1. A metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn comprises of: an aluminum tubes or bobbin, a rubber, a chemical or glue, characterizing in that, said aluminum tubes or bobbin is coated with a high abrasion synthetic rubber with the help of the chemical or glue to provide soft surface.

2. The metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 1, wherein the rubber SBR (styrene butadiene rubber) or NBR (nitrile-butadiene rubber) is coated on the aluminum tubes or bobbin.

3. A method to coat metal yarn carrier with resilient member on outer surface for partially oriented synthetic yarn comprising: a) the aluminum tubes or bobbin is grinded to make rough surface, b) the chemical or glue is applied on surface of aluminum tubes or bobbin make adhering surface, c) the rubber (2) sheet of thickness of 4-8 mm wrap around the aluminum tubes or bobbin and cut once the outer surface is covered with rubber, d) the aluminum tubes or bobbin coated with rubber is heated in furnace for one hour and curing process is applied, e) the aluminum tubes or bobbin coated with rubber is grinded to provide finishing.

4. The method to coat metal yarn carrier with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 3, wherein the heating and curing both process takes one day.

5. The metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 1, wherein the aluminum tubes or bobbin of size 110mm ID (Inner Diameter) x 116mm OD (Outer diameter) or 110mm ID x 115mm OD or 110mm ID x 114mm OD are developed from alloy 6082/6061/6063.

6. The metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 1 and 5, wherein extruded porthole aluminum bobbin used as feed stock or mother tube in T4 or M conditions for 6082 and 6061 alloy wherein T4 condition means solution treated porthole extruded bobbin which does not require solution treatment in later stages and M condition means as manufactured porthole extruded bobbin without solution treatment at extrusion stage and requires solution treatment at a later stage.

7. A method to manufacture the aluminum tubes or bobbin is by following steps: a) an alloy is casted into shape suitable for extrusion by continues or semi-continues casting i. e. round billet and the round tubes is extrude from billet into a required size, b) the cross section area of the aluminum tubes in cold drawing process from step (a) reduced to improving the surface finish and increase the tensile strength of the aluminum tubes with reference to extruded aluminum tubes, c) the cold drawn aluminum tubes from step (c) are straightened on hyperbolic 6 rolls machine to carry out with tubes input from one direction, d) the extruded tubes of M condition (manufactured condition) are solution treated at this stage followed by age hardening, e) the aluminum tubes in artificial age hardening process, are heated at 160 to 200° C for soaking time of 6 to 18 hours, f) the aluminum tubes form step (e) are cut to achieve required length followed by heat treatment.

8. The metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 1, wherein a bulk continuous filament yarn is also winded on metal yarn carrier coated with resilient member as high speed winder. Dated this on 1st of February, 2024

DESC:FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)
1. TITLE OF THE INVENTION: “A METAL YARN CARRIER COATED WITH RESILIENT MEMBER ON OUTER SURFACE FOR PARTIALLY ORIENTED YARN”
2. APPLICANT:
(A) Siddhi Engineers
(B) Indian
(C) “SIDDHI HOUSE”
6, Virkunj Society,
Near Vidyanagar School,
Usmanpura, Ahmedabad
Gujarat-380014

PROVISIONAL
The following specification describes the invention. þ COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF INVENTION:
The present invention relates to an aluminum yarn carrier for Partially Oriented synthetic Yarn (POY) on high speed winder. Particularly, the present invention relates to aluminum yarn carrier coated with resilient member on outer surface to hold Partially Oriented synthetic Yarn with the same tendency like paper tube.

BACKGROUND OF THE INVENTION
Polyester (PES) is one of important synthetic fibers. This synthetic fiber has several advantages e.g. good tenacity, resistance to the sunlight, easily to be processed and produced, widely used. One of the most frequently used processes to produce synthetic polymers fibers is melt spinning. This process includes polymer melt extrusion through a small capillary die then pulled by winding the filament at high speed while solidified using cooled air. Particularly, for polyester filament produced at high winding speed, i.e. 2500-3500 m/min is called Partially Oriented Yarn (POY), and then thermo mechanically drawn to improve its physical properties. The processing conditions (e.g. extrusion temperature, cooling process) significantly affect the physical properties of yarns/threads produced. For instance, textile materials used for sewing thread, rope, net should have high strength/tenacity of at least 7.5 g/d, while the ability to accept dyes, optical fiber is a secondary goal. Additionally, there are several factors that affect the melt spinning process are momentum and heat transport processes, melt rheological, molten polymer orientation, glass transition, stress induced, ratio of crystallization.
The main use of Polyester in Textile is for making yarns, of which nearly 40% of the world's production of direct polyester is used to make Polyester Yarn. Polyesters in different forms are widely used in textile applications to make polyester (PET) resin and filament yarn such as partial mono filament yarn, Drawn Textured Yarn (DTY), Fully Drawn Yarn (FDY), Polyester Staple Fiber (PSF), Polyester Spun Yarn (PSY), and Partially Oriented Yarn (POY). POY is a yarn produced from polyester fibers spun with molten spinning and derived from long filament fibers or continuous filament. The filament fibers used have low strength with a very high percentage of elongation.
POY threads are semi-finished threads made of melted PET chips and then through a spinning process. Polyester fibers spun with molten spinning generally produce POY yarns. These filaments are made from the melting of the polyester chip melt. In the spinning process, the speed of withdrawal affects the type of yarn produced, namely: a) At the speed of 500-1800 m / min produced the type of Un-Drawn Yarn (UDY) and Low Oriented Yarn (LOY); b) At the speed of 2600-4500 m / min generated type of Partially Oriented Yarn (POY); c) At speed of 2500-5000 m / min (with integrated drawing) produced the type of Fully Drawn Yarn (FDY); d) At a speed of 5000-6000 m / min produced a type of super high- speed yarn.
Fibers can be drawn either as an integral part of the spinning operation or in a separate step. Fibers such as nylon and polypropylene can be drawn without applying external heat (or at a temperature no greater than about 70 °C [160 °F])—a process referred to as cold drawing. Other fibers, such as polyester, that are spun at extremely high rates yield what is known as partially oriented yarns (POY)—i.e., filaments that are partially drawn and partially crystallized and that can be drawn at a later time during further operations. Many fibers, such as PET, require that a hot-drawing step follow the spinning process fairly soon, or they will become brittle. Avoiding such brittleness is part of the reason for preparing partially oriented yarns.
A paper tube used in the production of polyester synthetic fibers, comprising a paper tube body, two protruding bands are provided at both ends of the paper tube body, and the protruding bands are set as rounded corners. With the rapid increase in the output of polyester filaments in various countries, the use of paper tubes for winding filaments in the production of polyester synthetic fibers is very large. In order to save costs and avoid waste, it is necessary to recycle the paper tubes which also require additional cost, time and effort to manufacturers.
Especially when using recycled POY paper tubes, the broken end phenomenon is more prominent, and the one-time use of paper tubes will cause great waste and increase costs, and recycling and reusing paper tubes is the development direction of a conservation-oriented society. On the premise of using paper tubes, how to reduce the breakage rate in the unwinding process and increase the clean rate of POY raw yarn is an urgent problem to be solved in the spinning industry.
Paperboard tubes are formed of layers which have been adhered together during the manufacturing process. And the paperboard forming each of these layers is an orthotropic material having properties in the lengthwise or machine direction (MD) that are different from the properties of the same paperboard in the widthwise or cross machine direction (CD) due to the tendency for more paper fibers to be aligned along the MD as compared to CD. In addition, paperboard strength properties in the direction perpendicular to the plane of the paper are less than those of the paperboard in either the MD or CD, also due to fiber alignment.
Indeed, there is a need to have aluminum bobbin that consists of strength like metal tube to prevent end deformation and outer surface with properties like soft surface that is adaptive to other nearby components in abrasive condition.
OBJECT OF THE INVENTION:
The principal object of the present invention is to provide a metal carrier coated with resilient member on outer surface for partially oriented synthetic yarn.
The further object of the present invention is to provide a metal carrier coated with resilient member on outer surface for Bulk Continuous Filament Yarn as also High Speed Winder.
The further object of the present invention is to provide aluminum carrier prepared by cold drawn technique and further coated with high abrasion synthetic rubber.
The further object of the present invention is to provide aluminum alloy tube with outside coating of rubber material having excellent ductility, suitable tensile strength and proof stress.
The object of the present invention is to provide yarn carrier made from aluminum alloy 6061/6063/6082, coated with rubber on outer side, which is suitable for winding Nylon, HDPE, Polypropylene synthetic yarn.
The object of the present invention is to replace the paper tube with aluminum tube/bobbin having coated with rubber material on outer surface to provide fabric carrier for synthetic yarn.
Yet another object of the present invention is to provide an aluminum bobbin that consists of strength like metal tube to prevent end deformation and outer surface with properties like soft surface that is adaptive to other nearby components in abrasive condition.
SUMMARY:
A present invention discloses a metal carrier coated with resilient member on outer surface for partially oriented synthetic yarn. The present invention discloses aluminum bobbin prepared by cold drawn technique and further coated on outer surface with high abrasion synthetic rubber to provide soft surface to other nearby components in abrasive condition. The coating of resilient member i.e. rubber has carried out by threading or gluing outer surface to firmly hold continuous layer of rubber on outer surface of the bobbin. The metal carrier disclosed herein is considered as ideal replacement for paper tube used on synthetic yarn manufacturing. The bobbin disclosed herein can be used for multiple cycles up to 50-60 cycles compared to paper tubes. Further the aluminum cold drawn tubes provides accurate, vibration free, straight tube so that the rotation at very high R.P.M. during yarn winding operations is smooth.
BRIFE DISCRIPTION OF THE INVENTION:
Fig. 1 describes perspective view of the present invention.
Fig. 2 describes sectional side sectional view of the present invention.
Fig. 3 illustrates a flow chart for coating of rubber of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the parts illustrated. The invention is capable of other embodiments, as described above and of being practiced or carried out in a variety of ways. It is also to be understood that the phraseology and terminology employed herein is for the purpose of description and not for limitation. The invention may have various embodiments and they may be performed as described in the following pages of the complete specification.
Expandable mandrels are commonly used for winding rolls of web material such as films, foils, and tapes onto cores. After a core, or several cores, is positioned on a mandrel, the mandrel is expanded by a pressurized fluid, usually compressed air, to engage the inside of the core. The pressure is adjusted so that the core will not slip on the mandrel unless a predetermined web tension is exceeded.
Pneumatically actuated expandable mandrels, called air shafts in the industry, typically have one or more thin-walled cylindrical segments, or leaves, fitted around the circumference of a support shaft. The leaves are held to the shaft by spring loaded fasteners that allow the leaves to be expanded radially outward upon inflation of one or more resilient tubes extending along the length of the shaft. Alternatively, rows of axially-spaced spring loaded buttons extending the length of the support shaft may be used instead of continuous leaves.
The aluminum tubes or bobbin of size 110mm ID(Inner Diameter) x 116mm OD (Outer diameter) or 110mm ID x 115mm OD or 110mm ID x 114mm OD are developed from alloy 6082/6061/6063 and other different versions of all three alloys. The composition of all three alloys is shown in below tables.
6061 Alloy 6061 (Cr)
Element (%) Element (%)
Si 0.40-0.80 Si 0.6-1.3
Fe 0.7 Fe 0.6
Cu 0.15-0.40 Cu 0.1
Mn 0.15 Mn 0.4-1.0
Mg 0.80-1.20 Mg 0.4-1.2
Cr 0.04-0.35 Cr 0.2
Zn 0.25 Zn 0.1
Ti 0.15 Ti 0.25
Other Each 0.05 Other Each
Total 0.15 Total 0.3

Alloy 6082 (Regular) Alloy 6082 (Modified)
Element (%) Element (%)
Si 0.70 – 1.30 Si 0.80 – 1.20
Fe 0.50 Max Fe 0.30 Max
Cu 0.10 Max Cu 0.40 – 0.55
Mn 0.40 – 1.00 Mn 0.60 – 1.00
Mg 0.60 – 1.20 Mg 0.90 – 1.20
Ti 0.10 Max Ti 0.02 – 0.10
Cr 0.25 Max Cr 0.15 – 0.25
Zn 0.20 Max Zn 0.20 Max
Al Remainder Al Remainder

Alloy 6063 (Standard)
Element
(%)
Si 0.20 – 0.60
Fe 0.35 Max
Cu 0.10 Max
Mn 0.1 Max
Mg 0.45 – 0.90
Ti 0.10 Max
Cr 0.10 Max
Zn 0.10 Max
Al Remainder

Alloys 6082/6061/6063 have good mechanical property. To increase the strength of aluminum tube, process called cold drawing and hardening is done further while also providing precise thickness control, internal diameter and increases the strength of aluminum tube. The process will be explained below in detail.
Extruded porthole aluminum tubes (1) (6082/6061/6063) can be used as feed stock or mother tube in two different conditions i.e. T4 and M for all three alloys (6082/6061/6063) and its different versions. Here T4 condition means solution treated porthole extruded tubes which does not require solution treatment in later stages. M condition means porthole extrusions of alloy as manufactured without solution treatment. This tube requires solution treatment at a later stage. The alloy is casted into shape suitable for extrusion by continuous or semi-continuous casting i.e. Round Billet. The Billet is used to extrude required size round tubes. As this is a hot extrusion, there is a variation in thickness and limitation of achieving lower thickness for required diameter which leads to uneven mass distribution.
After the said extrusion, tensile strength of the aluminum tubes (1) is achieved on particular level from 140 to 235 MPa and percentage elongation is achieved in range of 14% - 21%. However, these mechanical properties are not sufficient for making aluminum tubes suitable for the application. Further, during hot extrusion, the dimensional tolerances achieved are wider. Hence to counter these issues, the extruded aluminum tubes are subsequently cold drawn at room temperature. This cold drawing process serves to reduce cross section area of the aluminum tubes while improving the surface finish and also to achieve close dimensional tolerance on internal diameter and thickness. In the cold drawing process, due to work hardening, tensile strength of the aluminum tubes increase to about 185 to 290 MPa while percentage elongation is decreased to about 6 to 12% with reference to extruded aluminum tubes.
During the cold drawing process an undesirable stress is developed in the aluminum tubes. Hence, to relieve surface stress, the cold drawn aluminum tubes are then straightened on hyperbolic 6 rolls machine. This straightening process is carried out with tubes inputs from one direction and if required, the tube direction is reversed and is again passed through the straightening machine with a view to make sure that straightness achieved is exceptionally good to the level of about 1/1500.
Once the desired mechanical properties in the resultant aluminum tubes (1) are achieved, the tubes with original starting of extruded tubes of M condition (as manufactured condition) are solution treated at this stage followed by Age Hardening.
In artificial age hardening process, the aluminum tubes are heated at about 160 to 200° C for soaking time of about 6 to 18 hours. The time generally depends upon the dimension and thickness of the tubes. The tensile strength shall go beyond 295 MPa and percentage elongation to a level of 10 to 16%. The resultant aluminum tubes obtained by the above method of the invention from the alloys 6061, 6082, 6063 and different versions of all three alloys are suitable for synthetic yarn. After the heat treatment the tubes cut to required length.
Once the tube is received with required length the coating of rubber (2) is followed in next step. The rubber (2) coating or lining is done through either chemical or mechanical method.
Referring Fig. 3, in chemical treatment, the outer surface of the tube will grind to make rough. Once the rough surface is received, chemical or glue is applied to make adhering surface for rubber material. The rubber (2) sheet having thickness of 4-8 mm will wrap around the bobbin and cut once the outer surface is covered with rubber in the moulding stage. In case of physical coating outer surface will threaded to make compatible with rubber layer.
The grade of rubber is preferred as high abrasion synthetic rubber that provides smooth or scratch-free environment to adjacent winding components. After moulding stage, the bobbin is heated in the furnace for one hour followed by curing process to provide toughness to the bobbin. The both heating and curing process takes one day. As the curing process done, the bobbin is again grinding to provide finishing touch and shape. As the finishing is done, the final product is passing through inspection stage followed by packing and dispatching of the product.
The rubber coating also provides proper gripping to initial winding of yarns that leads to provides associated technical advantages to yarn winders. If required, the bobbin is passed to the grooving stage for providing better griping before packing and dispatching. The metal carrier coated with resilient member on outer surface for partially oriented synthetic yarn is also used for a Bulk Continuous Filament Yarn. The bulk continuous filament yarn is winded on metal yarn carrier coated with resilient member as high speed winder.

The rubber coating on different alloys is shown in below tables.
Sr. No 1 2 3 4 5
Tube Material Aluminum Aluminum Aluminum Aluminum Aluminum
Alloy 6061,6082 6061,6082 6061,6082 6061,6082 6061,6082
Tube Length 150 200 280 300 330
Tube ID & OD 110 X116 110 X116 110 X116 110 X116 110 X116
Rubber Coating Thickness
Per Side 3mm 3mm 3mm 3mm 3mm
ØOD With Coating Ø122 Ø122 Ø122 Ø122 Ø122
Alu. Tube Weight In Gm 460 590 826 885 973
Rubber Weight In Gm 250 330 460 500 550
Total Product Weight In Gm 710 920 1286 1385 1523

The SBR (styrene butadiene rubber) or NBR (nitrile-butadiene rubber) is used for rubber coating on the bobbin according to their properties. SBR, or Styrene-butadiene rubber, is the most consumed synthetic rubber, widely used in place of natural rubber for similar applications. SBR is a general purpose rubber made up of 25% styrene and 75% butadiene joined in a co-polymer. The co-polymer means the molecules of these two materials connect into combined molecules with multiple units. The styrene added makes SBR cheaper while adding bonding and blending capabilities. The styrene also lends SBR its wear and abrasion resistance, as well as its strength. The Nitrile, also known as Buna-N or NBR (nitrile-butadiene rubber) is a type of synthetic rubber polymer. It's a copolymer made up of a combination of acrylonitrile and butadiene molecules. The rubber specification along with their properties of NBR and SBR is shown in below tables.
RUBBER SPECIFICATION
NBR(Nitrile Butadiene) SBR ( Styrene Butadiene)
Durometer or Hardness Range: 20 - 95 Shore A Hardness Range: 30 - 95 Shore A.

Tensile Strength Range: 200 - 3,500 PSI Tensile Strength Range: 500 - 3,000 PSI
Elongation (Range %): 350% - 650% Elongation (Range %): 450% - 600%
Abrasion Resistance: Good to Excellent Abrasion Resistance : Excellent.
Adhesion to Metal : Excellent Adhesion to Metal: Excellent.
Adhesion to Rigid Materials: Good to Excellent Adhesion to Rigid Materials: Excellent.
Compression Set: Good to Excellent Compression Set: Good to Excellent.
Impact Resistance: Fair to Good Impact Resistance: Excellent
Resilience I Rebound: Good Resilience I Rebound: Good
Tear Resistance: Good to Excellent Tear Resistance : Fair to Excellent
Vibration Dampening: Fair to Good Vibration Dampening: Fair to Good
High Temperature Range: +210° F to +250° F (99° C TO 121° C) High Temperature Range: +210° F to +250° F (99° C TO 121° C)
Water Resistance: Good to Excellent Water Resistance: Good to Excellent
Sunlight Resistance: Poor to Good Sunlight Resistance: Poor

In another embodiment of the present invention, the rubber coating or lining is applying on a mild steel tube to provide soft surface. Mild steel tubes are manufactured using low carbon steel. Due to low carbon content the pipes do not harden and are easy to use. They are resistant to corrosion, rust and other type of damages which is also makes them a cost- effective choice for long term use.
ADVANTAGES:
• Cold drawn aluminum alloy tube/bobbin provides close tolerance, good straightness, exceptional tensile strength, desired percentage elongation and required ductility.
• Rubber coating on the outer surface provides soft surface to adjacent components in the condition of abrasion with the bobbin.
• Yarn winder which leads to package build for higher downstream speeds and an optimum success rate for automatic yarn transfer, ensuring a high level of production efficiency
• A Metal Carrier/Bobbin which leads to reduction in the cost of per kg production of yarn due to life of many cycles compared to paper tube
• Rubber coating facilitates initial gripping of yarn over the yarn carrier with high speed rotation.
Reference Numerals
1. Aluminum tube (1)
2. Synthetic Rubber (2)

,CLAIMS:We claim:
1. A metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn comprises of:
an aluminum tubes or bobbin,
a rubber,
a chemical or glue,
characterizing in that,
said aluminum tubes or bobbin is coated with a high abrasion synthetic rubber with the help of the chemical or glue to provide soft surface.

2. The metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 1, wherein the rubber SBR (styrene butadiene rubber) or NBR (nitrile-butadiene rubber) is coated on the aluminum tubes or bobbin.

3. A method to coat metal yarn carrier with resilient member on outer surface for partially oriented synthetic yarn comprising:
a) the aluminum tubes or bobbin is grinded to make rough surface,
b) the chemical or glue is applied on surface of aluminum tubes or bobbin make adhering surface,
c) the rubber (2) sheet of thickness of 4-8 mm wrap around the aluminum tubes or bobbin and cut once the outer surface is covered with rubber,
d) the aluminum tubes or bobbin coated with rubber is heated in furnace for one hour and curing process is applied,
e) the aluminum tubes or bobbin coated with rubber is grinded to provide finishing.

4. The method to coat metal yarn carrier with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 3, wherein the heating and curing both process takes one day.

5. The metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 1, wherein the aluminum tubes or bobbin of size 110mm ID (Inner Diameter) x 116mm OD (Outer diameter) or 110mm ID x 115mm OD or 110mm ID x 114mm OD are developed from alloy 6082/6061/6063.

6. The metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 1 and 5, wherein extruded porthole aluminum bobbin used as feed stock or mother tube in T4 or M conditions for 6082 and 6061 alloy wherein T4 condition means solution treated porthole extruded bobbin which does not require solution treatment in later stages and M condition means as manufactured porthole extruded bobbin without solution treatment at extrusion stage and requires solution treatment at a later stage.

7. A method to manufacture the aluminum tubes or bobbin is by following steps:

a) an alloy is casted into shape suitable for extrusion by continues or semi-continues casting i. e. round billet and the round tubes is extrude from billet into a required size,
b) the cross section area of the aluminum tubes in cold drawing process from step (a) reduced to improving the surface finish and increase the tensile strength of the aluminum tubes with reference to extruded aluminum tubes,
c) the cold drawn aluminum tubes from step (c) are straightened on hyperbolic 6 rolls machine to carry out with tubes input from one direction,
d) the extruded tubes of M condition (manufactured condition) are solution treated at this stage followed by age hardening,
e) the aluminum tubes in artificial age hardening process, are heated at 160 to 200° C for soaking time of 6 to 18 hours,
f) the aluminum tubes form step (e) are cut to achieve required length followed by heat treatment.

8. The metal yarn carrier coated with resilient member on outer surface for partially oriented synthetic yarn as claimed in claim 1, wherein a bulk continuous filament yarn is also winded on metal yarn carrier coated with resilient member as high speed winder.

Dated this on 1st of February, 2024