Description:FIELD OF THE INVENTION:

[1] The present invention relates to the production of Nylon (PA6) Yarn with a tenacity greater than 10 grams per denier (GPD), and the method for its manufacture.

BACK GROUND OF THE INVENTION:
[2] The invention relates to the production of high-strength Nylon (PA6) yarn with a tenacity exceeding 10 grams per denier (GPD). This achievement is significant as it surpasses the typical maximum tenacity of commercial high tenacity yarns, which generally cap at around 9.5 GPD. The enhanced strength of this yarn offers substantial benefits, including the potential for reducing the quantity of yarn required in various applications such as tire cords, fishing lines, luxury yachts, conveyor belts, ropes, geo-grids, lashings, automotive seat belts, and industrial fabrics.
[3] The present invention utilizes Nylon 6 (PA6) chips as the raw material, treated with specific additives (KI, KBr, Cu (NO3)2) during the drying process. The chips are processed under controlled conditions of temperature and pressure, extruded, and spun into filaments through spinnerets. Key modifications in the process include increasing the cooling efficiency of the filaments through enhanced quenching and cooling methods. This includes increasing the number of spinnerets in the quenching zone and the length of the cooling screen, which collectively contribute to better uniformity and efficiency in filament cooling.
[4] The resultant yarn exhibits a tenacity consistently exceeding 10 GPD across various production runs, as demonstrated by test results. This represents a 6% improvement in strength compared to existing high tenacity yarns available commercially. The innovation enables manufacturers to achieve higher performance with reduced material usage, benefiting end-products such as tires, belts, ropes, and other industrial and consumer applications.
[5] The invention finds application across a wide range of industries where high-strength materials are critical. It enhances the performance and durability of products such as tires, fishing lines, industrial fabrics, and safety equipment like seat belts, while also potentially reducing costs and environmental impact through lower material consumption.
[6] By surpassing the conventional strength limits of Nylon PA6 yarn, the invention addresses the industry demand for stronger materials without compromising on other properties. The improved cooling methods ensure better quality control and consistency in yarn production, leading to superior end-products across various industrial and consumer applications.
[7] The key innovations lie in the increased quenching area achieved through longer cooling screens and optimized spinneret configurations. These improvements enable more effective cooling of filaments during production, resulting in yarn with significantly higher tenacity than previously achievable with standard processes. This novel approach not only enhances the performance of Nylon PA6 yarn but also sets a new benchmark in the industry.
OBJCETIVE OF THE INVENTION:

[8] The main objective of the invention is to develop a method for producing Nylon (PA6) yarn with a tenacity exceeding 10 grams per denier (GPD). This involves a comprehensive process that begins with the preparation of PA6 chips and proceeds through controlled extrusion, precise spinning, effective quenching, meticulous finishing, and optimal winding, ensuring the consistent production of high-quality yarn suitable for various industrial applications.

[9] Another objective of the present invention is to enhance the tenacity of the Nylon (PA6) yarn beyond 10 GPD by improving the quenching process. This improvement includes increasing the number of spinnerets in the quenching area while maintaining the total number of filaments constant, thereby reducing cooling depth and achieving more uniform cooling. Additionally, the invention extends the cooling length of the screen to further optimize the cooling efficiency of the yarn filaments.

[10] Yet another objective of the invention is to establish a detailed quenching configuration that maximizes cooling effectiveness. This configuration specifies parameters such as the number of quench positions, spinnerets per quench, spinning ends per quench, take-up ends per quench, spinneret characteristics (e.g., diameter, area), and specific dimensions of the quenching screen. These parameters collectively contribute to enhancing yarn properties and ensuring consistent production quality throughout the manufacturing process.

[11] Still another objective of the present invention is to offer a high-strength yarn that not only meets but exceeds industry standards, thereby enabling the production of lighter, stronger, and more durable products such as tires, belts, ropes, and industrial fabrics.

SUMMARY OF THE INVENTION:

[12] The invention involves the production of Nylon (PA6) yarn with a tenacity exceeding 10 grams per denier (GPD), which represents a notable advancement beyond conventional high tenacity yarn strengths. The process begins with the treatment of PA6 chips using specific additives during drying, followed by controlled extrusion and spinning through spinnerets under optimized temperature and pressure conditions. Key innovations include increasing the quenching area by utilizing longer cooling screens and modifying spinneret configurations to enhance filament cooling efficiency. This results in yarn that consistently demonstrates superior strength, as evidenced by test results exceeding 10 GPD across multiple production runs. The invention aims to provide manufacturers with a material that not only enhances the performance and durability of end-products like tires, belts, ropes, and industrial fabrics but also potentially reduces material usage due to its enhanced strength characteristics.

BRIEF DESCRIPTION OF DRAWINGS:
[13] The invention shall be described in further detail below under reference to theaccompanying drawings, in which:

[14] Fig.1 illustrates process flow chart;
[15] Fig.2 illustrates modified machine;
[16] Fig.3 illustrates modified quench system;
[17] Fig.4 illustrates Yarn processing flow diagram for >10 GPD; and
[18] Fig.5 illustrates Tumble Dryer.

DETAILED DESCRIPTION OF THE INVENTION
[19] Thefollowingdescriptionisprovidedtoassistinacomprehensiveunderstandingofexemplaryembodimentsoftheinvention.Itincludesvariousspecificdetailstoassistinthatunderstanding,butthesearetoberegardedasmerelyexemplary.
[20] Accordingly,thoseof ordinary skill intheartwill recognizethatvariouschanges and modifications of the embodiments described herein can be made withoutdeparting from the scope of the invention. In addition, descriptions of well-knownfunctionsandconstructionsare omittedforclarityandconciseness.
[21] Thetermsandwordsusedinthefollowingdescriptionandclaimsarenotlimited to the bibliographical meanings, but, are merely used by the inventor to enablea clearandconsistentunderstandingoftheinvention.
[22] Accordingly, it should be apparent to those skilled in the art that the followingdescriptionof exemplary embodiments of thepresentinventionareprovidedforillustrationpurposeonlyandnotforthepurposeoflimitingtheinventionasdefinedbytheappendedclaimsandtheirequivalents.
[23] It is to be understood that the singular forms “a,” “an,” and “the” include pluralreferentsunlessthe contextclearlydictatesotherwise.
[24] Features that are described and/or illustrated with respect to one embodiment,aspectsor implementationsmaybeusedin thesamewayor inasimilarwayin oneormore other embodiments and/or in combination with or instead of the features of theotherembodiments,aspectsorimplementations.
[25] Itshouldbeemphasizedthattheterm“comprises/comprising”whenusedinthisspecification is taken to specify the presence of stated features, integers, steps orcomponentsbutdoesnotprecludethepresenceoradditionofoneormoreotherfeatures,integers, steps,componentsorgroupsthereof.

[26] In the present invention, Low RV (3.00 to 3.10) PA6 chips is dried under vacuum to get high RV (3.40) chips with less than 0.05% moisture. Heat additive e.g. (KI, KBr, Cu (NO3)2) are added during drying. These dried chips are then transferred to the chip’s storage silos. Chips are then fed to the chip’s hopper under nitrogen blanketing.
[27] These chips are extruded in the extruder under set of temperature (275 degrees to 300 degrees) and pressurized to 150 ~200 Bar by extruder.
[28] This pressurized melt then enters in spinning beam where metering pump delivers the melt to various ends of spinning pack. Each spinning pack consists of various filters /Sand and spinneret.
[29] The polymer is filtered in pack and is spun through the holes of the spinneret, thus producing the filaments of the yarn.
[30] These filaments are then cooled down by air flow after passing no cooling zone/Preheater (To avoid sudden cooling). The cooled yarn passes though finish oil application system. Then it goes to multistage godet duos, where yarn is drawn, and same time is heat set by hot godets. Then the yarn is wound on to paper tubes on Winder to form Yarn package.
EXAMPLE: 1

[31] The production of Nylon (PA6) yarn with a tenacity greater than 10 GPD involves several stages, including the extrusion of melted polymer through a spinneret to form filaments. This process generates heat and potentially harmful fumes. Therefore, proper ventilation is crucial in the production environment for several reasons:
[32] Heat Dissipation: The extrusion and spinning processes generate heat. Proper ventilation helps dissipate this heat and maintain a safe and comfortable working environment.
[33] Fume Extraction: During the heating and melting of the PA6 chips, fumes may be released. These fumes need to be properly vented to ensure the safety of the workers and the integrity of the product.
[34] Humidity Control: In some cases, controlling the humidity in the production environment can be important for the properties of the final product. Ventilation can help control the humidity levels.
[35] Air Quality: Good ventilation improves the overall air quality in the production environment, contributing to the well-being of the workers and the quality of the product.
EXAMPLE: 2
(DRIED CHIPS(SOLIDS)

[36] The dried chips, also known as solids, required for the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD are essentially Polyamide 6 (PA6) chips.
[37] Here’s a bit more detail:
[38] Low Relative Viscosity (RV) PA6 Chips: The process begins with low RV (3.00 to 3.10) PA6 chips. These chips are dried under vacuum to get high RV (3.40) chips with less than 0.05% moisture.
[39] Heat Additives: During the drying process, heat additives such as KI, KBr, Cu (NO3)2 are added during drying. These additives help in achieving the desired properties in the final yarn.
[40] Extrusion: The dried chips are then extruded in the extruder under a set of temperature (275 degrees to 300 degrees) and pressurized to 150 ~200 Bar by the extruder. This process forms the basis of the yarn production.
[41] Spinning: The extruded melt then enters the spinning beam where a metering pump delivers the melt to various ends of the spinning pack. Each spinning pack consists of various filters/sand and a spinneret. The polymer is filtered in the pack and is spun through the holes of the spinneret, thus producing the filaments of the yarn.

EXAMPLE -3
(NITROGEN)
[42] In the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD, nitrogen plays a crucial role in several ways:
[43] Blanketing: Nitrogen is used for blanketing during the transfer of chips from the dryer to the machine’s silo. This process is done under nitrogen blanketing to prevent any oxidative degradation of the chips due to exposure to air.
[44] Safety: Nitrogen is an inert gas, which means it does not react with other substances easily. This property makes it safe to use in various stages of the production process.
[45] Incineration: When Nylon (PA6) is incinerated, it releases nitrogen along with water and carbon dioxide. This is part of the waste management process in the production of Nylon (PA6) yarn.

EXAMPLE 4
DRYER

[46] The dryer is essential for chip drying,increasing the Relative Viscosity (RV) from approximately 3.0–3.10 to 3.40, while also ensuring the chip moisture content remains below 0.05%. It is equipped with rotating system for mixing HR additives and a suction mechanism to maintain a vacuum. The drying process guarantees uniform mixing of heat additives, such as KI, KBr, and Cu(NO3)2. typical drying cycle is 16 hours per batch, The Dowtherm/Steam heating medium provides the necessary heat in the dryer. Final chips temperature depends upon final RV required and initial RV available and usually varies from 120 to 125 ºC.

EXAMPLE: 5
(EXTRUDER)

[47] Heating and Melting: The extruder’s functions involve heating and melting the Nylon (PA6). This process is done in the extruder, where the raw materials are heated and mixed.
[48] Extruder screw diameter varies from 90MM to 150MM and its length varies from 24 to 25 times of diameter, Extruder having 5 to 6 Heating zone and zone heater temp varies from 275 degree C to 300 Degree C.
[49] Controlling Extrusion Speed and Pressure: The extruder also controls the extrusion speed and pressure to ensure a consistent output.
[50] Forming the Yarn: Once the raw material is melted and mixed, it is forced through a spinneret, which is a metal plate with small holes. This forms the filaments of the yarn.
[51] Ensuring Uniform Filament Thickness: The extruder ensures uniform filament thickness for high-quality yarn production.
[52] In the context of sustainable textile production, Nylon (PA6) yarn extruders play a significant role. They utilize waste as raw material to extrude yarn or filaments for various applications in textile manufacturing and other waste products to create durable and sustainable yarns.
EXAMPLE: 6
POLYMER MANIFOLD (MOLTEN POLYMER)

[53] The polymer manifold, also known as the molten polymer, plays a crucial role in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD by:
[54] Polymerization: Nylon 6, the type of nylon used in this process, is formed by ring-opening polymerization. This involves the transformation of a monomer, in this case caprolactam, into a polymer. The molten polymer, or polymer manifold, is the result of this polymerization process.
[55] Extrusion: The molten polymer is then extruded through a spinneret to form the filaments of the yarn. The extruder controls the extrusion speed and pressure to ensure a consistent output.
[56] Formation of Yarn: The molten polymer is crucial in the formation of the yarn. It is forced through the holes of the spinneret, thus producing the filaments of the yarn.
[57] Properties of the Final Product: The properties of the final yarn product, such as its tenacity, are largely determined by the properties of the molten polymer. The polymer manifold can be modified during polymerization to introduce new chain end or functional groups, which changes the reactivity and chemical properties of the final product.
[58] In summary, the polymer manifold or molten polymer is a key component in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD, as it directly influences the properties and quality of the final product.

EXAMPLE-7
(SPIN PUMP MOTOR)

[59] The spin pump motor, also known as the metering pump, plays a crucial role in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD.
[60] Spin pump motor load is varying from 0.3 KW to 3 KW, Motor RPM varies from 400 RPM to 2850 RPM, Motor having 4 or 6 pole.
[61] Metering pump capacity varies from 3.5CC/outlet/1 RPM to 6.5 CC/outlet/1 RPM.
[62] Reduction gear box: Reduction gear box is a mechanical device that decrease the motor’s output speed while increase the output torque, generally gear box ratio varies from 40 to 60. (For example, Gear ratio 50:1 means motor’s 50 RPM converted in to 1 RPM).
[63] Controlled Extrusion: The spin pump motor controls the extrusion speed and pressure, ensuring a consistent output. This is crucial for maintaining the uniformity of the yarn filaments.
[64] Delivery of Melt: The spin pump motor delivers the molten polymer (extruded melt) to various ends of the spinning pack. Each spinning pack consists of various filters/sand and a spinneret.
[65] Formation of Yarn: The molten polymer is forced through the holes of the spinneret, thus producing the filaments of the yarn1. The spin pump motor plays a key role in this process by controlling the rate at which the molten polymer is fed into the spinneret.
[66] Quality of Final Product: The properties of the final yarn product, such as its tenacity, are largely determined by the precise control of the extrusion process, which is managed by the spin pump motor.
[67] In summary, the spin pump motor is a key component in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD, as it directly influences the properties and quality of the final product
EXAMPLE -8
(BEAM)
[68] The beam, also known as the spinning beam, plays a crucial role in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD.
[69] Delivery of Melt: The spinning beam is where the metering pump delivers the molten polymer (extruded melt) to various ends of the spinning pack1. Each spinning pack consists of various filters/sand and a spinneret1.
[70] Formation of Yarn: The molten polymer is forced through the holes of the spinneret, thus producing the filaments of the yarn1. The spinning beam plays a key role in this process by controlling the rate at which the molten polymer is fed into the spinneret1.
[71] Quality of Final Product: The properties of the final yarn product, such as its tenacity, are largely determined by the precise control of the extrusion process, which is managed by the spinning beam.
[72] In summary, the spinning beam is a key component in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD, as it directly influences the properties and quality of the final product
EXAMPLE -9
(METERING PUMP)

[73] The metering pump, also known as a spin pump, plays a vital role in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD.
[74] Metering pump capacity varies from 3.5CC/outlet/1 RPM to 6.5 CC/outlet/1 RPM.
[75] Consistent Flow Rate: The metering pump ensures a consistent flow rate of the molten polymer to the spinneret. This is crucial for maintaining the uniformity of the yarn filaments.
[76] Pressure Control: The metering pump controls the pressure of the molten polymer being fed into the spinneret. This helps in forming filaments of consistent thickness.
[77] Volume Control: The metering pump accurately measures and controls the volume of the molten polymer that is extruded. This is important for achieving the desired properties in the final yarn product.
[78] Quality of Final Product: The properties of the final yarn product, such as its tenacity, are largely determined by the precise control of the extrusion process, which is managed by the metering pump.
[79] In summary, the metering pump is a key component in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD,

EXAMPLE -10
(ANLEALER + SUPER HEATED STEAM)

[80] The use of an annealer and superheated steam is crucial in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD for several reasons:
[81] Thermal Treatment: The annealer provides a controlled environment for the thermal treatment of the nylon 6 fibers1. This treatment is essential for achieving the desired properties in the final yarn product.
[82] Superheated Steam: Superheated steam is used in the thermal treatment process. It provides the heat necessary for the treatment and has been found to have a significant effect on the properties of the nylon 6 fibers1. For example, it has been reported that the degree of the effect of thermal treatment of nylon 6 with superheated steam depends on the humidity in the chamber at the treating temperature.
[83] Improved Properties: The use of an annealer and superheated steam can lead to improved properties in the final yarn product. For instance, the crimp of yarn textured with steam is superior in character to the crimp of yarn treated with dry heat.
[84] Practical Process: The use of an annealer and superheated steam allows for a practical process for the thermal treatment of running yarns1. This makes it possible to conduct the treatment using a practical process such as texturing of yarn.
[85] In summary, an annealer and superheated steam are key components in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD, as they directly influence the properties and quality of the final product
EXAMPLE -11
(SPIN PACK)
[86] The spin pack plays a vital role in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD. Here’s why:
[87] Filtering: The spin pack contains various filters and sand that the molten polymer passes through before it is spun through the spinneret1. This filtering process removes any impurities or inconsistencies in the molten polymer, ensuring the quality of the final yarn product1.
[88] Formation of Yarn: The molten polymer is forced through the holes of the spinneret, thus producing the filaments of the yarn. The spin pack plays a key role in this process by controlling the rate at which the molten polymer is fed into the spinneret.
[89] Quality of Final Product: The properties of the final yarn product, such as its tenacity, are largely determined by the precise control of the extrusion process, which is managed by the spin pack.
[90] In summary, the spin pack is a key component in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD.
EXAMPLE: 12
[91] Filtering : Various type of filter is use from 20 mesh to 400 mesh
EXAMPLE: 13
[92] Spinneret: A spinneretis a key component of a spin pack, designed with multiple holes of specific diameters to extrude polymer into fine filaments. This precision tool is essential in shaping the physical characteristics of yarn. we use 42-70 holes spinneret with diameter of hole varies from 0.3 to 0.45 mm.
EXAMPLE -14
(POLYMER FILAMENT)
[93] Polymer filaments are the fundamental building blocks in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD. Here’s why:
1. Formation of Yarn: The molten polymer is forced through the holes of a spinneret, thus producing the filaments of the yarn. These filaments are then cooled and solidified to form the yarn.
2. Material Properties: The polymer filaments determine the properties of the final yarn product. Nylon 6, the type of nylon used in this process, is renowned for its superior mechanical properties, such as tensile strength and toughness. This allows it to be used in applications demanding durable and resilient materials.
3. Texturing: The polymer filaments can be textured to increase volume, resilience, moisture absorption, etc. Texturing methods have been developed to overcome the flat geometry and smooth surface of man-made fibers.
4. Quality of Final Product: The properties of the final yarn product, such as its tenacity, are largely determined by the properties of the polymer filaments. The polymer filaments can be modified during polymerization to introduce new chain end or functional groups, which changes the reactivity and chemical properties of the final product.
In summary, polymer filaments are a key component in the production of Nylon (PA6) yarn with a tenacity greater than 10 GPD

TABLE. 1Experimental report of Tenacity Achieved> 10 GPD
Denier 1480 BRC HT
Date M/c Denier B.S(Kg) %Elongation %EASL Tenacity(GPD) % HAS % OPU Tangles
18-02-2024 5 1479 15.19 23.1 12.59 10.27 8.5 1.07 4
19-02-2024 5 1479 15.41 23.3 12.50 10.42 8.5 1.05 4
20-02-2024 5 1490 15.32 23.2 12.47 10.28 8.6 1.04 4
21-02-2024 5 1491 15.24 23.1 12.46 10.19 8.5 0.95 3
22-02-2024 5 1489 15.23 23.7 12.46 10.22 8.6 0.90 3
Average 1486 15.28 23.3 12.50 10.28 8.5 1.00 4

TABLE.2

Denier 1260/210 BRC HT
Date M/c Denier B.S(Kg) %Elongation %EASL Tenacity(GPD) % HAS % OPU Tangles
18-08-2023 5 1273 13.14 21.6 11.48 10.32 7.4 0.98 5
19-08-2023 5 1271 13.12 21.4 11.42 10.32 7.7 5
20-08-2023 5 1279 13.03 20.9 11.58 10.18 8.0 1.08 6
21-08-2023 5 1272 12.92 21.0 11.57 10.16 7.3 0.93 5
22-08-2023 5 1280 12.95 21.1 11.37 10.11 7.3 1.04 4
23-08-2023 5 1275 12.76 20.6 11.14 10.17 7.1 3
24-08-2023 5 1276 12.87 20.6 11.48 10.09 7.9 0.99 4
Average 1276 12.93 21.0 11.35 10.19 7.5 0.97 5

The above Table1,2 showsExperimental report for production of Nylon (PA6) yarn with a tenacity greater than 10 GPD.

EXAMPLE: 15

[82] Cross Flow Quench: This system stabilizes the production of yarns. It helps in cooling the filaments after they are extruded from the spinneret.
TABLE. 3
Quench Parameter
Parameter Unit Standard Machine Modified machine
No of quench / Take up Position No 1 1
No of Spinneret /Quench No 4 10
No of Spinning ends / Quench No 4 10
No of Take up ends/ Quench No 4 2
No of holes / Spinneret No 210 42
Spinneret Dia MM 215 105
Spinneret Area MM² 36286.625 8654.625

Quench Length Meter 1.77 2.31
Quench Width Meter 1.12 1.36
Quench Blowing area M² 1.9824 3.1416

Spinneret area per Filament MM² 172.7934524 206.0625
Effective quench Area/ Filament MM² 1812 5775

EXAMPLE: 16

[83] Yarn Duct: The yarn duct guides the path of the yarn in the production process. It ensures the yarn moves smoothly from one stage to the next.
EXAMPLE: 17

[84] Kiss Roll: The kiss roll is used to apply finish or lubricant to the yarn. This helps in reducing friction and preventing damage to the yarn during subsequent processing stages.
EXAMPLE: 18
[85] Finish Nozzle: The finish nozzle is used to apply a protective coating or finish to the yarn. This enhances the yarn’s performance characteristics such as its resistance to abrasion.
EXAMPLE: 19
[86] Cutter and Aspirator: The cutter is used to cut the yarn to the desired length. The aspirator removes any waste or debris from the production process.
EXAMPLE: 20
[87] Migration: Migration refers to the movement of filaments within a yarn during the production process. Controlling migration is important for achieving uniformity and consistency in the yarn.
EXAMPLE: 21
[88] Interlacer: The interlacer is used to entangle the filaments in a yarn. This helps in improving the cohesion and stability of the yarn.
EXAMPLE: 22
[89] Godet Plate Form: Godet and separator roller is used in the production of nylon high tenacity yarn for drawing and heat setting , by drawing align the polymer molecules and imparts the desired strength and properties of yarn , the heat from godet helps to stabilize the molecular orientation achieved during draw process , we use 5 draw zone for achieve high tenacity , which surface speed varies from 600 to 3500 Meter per minute and temperature ranging from 50 degree to 215 degree C.
EXAMPLE: 23
[90] Yarn Guide Bar: The yarn guide bar helps in guiding the path of the yarn during the production process. It ensures the yarn is correctly aligned as it moves through the various stages of production.
EXAMPLE: 24
[91] Winder: The winder is used to wind the finished yarn onto bobbins or spools. This makes the yarn easier to handle and store.
EXAMPLE: 25
[92] Bobbin: The bobbin is the spool onto which the finished yarn is wound. It allows for easy storage and transport of the yarn.
he main advantages of the present invention are:
[93] Higher Tenacity: The primary advantage of the invention is the production of Nylon (PA6) yarn with a tenacity exceeding 10 grams per denier (GPD), which is significantly higher than conventional high tenacity yarns (typically up to 9.5 GPD). This allows for the creation of stronger and more durable products across various industries.
[94] Reduced Material Usage: By achieving higher strength per unit weight of yarn, the invention enables manufacturers to potentially reduce the quantity of yarn required in final products. This reduction in material usage can lead to cost savings and environmental benefits.
[95] Enhanced Performance: Products made from the high-tenacity Nylon PA6 yarn exhibit improved performance characteristics such as increased tensile strength and enhanced resistance to wear and tear. This makes them suitable for demanding applications in sectors like automotive, industrial, and consumer goods.
[96] Broader Application Potential: The yarn's superior strength and durability expand its potential applications, including but not limited to tire cords, fishing lines, conveyor belts, ropes, industrial fabrics, and safety equipment like seat belts. This versatility opens up new markets and opportunities for manufacturers.
[97] Consistency and Quality: The optimized manufacturing process ensures consistency in yarn quality, with reliable performance metrics such as tenacity, elongation, and modulus. This reliability is crucial for meeting stringent industry standards and customer expectations.
[98] Innovative Manufacturing Techniques: Innovations such as increased quenching area and optimized spinneret configurations not only contribute to higher yarn strength but also represent advancements in synthetic fiber production technology. These techniques set a new benchmark in the industry for achieving superior strength properties in Nylon PA6 yarn.
[99] Competitive Advantage: Companies adopting this invention gain a competitive edge by offering products with superior performance attributes, thereby attracting customers seeking high-quality, durable materials for their applications.
, Claims:CLAIM:
WE CLAIM:

1. A Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereoffollows the steps which comprisingthe steps of:

(a) Chips
• PA6 Chips (Low RV);
(b) Dryer
• Chips charging in to dryer;
• Add Chemicals (KI, KBr, Cu (NO3)2);
• Dry with steam and under vacuum to get desired high RV;
(c) Chips transfer to M/c silo
• Transfer chips under N2 blanketing;
(d) Extruder
• Chips are extruded at defined set of temperature and pressure;
(e) Spinning Beam
• Extruded Melt is fed to beam at 290~295-degree temp;
• This melt is pumped by metering pump and melt is fed to spinning pack;
(f) spinneret
• Melt received in spinning pack passes through set of filters /sand and finally fed to spinneret;
(g) Quenching
• Filaments coming out from spinneret are maintained at elevated temp by no cooling zone/preheater to avoid sudden cooling and after certain time cooled by cross flow air at 15-degree temp;
(h) Finish oil
• Finish oil is applied by Kiss roller and Finish nozzle after yarn has been cooled sufficiently;
(i) Drawing
• Yarn is drawn and heat set by multi stage duo godets at different temp ranging from 50 degree to 215 degree;and
(j) Winding
• After drawing yarn is fed to winder to make bobbins/packages.

Wherein Low RV (3.00 to 3.10) PA6 chips is dried under vacuum to get high RV (3.40) chips with less than 0.05% moisture;

Wherein Heat additive e.g. (KI, KBr, Cu (NO3)2) are added during drying;

Wherein these dried chips are then transferred to the chip’s storage silos and chips are then fed to the chip’s hopper under nitrogen blanketing;

Wherein these chips are extruded in the extruder under set of temperature (275 degrees to 300 degrees) and pressurized to 150 ~200 Bar by extruder;

Wherein this pressurized melt then enters in spinning beam where metering pump delivers the melt to various ends of spinning pack. Each spinning pack consists of various filters /Sand and spinneret;

Wherein the polymer is filtered in pack and is spun through the holes of the spinneret, thus producing the filaments of the yarn;

Wherein these filaments are then cooled down by air flow after passing no cooling zone/Preheater (To avoid sudden cooling);

Wherein the cooled yarn passes though finish oil application system;then it goes to multistage godet duos, where yarn is drawn, and same time is heat set by hot godets; and

Wherein thereafter the yarn is wound on to paper tubes on Winder to form Yarn package.

2. The Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereof as claimed in claim 1, wherein an extruder system comprising:
(a) An extruder screw with a diameter ranging from 90mm to 150mm and a length ranging from 24 to 25 times the diameter;
(b) 5 to 6 heating zones along the extruder barrel; and
(c) Zone heater temperatures varying from 275°C to 300°C.
3. The Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereof as claimed in claim 1, wherein a spin pump motor assembly comprising:
(a) A motor with a power rating varying from 0.3 kW to 3 kW;
(b) Operating at a speed ranging from 400 RPM to 2850 RPM; and
(c) Configured with either 4 or 6 poles.
4. The Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereof as claimed in claim 1, wherein a reduction gear box for the spin pump motor, comprising:
(a) A mechanical device that reduces the motor's output speed and increases output torque; and
(b) Gear ratio ranging from 40:1 to 60:1.
5. The Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereof as claimed in claim 1, wherein a metering pump system comprising:
(a) Capacity varying from 3.5 CC/outlet/1 RPM to 6.5 CC/outlet/1 RPM.
6. The Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereof as claimed in claim 1, wherein a spin pack assembly comprising:
(a) Various filters ranging from 20 mesh to 400 mesh; and
(b) Spinneret with 42 to 70 holes, each hole having a diameter ranging from 0.3 mm to 0.45 mm.
7. The Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereof as claimed in claim 1, wherein a godet and separator roller system for yarn production, comprising:
(a) 5 draw zones for achieving high tenacity;
(b) Surface speed ranging from 600 to 3500 meters per minute; and
(c) Temperature ranging from 50°C to 215°C.
8.The Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereof as claimed in claim 1, wherein to achieve higher tenacity, we increased quenching /Cooling for filaments in two ways:
(a) increased no of spinnerets in quench are, keeping total no of filaments in all spinnerets same andthereby reducing the cooling depth to get more uniform cooling. Usually one end in spinning (One spinneret) gives one end on winder. But in our case, we had employed 5 spinnerets in spinning /cooling area and then combined the same in take up /winder; and
(b) the cooling length of Screen was increased by almost 1.1 m (91.6%) to get additional cooling.

9. The Nylon (PA6) yarn having tenacity > 10 GPD and process for production thereof as claimed in claim 8, wherein the Quench comprises of:

(a) No of quench / Take up Position: 1 (Nos);
(b) Spinneret in one quench: 10 (Nos);
(c) No of Spinning Ends / quench: 10 (Nos);
(d) No of Take-up Ends/ quench: 2 (Nos);
(e) No of Holes per spinneret: 42 (Nos);
(f) Spinneret diameter: 105(MM);
(g) Spinneret Area: 8654.62(MM²);
(h) Spinneret used for 1 Take-up Yarn: 5 (Nos);
(i) No of Filaments/End of yarn: 210 (Nos);
(j) Quench Length: 2.31 (Meter);
(k) Quench Width: 1.36 (Meter);
(l) Area of Quench screen: 3.1416 (M²);
(m) Spinneret area /Filament: 206.0625(MM²); and
(n) Effective quench area /Filament: 5775(MM²).