1. SRINI FIBRE REINFORCEMENT

2. TOPICS Introduction History Of Tire Reinforcing Materials –Current Reinforcement Line-up Fibre Manufacturing Processes –Spinning / Drawing Fabric Production –Twisting/weaving –Processing Fibre Adhesives Property Comparison of different fabrics Summary

3. FUNCTIONS OF A TYRE 1.Provide load-carrying capacity 2.Provide cushioning 3.Transmit driving and braking torque 4.Produce cornering force 5.Provide dimensional stability 6.Resist abrasion 7.Provide steering response 8.Be durable & safe

4. DIFFERENT TYPES OF TYRES

5. TYRE COMPONENTS 1.THE TYRE IS A COMPOSITE OF A RELATIVELY LOW STRENGTH, HIGH ELONGATION RUBBER MATRIX & A HIGH STRENGTH, LOW ELONGATION TIRE CORD. 2.THE TYRE CORD GIVES THE TIRE SHAPE, SIZE, STABILITY, LOAD CARRYING CAPACITY, FATIGUE & BRUISE RESISTANCE. 3.TYRE CORDS ALSO AFFECT IMPACT RESISTANCE, RIDE, HANDLING, TREAD WEAR & FUEL ECONOMY. Overlay Belt Carcass Bead

6. COMPONENTS AND THEIR FUNCTIONS-1 OVERLAY: Placed on top of belt, often called cap ply, used to further improve crown area durability and high speed performance. BELT/BREAKER: Belts have lower angle than plies, provide tread area stiffness for improved tread wear & provide protection from foreign objects (e.g. rocks). Breakers have nearly the same angle as the plies and do not restrict the carcass plies, but provide crown area durability. CARCASS: Extending from bead-to-bead, often called ply, primary reinforcing & strength member of the tire.

7. COMPONENTS AND THEIR FUNCTIONS-2 BEAD: Multiple strands of wire, rubber coated & formed into extensible hoops, anchors ply & tire to the rim, also provides bulk & stiffness (in the bead area) to eliminate tire movement on the rim. FLIPPER: Provides a barrier between the ply and bead to prevent ply erosion CHIPPER: Provides lower bead-area stiffness to absorb deflection, and reduce chaffing

8. FIBER TERMINOLOGY-1 FILAMENT SMALLEST TEXTILE COMPONENT. A NEAR MICROSCOPIC, HAIRLIKE SUBSTANCE THAT MAY BE NATURAL OR SYNTHETIC. YARN - A CONTINUOUS STRAND SPUN FROM A GROUP OF NATURAL OR SYNTHETIC STAPLE FIBERS, OR FILAMENTS. PLY - ALL YARNS ARE SINGLE PLY, UNLESS TWISTED WITH ANOTHER YARN. - 2-PLY IF TWO YARNS ARE TWISTED TOGETHER AND 3-PLY IF THREE ARE TWISTED TOGETHER. - PLIED YARNS ARE USED TO MAKE YARNS STRONGER.

9. FIBER TERMINOLOGY-2 TIRE CORD - THE PRODUCT FORMED BY TWISTING TOGETHER TWO OR MORE PLIED YARNS. WARP - THE LENGTHWISE, VERTICLE CORDS CARRIED OVER AND UNDER THE WEFT. WEFT - ALSO CALLED FILL OR PICKS. THE LENGTHWISE, SELVAGE TO SELVAGE HORIZONTAL, YARNS CARRIED OVER AND UNDER THE WARP. - USED TO HOLD FABRIC TOGETHER THROUGH SUBSEQUENT PROCESSING OPERATIONS.

10. FIBER TERMINOLOGY-3 DENIER/DECITEX - TERM FOR THE LINEAR DENSITY(MASS PER UNIT LENGTH) OF A TEXTILE MATERIAL. DENIER - THE WEIGHT IN GRAMS OF 9000 METERS; - DECITEX IS WEIGHT IN GRAMS OF 10,000 METERS. TWIST - THE NUMBER OF TURNS ABOUT ITS AXIS PER UNIT LENGTH OF A YARN OR OTHER TEXTILE STRAND. CORD STRENGTH (Tenacity) - ULTIMATE TENSILE LOAD OR FORCE REQUIRED FOR RUPTURE. - FREQUENTLY, TIRE CORD STRENGTH IS EXPRESSED IN TERMS OF CENTINEWTONS PER TEX -CALLED TENACITY. -THE FORMULA FOR TENACITY IS = ( BREAK STRENGTH(N) /(DECITEX)*1000 = cN/TEX

11. FIBER TERMINOLOGY-4 CARCASS STRENGTH - CARCASS STRENGTH IS A FUNCTION OF CORD STRENGTH, CORD COUNT ( ENDS PER INCH -EPI ) AND NUMBER OF PLIES - CARCASS STRENGTH = ( CORD STRENGTH * CORD COUNT * NUMBER OF PLIES ) RIVET - SPACE AVAILABLE BETWEEN TWO ADJIOINING CORDS FOR GUM TO FILL- ALSO REFFERED AS FILL GUM SPACE.. - FORMULA IS - 1 - (ENDS PER INCH X CORD GAUGE) / ENDS PER INCH

12. HISTORY INTRODUCEDMATERIAL COMMENTS 1890’sBead wire Normal tensile 1900 Cotton Staple fibers, NO treating 1936Steel (Europe) Normal tensile/copper plated 1938Rayon Tension treating w/simple RFL 1947Nylon 6, 66 Treating w/modified RFL 1955Steel (USA) Normal tensile/brass plating 1962Polyester Treating w/modified RFL

13. HISTORY DATE MATERIALCOMMENTS 1966FiberglassTreating w/simple RFL 1974Aramid Heat treat w/special RFL 1982HMLS PET3T treating w /epoxy-based RFL 1986HT Steel/bead wireHigh tensile w/brass plating 1992ST SteelSuper tensile w/brass plating 1998UT SteelUltra tensile w/brass plating

14. New development -HYBRID HYBRID FABRIC- SOME EXAMPLES PET/NYLON ARAMID/NYLON

15. SINGLE END CORD SINGLE CORDS DIPPED TREATED USED IN VARIOUS APPLICATION- INCLUDING TYRE OF DIFFERENT MATERIAL SUCH AS NYLON, ARAMID, HYBRID

16. USAGE APPLICATIONPASSENGERRLT OVERLAYNylonNylon BELTSteelSteel CARCASSPolyesterPolyester BEADSteelSteel CHIPPER/FLIPPERNylonNylon

17. USAGE APPLICATIONAIRCRAFTFARMOTR RMT OVERLAYNylon n/aNylon n/a BELTNylonPolyester Steel/Nylon Steel CARCASSNylonNylon/Polyester Steel/Nylon Steel BEADSteelSteelSteel Steel CHIPPER/FLIPPERNylonn/aNylon Steel

18. FIBRE MANUFACTURING – SPINNING – SOLUTION SPINNING – MELT SPINNING DRAWING

19. FIBRE CHEMICAL COMPOSITION

20. RAYON Wood Pulp + NAOH Alkali Cellulose Shredded & Aged + CS 2 Cellulose Xanthate + NAOH Viscose Ripening Wet Spinning w/H 2 SO 4 RAYON Slashing

21. NYLON NYLON 66 Adipic Acid + NH3 Cyclohexane + Air + Air Adipic Acid Nylon Salt Polymerization + Melt Spinning Adiponitrile + H Hexamethylene Diamine Nylon 66

22. POLY ESTER Ethylene Glycol + DMT/TPA Polymerization Solid State Melt Spinning PolyEthylene Terephthalate (PET)

23. ARAMID Terephthalate Acid Polymerization Wet Spinning w/Sulfuric Acid p-Phenylenediamine p-phenylene terephthalomide (aka ARAMID) Common Trade Names Twaron ® & Kevlar ® Twaron ® & Kevlar ®

24. FABRIC PRODUCTION TWISTING WEAVING PROCESSING

25. CONVERSION OF CORD TO FABRIC STEP 1: TWISTING

26. TWISTINGYARN PLY TWIST CORD TWIST

27. TYRE CORD

28. TWISTING Linear density of base yarn (units: decitex) 1400 / 1 / 3, 315Z x 315S # of yarns in ply # Twist count & direction for cord (units: turns per meter) # plies in cord EXPLANATION

29. PERFORMANCE WITHOUT TWIST PERFORMANCE WITHOUT TWIST

30. EFFECT OF TWISTING Improves bundle integrity (holds filaments together) Improves bundle integrity (holds filaments together) Combines two or more yarns Combines two or more yarns Increases Durability & Elongation Increases Durability & Elongation Decreases Tensile Strength & Modulus Decreases Tensile Strength & Modulus

31. WEAVING The twisted cords lie in the machine direction, while the fill yarn is woven across the warp cords.The twisted cords lie in the machine direction, while the fill yarn is woven across the warp cords. Provides means to interlace the twisted cords with filling yarns to form a woven fabric.Provides means to interlace the twisted cords with filling yarns to form a woven fabric.

32. DIP PROCESSING Application of adhesive Application of adhesive Enhance the physical properties of the fabric Enhance the physical properties of the fabric Stabilize the fabric for subsequent plant application Stabilize the fabric for subsequent plant application Equalize differences between yarn sources Equalize differences between yarn sources

33. DIPPING PROCESS APPLICATION OF ADHESIVE & TREATMENT OF FABRIC UNDER CONTROLLED CONDITIONSAPPLICATION OF ADHESIVE & TREATMENT OF FABRIC UNDER CONTROLLED CONDITIONS –TIME –TEMPERATURE –TENSION DIFFERENCES RESULTING FROM SOURCE OF SUPPLY & MILL PRODUCTION VARIANCES ARE REDUCEDDIFFERENCES RESULTING FROM SOURCE OF SUPPLY & MILL PRODUCTION VARIANCES ARE REDUCED –ADHESION –TENSILE PROPERTIES –THERMAL STABILITY –DURABILITY FABRIC PROCESSING IMPARTS ABOVE CHARACTERISTICS BY CONTROLLING THE PHYSICAL STATE OF FIBREFABRIC PROCESSING IMPARTS ABOVE CHARACTERISTICS BY CONTROLLING THE PHYSICAL STATE OF FIBRE –AMORPHOUS AREAS ARE PLASTICIZED BY MOISTURE & HEAT –TENSION IS APPLIED TO CREATE LINEAR ORIENTATION ALONG THE FIBER AXIS –TIME, TEMPERATURE & TENSION RELATIONSHIPS ARE THUS CRITICAL.

34. DIP UNIT MULTI STAGE DIP UNIT MULTI STAGE DIP UNIT

35. DIPPING PROCES EACH FIBRE TYPE & CORD CONSTRUCTION REQUIRES A UNIQUE PROCESSEACH FIBRE TYPE & CORD CONSTRUCTION REQUIRES A UNIQUE PROCESS SPEED DIFFERENTIAL, BETWEEN PULL ROLLS, PROVIDE SPECIFIED STRETCH FOR EACH ZONE.SPEED DIFFERENTIAL, BETWEEN PULL ROLLS, PROVIDE SPECIFIED STRETCH FOR EACH ZONE. HIGH TEMPERATURES REQUIRED TO ACTIVATE THE ADHESIVE & ESTABLISH DESIRED CORD PROPERTIESHIGH TEMPERATURES REQUIRED TO ACTIVATE THE ADHESIVE & ESTABLISH DESIRED CORD PROPERTIES MULTIPLE ZONE PROCESS REQD FOR DOUBLE DIP SYSTEM FOR FIBERS SUCH A POLYESTER, NYLON & ARAMID.MULTIPLE ZONE PROCESS REQD FOR DOUBLE DIP SYSTEM FOR FIBERS SUCH A POLYESTER, NYLON & ARAMID.

36. TEMPERATURE VS SHRINKAGE

37. DIP PICK UP VS ADHESION

38. EFFECT OF TIME AND TEMP

39. PURPOSE OF DIP Bond dissimilar materials Transfer stresses from high modulus fiber to low modulus rubber Cushion fibers from fretting

40. SIMPLE DISPLAY Wide array of compositions and application techniques available for fiber adhesives Fiber type, end use and production requirements define limits to design –Coated fiber form (yarn, cord, or fabric) –Mechanical requirements (coating thickness, penetration, flexibility) –Chemical requirements (bonding to fiber and rubber matrix) –Service requirements (temperature, fatigue, age) UNTREATED FIBER ADHESIVE / HEAT TREATED FIBER CURED RUBBER COMPOSITE DIP UNIT

41. MECHANISM OF RFL DIP

42. DIP ON PLY ESTER Polyester fiber has weaker interaction with RFL adhesives than nylon or rayon –Hydrogen bonding much weaker with polyester –Energetics unfavorable for RF resin/polyester interaction Epoxy resins applied to fiber or combined with RFL adhesive to provide adhesion –Epoxy resin selected for best compatibility with fiber –Resin components in RFL adhesive bond with epoxy

43. TENACITY POLY ESTE R NYLON FIBE RGL ASS ARA MID

44. CORD MODULAS POLYESTER NYLON FIBER GLAS S ARAMID

45. ADHESION POLYESTER NYLON FIB ER GL ASS ARAMID

46. DURABILITY POLYESTER NYLON FIBER GLASS ARAMID

47. SUMMARY THE DEGREE OF FREEDOM AVAILABLE TO TIRE ENGINEER IN DESIGNING A TIRE COMPOSITE INCLUDE: 1. CHOICE OF A MULTITUDE OF CORD MATERIALS (RAYON, NYLON, POLYESTER, FIBERGLASS, ARAMID ETC) 2.AN ARRAY OF CORD CONSTRUCTIONS- e g 2-ply, 3-ply etc. 3.CORD TWIST LEVEL (e g 315Zx315S, 394Zx394S, etc.), balance vs. unbalanced etc. 4.VARIETY OF LINEAR DENSITIES 5.SELECTION OF RIVET AND NUMBER OF REINFORCEMENT LAYERS FOR VARIOUS COMPONENTS e g # OF PLIES - 10 Ply Actual, # OF BELTS, CHIPPERS, EPI COUNT etc.

48. SUMMARY SELECTION OF REINFORCMENT MATERIAL/CONSTRUCTION KEY TO OPTIMIZING IN-TIRE COMPOSITE PERFORMANCE.