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US 10,767,281 B2Granted
Polyester fiber blends and methods of manufacturing same
AssigneeAladdin Manufacturing Corporation
InventorsJames L. Williams, Mark G. Dye, Jonathan Skelley, Thomas R. Clark
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Abstract
This application is directed to polymer blends of polyethylene naphthalate, polytrimethylene terephthalate, and polyethylene naphthalate, for use in fibers, such as carpet fibers, and other applications. This application is also directed to methods of producing such polymer blends and fibers.
Claims20
A fiber comprising a polymer blend, said polymer blend comprising:
- a) about 1% by weight—about 15% by weight polytrimethylene terephthalate polymer;
- and
- b) about 1% by weight—about 15% by weight polyethylene naphthalate polymer;
- wherein the remainder of said polymer blend is polyethylene terephthalate polymer;
- wherein the fiber is a bulked continuous filament (BCF).
2 more elements
A method of manufacturing bulked continuous carpet filament, said method comprising:
- (A) providing a multi-screw extruder that comprises:
- (i) a first satellite screw extruder, said first satellite screw extruder comprising a first satellite screw that is mounted to rotate about a central axis of said first satellite screw;
- (ii) a second satellite screw extruder, said second satellite screw extruder comprising a second satellite screw that is mounted to rotate about a central axis of said second satellite screw;
- and
- (iii) a pressure regulation system that is adapted to maintain a pressure within said first and second satellite screw extruders between about 0 millibars and about 1.8 millibars;
- (B) using said pressure regulation system to reduce a pressure within said first and second satellite screw extruders to between about 0 millibars and about 1.8 millibars;
- (C) while maintaining said pressure within said first and second satellite screw extruders between about 0 millibars and about 1.8 millibars, passing a melt comprising a polymer through said multi-screw extruder so that:
- (1) a first portion of said melt passes through said first satellite screw extruder, and (2) a second portion of said melt passes through said second satellite screw extruder;
- and
- (D) after said step of passing said melt of polymer through said multi-screw extruder, forming said polymer into a bulked continuous carpet filament;
- wherein said bulked continuous carpet filament comprises a polymer blend comprising
- a) about 1% by weight—about 15% by weight polytrimethylene terephthalate polymer (PTT);
- and
- b) about 1% by weight—about 15% by weight polyethylene naphthalate polymer (PEN);
- wherein the remainder of said polymer blend is polyethylene terephthalate polymer (PEN);
- and
- wherein the PTT is or is not dried prior to step (C).
14 more elements
A method of manufacturing a fiber comprising a polymer blend of PET, PEN, and PTT, comprising:
- a) providing a plurality of pellets, each pellet comprising PET, PEN, and PTT;
- and
- b) melting said plurality of pellets with an extruder so as to form a melt;
- and
- c) processing said melt with a spinning machine, so as to form said fiber;
- wherein said fiber is a bulked continuous filament (BCF);
- and
- wherein said fiber comprises a polymer blend, said polymer blend comprising:
- c) about 1% by weight—about 15% by weight polytrimethylene terephthalate polymer;
- and
- d) about 1% by weight—about 15% by weight polyethylene naphthalate polymer;
- wherein the remainder of said polymer blend is polyethylene terephthalate polymer.
9 more elements
Dependencies are inferred from the claim text.