Methods for manufacturing bulked continuous filament
AssigneeAladdin Manufacturing Corporation
InventorThomas R. Clark
Life of this patent
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Abstract
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.
Claims20
A method for manufacturing bulked continuous carpet filament, the method comprising:
- reducing a pressure within a chamber to reach a chamber pressure of below about 5 millibars;
- melting a plurality of polymer flakes to create a polymer melt;
- transferring the polymer melt to an interior of the chamber;
- separating the polymer melt into a plurality of different streams, the plurality of different streams comprising at least four streams of the polymer melt;
- exposing each of the at least four streams of the polymer melt to the chamber pressure of below about 5 millibars while the at least four streams of the polymer melt are in the chamber;
- after exposing the at least four streams of the polymer melt to the chamber pressure of below about 5 millibars, recombining the at least four streams into a single polymer stream;
- and
- forming polymer from the single polymer stream into bulked continuous carpet filament.
A method of manufacturing bulked continuous carpet filament, the method comprising:
- separating a polymer melt into at least eight streams such that each of the at least eight stream is at least partially exposed to a chamber pressure within a chamber of less than about 5 millibars;
- after the at least eight streams are exposed to the chamber pressure of less than about 5 millibars, recombining the at least eight streams into a single polymer stream;
- and
- forming polymer from the single polymer stream into bulked continuous carpet filament.
A method for manufacturing bulked continuous carpet filament, the method comprising:
- providing a pressure regulation system;
- using the pressure regulation system to reduce a chamber pressure within a chamber to below about 5 millibars;
- after using the pressure regulation system to reduce the chamber pressure to below about 5 millibars, providing a polymer melt to the chamber;
- increasing a surface area of the polymer melt exposed to an interior of the chamber utilizing at least eight different streams of the polymer melt;
- 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;
- 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
- forming polymer from the single polymer stream into bulked continuous carpet filament.
Dependencies are inferred from the claim text.