Nylon is a synthetic polymer that is widely used in various industries due to its strength, durability, and versatility. There are several grades or types of nylon available, each with its own specific properties and applications. As a manufacturing engineering company, SJS Products, a Jamcor Corporation, understands the importance of providing detailed information about different grades of Nylon, their manufacturing processes, and the most common applications.
1. Nylon Production
The production of raw nylon for use in part manufacturing involves several steps, including polymerization, pelletization, and packaging. It's important to note that the specific details and variations of the production process can depend on the manufacturer, the type of nylon being produced, and the intended application. Manufacturers may incorporate additional steps or modifications to meet specific requirements and quality standards.
- Polymerization: Nylon is typically produced through the polymerization of specific monomers, depending on the desired type of nylon. The monomers undergo a chemical reaction, often in the presence of catalysts, heat, and pressure, to form long chains of nylon polymer. The polymerization process can be conducted using different techniques, such as batch, continuous, or semi-continuous methods.
- Polymer Solidification: After polymerization, the nylon polymer is in a molten or semi-molten state. To solidify the nylon, the polymer is cooled either by air or in a water bath, depending on the specific requirements of the manufacturing process.
- Pelletization: Once the nylon polymer has solidified, it is typically converted into pellet or chip form for ease of handling and transportation. The solid nylon is passed through a pelletizer or granulator, which cuts it into small, uniform-sized pellets or chips. Pelletization helps in maintaining consistent material properties and facilitates accurate metering during the injection molding or extrusion process.
- Drying: Nylon has a tendency to absorb moisture from the environment, which can affect its properties and processing characteristics. Before use in part manufacturing, the nylon pellets or chips are often subjected to a drying process to reduce the moisture content. Drying is typically accomplished by placing the nylon material in a hopper or drying equipment, where heated air or desiccant materials remove the moisture.
- Packaging: Once the nylon pellets or chips are dried, they are packaged into bags or containers to protect them from moisture, contamination, and physical damage. The packaging may include proper labeling and information about the nylon grade, batch number, and other relevant details for traceability and quality control purposes. The packaged raw nylon is then ready for shipment and subsequent use in part manufacturing processes such as injection molding, extrusion, or other applicable techniques.
Nylon pellets ready for use in part manufacturing
2. Nylon Grades
- Nylon 6 (Polyamide 6 or PA6): a widely used nylon grade that belongs to the family of polyamides. Nylon 6 offers moderate thermal heat resistance. It can withstand temperatures up to around 120-150°C (250-302°F) without significant deformation or softening. It is one of the earliest and most common types of nylon. Here are some other names that Nylon 6 may be referred to:
- Perlon: Perlon is a trade name for Nylon 6 that is commonly used in the textile industry. It is known for its excellent strength, elasticity, and abrasion resistance, making it suitable for applications like clothing, hosiery, and upholstery.
- Capron: Capron is another trade name for Nylon 6, mainly used by the DuPont company. Capron is a versatile nylon grade with various applications in automotive parts, electrical connectors, and consumer goods.
- Grilamid: Grilamid is a trade name for Nylon 6 that is used by the EMS Group. Grilamid Nylon 6 is known for its high strength, impact resistance, and excellent molding properties. It finds applications in industries such as sports equipment, eyewear frames, and automotive components.
- Ultramid: Ultramid is a trade name for Nylon 6 that is used by the BASF company. Ultramid Nylon 6 offers a wide range of properties, including mechanical strength, stiffness, and chemical resistance. It is used in various industries, including automotive, electrical, and consumer goods.
Nylon fibers in various colors for use in textiles
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Nylon 6,6 (Polyamide 6,6 or PA6,6): a synthetic polymer that belongs to the family of polyamides. It is a widely used nylon grade known for its excellent mechanical properties and heat resistance. Nylon 6,6 exhibits better thermal heat resistance compared to Nylon 6. It can withstand higher temperatures, typically up to about 180-200°C (356-392°F) without severe degradation. Here are some other names that Nylon 6,6 may be known by:
- Perlon 66: Perlon 66 is a trade name for Nylon 6,6 that is commonly used in the textile industry. It is known for its exceptional strength, durability, and resistance to abrasion. Perlon 66 is used in applications such as high-quality fabrics, carpets, and industrial textiles.
- Capron 6,6: Capron 6,6 is another trade name for Nylon 6,6, primarily used by the DuPont company. Capron 6,6 offers enhanced mechanical properties compared to Nylon 6, making it suitable for applications requiring high tensile strength, impact resistance, and heat resistance. It is commonly used in automotive parts, electrical connectors, and industrial components.
- Durethan: Durethan is a trade name for Nylon 6,6 that is used by the Lanxess company. Durethan Nylon 6,6 is known for its excellent mechanical properties, dimensional stability, and resistance to chemicals and heat. It is utilized in various industries, including automotive, electrical, and engineering applications.
- Zytel: Zytel is a trade name for Nylon 6,6 that is used by the DuPont company. Zytel Nylon 6,6 offers a balance of strength, stiffness, and heat resistance, making it suitable for demanding applications. It is commonly used in automotive components, electrical connectors, and consumer goods.
Components in various shapes produced from nylon
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Nylon 4,6 (Polyamide 4,6 or PA4,6): a specialty nylon grade that offers specific advantages in terms of mechanical strength and heat resistance. Nylon 4,6 offers excellent thermal heat resistance. It can withstand temperatures of around 220-230°C (428-446°F) without significant loss of properties. Nylon 4,6's superior heat resistance makes it suitable for applications requiring prolonged exposure to high temperatures or in environments with elevated thermal stresses. Here are some other names that Nylon 4,6 may be known by:
- Stanyl: Stanyl is a trade name for Nylon 4,6 that is used by the DSM company. Stanyl Nylon 4,6 is known for its exceptional mechanical strength, stiffness, and heat resistance. It offers improved dimensional stability compared to other nylon grades. Stanyl is commonly used in high-performance engineering applications such as automotive parts, electrical connectors, and industrial equipment.
- Akulon: Akulon is a trade name for Nylon 4,6 that is used by the DSM company. Akulon Nylon 4,6 offers a balance of mechanical properties, chemical resistance, and heat resistance. It is suitable for applications that require high strength and dimensional stability, such as gears, bearings, and structural components.
- Zytel HTN: Zytel HTN is a trade name for Nylon 4,6 that is used by the DuPont company. Zytel HTN Nylon 4,6 offers excellent strength, stiffness, and heat resistance. It is often used in demanding applications where resistance to high temperatures, chemicals, and mechanical stress is required. Zytel HTN is commonly found in automotive components, electrical connectors, and industrial machinery.
Bearings with nylon rollers
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Nylon 6,10 (Polyamide 6,10 or PA6,10): a specialty nylon grade that offers specific properties and advantages in various applications. The approximate thermal heat resistance of Nylon 6,10 ranges from about 160°C to 180°C (320°F to 356°F). It can maintain its mechanical properties and dimensional stability within this temperature range. This makes Nylon 6,10 suitable for applications that involve exposure to moderate to high temperatures. Here are some other names that Nylon 6,10 may be known by:
- Zytel HTN: Zytel HTN is a trade name for Nylon 6,10 that is used by the DuPont company. Zytel HTN Nylon 6,10 offers a combination of mechanical strength, chemical resistance, and dimensional stability. It is often used in demanding applications where resistance to high temperatures, chemicals, and mechanical stress is required. Zytel HTN is commonly found in automotive components, electrical connectors, and industrial machinery.
- Utramid A: Utramid A is a trade name for Nylon 6,10 that is used by the BASF company. Utramid A Nylon 6,10 offers good mechanical properties, chemical resistance, and dimensional stability. It is suitable for various applications such as tubing, hoses, and fuel tanks in automotive, industrial, and fluid handling industries.
- Nylatron: Nylatron is a trade name for Nylon 6,10 that is used by the Quadrant Engineering Plastics company. Nylatron Nylon 6,10 is known for its high strength, wear resistance, and low friction properties. It is often used in applications such as gears, bearings, and wear components in industrial machinery and equipment.
Electrical connectors with nylon overmold
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Nylon 12 12 (Polyamide 12 or PA12): a specialty nylon grade that offers unique properties and advantages in various applications. Nylon 12 exhibits good thermal heat resistance. It can withstand temperatures up to approximately 150-160°C (302-320°F) without significant degradation. While not as heat-resistant as some other grades, Nylon 12's flexibility and impact resistance make it suitable for various applications in environments with moderate thermal stresses. Here are some other names that Nylon 12 may be known by:
- Grilamid: Grilamid is a trade name for Nylon 12 that is used by the EMS Group. Grilamid Nylon 12 offers a balance of mechanical strength, flexibility, and chemical resistance. It is commonly used in applications such as sports equipment, eyewear frames, and automotive components.
- Vestamid: Vestamid is a trade name for Nylon 12 that is used by the Evonik Industries company. Vestamid Nylon 12 offers good mechanical properties, chemical resistance, and low moisture absorption. It finds applications in industries such as automotive, electrical, and consumer goods.
- Rilsan: Rilsan is a trade name for Nylon 12 that is used by the Arkema company. Rilsan Nylon 12 is known for its excellent flexibility, impact resistance, and chemical resistance. It is often used in applications such as tubing, hoses, and coatings in various industries.
- Pebax: Pebax is a trade name for Nylon 12 that is used by the Arkema company. Pebax Nylon 12 offers a unique combination of flexibility, elasticity, and toughness. It is commonly used in applications such as sports footwear, medical devices, and industrial components.
Hosing made from nylon
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Bio-based or eco-friendly nylons: Bio-based or eco-friendly nylons are a category of nylons that are derived from renewable and sustainable sources, reducing their environmental impact compared to traditional petroleum-based nylons. These eco-friendly nylons are often referred to by different names, depending on the specific source and manufacturing process. Here are some examples:
- Bio-based Nylon: Bio-based nylon, also known as bio-nylon or renewable nylon, is made from renewable biomass sources such as plant-derived feedstocks or agricultural by-products. One common bio-based nylon is made from castor oil, extracted from the seeds of the castor plant. It is often referred to as Castor Oil-based Nylon or CO-based Nylon.
- Eco-Nylon: Eco-nylon is a generic term used for nylons that have been developed with a reduced environmental impact, often achieved through sustainable sourcing and manufacturing practices. Eco-nylon may encompass various types of bio-based or recycled nylons.
- ECONYL: ECONYL is a brand of eco-nylon developed by the Aquafil Group. It is made from 100% regenerated nylon, which includes post-consumer waste materials such as discarded fishing nets, fabric scraps, and carpets.
- Nilit EcoCare: Nilit EcoCare is another brand of eco-friendly nylon produced by Nilit, a global nylon manufacturer. This eco-friendly nylon is made from post-industrial waste materials and incorporates recycled content in its production.
- Q-Nova: Q-Nova® is a sustainable nylon fiber developed by Fulgar, a leading fiber producer. It is made from recycled raw materials, reducing the need for virgin fossil resources.
- Renewably Sourced Nylon: Some eco-friendly nylons may be simply referred to as renewably sourced nylons, indicating their origin from renewable feedstocks or recycled materials.
3. Nylon Part Production
- Melt Spinning: Melt spinning is a widely used process for manufacturing nylon fibers, filaments, and yarns. The nylon pellets or chips are melted and extruded through spinnerets, which are devices with small holes. As the molten nylon is extruded, it solidifies into continuous filaments or fibers when it comes into contact with a cooling medium, such as air or water.
Melt spinning diagram
- Injection Molding: Injection molding is commonly employed to produce nylon parts with complex shapes and precise dimensions. The nylon material is heated and injected into a mold cavity under high pressure. After cooling and solidification, the mold is opened, and the finished nylon part is ejected. Injection molding is suitable for manufacturing a wide range of nylon products, including automotive components, electrical connectors, and consumer goods.
Example of injection molding
- Extrusion: Extrusion is a versatile process used for manufacturing various nylon products, including sheets, rods, tubes, and profiles. In this process, the nylon material is melted and forced through a die, which shapes the molten nylon into the desired form. The extruded nylon is then cooled and solidified before being cut or further processed.
Ports made from extrusion
- Blow Molding: Blow molding is primarily used for producing hollow nylon objects, such as bottles, containers, and tanks. The process involves melting the nylon resin and injecting it into a mold cavity, where it takes the shape of the mold. A controlled amount of air or gas is then introduced to expand and conform the molten nylon to the mold walls. After cooling, the mold is opened, and the final nylon product is removed.
Blow mold diagram
In summary, nylon is a very versatile material and is used in many industries. Its relatively ease of manufacturability, durability, and range of thermal resistance lends itself to a wide array of applications. At SJS Products, a Jamcor Corporation, we hope to provide the highest quality nylon components to fit any application you may have. Reach out to discuss with our knowledgeable staff about fulfilling your nylon manufacturing needs.
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