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1、Steel Cord Construction Trends and the Developments in Bekaert钢帘线结构市场趋势及贝卡尔特的新产品开发钢帘线结构市场趋势及贝卡尔特的新产品开发 Contents 内容内容Why Steel Cord Reinforced Radial Tires ? 为何选用钢帘线增强子午胎？Steel Cord Construction Trends and Bekaert Developments 钢帘线结构市场趋势及贝卡尔特的新品开发 - Belts of Passenger Tires 乘用胎带束层 - Belts of Light / S
2、mall truck Tires 轻型/小型卡车胎带束层 - Belts of Medium/Heavy Truck Tires 中型/重型卡车胎带束层 - Carcasses of Truck Tires 卡车胎胎体Why Radials ? 为何用子午胎？为何用子午胎？Endurance 耐久性耐久性Radial tires run much cooler under all conditions (high speeds , high loads) and show higher durability compared to bias tires. 子午胎在所有的条件下（高速，重载）服役
3、温度更低，因而较斜胶胎具有更好的耐久性Why Radials ? 为何用子午胎？为何用子午胎？ Fuel Economy 燃油经济性燃油经济性Radial tires and especially steel reinforced radials have lower Rolling Resistance leading to better fuel economy.Lower aspect ratio helps further. 子午胎尤其是钢帘线增强的子午胎因其滚动阻力较小而具有较佳的燃油经济性。小的高宽比对此有进一步的贡献。Why Radials ? 为何用子午胎？为何用子午胎？ Va
4、lue for the Money 花钱值不值花钱值不值 0102030405060701980198119821983198419851986198719881989199019911992199319941995199619971998Avg price (inflation adjusted)05101520253035404550Avg. miles receivedAvg. price*USA Market* Average price adjusted for inflation - Base Yr 82-84=100Increasing average mileage vs. d
5、ecreasing price 子午胎平均里程不断上升而价格不断下降Why Radials ? 为何用子午胎？为何用子午胎？ Lower tire cost 轮胎成本更低轮胎成本更低Bias Tire 斜胶斜胶10.00-20 Radial Tire 子午子午11 R 22.5Why Radials? 为何用子午胎？为何用子午胎？ Retreadibility 可翻性可翻性Radial Truck and bus tires get ,in the average, more than one retreads in USA. As a result , 55-60% of all tires
6、 are retreaded ones. 在美国，子午卡车胎及公共汽车胎平均翻修一次以上。因而在所有正在使用的轮胎中大约有55-60%被翻修一次。USA MarketSteel Cord Construction Trends 钢帘线结构趋势钢帘线结构趋势Belts of Passenger Tires 乘用胎带束层乘用胎带束层Nx1 type cords allowing rubber penetration gained popularity in recent years over m+n types 近年来渗胶良好的 NX1型帘线较M+N型更为普及HT types became alm
7、ost an industry standard. 高强度几乎成为行业标准Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt Constructions- Passenger Tires 乘用胎带束层乘用胎带束层3X0.30 HT Betru0 N tension20 N tensionnx1 Type Betru Cords: NX1 型贝特鲁帘线It improves rubber penetration without excessive increase of diameter and cord elongation at low loads(LLE)
8、. 较传统帘线它改善了渗胶性能而并未很大程度地增大帘线直径及低载荷延伸Insulation compound requirement goes down and ply gages are low. Cord processability in tire plants also improves. 带束层胶料的用量降低因而帘布更薄。帘线在轮胎厂的工艺性能亦得到了改善 Strength and Fatigue Level losses are negligible. So , Betru preforming can be used both for belt and carcass reinf
9、orcement. 帘线的强度及疲劳性能的损失可以忽略不计。所以，贝特鲁变形技术不仅可应用于带束层帘线，亦可应用于胎体帘线Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt Constructions- Passenger Tires 乘用胎带束层乘用胎带束层Betru Technology preforms the filaments lightly and creates microgaps along the cord which do not close with moderate tensions 贝特鲁技术给钢丝施加轻微变形，使钢丝与钢丝之间产生微
10、小间隙以保证渗胶。这种间 隙能承受一定的张力而不闭合Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt Constructions- Passenger Tires 乘用胎带束层乘用胎带束层Open Cords have significantly higher structural elongation (LLE) and high diameter as a result of heavy preformation. Betru cord has a high tenacity and compactness ; both important for ef
11、fective reinforcement 开放型帘线具有明显高的结构延伸率（LLE），因钢丝变形较大，所以帘线直径亦较大。而贝特鲁帘线则韧度高且结构紧凑。这两点对轮胎的有效增强都很重要Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt Constructions- Passenger Tires 乘用胎带束层乘用胎带束层Betru cord as well as 2X1 and 2+1 cords came out to be fully rubber penetrated in all the tests 所有的试验表明，贝特鲁及2*1和2+1帘线均为全渗
12、胶 It is clear that Open Cord closes with 20 N tension during curing 开放型帘线在20N的硫化应力下将闭合。这一点已毋庸置疑。Equal Strength Cord Replacement - PCR Belt帘线的等强替换帘线的等强替换 乘用胎带束层乘用胎带束层Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt Constructions- Passenger Tires 乘用胎带束层乘用胎带束层Conclusions 结论结论There is a trend for nx1 type cor
13、ds with improved rubber penetration. 使用渗胶性能得到改善的 N*1型帘线是一种趋势2X1 types need higher cord end counts and result less space between cords.This also means many creel positions and longer creel loading times. 2*1型帘线需要更高的密度，因而帘线间的间距更小。这也意味着在锭子房需要更多的放线位置以及更长的上工字轮时间Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt
14、Constructions- Passenger Tires 乘用胎带束层乘用胎带束层Conclusions 结论结论Rubber penetration of “open” cords are sensitive to processing and curing tensions. Its high LLE is a disadvantage for tire handling 开放型帘线的渗胶效果对工艺过程中和硫化时的应力很敏感。它的高LLE（低载荷延伸）对轮胎操纵过程亦不利 Hence, 3x1 HT/ST Betru cords stick out as the best altern
15、atives for PCR tire belts. 所以，3*1HT/STBetru 自然傲视其它帘线，成为乘用胎带束层帘线的最佳选择 Steel Cord Construction Trends钢帘线结构趋势钢帘线结构趋势Belts of Light Truck/Small Truck Tires 轻轻 / 小型卡车胎带束层小型卡车胎带束层Steel Cord Construction TrendsBelts of Medium/Heavy Truck Tires中中 / 重型卡车胎带束层重型卡车胎带束层Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Belt C
16、onstructions- Medium Truck Tires 中型卡车胎带束层中型卡车胎带束层A Constructions such as 3+6 X (0.20/0.35) NT or HT S/Z , 10/18 is still very popular. 诸如3+6 *(0.20/0.35)NT 或HT 依然流行Bekaert now offers 1+6 X(0.365/0.35) Betru HT S and 5X0.38 Betru HT S for better performance and improved economy. 但贝卡尔特提供的1+6*（0.365/0.
17、35)HT贝特鲁和5*0.38HT贝特鲁帘线表现更佳且更经济 Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Belt Constructions- Medium Truck Tires 中型卡车胎带束层中型卡车胎带束层All tests show improved rubber penetration for 1+6 Betru cords. Hence , corrosion and core migration risks are further reduced. 所有的试验表明1+6贝特鲁帘线的渗胶（较3+6）得到了改善。因而腐蚀及芯线移位的风险被进一步降低B
18、ekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Belt Constructions- Medium Truck Tires 中型卡车胎带束层中型卡车胎带束层Equal end count replacement with Betru cords is possible with some performance improvement and cost reduction 用（1+6）贝特鲁等密度替换（3+6）是可能的，并且性能改善成本降低Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Belt Constructions- Medium T
19、ruck Tires 中型卡车胎带束层中型卡车胎带束层5x0.38 HT BetruBekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Belt Constructions- Medium Truck Tires 中型卡车胎带束层中型卡车胎带束层All sections show good rubber penetration 所有横截面均渗胶很好Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt Constructions- Heavy Truck Tires 重型卡车胎带束层重型卡车胎带束层A Construction such as
20、 3+9+15X0.22+1 S/S/Z/S is still popular. 诸如3+9+15*0.22+1之类结构依然流行Although rubber penetration is not full and cost is high , it has a good overall performance under “on and off” road service 尽管该结构渗胶不充分且较贵，但其在各种路况下综合表现良好Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt Constructions- Heavy Truck Tires 重型卡车胎带束
21、层重型卡车胎带束层Bekaert now offers4+6X0.38 Betru HT /S for an improved performance and better economy. 贝卡尔特现提供 的4+6*0.38HTBetru 表现更佳且更经济Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Belt Constructions- Heavy Truck Tires 重型卡车胎带束层重型卡车胎带束层Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Belt Constructions/Protection Layer - Truc
22、k Tires卡车胎保护层卡车胎保护层Classical protection layer cords (e.g. 4X4x0.22 HE , 3x7x0.22 HE) have less than full rubber penetration. 经典保护层帘线如4*4*0.22HE及3*7*0.22HE渗胶不充分They are also expensive due to small filament diameter and very short lay lengths. 因钢丝直径细，捻距短，这类帘线价格很贵Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Be
23、lt Constructions/Protection Layer - Truck Tires卡车胎保护层卡车胎保护层The HI cords have high elongation before or after rubber embedment and full rubber penetration. 贝卡尔特的HI抗冲击帘线在埋胶前后均具有很高的断裂延伸率，而且为全渗胶Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Belt Constructions/Protection Layer - Truck Tires卡车胎保护层卡车胎保护层A “HI” Cord
24、such as 5X0.38 HI ensure - improved corrosion resistance - impact absorption - a lower ply gage/ weight - a lower cost in the tire诸如诸如5*0.38HI之抗冲击帘线能确保之抗冲击帘线能确保-抗腐蚀能力得到改善抗腐蚀能力得到改善-吸收冲击能吸收冲击能-更低的帘布厚度更低的帘布厚度/重量比重量比-更低的成本更低的成本Steel Cord Construction Trends 钢帘线结构趋势钢帘线结构趋势Carcasses of Truck Tires 卡车胎胎体卡车
25、胎胎体Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发 Carcass Cords 胎体钢帘线胎体钢帘线Cord constructions for life time improvement * High Fatigue Resistance - Small filament diameters - Higher Tensile Strengths - Good /Robust Production Process * High Fretting Resistance - Compact Cords with line contacts - Wrapless Cor
26、ds - Rubber Penetrating Cords能延长轮胎寿命的胎体帘线具有 * 高的抗疲劳性能 - 细的钢丝直径 - 更高的强度 - 好而稳固的生产过程 * 高的抗磨损能力 - 钢丝间呈线接触的紧密型帘线 - 无外绕帘线 - 渗胶好的帘线Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Small/Medium Truck Tires 小小/中型卡车胎胎体帘线中型卡车胎胎体帘线Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Small/Medium Truck Ti
27、res 小小/中型卡车胎胎体帘线中型卡车胎胎体帘线All cords have comparable stiffness, compression and impact resistance results 以上所有帘线在刚度，抗压及抗冲击方面的测试结果相差不大 Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Small/Medium Truck Tires 小小/中型卡车胎胎体帘线中型卡车胎胎体帘线3+8 gives the best rubber penetration due to more space it has betwe
28、en the outside filaments。3+8的渗胶最好，因其外层钢丝之间间距较大Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Small/Medium Truck Tires 小小/中型卡车胎胎体帘线中型卡车胎胎体帘线Fatigue resistance results are somewhat higher with compact cords due to lower internal contact stresses 由于内部接触应力相对更低，紧密型帘线的抗疲劳性能稍好Bekaert Developments 贝卡
29、尔特新品开发贝卡尔特新品开发Carcass Cords - Fretting Evaluation 胎体帘线的抗磨损评估胎体帘线的抗磨损评估Endless Belt Test 环带试验Test conditions： 试验条件Pulley diameter轮径: 143 mmAxial load 轴向载荷: 400 N/mmTest Duration 周次: 40-100-150 Million CyclesEvaluation of fretting damage： 磨损评估Loss of BL filaments 钢丝破断拉力损失Loss of bending ductility of f
30、ilaments(Dynamic Bending test) 钢丝韧塑性损失（动态弯曲试验）Visual analysis / Erosion in filaments 目测钢丝表面磨损Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Small/Medium Truck Tires 小小/中型卡车胎胎体帘线中型卡车胎胎体帘线Bekaert Developments贝卡尔特新品开发贝卡尔特新品开发 Carcass Cords of Small/Medium Truck Tires 小小/中型卡车胎胎体帘线中型卡车胎胎体帘线3+9X0.2
31、23+8X0.22 HT3+9X0.22+1After 100 million cycles循环1亿次以后Bekaert Developments贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Small/Medium Truck Tires 小小/中型卡车胎胎体帘线中型卡车胎胎体帘线3X0.22+9X0.20cc3X0.22+9X0.20cc+1After 100 million cycles循环1亿次以后Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Small/Medium Truck Tires 小小/中型卡
32、车胎胎体帘线中型卡车胎胎体帘线Conclusions 结论结论S/S type two layer cords and 12 compact cords perform similarly in most static and dynamic lab tests 3+9 S/S 双层帘线和紧密型帘线在大多数实验室静态及动态试验中表现相近双层帘线和紧密型帘线在大多数实验室静态及动态试验中表现相近Wrapless cords 3+8X0.22 S/S 3X0.22+9X0.20cc S give best fretting performance (Endless Belt test) Howev
33、er, they are also more difficult to process in tire plants. 无外绕的无外绕的3+8*0.22 S/S 和和3*0.22+9*0.20CC S帘线的抗磨损性能最好，但帘线的抗磨损性能最好，但它们在轮胎厂的工艺性能亦更加困难它们在轮胎厂的工艺性能亦更加困难Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Heavy Truck Tires 载重胎胎体帘线载重胎胎体帘线Still classical layer constructions such as 3+9+15* (0.175
34、 or 0.22)+1 SSZS 3+9+15* (0.175 or 0.22) SSZ or 3+8+13 SSZ are used where target life time is less than 1/2 million kms. 在轮胎寿命小于在轮胎寿命小于50万公里的地区依然是以上经典结构万公里的地区依然是以上经典结构Bekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Heavy Truck Tires 载重胎胎体帘线载重胎胎体帘线But , 19 compact cords such as 1+18cc * ( 0.20/
35、0175 ) S ( 0.22/0.20) S ( 0.25/0.22 ) S are gaining popularity in US and Europe where 2-3 times retreading is very common. 但在但在2-3次翻胎非常普遍的欧美，紧密型帘线次翻胎非常普遍的欧美，紧密型帘线19CC的使用正越来越广泛的使用正越来越广泛An equally performing layer cord 1+6+12 S/S with improved economy is being developed in Bekaert 贝卡尔特正在开发具有相同性能的层状帘线1
36、+6+12 S/S。它的经济性更佳。Carcass Cords of Heavy Truck Tires Endless Belt Test Comparison 环带试验比较3+9+15x0.175 NT +1Before 试验前试验前After 试验后试验后3+9+15x0.175 NTbeforeafter3+8+13x0.175 NTBefore 试验前试验前After 试验后试验后0.20+18x0.175 cc NTBekaert Developments 贝卡尔特新品开发贝卡尔特新品开发Carcass Cords of Heavy Truck Tires 载重胎胎体帘线载重胎胎体
37、帘线Conclusion 结论结论3+9+15x0.175 NT +1 S/S/Z/Spoor fretting performance due to SZ point contacts and the wrap.由于S向与Z向之间的点接触及外绕丝的存在，该结构耐磨损性能较差3+9+15x0.175 NTImprovement on outside filaments compared to wrapped version和有外绕结构相比，该结构外层钢丝（磨损）情况有所改善3+8+13x0.175 NTSame as previous cord. Rubber penetration can
38、not stop fretting between filaments of different layers情况和上一结构类似。渗胶并不能阻止不同层钢丝间的磨损0.20+18x0.175 cc NT Best cord: line contacts between filaments , no wrap. 该结构最好：钢丝间线接触，无外绕Conclusion 结论结论Bekaert not only follows the reinforcement trends but also create them in cooperation with most major tire makers.
39、 贝卡尔特不仅紧随轮胎增强材料的发展趋势，而且和大多数主要轮胎制造商通力合作，从而缔造这一趋势。Thanks to his excellent global positioning, Bekaert can understand the local needs and develop/adapt products accordingly. 贝卡尔特的全球定位使其能精确理解不同区域的不同需求，并开发/调整出与之相适应的产品Bekaert is committed to serve the Tire Industry in China with local resources and top priority global support. 贝卡尔特决心以本土化的资源和全球的优先支持为中国轮胎工业作出贡献
