Methods for manufacturing bulked continuous carpet filament

• US 10,538,016 B2
• Filed: 06/05/2019
• Issued: 01/21/2020
• Est. Priority Date: 05/31/2012
• Status: Active Grant

• Current Assignee: Aladdin Manufacturing Corporation (Mohawk Industries Incorporated)
• Original Assignee: Aladdin Manufacturing Corp. (China) (Mohawk Industries Incorporated)
• Inventors: Clark, Thomas R.
• Primary Examiner(s): Tentoni, Leo B
• Application Number:
  US16/432,579
• Publication Number:
  US 20190283278A1
• Time in Patent Office: 230 Days
• Field of Search: 264 401, 264101, 264102, 2641761, 26421121, 26421122, 26421123
• CPC Class Codes: B01D 29/0095 Flat filtering elements B01D25/12, B01D25/26 take precedence
• CPC Class Codes: B29B 13/00 Conditioning or physical treatment of the material to be shaped chemical aspects C08J3/00 ; heating, cooling or curing during shaping B29C35/00; thermal after-treatment B29C71/02
• CPC Class Codes: B29B 13/065 of powder or pellets
• CPC Class Codes: B29B 17/00 Recovery of plastics or other constituents of waste material containing plastics; volume reduction of waste plastics, e.g. by mechanical compacting or melting disposal of solid waste B09B; chemical recovery C08J11/00
• CPC Class Codes: B29B 17/0042 for shaping parts, e.g. multilayered parts with at least one layer containing regenerated plastic
• CPC Class Codes: B29B 17/02 Separating plastics from other materials
• CPC Class Codes: B29B 17/0412 to large particles, e.g. beads, granules, flakes, slices
• CPC Class Codes: B29B 2013/002 Extracting undesirable residual components, e.g. solvents, unreacted monomers, from material to be moulded
• CPC Class Codes: B29B 2013/005 Degassing undesirable residual components, e.g. gases, unreacted monomers, from material to be moulded
• CPC Class Codes: B29B 2017/0015 Washing, rinsing
• CPC Class Codes: B29B 2017/0224 Screens, sieves
• CPC Class Codes: B29B 2017/0289 Washing the materials in liquids
• CPC Class Codes: B29B 2017/0484 Grinding tools, roller mills or disc mills
• CPC Class Codes: B29B 7/485 with three or more shafts provided with screws
• CPC Class Codes: B29B 7/726 Measuring properties of mixture, e.g. temperature or density B29B7/724 takes precedence
• CPC Class Codes: B29B 7/86 for working at sub- or superatmospheric pressure B01F33/70 takes precedence
• CPC Class Codes: B29B 9/065 under-water, e.g. underwater pelletizers
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 2793/00 Shaping techniques involving a cutting or machining operation
• CPC Class Codes: B29C 2948/922 Viscosity; Melt flow index [MFI]; Molecular weight
• CPC Class Codes: B29C 2948/9238 : Feeding, melting, plasticising or pumping zones, e.g. the melt itself
• CPC Class Codes: B29C 2948/92514 : Pressure
• CPC Class Codes: B29C 2948/92876 : Feeding, melting, plasticising or pumping zones, e.g. the melt itself
• CPC Class Codes: B29C 48/0022 : combined with cutting
• CPC Class Codes: B29C 48/022 : characterised by the choice of material
• CPC Class Codes: B29C 48/05 : Filamentary, e.g. strands
• CPC Class Codes: B29C 48/144 : at the plasticising zone
• CPC Class Codes: B29C 48/145 : at a venting zone
• CPC Class Codes: B29C 48/147 : after the die nozzle
• CPC Class Codes: B29C 48/255 : Flow control means, e.g. valves flow dividers B29C48/695
• CPC Class Codes: B29C 48/2552 : provided in the feeding, melting, plasticising or pumping zone, e.g. screw, barrel, gear-pump or ram
• CPC Class Codes: B29C 48/345 : Extrusion nozzles comprising two or more adjacently arranged ports, for simultaneously extruding multiple strands, e.g. for pelletising
• CPC Class Codes: B29C 48/375 : Plasticisers, homogenisers or feeders comprising two or more stages
• CPC Class Codes: B29C 48/38 : using two or more serially arranged screws in the same barrel
• CPC Class Codes: B29C 48/385 : using two or more serially arranged screws in separate barrels
• CPC Class Codes: B29C 48/425 : using three or more screws serially arranged screws B29C48/38, B29C48/385
• CPC Class Codes: B29C 48/43 : Ring extruders
• CPC Class Codes: B29C 48/435 : Sub-screws
• CPC Class Codes: B29C 48/44 : Planetary screws
• CPC Class Codes: B29C 48/69 : Filters or screens for the moulding material
• CPC Class Codes: B29C 48/70 : comprising means for dividing, distributing and recombining melt flows
• CPC Class Codes: B29C 48/765 : in the extruder apparatus
• CPC Class Codes: B29C 48/766 : in screw extruders
• CPC Class Codes: B29C 48/767 : through a degassing opening of a barrel
• CPC Class Codes: B29C 48/802 : Heating
• CPC Class Codes: B29C 48/92 : Measuring, controlling or regulating
• CPC Class Codes: B29C 69/001 : a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence
• CPC Class Codes: B29D 99/0078 : Producing filamentary materials
• CPC Class Codes: B29K 2067/003 : PET, i.e. poylethylene terephthalate
• CPC Class Codes: B29K 2105/0067 : Melt
• CPC Class Codes: B29K 2105/26 : Scrap or recycled material
• CPC Class Codes: C08J 11/04 : of polymers
• CPC Class Codes: C08J 11/06 : without chemical reactions
• CPC Class Codes: C08J 2367/02 : Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: D01D 1/103 : De-aerating
• CPC Class Codes: D01D 1/106 : Filtering
• CPC Class Codes: D01D 5/00 : Formation of filaments, threads, or the like
• CPC Class Codes: D01D 5/08 : Melt spinning methods D01D5/0023 takes precedence
• CPC Class Codes: D01F 6/62 : from polyesters
• CPC Class Codes: D10B 2503/04 : Floor or wall coverings; Carpets
• CPC Class Codes: Y02P 20/143 : the feedstock being recycled material, e.g. plastics
• CPC Class Codes: Y02W 30/62 : Plastics recycling; Rubber recycling

Abstract

A method of manufacturing bulked continuous carpet filament from recycled polymer. In various embodiments, the method includes: (1) reducing recycled polymer material into polymer flakes; (2) cleansing the polymer flakes; (3) melting the flakes into a polymer melt; (4) removing water and contaminants from the polymer melt by dividing the polymer melt into a plurality of polymer streams and exposing those streams to pressures below 5 millibars; (5) recombining the streams; and (6) using the resulting purified polymer to produce bulked continuous carpet filament.

Claims

1. A method of manufacturing bulked continuous carpet filament, the method comprising:

melting a plurality of polymer flakes to create a first stream of polymer melt;

routing the first stream of polymer melt through a separation element to generate multiple streams of polymer melt;

exposing the multiple streams of polymer melt to a pressure within a multiple stream section of a melt processing unit to a pressure between about 0 millibars and about 5 millibars;

while maintaining the pressure of the multiple stream section of the melt processing unit between about 0 millibars and about 5 millibars, allowing the multiple streams of polymer melt to pass through the multiple stream section of the melt processing unit into a receiving section of the melt processing unit;

recombining the multiple streams of polymer melt into at least one stream of polymer melt at the receiving section of the melt processing unit; and

providing polymer from the at least one stream of polymer melt to at least one spinning machine configured to form the polymer from the at least one stream of polymer melt into bulked continuous carpet filament.

2. The method of claim 1, wherein the separation element comprises an extruder having at least eight satellite screws and each of the at least eight satellite screws is respectively dimensioned to produce one of the multiple streams of polymer melt from polymer from the first stream of polymer melt.

3. The method of claim 1, wherein allowing the multiple streams of polymer melt to pass through the multiple stream section of the melt processing unit into a receiving section of the melt processing unit comprises allowing the multiple streams of polymer melt to fall through the multiple stream section of the melt processing unit under the weight of gravity.

4. The method of claim 3, wherein exposing the multiple streams of polymer melt to the pressure within the multiple stream section of a melt processing unit comprises exposing a surface area of each of the multiple streams of polymer melt to the pressure within the multiple stream section of the melt processing unit.

5. The method of claim 3, wherein the pressure within the multiple stream section of the melt processing unit has been selected to produce a desired intrinsic viscosity associated with the at least one stream of polymer melt.

6. The method of claim 5, further comprising determining an intrinsic viscosity of the at least one stream of polymer melt, and, in response to determining the intrinsic viscosity of the at least one stream of polymer melt, adjusting the pressure within the multiple stream section of the melt processing unit.

7. The method of claim 6, wherein maintaining the pressure of the multiple stream section of the melt processing unit between about 0 millibars and about 5 millibars comprises maintaining the pressure of the multiple stream section of the melt processing unit between about 0 millibars and about 1.5 millibars.

8. The method of claim 1, wherein maintaining the pressure of the multiple stream section of the melt processing unit between about 0 millibars and about 5 millibars comprises maintaining the pressure of the multiple stream section of the melt processing unit between about 0 millibars and about 1.5 millibars.

9. The method of claim 1, wherein the multiple streams of polymer melt comprise at least 100 streams of polymer melt.

10. The method of claim 1, wherein the separation element comprises a plate defining a plurality of holes that are each respectively dimensioned to produce one of the multiple streams of polymer melt from polymer from the first stream of polymer melt.

11. The method of claim 1, further comprising:

determining that an intrinsic viscosity of the at least one stream of polymer melt is below a predetermined level; and

in response to determining that the intrinsic viscosity of the at least one stream of polymer melt is below the predetermined level, substantially automatically reducing the pressure of the multiple stream section of the melt processing unit.

12. The method of claim 1, wherein the plurality of polymer flakes is derived, at least in part, from polyethylene terephthalate (PET) flakes that are derived from recycled PET containers.

13. The method of claim 1, wherein exposing the multiple streams of polymer melt to the pressure within the multiple stream section of the melt processing unit comprises simultaneously exposing the multiple streams of polymer melt to the pressure within the multiple stream section of the melt processing unit while the multiple streams of polymer melt fall through the multiple stream section of the melt processing unit into the receiving section of the melt processing unit.

14. The method of claim 13, wherein recombining the multiple streams of polymer melt into the at least one stream of polymer melt at the receiving section of the melt processing unit comprises recombining the multiple streams of polymer melt into the at least one stream of polymer melt using a single screw extruder.

15. A method of manufacturing bulked continuous carpet filament, the method comprising:

melting a plurality of polymer flakes to create a first stream of polymer melt;

routing the first stream of polymer melt through a separation element to generate multiple streams of polymer melt;

exposing the multiple streams of polymer melt to a pressure within a multiple stream section of a melt processing unit to a pressure between about 0.5 millibars and about 1.2 millibars;

while maintaining the pressure of the multiple stream section of the melt processing unit between about 0.5 millibars and about 1.2 millibars, allowing the multiple streams of polymer melt to pass through the multiple stream section of the melt processing unit into a receiving section of the melt processing unit;

recombining the multiple streams of polymer melt into at least one stream of polymer melt at the receiving section of the melt processing unit; and

providing polymer from the at least one stream of polymer melt to at least one spinning machine configured to form the polymer from the at least one stream of polymer melt into bulked continuous carpet filament.

16. The method of claim 15, wherein the separation element comprises an extruder having at least eight satellite screws and each of the at least eight satellite screws is respectively dimensioned to produce one of the multiple streams of polymer melt from polymer from the first stream of polymer melt.

17. The method of claim 15, wherein allowing the multiple streams of polymer melt to pass through the multiple stream section of the melt processing unit into a receiving section of the melt processing unit comprises allowing the multiple streams of polymer melt to fall through the multiple stream section of the melt processing unit under the weight of gravity.

18. The method of claim 17, wherein exposing the multiple streams of polymer melt to the pressure within the multiple stream section of a melt processing unit comprises exposing a surface area of each of the multiple streams of polymer melt to the pressure within the multiple stream section of the melt processing unit.

19. The method of claim 17, wherein the pressure within the multiple stream section of the melt processing unit has been selected to produce a desired intrinsic viscosity associated with the at least one stream of polymer melt.

20. The method of claim 19, further comprising determining an intrinsic viscosity of the at least one stream of polymer melt, and, in response to determining the intrinsic viscosity of the at least one stream of polymer melt, adjusting the pressure within the multiple stream section of the melt processing unit.

21. The method of claim 15, wherein the multiple streams of polymer melt comprise at least 100 streams of polymer melt.

22. The method of claim 15, wherein the separation element comprises a plate defining a plurality of holes that are each respectively dimensioned to produce one of the multiple streams of polymer melt from polymer from the first stream of polymer melt.

23. The method of claim 15, further comprising:

determining that an intrinsic viscosity of the at least one stream of polymer melt is below a predetermined level; and

in response to determining that the intrinsic viscosity of the at least one stream of polymer melt is below the predetermined level, substantially automatically reducing the pressure of the multiple stream section of the melt processing unit.

24. The method of claim 15, wherein the plurality of polymer flakes is derived, at least in part, from polyethylene terephthalate (PET) flakes that are derived from recycled PET containers.

25. The method of claim 15, wherein exposing the multiple streams of polymer melt to the pressure within the multiple stream section of the melt processing unit comprises simultaneously exposing the multiple streams of polymer melt to the pressure within the multiple stream section of the melt processing unit while the multiple streams of polymer melt fall through the multiple stream section of the melt processing unit into the receiving section of the melt processing unit.

26. The method of claim 25, wherein recombining the multiple streams of polymer melt into the at least one stream of polymer melt at the receiving section of the melt processing unit comprises recombining the multiple streams of polymer melt into the at least one stream of polymer melt using a single screw extruder.