Methods for manufacturing bulked continuous filament

  • US 10,639,818 B2
  • Filed: 07/20/2018
  • Issued: 05/05/2020
  • Est. Priority Date: 05/31/2012
  • Status: Active Grant
First Claim
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1. A method of manufacturing bulked continuous carpet filament from post-consumer material, the method comprising:

  • providing a means for preparing flakes of PET polymer from the post-consumer material for melting and purifying;

    providing a means for melting and purifying the flakes of PET polymer into a polymer melt at a pressure between about 0.5 millibars and about 5 millibars, wherein providing the means for melting and purifying the flakes of PET polymer into the polymer melt at the pressure between about 0.5 millibars and about 5 millibars comprises;

    routing wet flakes of PET polymer directly into an extruder;

    providing a means for melting the wet flakes of PET polymer into the polymer melt within the extruder;

    providing a means for reducing the pressure within the extruder to between about 0.5 millibars and about 5 millibars; and

    providing a means for filtering the polymer melt to remove contaminants; and

    providing a means for transforming the polymer melt into a bulked continuous carpet filament, wherein providing the means for melting the wet flakes of PET polymer into the polymer melt within the extruder comprises;

    providing a multi-screw extruder configured to receive the wet flakes of PET polymer and creating the polymer melt within the multi-screw extruder, the multi-screw extruder comprising;

    a multi-screw extruder housing that defines at least four satellite screw barrels;

    at least four satellite screws each mounted within a respective one of the at least four satellite screw barrels and each mounted to rotate about a respective central axis of each of the at least four satellite screws; and

    a means for maintaining a pressure within each of the respective satellite screw barrels between about 0.5 millibars and about 5 millibars.

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