This article will take an in-depth look at nylon tubing.
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This section explores nylon tubing, including its production methods and operational principles.
Nylon tubing, or polyamide tubing, is crafted from polyamide resin, offering excellent abrasion resistance. It is designed for use in environments with high pressure and temperature. Additionally, nylon tubing is highly adaptable and certain types are resistant to degradation when exposed to chemical solutions.
Nylon tubing is equipped with UV stabilization, making it ideal for use in sunny or warm environments. It is also highly flexible, allowing it to fit into various intricate configurations. Thanks to its elastic memory, nylon tubing can be bent and flexed repeatedly over time without showing signs of wear or cracking.
At subzero temperatures, nylon tubing maintains its impact resistance and has minimal moisture absorption. It typically retains its size and shape well, even under cold conditions. This tubing is also effective against a range of substances, including solvents, alkalis, greases, oils, petroleum products, and various types of mold and fungi.
In industrial applications, nylon tubing proves to be highly valuable. It is used in diverse areas such as robotics, hydraulic systems, fuel and vacuum lines, brake and air lines, oil and chemical processing, and tool lubrication systems. Additionally, nylon tubing is employed in food processing and pneumatic systems that utilize compressed air for machinery automation.
When compared to other nylon resins, the nylon plastic tubing has a smaller bend radius and allows for a lighter weight wall. Some of the properties obtained by the nylon tubing are because of the molecular structure of the nylon compared to other types of plastics such as polycarbonate. Some properties of this nylon include it having a melting point of about 374°F (190°C); this is even higher than the same contained properties for other resins.
Additionally, the crystalline structure of nylon enhances its durability against wear and chemical exposure. Nylon tubing consists of hollow channels made from solid nylon material. Although nylon is commonly used in textile fibers, when it is in its solid form, it becomes an excellent choice for manufacturing plastic tubes and other plastic products.
The processes required for the manufacture of nylon tubing include plastic extrusion or plastic co-extrusion, processes that are noted in detail below.
The initial stage in manufacturing nylon tubing involves the plastic extrusion process. During this phase, the raw material, typically in the form of small beads known as nurdles or resin, is fed into the extruder's barrel from a top-mounted hopper. Additives such as colorants and UV stabilizers, which may be in pellet or liquid form, are introduced either directly into the extruder or mixed with the resin before entering the hopper.
The plastic extrusion process shares many similarities with plastic injection molding in terms of extruder technology. However, extrusion is typically a continuous operation. Pultrusion, a related method, produces similar profiles in continuous lengths with reinforcement by pulling the finished product through a die, as opposed to extruding polymer melts through one.
The material begins by entering the feed throat, an opening at the rear of the barrel, where it encounters the rotating screw. This screw, which commonly rotates at about 120 rpm, pushes the plastic beads forward into the heated barrel. The extrusion temperature often exceeds the set barrel temperature due to effects like viscous heating.
In most extrusion systems, a specific heating profile is applied to the barrel. This profile usually involves three or more PID-controlled heating zones that gradually raise the temperature from the rear, where the plastic enters, towards the front. This controlled heating process ensures that the plastic beads melt evenly as they move through the barrel, helping to prevent overheating and polymer degradation.
Additional heat is generated by the high pressure and friction within the barrel.
If the extrusion line operates efficiently, the heaters can sometimes be turned off, with the temperature of the melt being regulated by the internal pressure and friction. Many extruders are equipped with cooling fans to manage excess heat, and cast-in cooling jackets are used if air cooling alone is inadequate.
As the molten plastic exits the screw at the front of the barrel, it flows through a screen pack designed to filter out contaminants from the melt. These screens are reinforced by a breaker plate, a thick metal disc with numerous holes, to withstand pressures that can exceed 5000 psi (34 MPa). The breaker plate and screen pack also generate back pressure within the barrel, which is essential for the consistent melting and thorough mixing of the polymer. The pressure can be adjusted by modifying the composition of the screen packs, including the number of screens, their mesh size, and other factors.
The combination of the screen pack and breaker plate helps to eliminate rotational memory in the molten plastic, which also aids in reducing longitudinal memory. After passing through this setup, the molten plastic moves into a die that shapes the final product. The die must be precisely engineered to ensure that the molten plastic flows uniformly from a cylindrical shape to the desired profile, preventing unwanted residual stresses that can lead to warping during cooling. While a wide variety of shapes can be produced, the process is limited to continuous profiles.
Subsequently, the extruded product is cooled, typically by drawing it through a water bath. Due to plastic's effective thermal insulation properties, it cools slowly; it transfers heat 200 times more slowly than steel. To prevent the newly formed tube or pipe from collapsing, the water bath within the extrusion line is maintained under a controlled vacuum.
For products such as plastic sheeting, cooling is achieved by pulling the material through cooling rolls. In the case of very thin sheeting and films, air cooling can be an effective initial cooling method, as seen in blown film extrusion. Additionally, plastic extruders are employed to reprocess recycled plastic waste and other raw materials following sorting, blending, and cleaning.
Nylon rods are not always composed entirely of nylon. In some cases, they are co-extruded with other materials, such as metals. Co-extrusion is a modified extrusion technique where a single product is created from a combination of two or more different materials. This process involves multiple extruders feeding into a single die, each melting a specific polymer intended for the final product.
Once the materials are melted, they are introduced into the die at a consistent volume and speed. As the materials enter the die simultaneously, they form distinct layers. The purpose of co-extrusion is to create a product that combines the unique properties and benefits of each material, achieving characteristics that a single polymer alone cannot provide.
In order to lower material costs or to strengthen the core of the rod, manufacturers often choose to co-extrude a plastic rod with a different type of plastic or other material. In applications that require little structural strength, the issue of low-cost co-extrusion materials is usually considered.
In applications requiring enhanced structural support, the rod is often filled with a component metal. Beyond the primary characteristics, the plastic co-extrusion process also aims to improve wear resistance and reduce oxygen permeability.
Similar to extrusion, pultrusion is a continuous feed process used to create tubing profiles. However, unlike extrusion, pultrusion involves pulling reinforced fibers that have been saturated with a thermoplastic resin through a die. Polymerization occurs as the fibers pass through the die. Pultrusion is a low-maintenance and efficient method for producing plastic tubing that is resistant to corrosion and exhibits low thermal conductivity.
A variant of pultrusion known as radius pultrusion is employed to produce curved profiles in two or three dimensions. This modified process is advantageous for applications requiring complex textile reinforcements with minimal distortion, making it useful for tasks that benefit from such intricate designs.
While not always necessary, some manufacturers opt for additional processing of their plastic rods through secondary methods. These can include drilling, painting, deburring, powder coating, labeling, industrial finishing, and notching. The plastic rods can be produced in clear or various colors, including custom-matched shades.
Extruded nylon tubing is highly favored by many manufacturers for its versatility and the wide range of material options available in the plastic extrusion process. Nylon rods are an excellent option for those seeking cost-effective, rapid, and durable solutions.
Nylon and polyurethane are two popular materials used in plastic tubing, each with distinct properties. Polyurethane offers excellent flexibility and is well-suited for applications involving tight bends, such as in robotic equipment, and is commonly used for medium-pressure applications. On the other hand, nylon performs well under higher pressures, resists stress cracking, and provides superior resistance to chemicals and heat compared to polyurethane. Both materials also exhibit strong abrasion resistance.
In the United States and Canada, a wide range of machines are used to produce nylon tubing. These machines are crucial in today’s industries, as nylon tubing is widely employed in sectors such as automotive, aerospace, medical, and food and beverage, offering a durable and flexible option for transporting fluids and gases. Below, we explore some of the leading machines used in this process and highlight their distinctive features and capabilities.
Features: The DSREV Extruder is widely favored for manufacturing nylon tubing because of its impressive productivity and dependability. It boasts advanced control systems for precise temperature and pressure management, ensuring uniform tube dimensions and consistent wall thickness. Its energy efficiency and versatility with different polymer materials, including nylon, have made it a popular choice in the industry.
Features: Conair MedLine® Co-Extruders are highly regarded for their capability to produce multi-layered nylon tubing. These co-extruders facilitate the blending of various materials, enhancing the tubing's properties, such as improved barrier performance or increased strength. The machines feature intuitive interfaces and offer seamless integration with downstream equipment.
Features: The Nylon Tube Extrusion Line by Allied Supreme is tailored for manufacturing nylon tubing. It comes with sophisticated temperature and pressure control systems to maintain uniform tube dimensions and wall thickness. Known for its high productivity and versatility, this machine is ideal for a range of industrial applications.
Features: AET's Nylon Tubing Extruder is recognized for its accuracy and dependability in producing nylon tubing. It boasts a high-performance screw and barrel design that ensures efficient melting and extrusion of nylon. The machine’s user-friendly operation and minimal maintenance requirements contribute to its popularity for nylon tubing manufacturing.
Features: American Kuhne provides specialized extrusion lines designed specifically for nylon tubing production. Their equipment is engineered to handle the distinct characteristics of nylon, ensuring precise control over the extrusion process and consistent tube quality. These extrusion lines can be customized to meet diverse production needs, making them a favored choice for industries that require high-quality nylon tubing.
Please note that the details and availability of specific models may have changed since this information was posted. For the most current details on top machines used for nylon tubing production in the United States and Canada, it is advisable to consult with industry experts, manufacturers, and suppliers.
Nylon tubing comes in various types, including high-pressure nylon tubing, flexible or ultra-soft nylon tubing, coiled nylon tubing, DOT-approved nylon tubing, standard nylon tubing, nylon mini coils, as well as nylon 6 and nylon 66 tubing.
The most prevalent type is nylon 6, known for its moisture resistance and consequently, its enhanced corrosion resistance compared to other nylon types. Nylon 6 is produced from a single monomer—a simple molecule with multiple sites for additional monomer bonding. This standard nylon comprises six carbon atoms, which is reflected in its name, nylon 6.
DOT nylon tubing is designed to meet Department of Transportation standards, which is why it bears the DOT designation. This type of tubing is made from an engineered polyester blend, offering greater flexibility over extended periods compared to standard nylon tubing. As a result, DOT nylon tubing is commonly used in vehicle brake lines.
DOT nylon tubing is capable of enduring extreme conditions, with a temperature range from -85°F (-65°C) to over 200°F (93°C). It is designed to be flexible, lightweight, and resistant to fatigue. Additionally, DOT nylon tubing maintains dimensional stability and provides excellent resistance to abrasion and vibration.
High-pressure nylon tubing is engineered for diverse applications and can endure exposure to natural solvents, hydraulic fluids, alkali solutions, diluted acids, and oils. It is known for its strength and rigidity, offering excellent abrasion resistance, particularly in environments with high heat, pressure, and vibration. With enhanced tensile strength, high-pressure nylon tubing is commonly used in the chemical and transportation industries, as well as in automotive applications.
High-pressure nylon tubing is used in various applications, including brake lines, hydraulic hoses, robotics, vacuums, air systems, high-pressure gas lines, and grease transfer. It is designed to handle working pressures up to 800 psi and can withstand temperatures up to 200°F (93°C). This type of tubing is also available in high-temperature variants suited for elevated temperature conditions.
Flexible nylon tubing, often referred to as super soft nylon tubing, is manufactured from nylon 11 resin. This resin imparts a high degree of flexibility to the tubing. Super soft nylon tubing offers several advantages, including dimensional stability and resistance to chemicals, abrasion, impact, heat, and moisture.
Nylon 11, derived from castor beans, is suitable for applications where polyurethane may not be viable. It is used in environments such as fuel lines, gas detection systems, lubrication lines, coolant and refrigeration systems, pneumatic equipment, robotics, and suspension lines.
Nylon coils are spiral formations of nylon tubing that can be extended and retracted, offering increased flexibility. They are commonly used for transporting compressed air or liquids over short distances. These coiled nylon tubes automatically retract and extend, providing a cost-effective and lightweight solution for delivering air to pneumatic tools.
The nylon tubing used in nylon coils is designed to avoid scratching paint, making it suitable for use with articulated brake coils in semi-trucks. Additionally, this type of nylon tubing is also employed for feeding and watering livestock.
Nylon mini coils offer similar flexibility to larger nylon tubing coils but in a more compact form. These mini coils feature pigtails at each end, which facilitate easy connections with other components or mechanisms.
Nylon mini coils are well-suited to handle high pressure, making them particularly useful in confined spaces. They are resistant to abrasion and can operate effectively in environments with pressures up to 298 pounds per square inch (PSI).
These mini coils benefit from coil memory, which allows them to return to their original shape after extension. Nylon mini coils are commonly used in control circuits, robotics, smaller pneumatic tools, and other applications requiring flexible motion.
Alongside nylon 6, nylon 66 is another widely used type of nylon tubing. Although similar, they possess distinct characteristics due to differences in their chemical structures. Nylon 6 is composed of a single monomer with 6 carbon atoms, while nylon 66 consists of two different monomers. Additionally, nylon 6 tubing generally offers better resistance to stress and impact compared to nylon 66 tubing.
Nylon 6 tubing experiences less shrinkage during molding, which facilitates easier coloration. On the other hand, nylon 66 tubing, with its more crystalline structure, offers superior resistance to acids and chemicals and has a higher water absorption capacity. Additionally, nylon 66 tubing is more resistant to heat.
Both nylon 6 and nylon 66 tubing share several qualities, including ease of machining, smooth sliding capability, electrical insulation, high mechanical strength, fatigue resistance, vibration resistance, and durability against x-rays and gamma rays. Nylon 6 tubing is commonly used in military applications and industrial settings, including gears, firearm components, and automotive engine compartments.
Customized nylon tubing is tailored for specific applications, incorporating properties that suit particular needs. Various options are available in custom nylon tubing, including those listed below.
Nylon tubing can be manufactured in custom colors to meet specific requirements. Available colors can range widely, including options such as neon, red, blue, and orange, among others.
Nylon tubing can be precisely cut to various lengths based on the project's requirements. This process is designed to minimize waste, reduce costs, and ensure accurate measurements for each cut.
Coiling is a popular and efficient method for organizing flexible plastic tubing while maximizing its usable length. By customizing the diameter of the nylon tubing, you also influence the coil's retractability and the length to which the tubing can be extended and still function effectively.
With advanced co-extrusion techniques, it is possible to combine multiple materials in a single tube, overcoming the limitations of using just one type. By forcing different materials through the same die, you can create a nylon plastic tubing that integrates all the desired properties for a particular application.
This process is used as an alternative to the high cost of injection molded parts. The formed shapes are able to eliminate problems such as space constraints and kinking. These formed shapes also make installation much easier.
Two or more tubes, regardless of color or size, can be fused together to streamline troubleshooting, replacement, or line tracing. Additionally, these tubes can be easily separated without leaving any residue behind.
Different materials can be used to produce nylon tubing tailored for specific applications. Examples include nylon 6, nylon 66, nylon 11, and nylon 12, each offering unique properties. For instance, nylon 6 is composed of a single monomer with 6 carbon atoms, while nylon 66 consists of two monomers.
Comparatively, nylon 6 tubing generally performs better in terms of stress and impact resistance and exhibits less shrinkage during molding, which facilitates easier coloring. Conversely, nylon 66 tubing, with its more crystalline structure, provides enhanced resistance to acids, chemicals, and water absorption, along with superior heat resistance.
This chapter will explore the various applications and advantages of nylon tubing.
Nylon tubing is valued for its lightweight and flexible characteristics, making it suitable for a range of applications. It is commonly used in pneumatic systems, including aircraft control mechanisms. Additionally, nylon tubing is employed in automotive fuel lines, refrigerator water lines, and other applications requiring resistance to cracking and heat. In certain cases, nylon tubing can serve as a substitute for metal tubing due to its advantageous properties. Some types of nylon tubing are FDA-approved, making them suitable for use in the food and beverage industry as well.
Nylon tubing is also used in medical technology, aerospace, filtration, irrigation, refrigerants, and laboratories. Nylon tubing has become very useful in industries and some of its application areas include robotics, hydraulic hoses, and fuel lines, in different varieties of vacuum lines, vapor lines, brake lines, air lines, oil processing lines, chemical processing lines, and tool lubricating systems. Nylon tubing can be included in pneumatic systems which make use of compressed air so as to supply power to machinery automatically. Nylon tubing can also be used in printers and agricultural equipment.
Nylon tubing made from nylon 12 polymers exhibits excellent properties, including high resistance to abrasion, cold temperatures, and heat. In the pneumatic sector, its precise tolerance allows for seamless compatibility with push-in and compression fittings.
In the brewery and beverage industries, nylon tubing is used for carbon dioxide gas lines and can withstand high temperatures. It is lightweight, heat-stabilized, and resistant to stress cracking. The advantages of nylon tubing include its strength, flexibility, light weight, resistance to corrosion and chemicals, dimensional stability, and a tight bend radius.
Nylon tubing, also known as polyamide tubing, is a type of tubing made from polyamide resin that has a strong resistance to abrasion and is used in high-pressure and high-temperature applications. The processes of plastic extrusion and plastic co-extrusion are used in the production of nylon tubing. Nylon tubing products are hollow channels made up of solid nylon. This type of tubing is also very versatile, and some of its varieties will not even degrade when used in chemical solutions. Nylon tubing contains UV stabilization, which be handy when they are being used in warmer areas and where there is a direct exposure to sunlight. Nylon tubing is also very flexible and can be used to fit into many different complex designs.
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