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公开(公告)号：US10427328B2
公开(公告)日：2019-10-01
申请号：US16220733
申请日：2018-12-14
发明人： Thomas R. Clark
IPC分类号： D01F1/06 , D02G3/24 , B29B17/02 , C08J11/06 , D01D5/00 , C08J11/04 , D01D1/10 , D01F6/62 , B29B17/00 , B01D29/00 , D01D5/08 , B29D99/00 , B29C48/05 , B29C48/38 , B29C48/92 , B29C48/14 , B29C48/385 , B29C48/425 , B29C48/435 , B29C48/76 , B29C48/255 , B29C48/43 , B29C48/70 , B29C48/44 , B29K67/00 , B29K105/26 , B29K105/00 , B29B13/00
摘要： A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 5 millibars. The streams are recombined into a single polymer stream and formed into bulked continuous carpet filament.
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公开(公告)号：US11780145B2
公开(公告)日：2023-10-10
申请号：US16993585
申请日：2020-08-14
发明人： Thomas R. Clark
IPC分类号： D02G3/24 , B29C48/44 , B29D99/00 , B29C48/05 , B29C48/38 , B29C48/92 , B29C48/385 , C08J11/04 , D01D1/10 , D01F6/62 , B29C48/255 , B29C48/70 , B29C48/43 , B29C48/76 , B29C48/40 , B29C48/425 , B29C37/00 , B29B7/42 , D01D5/00 , B29B17/00 , C08J11/06 , B01D29/00 , B29B17/02 , D01D5/08 , B29C48/14 , B29C48/435 , B29B13/00 , B29K67/00 , B29K105/00 , B29K105/26
CPC分类号： B29C48/44 , B01D29/0095 , B29B7/427 , B29B17/00 , B29B17/02 , B29C37/006 , B29C48/05 , B29C48/2552 , B29C48/38 , B29C48/385 , B29C48/40 , B29C48/425 , B29C48/43 , B29C48/70 , B29C48/767 , B29C48/92 , B29D99/0078 , C08J11/04 , C08J11/06 , D01D1/103 , D01D1/106 , D01D5/00 , D01D5/08 , D01F6/62 , B07C2501/0036 , B29B2013/002 , B29B2013/005 , B29B2017/0015 , B29B2017/0203 , B29B2017/0224 , B29C48/144 , B29C48/255 , B29C48/435 , B29C48/766 , B29C2791/003 , B29C2791/006 , B29C2948/922 , B29C2948/9238 , B29C2948/9239 , B29C2948/92514 , B29C2948/92876 , B29K2067/003 , B29K2105/0067 , B29K2105/26 , C08J2367/02 , D10B2503/04 , H05K999/99 , Y02P20/143 , Y02W30/62 , Y02W30/64
摘要： A method for manufacturing bulked continuous carpet filament, the method comprising: (1) reducing a chamber pressure within a chamber to below about 5 millibars; (2) after reducing the chamber pressure to below about 5 millibars, providing a polymer melt to the chamber; (3) separating the polymer melt into at least eight streams; (4) while the at least eight streams of the polymer melt are within the chamber, exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars; (5) after exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars, recombining the at least eight streams into a single polymer stream; and (6) forming polymer from the single polymer stream into bulked continuous carpet filament.
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公开(公告)号：US11618973B2
公开(公告)日：2023-04-04
申请号：US16645137
申请日：2018-09-14
发明人： Thomas R. Clark
IPC分类号： B29C48/00 , D01D1/06 , B29C48/425 , B29B7/72 , D01F1/04 , B29C48/36 , B29B7/88 , B29B7/32 , B29B7/60 , B29C48/17 , B29B7/94 , D01D5/08 , B29K105/26 , B29B7/74 , B29C48/435 , B29K67/00 , D01F6/62
摘要： Method and system for manufacturing bulked continuous filament having tonal coloring from PET comprising: an extruder (202); a static mixing assembly (208) coupled to the extruder and comprising a housing and one or more individual static mixing elements disposed within the housing; the method and system further comprising a plurality of colorant ports along a length of the static mixing assembly such that each of the plurality of colorant ports is configured to provide colorant (204) to a polymer stream at a different location along the length of the static mixing assembly, and one or more spinning machines (212) positioned downstream of the static mixing assembly and coupled to the static mixing assembly to receive the colored polymer stream. The spinning machine(s) may be configured to form the colored polymer stream into bulked continuous carpet filament having a tonal color effect.
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公开(公告)号：US11446617B2
公开(公告)日：2022-09-20
申请号：US16340718
申请日：2018-03-26
发明人： Harald Rust
IPC分类号： B01F27/232 , B29C48/255 , B29C48/25 , B29C48/455 , B29C48/375 , B29C48/425 , B29C48/435 , B29C48/505 , B29C48/85 , B29B7/48 , B29B7/82 , B29B7/72 , B29C48/515 , B29C48/44 , B29C48/365 , B29B7/42 , B29B7/46 , B29C48/39 , B29C48/29 , B29C48/84 , B29C48/285
摘要： Various measures increase the cooling effect on a planetary roller extruder section/module. Those measures include a choke being arranged at an outlet of the planetary roller extruder section or module, a distance between centerlines of adjacent planetary spindles being at least equal to an outer diameter of the planetary spindles, providing a pressurized melt supply, having a cooling section composed of several sections/modules, providing at least one section/module in which a flow, during melt supply is converse to the conveying direction of the extruder, and providing cooling tubes arranged within the central spindle.
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公开(公告)号：US11427694B2
公开(公告)日：2022-08-30
申请号：US16866708
申请日：2020-05-05
发明人： Thomas R. Clark
IPC分类号： B29B17/00 , C08J11/04 , B29D99/00 , B29C48/435 , B29C48/05 , B29C48/00 , B29C48/38 , B29C48/92 , B29C48/14 , B29C48/385 , D01D1/10 , D01F6/62 , B29C48/76 , B29C48/255 , B29C48/44 , B29C48/43 , B29C48/525 , B29C48/40 , B29C48/425 , D02G3/24 , B29B13/06 , B29B17/02 , B29B17/04 , D01D5/08 , B29K67/00 , B29L31/00 , B29B13/00 , B29K105/26
摘要： A method of manufacturing bulked continuous carpet filament, in various embodiments, comprises: (A) providing an expanded surface area extruder; (B) providing a spinning machine having an inlet that is operatively coupled to an expanded surface area extruder outlet; (C) using a pressure regulation system to reduce the pressure within the expanded surface area extruder; (D) passing a plurality of flakes comprising recycled PET through the expanded surface area extruder to at least partially melt the plurality of flakes to form a polymer melt; and (E) 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. In some embodiments, the method may include passing the plurality of flakes comprising recycled PET through a PET crystallizer prior to extrusion.
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公开(公告)号：US10751915B2
公开(公告)日：2020-08-25
申请号：US15348591
申请日：2016-11-10
发明人： Thomas R. Clark
IPC分类号： B29B7/32 , B29B7/88 , B29B13/02 , D01D5/08 , D01F6/62 , D01D4/06 , D01F1/06 , D01F1/04 , B29B7/74 , B29B7/94 , B29C48/05 , B29C48/025 , B29C48/425 , B29C48/435 , B29C48/36 , B29K67/00 , B29K105/26 , B29K105/00 , B29L31/00 , B29B7/42 , B29B7/72 , B29B7/46
摘要： A method of manufacturing a plurality of colors of bulked continuous carpet filament from a single multi-screw extruder which, in various embodiments, comprises: (A) passing PET through an extruder that melts the PET and purifies the resulting PET polymer melt; (B) splitting the extruded polymer melt into a plurality of melt streams and adding a colorant to each of the plurality of melt streams; (C) using one or more static mixers (e.g., thirty six static mixers) to substantially uniformly mix (e.g., homogeneously mix) each of the plurality of melt streams with its respective added colorant; and (D) feed each of the uniformly mixed and colored plurality of melt streams into a respective spinning machines that turns the polymer into filament for use in manufacturing carpet, rugs, and other products.
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公开(公告)号：US20200262122A1
公开(公告)日：2020-08-20
申请号：US16866702
申请日：2020-05-05
发明人： Thomas R. Clark
IPC分类号： B29C48/05 , B29C48/44 , B29C48/69 , B29C48/43 , B29C48/40 , D01D5/08 , B29B17/04 , B29B13/06 , B29B17/02 , B29B17/00 , B29D99/00 , D01F6/62 , D01D1/10 , C08J11/04 , B29C48/435 , B29C48/425 , B29C48/385 , B29C48/92 , B29C48/38
摘要： A method of manufacturing bulked continuous carpet filament which, in various embodiments, comprises: (A) washing a plurality of flakes of recycled PET; (B) providing a PET crystallizer; (C) after the step of washing the plurality of flakes, passing the plurality of flakes of recycled PET through the PET crystallizer; (D) at least partially melting the plurality of flakes into a polymer melt; (E) providing a multi-rotating screw (MRS) extruder having an MRS section; and a vacuum pump in communication with the MRS section; (F) using the vacuum pump to reduce a pressure within the MRS Section; (G) after the step of passing the plurality of flakes through the PET crystallizer, passing the polymer melt through the MRS Section; and (H) after the step of passing the polymer melt through the MRS extruder, forming the polymer melt into bulked continuous carpet filament.
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公开(公告)号：US10654211B2
公开(公告)日：2020-05-19
申请号：US16220905
申请日：2018-12-14
发明人： Thomas R. Clark
IPC分类号： D02G3/24 , B29C48/425 , B29D99/00 , B29C48/435 , B29C48/05 , B29C48/00 , B29C48/38 , B29C48/92 , B29C48/14 , B29C48/385 , C08J11/04 , D01D1/10 , D01F6/62 , B29B17/00 , B29C48/255 , B29C48/76 , B29C48/44 , B29C48/43 , B29B13/06 , B29B17/02 , B29B17/04 , D01D5/08 , B29K67/00 , B29L31/00 , B29B13/00 , B29K105/26
摘要： A method of manufacturing bulked continuous carpet filament which, in various embodiments, comprises: (A) grinding recycled PET bottles into a group of flakes; (B) washing the flakes; (C) identifying and removing impurities, including impure flakes, from the group of flakes; (D) passing the group of flakes through an expanded surface area extruder while maintaining a pressure within the expanded surface area extruder below about 25 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.
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公开(公告)号：US10647046B2
公开(公告)日：2020-05-12
申请号：US16213694
申请日：2018-12-07
发明人： Thomas R. Clark
IPC分类号： B29B17/04 , B29C48/05 , D01D1/10 , B29C48/38 , B29C48/92 , B29C48/385 , B29C48/425 , B29C48/435 , C08J11/04 , D01F6/62 , B29D99/00 , B29B17/00 , B29B17/02 , B29C48/40 , B29C48/43 , B29C48/69 , B29C48/44 , B29B13/06 , D01D5/08 , B29K67/00 , B29L31/00 , B29B13/00 , B29C48/00 , B29C48/14 , B29C48/25 , B29K105/26 , B29C48/02
摘要： A method of manufacturing bulked continuous carpet filament which, in various embodiments, comprises: (A) grinding recycled PET bottles into a group of flakes; (B) washing the flakes; (C) identifying and removing impurities, including impure flakes, from the group of flakes; (D) passing the flakes through a PET crystallizer; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 millibars; (F) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (G) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.
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公开(公告)号：US10532495B2
公开(公告)日：2020-01-14
申请号：US16220733
申请日：2018-12-14
发明人： Thomas R. Clark
IPC分类号： D01F1/06 , D02G3/24 , B29B17/02 , C08J11/06 , D01D5/00 , C08J11/04 , D01D1/10 , D01F6/62 , B29B17/00 , B01D29/00 , D01D5/08 , B29D99/00 , B29C48/05 , B29C48/38 , B29C48/92 , B29C48/14 , B29C48/385 , B29C48/425 , B29C48/435 , B29C48/76 , B29C48/255 , B29C48/43 , B29C48/70 , B29C48/44 , B29K67/00 , B29K105/26 , B29K105/00 , B29B13/00
摘要： A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 5 millibars. The streams are recombined into a single polymer stream and formed into bulked continuous carpet filament.
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