Methods for manufacturing bulked continuous filament from colored recycled PET

  • US 11,007,673 B2
  • Filed: 08/12/2019
  • Issued: 05/18/2021
  • 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 an extrusion system that comprises;

    (i) a first extruder;

    (ii) a second extruder; and

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

    (B) using the pressure regulation system to reduce a pressure within the first and second 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 additives;

    (E) adding the one or more color additives 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 additives by weight;

    (F) while maintaining the pressure within the first and second extruders between about 0 millibars and about 5 millibars, passing the plurality of polymer flakes and the one or more color additives through the extrusion system to form a polymer melt so that;

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

    (G) after the step of passing the polymer melt through the extrusion system, forming the recycled polymer into bulked continuous carpet filament.

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