SYSTEMS AND METHODS FOR MANUFACTURING BULKED CONTINUOUS FILAMENT

• US 20150069652A1
• Filed: 11/18/2014
• Published: 03/12/2015
• Est. Priority Date: 05/31/2012
• Status: Active Grant

• Current Assignee: Aladdin Manufacturing Corporation (Mohawk Industries Incorporated)
• Original Assignee: Mohawk Industries Incorporated
• Inventors: Clark, Thomas R.
• Granted Patent: US 9,636,845 B2
• Time in Patent Office: Days
• US Class Current: 264/143
• CPC Class Codes: B29B 17/0026 by agglomeration or compacting
• CPC Class Codes: B29B 17/0412 to large particles, e.g. beads, granules, flakes, slices
• CPC Class Codes: B29B 7/426 with consecutive casings or screws, e.g. for charging, discharging, mixing
• CPC Class Codes: B29B 7/485 with three or more shafts provided with screws
• CPC Class Codes: B29B 7/487 with consecutive casings or screws, e.g. for feeding, discharging, mixing
• CPC Class Codes: B29B 7/7461 Combinations of dissimilar mixers
• CPC Class Codes: B29B 7/748 Plants B29B7/7433, B29B7/7485, B29B7/7495 take precedence
• CPC Class Codes: B29B 7/7485 with consecutive mixers, e.g. with premixing some of the components
• CPC Class Codes: B29B 7/86 for working at sub- or superatmospheric pressure B01F33/70 takes precedence
• CPC Class Codes: B29B 9/06 in the form of filamentary material, e.g. combined with extrusion
• CPC Class Codes: B29B 9/12 characterised by structure or composition
• CPC Class Codes: B29C 2948/92514 Pressure
• CPC Class Codes: B29C 48/04 Particle-shaped making granules B29B9/00
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• 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 48/40 using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
• CPC Class Codes: B29C 48/404 the screws having non-intermeshing parts
• 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 48/911 : Cooling
• CPC Class Codes: B29C 48/919 : using a bath, e.g. extruding into an open bath to coagulate or cool the material
• 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 2105/26 : Scrap or recycled material
• CPC Class Codes: C08J 11/04 : of polymers
• 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: D01F 6/62 : from polyesters
• 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 recycling PET into PET nurdles, comprises: (A) grinding recycled PET bottles into a group of flakes; (B) washing the flakes; (C) identifying and removing impurities, including impure flakes, from the group of flakes; (D) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into PET nurdles. In various embodiments, the polymer melt is formed into PET nurdles using any suitable technique such as, for example, any suitable strand pelletizing or melt pelletizing techniques.

Claims

1. A method of manufacturing PET nurdles, said method comprising:

providing a multi-screw extruder that comprises;

(i) a first satellite screw extruder, said first satellite screw extruder comprising a first satellite screw that is mounted to rotate about a central axis of said first satellite screw;

(ii) a second satellite screw extruder, said second satellite screw extruder comprising a second satellite screw that is mounted to rotate about a central axis of said second satellite screw; and

(iii) a pressure regulation system that is adapted to maintain a pressure within said first and second satellite screw extruders below about 18 millibars;

using said pressure regulation system to reduce a pressure within said first and second satellite screw extruders to below about 18 millibars;

while maintaining said pressure within said first and second satellite screw extruders below about 18 millibars, passing a melt comprising recycled polymer through said multi-screw extruder so that;

(1) a first portion of said melt passes through said first satellite screw extruder, and (2) a second portion of said melt passes through said second satellite screw extruder;

after said step of passing said melt of recycled polymer through said multi-screw extruder, pelletizing said polymer melt into a plurality of polymer nurdles.

2. The method of claim 1, whrein pelletizing said polymer melt comprises:

passing said polymer melt through a cooling bath to form a plurality of polymer strands; and

after said step of passing said polymer melt through said cooling bath, forming said plurality of polymer strands into said plurality of polymer nurdles.

3. The method of claim 2, said cooling bath is configured to at least partially harden said polymer melt into said plurality of polymer strands.

4. The method of claim 3, wherein said cooling bath is configured to maintain a temperature of between about 140 degrees Celsius and about 230 degrees Celsius within said cooling bath.

5. The method of claim 4, wherein said cooling bath is configured to maintain a temperature of about 180 degrees Celsius within said cooling bath.

6. The method of claim 2, wherein said cooling bath is configured to at least partially crystallize said polymer melt.

7. The method of claim 3, wherein said cooling bath comprises at least one surfactant.

8. A method of manufacturing PET nurdles comprising the steps of:

grinding a plurality of recycled PET bottles into a group of polymer flakes;

washing said group of polymer flakes to remove at least a portion of one or more contaminants from a surface of said flakes, said group of flakes comprising a first plurality of flakes that consist essentially of PET and a second plurality of flakes that do not consist essentially of PET;

after said step of washing said first plurality of flakes;

(i) scanning said washed group of flakes to identify said second plurality of flakes,

(ii) separating said second plurality of flakes from said first plurality of flakes;

melting said second plurality of flakes to produce a polymer melt;

providing an extruder that extrudes material in a plurality of different extrusion streams;

reducing a pressure within said extruder to between about 0 millibars and about 25 millibars;

while maintaining said pressure within said extruder between about 0 millibars and about 25 millibars, passing said polymer melt through said extruder so that said polymer melt is divided into a plurality of extrusion streams, each having a pressure between about 0 millibars and about 25 millibars;

after passing said polymer melt through said extruder, filtering said polymer melt through at least one filter; and

after passing said polymer melt through said filter, pelletizing said polymer melt to form a plurality of PET nurdles.

9. The method of claim 8, wherein pelletizing said polymer melt comprises:

at least partially hardening said polymer melt into one or more polymer strands; and

cutting said one or more polymer strands into said PET nurdles.

10. The method of claim 9, wherein at least partially hardening said polymer melt comprises passing said polymer melt through one or more cooling baths.

11. The method of claim 10, wherein said one or more cooling baths are configured to maintain a temperature within said one or more cooling baths that is substantially similar to a maximum crystallization temperature of said polymer melt.

12. The method of claim 11, wherein said maximum crystallization temperature is between about 140 degrees Celsius and about 230 degrees Celsius.

13. The method of claim 12, wherein said maximum crystallization temperature is about 180 degrees Celsius.

14. the method of claim 8, wherein pelletizing said polymer melt comprises pelletizing said polymer melt using a pelletizing technique selected from a group consisting of:

i. one or more melt pelletizing techniques; and

ii. one or more strand pelletizing techniques.

15. A method of manufacturing PET nurdles from recycled PET, said method comprising:

(A) melting a plurality of flakes consisting essentially of recycled PET to form a polymer melt;

(B) providing a multi-screw extruder that comprises;

(i) a first satellite screw extruder, said first satellite screw extruder comprising a first satellite screw that is mounted to rotate about a central axis of said first satellite screw;

(ii) a second satellite screw extruder, said second satellite screw extruder comprising a second satellite screw that is mounted to rotate about a central axis of said second satellite screw;

(iii) a third satellite screw extruder, said third satellite screw extruder comprising a third satellite screw that is mounted to rotate about a central axis of said third satellite screw;

(iv) a fourth satellite screw extruder, said fourth satellite screw extruder comprising a fourth satellite screw that is mounted to rotate about a central axis of said fourth satellite screw; and

(v) a pressure regulation system that is adapted to maintain a pressure within said first, second, third, and fourth satellite screw extruders between about 0 millibars and about 5 millibars;

(C) using said pressure regulation system to reduce a pressure within said first, second, third, and fourth satellite screw extruders to between about 0 millibars and about 5 millibars;

(D) while maintaining said pressure within said first, second, third, and fourth satellite screw extruders between about 0 millibars and about 5 millibars, passing a melt comprising recycled polymer through said multi-screw extruder so that;

(1) a first portion of said melt passes through said first satellite screw extruder, (2) a second portion of said melt passes through said second satellite screw extruder, (3) a third portion of said melt passes through said third satellite screw extruder, and (4) a fourth portion of said melt passes through said fourth satellite screw extruder; and

(E) after said step of passing said polymer melt through said multi-screw extruder, forming said polymer melt into a plurality of PET nurdles.

16. The method of claim 15, wherein forming said polymer melt into said plurality of PET nurdles comprises pelletizing said polymer melt using one or more melt pelletizing techniques.

17. The method of claim 16, wherein said one or more melt pelletizing techniques comprise:

extruding said polymer melt through one or more dies; and

cutting said die extruded polymer melt into said plurality of PET nurdles.

18. The method of claim 17, wherein said one or more melt pelletizing techniques further comprise at least partially solidifying and at least partially crystallizing said plurality of PET nurdles.

19. The method of claim 16, wherein forming said polymer melt into said plurality of PET nurdles comprises one or more strand pelletizing techniques.

20. The method of claim 19, wherein said one or more strand pelletizing techniques comprise:

at least partially solidifying said polymer melt into one or more polymer strands; and

cutting said one or more polymer strands into said plurality of PET nurdles.

21. The method of claim 15, further comprising using said pressure regulation system to reduce a pressure within said first, second, third, and fourth satellite screw extruders to between about 0 millibars and about 1 millibar.