US 2021/0172088 A1 · BULKED CONTINUOUS CARPET FILAMENT MANUFACTURING FROM POLYTRIMETHYLENE TEREPHTHALATE

Abstract

A method of manufacturing bulked continuous carpet filament from polytrimethylene terephthalate (PTT) with polyethylene terephthalate (PET) comprises: (1) splitting the PTT stream extruded from the primary extruder into a number of polymer streams, each of the plurality of polymer streams having an associated spinning machine; (2) adding a colorant to each split polymer stream; (3) adding PET to the extruded polymer stream downstream of the primary extruder; (4) using one or more static mixing assemblies for each split polymer stream to substantially uniformly mix each split polymer stream and its respective colorant and PET; and (5) spinning each polymer stream with its substantially uniformly mixed colorant and any additives into BCF using the respective spinning machine.

Claims20

Dependent claims

A method of manufacturing bulked continuous carpet filament from polytrimethylene terephthalate (PTT), the method comprising:

providing an extruder;
using the extruder to at least partially melt the PTT into a polymer stream and at least partially purify the polymer stream;
providing a static mixing assembly downstream of the extruder;
adding polyethylene terephthalate (PET) to the polymer stream downstream of the extruder and before the static mixing assembly or along a length of the static mixing assembly between an upstream end and a downstream end of the static mixing assembly;
using the static mixing assembly to mix the polymer stream with the PET to create a mixed polymer stream;
and
forming the mixed polymer stream into bulked continuous carpet filament.

4 more elements

A method of manufacturing bulked continuous carpet filament from polytrimethylene terephthalate (PTT), the method comprising:

providing an extruder;
using the extruder to at least partially melt the PTT into a polymer stream and at least partially purify the polymer stream;
providing a static mixing assembly downstream of the extruder;
adding a molten polymeric masterbatch to the polymer stream before the static mixing assembly or along a length of the static mixing assembly between an upstream end and a downstream end of the static mixing assembly;
using the static mixing assembly to mix the polymer stream with the molten polymeric masterbatch to create a colored polymer stream;
and
forming the colored polymer stream into bulked continuous carpet filament.

4 more elements

Dependencies are inferred from the claim text.

Bulked continuous carpet filament manufacturing from polytrimethylene terephthalate

Life of this patent

Bulked continuous carpet filament manufacturing from polytrimethylene terephthalate

Life of this patent

Abstract

Claims20