4 to 5 percent longer.
• a hybrid cord of this construction formed into a woven or knit fabric is particularly suitable for use in components that are subject to burst pressure testing at low temperatures such as room temperature and fatigue testing at high temperatures such as 175 degrees C.
• An example of such a component is a turbocharger hose where the cords provide structural reinforcement to an elastomeric material. Similar applications may be found in other mechanical rubber goods applications such as conveyor belts and tires.
• a p-aramid ply may be from 3 to 5 percent longer than a polyoxadiazole ply or a polyoxadiazole ply may be from 1 to 10 percent longer than a m-aramid ply.
• the plies may have the same or different twist. In some embodiments,
• the plies have zero twist.
• the pulleys may be adapted to fit any cabling machine such as those available from Oerlikon Saurer, Charlotte, NC or Verdol, Valence, France or Aalidhra Textile Engineers Ltd., Surat, India.
• the invention is also directed to a method of providing a cord with predetermined twist and component ply lengths having the steps of
• Another embodiment pertains to a method of providing a hybrid cord with predetermined twist and component ply lengths by adjusting tension leads to force a length differential that accomplishes the goal outlined above wherein the size of the pulley is increased.
• This embodiment comprises the steps of:
• a cabling machine of Fig. 1 may be used with a yarn tension device (not shown) located before each yarn feed-in pulley.
• a yarn tension device not shown
• Several types of tension devices are available on the market and are suitable for use.
• the component plies can have various combinations of twist.
• the plies can all have zero twist; the component plies all have the same twist; or least two of the component plies can have a different twist.
• the para-aramid yarns used were Kevlar® K29 1 100 dtex available from E.I. DuPont de Nemours and Company, Wilmington, DE.
• nylon yarns used were PA66 1400 dtex available from Invista, Wilmington, DE.
• Cords were formed on an Oerlikon Allma CC3 cable cording machine with each cord comprising one p-aramid yarn and one nylon yarn. All of the cords had a twist multiplier of 6.5. One cord had both component yarns of equal length from passing both yarns over pulleys of equal diameter. Other cords had p-aramid yarns of a length 5%, 10% and 20% longer than the nylon yarns from using pulleys in which the diameter of the pulleys over which the p-aramid yarns passed were respectively of 5%, 10% and 20% greater diameter than those over which the nylon yarns passed. The cords were then tested for mechanical performance on an Instron® universal test machine model 5500. The test method was ASTM D885-07. Load vs. elongation at break profiles for the examples are shown in Figure 4.
• the curves in Fig. 4 demonstrate how the behavior of hybrid cords can be modified with different pulley ratios without changing the twist level of the cords.
• 100/100 denotes that the diameter of the pulley over which the Kevlar ® yarn was the same as the diameter of the pulley over which the nylon yarn was fed.
• Kevlar ®/nylon hybrid 105/100 denotes that the diameter of the pulley over which the Kevlar ® yarn was fed was 5% larger than the diameter of the pulley over which the nylon yarn was fed and similarly for the other curves in Fig. 4.
• higher elongations and lower initial modulus are desired and can be achieved by using a larger pulley for the Kevlar® ply.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Crystallography & Structural Chemistry (AREA)
• Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
• Ropes Or Cables (AREA)
• Rigid Pipes And Flexible Pipes (AREA)

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Publications (1)

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• 2013
  • 2013-09-26 US US14/037,459 patent/US20140237983A1/en not_active Abandoned
• 2014
  • 2014-02-20 EP EP14707921.4A patent/EP2961869B1/en active Active
  • 2014-02-20 CN CN201480010917.8A patent/CN105026628A/zh active Pending
  • 2014-02-20 WO PCT/US2014/017244 patent/WO2014133851A1/en not_active Ceased
  • 2014-02-20 JP JP2015558932A patent/JP6336491B2/ja active Active

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