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Specialty Engineered Yarns There Is A Difference!

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Presentation on theme: "Specialty Engineered Yarns There Is A Difference!"— Presentation transcript:

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2 Specialty Engineered Yarns There Is A Difference!

3 Specialty Engineered Yarns MARKETS: Telecommunication Fiber Optics Copper Cable Power Cables Control Appliance Umbilical Cables Mechanical Rubber Hoses Drive Belts PRODUCTS: Binders Braiders Fillers I.D. Markers Lacing Cords Motor Tie Cords Ripcords Semi-Conductive Serving Tubes Strength Members CONSTRUCTIONS: Cable Twist Low Twist Flat Yarn Twisting to Specs. FIBERS: Acetate Acrylic Cotton Polyester Glass Para-Aramid Polyethylene Polypropylene Nomex® Nylon FIBERS continued: Ryton® (PPS) Viscose PTFE

4 FINISHES: Low-Extractable Lube Non-Wick Nylon Polyurethane Water Swellable COLORS: Dyed to Match NEMA Specs. U.L. Specs. Custom Specs PACKAGES: Straight Edge Beveled Edge Cones To 11.5” Lengths To 11.5” Diameters Multi-End Winding Single End Winding Custom Specs. Specialty Engineered Yarns

5 2 - General SEY Markets Wire & Cable Mechanical Rubber Goods V Belts Wire & Cable

6 2 - Wire & Cable Markets Telecommunication Power Generally similar manufacturing processes are used in both of these Wire & Cable Markets.

7 Telecommunication Cable Ripcord 2 - Primary Types – Copper Cables Fiber Optic Cables

8 Definitions: Copper Cables - Power or telecommunication cables that have a copper core or have a stranded copper core inside. The copper is used to carry the power or signal. Generally copper cables are constructed using Binders, Ripcords and Marker Yarns. Some also have Filler Yarns. All of the textiles are sold either soft or non-wicking. Fiber Optic Cables - Used for telecommunication cables that have a glass core or is stranded. The glass is used to carry the signal. Generally glass cables are constructed using Binders, Ripcords and Marker Yarns. Some also have Filler Yarns. All of the textiles are sold with a water swellable finish to prevent leaks if the outer shell gets nicked. Most aerial cables have a strength member to prevent elongation of the glass and reduce signal strength.

9 Specialty yarns that are used in the manufacturing of Wire or Cables to do one or more of the following: To help hold the bundles of components together (binder). To add strength (strength member). To fill void spaces in the construction (filler). To help in identifying the cables origin (marker). To assist in opening the jacket (ripcord). Specialty yarns that are used in the manufacturing of Wire or Cables to do one or more of the following: To help hold the bundles of components together (binder). To add strength (strength member). To fill void spaces in the construction (filler). To help in identifying the cables origin (marker). To assist in opening the jacket (ripcord). Wire & Cable Yarns Outer Jacket Inner Jacket Strength Member Binder Yarn Central Strength Member Ripcord Water Blocking Agent

10 Marker Yarns Ripcord Mylar Tape Binder Yarn 1500dX1 Non-wick beveled edge package. Pkg Size = 7” X 5” X 8” – hard wind. Typical Wire & Cable Process The Marker Packages are supplying yarn to the cable as it is pulled through the machine. One marker yarn indicates the year the cable is manufactured, and the other marker yarn indicates the Company & Location where the cable was made. The Ripcord Tube is supplying yarn to the cable as it is pulled through the machine. The type of ripcord is dependent on the type of jacket used to hold the bundle of wires together. An armoured jacket will require a cable twisted ripcord. The Mylar Tape is wrapped around the cable holding the wires together an providing an added moisture barrier for the cable. This Tape can be made of copper, metal or other materials depending on the end-use of the cable. The Binder Cob is rotating at a very high speed around the Cable (over 2000 RPM) wrapping the Binder Yarn around the Mylar Tape that is holding the bundle of wires together prior to Jacketing. Due to this high speed, a tremendous amount of tension is applied to the yarn. The Binder Cob slides on a spindle that is only slightly smaller than the inside diameter of the Tube. Therefore, the inside tube diameter is very critical.

11 Wires used for Telecommunication Cables come in only 10 colors. However, bundles of wires are bound with a Polypropylene ID Tape that comes in 10 colors. Sometimes more than one ID Tape is used on larger cable bundles. Marker Yarns Ripcord Copper Tape Binder Yarn Typical Wire & Cable Process Here a Planetary Set-up is used where the bombs of Binder Yarn are rotating around the cable holding the Copper tape (armour) and cable together until it goes through the final jacketing process

12 Definitions: Binder Yarns - Refers to yarns that are used to wrap a bundle of stranded, insolated wires in the manufacturing of Cables. The purpose of Binders is to hold the bundle together until the jacketing operation. Most Binder yarns are made in either with a Low Twist or a Flat Yarn Polyester construction. Other fibers are also available. Binder yarns are also available in Soft, with a Non-Wicking finish or with a Water Swellable finish. A&E’s brand = Anetec Binder Yarns. Binder Yarn Photo of 19 strand medium voltage power cable. Binder yarn – soft and no twist.

13 Precision wound Binder Yarns that consistently deliver more length per tube! Telecommunication Wire Mfg. Process

14 Fibers High Tenacity Polyester Mid Tenacity Polyester Other Fibers Yarn Constructions Low Twist Flat Yarn Finishes Non-Wicking Soft (Wicking) Water Swellable Yarn Packages Diameters up to 11.5 Inches Lengths up to 11 Inches Multiple End Winding Available All Sizes of Binder Packages

15 Definitions: High Tenacity Polyester - Refers to FOY polyester yarns that have a greater strength per size. Using high tenacity Polyester yarns allows you to down- size the yarn bundle but still meet minimum strength requirements. Smaller yarn sizes allows A&E to wind more yarn on a package, which means fewer work stoppages. Example: Generally high tenacity polyester will be 7.8 to 8.3 gpd. Mid Tenacity Polyester - Refers to FOY polyester yarns that have a lower strength per size than High Tenacity Polyester yarns. Using mid tenacity Polyester yarns means you will have to use a larger yarn bundle to meet minimum strength requirements. Larger yarn sizes means there will be less yarn wound on a package, which means more work stoppages. Generally, mid tenacity polyester will be 5.5 to 6.3 gpd.

16 Definitions: Low Twist Construction - Refers to any type of yarn that has a low level of twist (single ply or multi-ply). These yarns are oval shaped and their primary usage is in Binder yarns and Ripcords for unarmored cables. Flat Yarn Construction - Is a non-twisted monocord construction to provide the lowest profile so less jacketing material is required. The primary use is for Binder Yarns. Flat Yarn Low Twist Cable Twist Jacket Diameter

17 Copper Cables (gel filled – “flooded”)  Soft (Wicking)  Nonwick Finishes for Wire & Cable Industry Fiber Optic Cables (dry filled)*  Water Swellable  Nonwick

18 Definitions: Non-Wicking Finish – Refers to a finish applied to SEY yarns that inhibits the passage of water along the yarn providing a barrier against moisture migration. This finish is topically applied. Our in-line non-wick product has a optical indicator (tan color) to show the presence of non-wick solution. Soft (Wicking) Finish – Refers to an SEY yarn that will not inhibit the passage of water along the yarn. Usually this is a bright white color as compared to the non-wick product. Water Swellable Finish – Refers to a finish that when it gets wet swells to prevent the passage of moisture into the cable or wire. This Finish swells to inhibit the passage of moisture through the jacket that keeps the cable dryer allowing for a better signal.

19 Definitions: Multiple End Winding – Refers to the ability to wind multiple ends together. The individual yarns can be designed to run parallel to each other or they can cross over each other. This product can be unwound to either separate yarn paths or through a single yarn path.

20 FeaturesBenefits Precision Wound Packages - Fewer Faults - More Consistent Quality Binding - Increased Line Speed - Capable of building larger package sizes - Reduced Operator Intervention due to Breakage's Increased Yield Per Tube - Fewer Machine Stoppages - More Production Output - Higher Profits Low Twist Yarn Constructions - Excellent Filament Integrity for Protection Flat Binder Yarn - Lower Yarn Profile Non-wick Finish - Reduces Moisture Migration Water Swelled Finish - Better Protection against Leaks - Dryer Cable - Better signal

21 Definitions: Ripcord Yarns – Refers to a yarn bundle that is inside the inner and outer Jackets that is used to slit open the Jackets for easier access to the copper or fiber-optic strands. Ripcords can be made from Aramids, Polyester and Nylon. They can also be made with either a Cable Twist, Low Twist or in a Flat Yarn construction. Generally a Cable Twist is recommended on Cables with Armoured Jackets. Outer Jacket Inner Jacket Strength Member Binder Yarn Central Strength Member Ripcord Water Blocking Agent Ripcords Cable Twist Construction - Refers to a two end construction used primarily for Ripcords used on cables with armoured jackets. ONLY available in 2 ply. Cable Twisted yarns typically have 5 to 6 twist per inch producing a round cross-section.

22 High Performance Precision Wound Packages Telecommunication Cable Ripcord

23 Fibers Aramids Polyester Nylon Yarn Constructions Cable Twist Low Twist Flat Yarn Finishes Non-Wicking Soft (Wicking) Water Swellable Yarn Packages Diameters up to 11.5 Inches Lengths up to 11 Inches

24 FeaturesBenefits Cable Twisted Ripcord- Improved Tearing Action - Better Abrasion Resistance - Fewer Ripcord Failures - Ideal for Armored Cables Low Twist Ripcord- Increased Yield Compared To Cable Twisted - Not recommended For Armored Cables Precision Wound Packages- Better Quality Ripcord - Increased Line Speed - Reduced Operator Intervention Due To Breaks

25 FeaturesBenefits Increased Yield Per Tube- Fewer Machine Stoppages due to more yarn per package - More Production Output - Higher Profits Non-wick Finish- Helps prevent moisture migration Water Swelled Finish- Better Protection Against Leaks - Dryer Cable - Better signal

26 Definitions: Marker Yarns – Refers to textile yarns that are introduced for identification purposes. The yarns are used to identify the manufacturer, the manufacturing location, date of manufacture, and also identify NEMA requirements. A&E’s brand name for this product is Anetec Marker Yarns. Marker Yarns Copper Tape

27 Precision Wound Marker Yarns That Make Your Products Easy To Identify

28 Fibers Polyester Nylon Finishes Non-Wicking Wicking Yarn Constructions Low Twist Flat Yarn Twisted Textured Yarn Packages Diameters up to 11.5 Inches Lengths up to 11 Inches Cones or Straight Build

29 FeaturesBenefits Consistent Colors- Your identification Standard Can Be Global High Energy Dyes- Excellent Color Fastness Precision Wound Packages- Reduced Operator Intervention Due To Breakage Increased Yield Per Tube- Fewer Machine Stoppages - More Production Output - Higher Profits * Non-Wick Finishes Available.

30 Package Constructions Bombs Cones Tubes Spools Cob Braider Tubes ConeBomb Cones Tube Cob Spool Cob

31 All Cobs are slit for easier removal of the package from customer’s equipment. Most cob walls are.25” thickness. Slit in Cob

32 Straight Build Package - Refers to any type of package that has shoulders that are wound perpendicular to the yarn carrier. These types of packages offer the greatest cubic volume for yarn space. Traditionally the corners of these packages are weak points and they do not stand up well to high levels of centrifugal force. Definitions: Bi-conical – Refers to a package that has a gradual taper on both ends. Usually they are not as hard as a straight or beveled edge package, however they cannot hold as much yarn. Beveled Shoulder Package - Refers to a package that is tapered on both ends with sharp corners allowing for more yardage than a bi-conical package. This package will withstand higher levels of centrifugal force than a straight build package.

33 Ordering the right package size is very critical on SEY Products for proper operation. Therefore, the following dimensions must be obtained before an order for SEY can be processed. Package Dimensions - Length Inside Diameter Outside dimeter 7” X 5” X 8” Definitions: Length Inside Diameter of Cob Outside Diameter

34 7 inches Found on PO 8 inches 6 1/2 inches 5 inches Length Inside Diameter Width Beginning Traverse Ending Traverse Beveled Edge Package Key Dimensions

35 Control Umbilical Appliance Appliance Cable Umbilical Cable Control Cable

36 Control Cables - Refers to power cables used to carry either medium or high voltage current for industrial applications or from curb to residence. Generally, control cables are constructed using Binders, Ripcords, and Fillers. Textile yarns used in control cables are usually soft finish.

37 Umbilical Cables - Generally, refers to sealed cables that are used for running power cables and other operational lines to Deep Well Drilling Applications, Submersibles, or other Remote Control devices. Generally, ripcords are not used because when an umbilical cable is used for so many pulls, it is replaced. Umbilical cables are used to retrieve the powered unit. Products used would include Binders, Strength Members, Fillers, and Braiders.

38 Appliance Cables - Power cables used in appliances to carry low to medium voltage. These cables generally have a braided jacket that is made from polyester. In some special applications, appliance cables can also have braided jackets made from special fibers like glass, Nomex, nylon, etc. Also, many appliance cables are hermetically sealed. These cables are also used for instrumentation in the aviation industry.

39 Power Cables also use Binders and Ripcords similar to Telecommunication Cables. POWER CABLES

40 Definitions: Braider Yarns - Refers to yarns used in the manufacturing of power cables. The Braider Yarns act as an insulator when used in conjunction with a Mylar tape. Braider Yarns can be made from Polyester, Nylon, Nomex, Fiberglass, or Cotton. They are usually produced in either a Low Twist or Flat Yarn Construction. Inner Braid Outer Braid Braider Yarns

41 Precision Wound Braider Yarns That Provide Superior Coverage! High Performance Precision Wound Packages

42 Fibers Polyester Nylon Nomex Fiberglass Cotton Finishes Prepared for Hermetic Finish Polyamide Others Yarn Constructions Low Twist Flat Yarn Yarn Packages Diameters up to 3.5 Inches Lengths up to 6.5 Inches Biconical

43 Definitions: Polyester Braider Yarns – most common braider yarn used in most appliances produced today. Nylon Braider Yarns – used on some wiring harnesses and railroad signal cables. Nomex Braider Yarns – used for the Department of Defense work & used in aviation products. Fiber Glass Braider Yarns – used for petrochemical cables to withstand high temperature. Cotton Braider Yarns – used for appliances, umbilical cables where the specs have not been updated.

44 Definitions: Prepared for Hermetic Finish – Hermetic Finish Cables are sealed cables that have been purified. Braider Yarns prepared for Hermetic processing have been sterilized in an autoclave. Most appliance cables being made today are Hermetically processed. The most common size yarn used for this application is a 250d polyester.

45 FeaturesBenefits High Fill Count Yarn- Better Spread - Better Coverage Precision Wound Packages- Deliver Better Quality High Fill Count Yarn - Reduced Filament Damage - Reduced Operator Intervention due to Breaks Custom Wind Angles- More consistent feed to the Braider Carrier Increased Yield Per Tube- Fewer Machine Stoppages - More Production Output - Higher Profits High Energy Dyes- Excellent Resistance to Heat Sublimation Hermetic Finish- Compliance to all Standards

46 Individual End Control …. Can your current Supplier Do This! Individual End Control …. Can your current Supplier Do This! Increase Line Speeds Higher Yield Per Package (Up To 26%) Fewer Stoppages Consistent Yarn Tensions Fewer Defects - Better Quality Increase Line Speeds Higher Yield Per Package (Up To 26%) Fewer Stoppages Consistent Yarn Tensions Fewer Defects - Better Quality

47 7 inches Found on PO 8 inches 6 1/2 inches 5 inches Length Inside Diameter Width Beginning Traverse Ending Traverse Package Size Based on Specs

48 Specialty Engineered Yarns

49 Mechanical Rubber Yarns Specialty yarns that are used in the manufacturing of Mechanical Rubber to do one or more of the following: Help in holding the bundles of components together. Add strength. Mechanical Rubber Yarns Specialty yarns that are used in the manufacturing of Mechanical Rubber to do one or more of the following: Help in holding the bundles of components together. Add strength. Major SEY Markets V Belts Hoses

50 Specialty Engineered Yarns Check Out Our Web Site! www.amefird.com


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