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SYSTEMS AND METHODS FOR MANUFACTURING BULKED CONTINUOUS FILAMENT FROM COLORED RECYLED PET

  • US 20170152611A1
  • Filed: 01/30/2017
  • Published: 06/01/2017
  • Est. Priority Date: 05/31/2012
  • Status: Active Grant
First Claim
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1. A method of manufacturing bulked continuous carpet filament, the method comprising:

  • (A) providing a multi-screw extruder that comprises;

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

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

    (iii) a pressure regulation system that is adapted to maintain a pressure within the first and second satellite screw extruders between about 0 millibars and about 5 millibars;

    (B) using the pressure regulation system to reduce a pressure within the first and second satellite screw extruders to between about 0 millibars and about 5 millibars;

    (C) providing a plurality of polymer flakes, the plurality of polymer flakes comprising between about six percent and about ten percent colored recycled polyethylene terephthalate (PET) flakes and balance substantially clear recycled PET flakes;

    (D) providing one or more color concentrates;

    (E) adding the one or more color concentrates to the plurality of polymer flakes such that the resulting mixture comprises between about zero percent and about three percent of the one or more color concentrates by weight;

    (F) while maintaining the pressure within the first and second satellite screw extruders between about 0 millibars and about 5 millibars, passing the plurality of polymer flakes and the one or more color concentrates through the multi-screw extruder to form a polymer melt so that;

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

    (G) after the step of passing the polymer melt through the multi-screw extruder, forming the recycled polymer into bulked continuous carpet filament.

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