Methods for manufacturing bulked continuous filament

  • US 10,654,211 B2
  • Filed: 12/14/2018
  • Issued: 05/19/2020
  • Est. Priority Date: 05/31/2012
  • Status: Active Grant
First Claim
Patent Images

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

  • (A) washing a plurality of flakes comprising recycled PET;

    (B) providing a PET crystallizer;

    (C) after the step of washing the plurality of flakes comprising recycled PET, passing at least a portion of the plurality of flakes comprising recycled PET through the PET crystallizer to at least partially dry a surface of the plurality of flakes comprising recycled PET;

    (D) providing an expanded surface area extruder, wherein the expanded surface area extruder defines an expanded surface area extruder inlet and an expanded surface area extruder outlet and comprises;

    a plurality of satellite screws, each of the plurality of satellite screws being at least partially housed within a respective extruder barrel and mounted to rotate about its respective central axis; and

    a satellite screw extruder support system that is adapted to orbitally rotate each of the plurality of satellite screws about a main axis as each of the plurality of satellite screws rotate about its respective central axis, the main axis being substantially parallel to each respective central axis;

    (E) providing a pressure regulation system configured to reduce a pressure within at least a portion of the expanded surface area extruder below about 25 mbar;

    (F) providing a spinning machine defining a spinning machine inlet, wherein the spinning machine inlet is operatively coupled to the expanded surface area extruder outlet;

    (G) using the pressure regulation system to reduce the pressure within the at least a portion of the expanded surface area extruder below about 25 mbar;

    (H) after passing the plurality of flakes comprising recycled PET through the PET crystallizer, passing the plurality of flakes comprising PET flakes through the expanded surface area extruder via the expanded surface area extruder inlet to at least partially melt the plurality of flakes to form a polymer melt such that at least a portion of the polymer melt passes through each the respective satellite screw; and

    (I) substantially immediately after passing the plurality of flakes through the expanded surface area extruder, using the spinning machine to form the polymer melt into bulked continuous carpet filament.

View all claims
    ×
    ×

    Thank you for your feedback

    ×
    ×