WO2016072665A1

WO2016072665A1 - Cable bead manufactured by single welding and method of manufacturing the cable bead

Info

Publication number: WO2016072665A1
Application number: PCT/KR2015/011531
Authority: WO
Inventors: Jae Duk Im; Ok Shil PARK; Byung Ho Lee; Dong Gil Kim
Original assignee: Hongduk Industrial Co., Ltd.
Priority date: 2014-11-04
Filing date: 2015-10-30
Publication date: 2016-05-12
Also published as: KR20160052175A; KR101692503B1; CN107074043B; CN107074043A

Abstract

Provided are a cable bead manufactured using single welding and a method of manufacturing the cable bead. The method comprising manufacturing a core wire and stranding a twist cable by twisting a layer wire around an outer circumferential surface of the core wire; butt-welding both end portions of the twist cable; primarily and secondarily heat-treating the butt-welded twist cable; and grinding or cutting a butt-welded portion such that a diameter of the welded portion is greater than about 100% of and less than about 110% of a diameter of the twist cable.

Description

CABLE BEAD MANUFACTURED BY SINGLE WELDING AND METHOD OF MANUFACTURING THE CABLE BEAD

One or more exemplary embodiments relate to a cable bead manufactured using single welding and a method of manufacturing the cable bead, and more particularly, to a cable bead manufactured using single welding and a method of manufacturing the cable bead, in which a twist cable stranded by twisting a core wire and a layer wire is butt welded to manufacture a cable bead, thereby increasing work efficiency and productivity while cutting down cost.

A tire is mounted on a rim forming an outer circumference of a tire wheel. Overall performance of the tire, such as mountability and handling stability, depends on a coupling relationship between the tire and the rim, designing of a coupling part is of high importance. That coupling portion between the rim of the tire wheel and the tire is called a bead portion. Generally, into a bead portion of a tire for a vehicle is inserted a ring bead core passing through a grommeting process of winding four through six steel wires in the form of layers to form a four-to-six-layer structure. The bead core fixes and supports a carcass plier which is coated with relatively solid rubber to form a tire body. That is, the bead core is used as a reinforcing material for a pneumatic tire. Various forces working by rotation of a tire, an air pressure inside the tire, and a load delivered through the ground are delivered to the bead core. The bead core in such an environment is beneficial in terms of mountability with respect to the tire, but may also cause a step between wires due to the layer structure formed by the grommeting process.

Meanwhile, a cable bead is made by spirally winding a layer steel wire several times around an outer circumferential surface of a ring core wire, both end portions of which are butt welded without the grommeting process, and then by fixing both end portions of the layer steel wire with a pipe or clip-type apparatus. Like the bead core, the cable bead is also used as a reinforcing material for a tire. The cable bead maintains a shape that is globally similar with that of the bead core and has superior resistance against deformation caused by moment of inertia and strong points in light of handling stability. However, a separate manufacturing machine is needed and a manufacturing process is complex, showing weak points in an economical aspect.

More specifically, a conventional cable bead is manufactured through a manufacturing process described below.

As shown in FIG. 1, a core wire is manufactured by a series of wire manufacturing operations including surface treatment, pateting, drawing, and so forth. The manufactured core wire is cut into a predetermined length and both end portions thereof are butt welded to form a core ring 1. A layer wire 2 is also manufactured by the series of wire manufacturing operations including surface treatment, pateting, drawing, and the like.

The ring core 1 is mounted on a plier (not shown) separately manufactured for manufacturing of a cable bead 4, and the layer line 2 of one ply is wound by spirally rotating around an outer circumference of the ring core 1, which is called cabling.

More specifically, the layer wire 2 is separately wound around a small bobbin (not shown) which is almost orthogonal to a rotating axis of the plier and is free to rotate, and is drawn to the ring core 1. The small bobbin revolves to prevent distortion. The layer wire 2 is spirally around the core ring 1 which rotates by revolution of the plier. Through this process, the cable bead 4 is manufactured in which the layer wire 2 is spirally twisted around the outer circumferential surface of the core ring 1.

The layer wire 2 repeats rotation from at least six times to a maximum of thirty times, depending on a required structure of the cable bead 4, taking much time for processing. Moreover, a process of fixing the layer wire 2 to the core ring 1 has to be performed, which is not favorable to productivity.

Once cabling for spirally winding the layer wire 2 around the core ring 1 is completed, sleeving for fixing both end portions of the layer wire 2 with a pipe 3 has to be performed as shown in FIG. 2, making the cable bead manufacturing process troublesome.

Furthermore, if the layer wire 2 is formed in the form of a plurality of layers on the core ring 1, cabling and sleeving have to be performed repetitively for each ply, making the manufacturing process cumbersome and increasing a manufacturing cost and a labor cost due to a need for separate equipment and labor force for each layer.

One or more exemplary embodiments include a cable bead manufactured by single welding and a method of manufacturing the cable bead, in which a twist cable stranded by twisting a core wire and a layer wire is butt welded to manufacture a cable bead, thereby increasing work efficiency and productivity while cutting down cost.

According to one or more exemplary embodiments, a method of manufacturing a cable bead based on single welding includes manufacturing a core wire and stranding a twist cable by twisting a layer wire around an outer circumferential surface of the core wire; butt-welding both end portions of the twist cable; primarily and secondarily heat-treating the butt-welded twist cable; and grinding or cutting a butt-welded portion such that a diameter of the welded portion is greater than about 100% of and less than about 110% of a diameter of the twist cable.

According to one or more embodiments of the present invention, it is desirable further comprising plating the welded portion with metal that is the same as metal used to plate the layer wire.

According to one or more embodiments of the present invention, it is desirable further comprising coupling a clip ring, plated with metal that is the same as metal used to plate the layer wire, to the welded portion.

According to one or more embodiments of the present invention, it is desirable further comprising plating the layer wire, wherein a thickness of a plated layer on the layer wire is about 0.1m through about 1.0m.

According to one or more embodiments of the present invention, it is desirable that current and voltage used for the primarily or secondarily heat-treating are less than welding current and welding voltage used for the butt-welding.

According to one or more exemplary embodiments, a cable bead manufactured using single welding includes a twisted portion in which a layer wire is twisted around an outer circumferential surface of a core wire; a welded portion in which both end portions of the twisted portion are butt-welded; and a clip ring coupled to the welded portion, wherein a diameter of the welded portion is greater than about 100% of and less than about 110% of a diameter of the twist cable in which the core wire and the layer wire are twisted.

According to one or more embodiments of the present invention, it is desirable that the welded portion is plated with metal that is the same as metal used to plate the layer wire.

According to one or more embodiments of the present invention, it is desirable that the clip ring is plated with metal that is the same as metal used to plate the layer wire.

According to one or more embodiments of the present invention, it is desirable further comprising a plated layer plated on the layer wire, wherein a thickness of the plated layer is about 0.1m through about 1.0m.

Additional aspects will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the presented embodiments.

In the cable bead manufactured using single welding and the method of manufacturing the cable bead according to the present disclosure, the twist cable 30 stranded by twisting the layer wire 20 around the outer circumferential surface of the core wire 10 is cut into a predetermined length and both end portions thereof are butt-welded, thereby simplifying a manufacturing process, improving productivity, and cutting down a manufacturing cost, when compared to a conventional case where a cable bead is made by butt-welding a ring-shape core wire and twisting a layer wire around the outer circumferential surface of the core wire.

Moreover, in the cable bead manufactured using single welding and the method of manufacturing the cable bead according to the present disclosure, the cable bead is manufactured by butt-welding the twist cable stranded by twisting the core wire and the layer wire, increasing work efficiency and productivity while saving a manufacturing cost.

These and/or other aspects will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings in which:

FIG. 1 shows a conventional cable bead manufacturing process.

FIG. 2 shows a main portion of a cable bead manufactured by a conventional cable bead manufacturing process shown in FIG. 1.

FIG. 3 shows a cable bead manufacturing process according to an embodiment of the present disclosure.

FIG. 4 is a flowchart of a cable bead manufacturing process according to an embodiment of the present disclosure.

FIG. 5 is a flowchart of a cable bead manufacturing process according to another embodiment of the present disclosure.

FIG. 6 shows a cable bead manufactured by a cable bead manufacturing process shown in FIG. 3.

FIG. 7 shows a diameter of a welded portion and a cable diameter.

FIG. 8 shows a cable bead according to an embodiment of the present disclosure.

Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. In this regard, the present embodiments may have different forms and should not be construed as being limited to the descriptions set forth herein. Accordingly, the exemplary embodiments are merely described below, by referring to the figures, to explain aspects of the present description.

FIG. 3 shows a cable bead manufacturing process according to an embodiment of the present disclosure. FIG. 4 is a flowchart of a cable bead manufacturing process according to an embodiment of the present disclosure. FIG. 5 is a flowchart of a cable bead manufacturing process according to another embodiment of the present disclosure. FIG. 6 shows a cable bead manufactured by a cable bead manufacturing process shown in FIG. 3. FIG. 7 shows a diameter of a welded portion and a cable diameter. FIG. 8 shows a cable bead according to an embodiment of the present disclosure.

A process of manufacturing a cable bead according to an embodiment of the present disclosure may include operation S1 of manufacturing a core wire 10 and stranding a twist cable 30 by twisting a layer wire 20 around an outer circumferential surface of the core wire 10, operation S2 of butt-welding both end portions of the twist cable 30, operation S3 of primarily and secondarily heat-treating the butt-welded twist cable 30, and operation S4 of grinding or cutting a butt-welded portion 50 such that the butt-welded portion 50 has a diameter D that is less than 110% of a diameter d of the twist cable 30.

First, a method of manufacturing a cable bead according to an embodiment of the present disclosure includes operation S1 of manufacturing a core wire 10 and a layer wire 20 and then stranding a twist cable 30 by twisting the layer wire 20 around the outer circumferential surface of the core wire 10.

The layer wire 20 is spirally twisted around the outer circumferential surface of the core wire 10. Next, the twist cable 30 is cut into a predetermined length. The twist cable 30 may have a form in which one layer wire 20 is twisted around one core wire 10 or the outer wire 20 of several plies is twisted around one core wire 10. The core wire 10 and the layer wire 20 may have the same diameter or different diameters.

As shown in FIG. 3, the core wire 10 and the layer wire 20 are manufactured mainly by surface treatment, patenting, drawing, and so forth.

More specifically, drawing may include primary and secondary drawing processes or an additional process such as quenching heat treatment or coating. Manufacturing of the core wire 10 and the layer wire 20 is based on a general wire process and thus will not be described in detail.

According to the current embodiment of the present disclosure, the core wire 10 may use a low carbon steel wire rod or a high carbon steel wire rod having 0.05% to 0.7% by weight of carbon contents. The layer wire 20 may use a high carbon steel wire rod having 0.5% to 1.03% by weight of carbon contents.

The layer wire 20 is plated with bronze, brass, or zinc. Typically, plating is performed using electroplating or displacement plating, and a thickness of a plated layer is about 0.1 through 1.0m. Through the plating, an adhesive force with a tire is improved.

Next, both end portions of the twist cable 30 cut into the predetermined length are butt welded in operation S2. As shown in FIG. 6, the twist cable 30 is in a form in which the layer wire 20 is twisted around the outer circumferential surface of the core wire 10, and the both end portions of the twist cable 30 are approached to each other such that the facing core wire 10 and the facing layer wire 20 are disposed to be welded to each other, and then are welded.

Welding current, Welding voltage, and cooling time after welding vary with a diameter of the twist cable 30. More specifically, if the diameter of the twist cable 30 is greater than about 4 mm and less than about 5 mm, the welding current may be about 855A (greater than 80A and less than 90A), welding voltage may be about 252 V (greater than 23 V and less than 27V) and the cooling time may be about 50.5 seconds (greater than 4.5 seconds and less than 5.5 seconds).

If the diameter of the twist cable 30 is greater than about 6mm and less than about 7mm, the welding current may be 1105A for Ampere (greater than about 115A and less than about 105A), the welding voltage may be about 302V for Voltage (greater than 28V and less than 32V), and the cooling time may be 50.5 seconds (greater than 4.5 seconds and less than 5.5 seconds).

Next, the butt welded twist cable 30 is treated with heat in operation S3.

According to the current embodiment of the present disclosure, the heat treatment means applying current and voltage to the butt-welded portion 50 for a predetermined time to heat the butt-welded portion 50. The heat treatment is intended to induce spherodization of carbon tissues through heat treatment after welding because fibrous pearlite tissues are changed into quick frozen tissues due to butt welding.

According to the current embodiment of the present disclosure, heat treatment is performed twice, and current and voltage for primary heat treatment or secondary heat treatment are less than welding current and welding voltage for butt welding. Since current and voltage for primary heat treatment or secondary heat treatment are less than those for butt welding, it is possible to prevent excessive spherodization of the carbon tissues and to prevent the welded portion 50 from being easily separated.

Next, grinding or cutting is performed in operation S4.

The grinding is performed to remove an unnecessary burr generated in the welded portion 50, welding for which has been completed, by mechanical grinding or cutting. As shown in FIG. 7, according to the current embodiment, the diameter of the welded portion 50 butt-welded by grinding or cutting is less than 110% of the diameter of the twist cable 30. If the diameter of the welded portion 50 exceeds 110% of the diameter of the twist cable 30 after the grinding and the cutting, the welded portion 50 excessively protrudes from the twist cable 30, degrading an adhesive force with respect to the tire, such that the diameter of the welded portion 50 needs to be larger than the diameter of the twist cable 30 by the minimum possible amount, thereby preventing damage to the twist cable 30 during the grinding or the cutting.

Meanwhile, according to the current embodiment of the present disclosure, as shown in FIG. 5, the method may further include operation S5 of plating the welded portion 50 and operation S6 of coupling a clip ring 60 to the welded portion 50.

Operation S5 of plating the welded portion 50 is an operation of plating the welded portion 50 with the same metal as that used to plate the layer wire 20 after the grinding or the cutting.

The layer wire 20 is plated with bronze, brass, or zinc as described above, and the welded portion 50 is plated with the same metal as that used to plate the layer wire 20, thus improving an adhesive force with respect to the tire.

Operation S6 of coupling the clip ring 60 to the welded portion 50 is an operation of coupling the clip ring 60 plated with the same metal as that used to plate the layer wire 20 to the welded portion 50. The clip ring 60 structurally protects the welded portion 50 and is plated with the same metal as that used to plate the layer wire 20, contributing to improvement of an adhesive force with respect to the tire.

Operation S6 of coupling the clip ring 60 to the welded portion 50 may be performed, after the plating of the welded portion 50 is performed or skipped.

A cable bead 100 according to another embodiment of the present disclosure is provided.

As shown in FIG. 8, the cable bead 100 according to another embodiment of the present disclosure is manufactured by the above-described method of manufacturing a cable bead, and may include a twisted portion 40, the welded portion 50, and the clip ring 60.

The twisted portion 40 indicates a portion in which the core wire 10 and the layer wire 20 are twisted around the outer circumferential surface of the core wire 10, and the welded portion 50 indicates a portion in which both end portions of the twisted portion 40 are butt-welded.

That is, as described above in detail of the method of manufacturing the cable bead, the twist cable 30 is stranded by twisting the layer wire 20 around the outer circumferential surface of the core wire 10, and the twist cable 30 is cut into a predetermined length and both end portions thereof are butt-welded, thus manufacturing a ring cable. In this case, a portion of the layer wire 20 twisted around the outer circumferential surface of the core wire 10 corresponds to the twisted portion 40, and a portion where the both end portions of the twist cable 30 are welded together corresponds to the welded portion 50.

Processes of manufacturing the core wire 10 and the layer wire 20 and a process of stranding the twist cable 30 using the core wire 10 and the layer wire 20 are based on generally known methods. The core wire 10 and the layer wire 20 are made of carbon steel as described above, and the layer wire 20 is plated with bronze, brass, or zinc to improve an adhesive force with respect to the tire. Structures of the core wire 10 and the layer wire 20 have already been described in the foregoing description of the cable bead manufacturing process and thus will not be described in detail.

As shown in FIG. 8, the clip ring 60 is a member in the form of a ring coupled to the welded portion 50 to protect the welded portion 50. According to an embodiment of the present disclosure, the clip ring 60 is plated with the same metal as that used to plate the layer wire 20.

According to the current embodiment of the present disclosure, the diameter of the welded portion 50 is greater than about 100% of and less than about 110% of the diameter of the twist cable 30 made by twisting the core wire 10 around the layer wire 20. According to the current embodiment of the present disclosure, the twist cable 30 is stranded by twisting one layer wire 20 around the outer circumferential surface of the core wire 10 or twisting a plurality of layer wires around the outer circumferential surface of the core wire 10. After the twist cable 30 is cut into a predetermined length, both end portions thereof are butt-welded.

The welded portion 50 of the butt-welded twist cable 30 is mechanically grinded or cut to remove an unnecessary burr generated after the welding. The diameter of the welded portion 50 is reduced due to the grinding or the cutting, and the final diameter of the welded portion 50 is greater than about 100% of and less than about 110% of the diameter of the twist cable 30. A reason for setting the diameter of the welded portion 50 in the foregoing range has already been described and thus will not be described again.

The welded portion 50 may be plated with the same metal as that used to plate the layer wire 20. The layer wire 20 is plated with bronze, brass, or zinc, and the welded portion 50 is plated with the same metal as that used to plate the layer wire 20 after the grinding or the cutting. The effects of the plating of the welded portion 50 have already been described and thus will not be described again.

As such, in the cable bead manufactured using single welding and the method of manufacturing the cable bead according to the present disclosure, the twist cable 30 stranded by twisting the layer wire 20 around the outer circumferential surface of the core wire 10 is cut into a predetermined length and both end portions thereof are butt-welded, thereby simplifying a manufacturing process, improving productivity, and cutting down a manufacturing cost, when compared to a conventional case where a cable bead is made by butt-welding a ring-shape core wire and twisting a layer wire around the outer circumferential surface of the core wire.

It should be understood that exemplary embodiments described herein should be considered in a descriptive sense only and not for purposes of limitation. Descriptions of features or aspects within each exemplary embodiment should typically be considered as available for other similar features or aspects in other exemplary embodiments.

While one or more exemplary embodiments have been described with reference to the figures, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the inventive concept as defined by the following claims.

Claims

A method of manufacturing a cable bead based on single welding, the method comprising:

manufacturing a core wire and stranding a twist cable by twisting a layer wire around an outer circumferential surface of the core wire;

butt-welding both end portions of the twist cable;

primarily and secondarily heat-treating the butt-welded twist cable; and

grinding or cutting a butt-welded portion such that a diameter of the welded portion is greater than about 100% of and less than about 110% of a diameter of the twist cable.
The method of claim 1, further comprising plating the welded portion with metal that is the same as metal used to plate the layer wire.
The method of claim 1, further comprising coupling a clip ring, plated with metal that is the same as metal used to plate the layer wire, to the welded portion.
The method of claim 1, further comprising plating the layer wire,

wherein a thickness of a plated layer on the layer wire is about 0.1m through about 1.0m.
The method of claim 1, wherein current and voltage used for the primarily or secondarily heat-treating are less than welding current and welding voltage used for the butt-welding.
A cable bead manufactured using single welding, comprising:

a twisted portion in which a layer wire is twisted around an outer circumferential surface of a core wire;

a welded portion in which both end portions of the twisted portion are butt-welded; and

a clip ring coupled to the welded portion,

wherein a diameter of the welded portion is greater than about 100% of and less than about 110% of a diameter of the twist cable in which the core wire and the layer wire are twisted.
The cable bead of claim 4, wherein the welded portion is plated with metal that is the same as metal used to plate the layer wire.
The cable bead of claim 4, wherein the clip ring is plated with metal that is the same as metal used to plate the layer wire.
The cable bead of claim 6, further comprising a plated layer plated on the layer wire,

wherein a thickness of the plated layer is about 0.1m through about 1.0m.