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SYSTEMS AND METHODS FOR MANUFACTURING BULKED CONTINUOUS FILAMENT

  • US 20150069655A1
  • Filed: 11/18/2014
  • Published: 03/12/2015
  • Est. Priority Date: 05/31/2012
  • Status: Active Grant
First Claim
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1. A method of manufacturing bulked continuous carpet filament, said method comprising:

  • (A) providing a first extruder, said first extruder comprising;

    a first extruder inlet and a first extruder outlet; and

    a pressure regulation system that is adapted to maintain a pressure within said first extruder below about 18 millibars;

    (B) using said pressure regulation system to reduce a pressure within said first extruder to below about 18 millibars;

    (C) while maintaining said pressure within said first extruder below about 18 millibars, passing a plurality of flakes of recycled PET through said first extruder via said first extruder inlet to at least partially melt said plurality of flakes into a polymer melt;

    (D) providing at least one spinning machine comprising at least one spinning machine inlet, wherein said at least one spinning machine inlet is substantially directly coupled to said first extruder outlet;

    (E) after said step of passing said polymer melt through said first extruder, substantially immediately forming said polymer melt into bulked continuous carpet filament using said at least one spinning machine.

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