A method of recycling a PET-containing material comprises: (1) providing an MRS extruder having an MRS section comprising a plurality of satellite screws and an outlet; (2) providing a vacuum pump in communication with the MRS section; (3) providing a spinning machine comprising an inlet, wherein the inlet is directly coupled to the outlet of the MRS extruder; (4) heating a plurality of PET-containing flakes in the MRS extruder to form a PET-containing melt; (5) increasing a surface area of the PET-containing melt by distributing the PET-containing melt across the plurality of satellite screws in the MRS extruder; (6) drawing off vapors from the PET-containing melt by reducing the pressure in the MRS section with the vacuum pump; (7) collating the PET-containing melt in the MRS extruder; and (8) extruding the PET-containing melt through the outlet of the MRS extruder into the inlet of the spinning machine.

A manufacturing method can be carried out using simple equipment and makes it possible to efficiently manufacture many continuous fiber-reinforced thermoplastic resin sheets in a short period of time. The above problem is overcome by a method for manufacturing a continuous fiber-reinforced thermoplastic resin sheet including: an impregnation step for impregnating continuous fiber with a thermoplastic resin solution containing a halogen-containing organic solvent and a thermoplastic resin containing at least one resin from among polycarbonate resins and polyarylate resins; and a solvent removal step for removing, under exposure to IR radiation, the halogen-containing organic solvent from the continuous fiber impregnated with the thermoplastic resin solution. In the solvent removal step, the distance between a heater for emitting the IR radiation and the continuous fiber is 400 mm or less, and the temperature of a heating element for radiating the IR radiation in the heater is 260 C. or higher.

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.

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) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 25 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.

Disclosed are a car interior sheet manufactured by using a defective product (defective hygiene product) among hygiene products such as tissues or diapers including wet-strength paper made of pulp including plastic or super absorbent polymer (SAP). The car interior sheet is manufactured by attaching surface layers such as a nonwoven fabric to both surfaces of a base layer thereof including 30-50 weight % of a pulverized material, 5-15 weight % of additives, and 30-50 weight % of thermoplastic resin. The car interior sheet represents a low manufacturing cost, and does not generate environmental hazardous materials. The car interior sheet represents superior impact resistance at high and low temperatures, has a superior moisture absorption rate due to the SAP, so that the car interior sheet is rapidly dried after the moisture has been absorbed.

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.

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 MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 1.5 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.

Disclosed are a car interior sheet manufactured by using a defective product (defective hygiene product) among hygiene products such as tissues or diapers including wet-strength paper made of pulp including plastic or super absorbent polymer (SAP). The car interior sheet is manufactured by attaching surface layers such as a nonwoven fabric to both surfaces of a base layer thereof including 30-50 weight % of a pulverized material, 5-15 weight % of additives, and 30-50 weight % of thermoplastic resin. The car interior sheet represents a low manufacturing cost, and does not generate environmental hazardous materials. The car interior sheet represents superior impact resistance at high and low temperatures, has a superior moisture absorption rate due to the SAP, so that the car interior sheet is rapidly dried after the moisture has been absorbed.

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 MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 1.5 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.

A process for the processing of an undried particulate polymer or polymer mixture by means of a single- or multiscrew extruder comprising a barrel comprising one or more screws, a feed section intended for the polymer and provided on the barrel and, provided on the barrel, a melting region in which the polymer or polymer mixture melts, where the undried polymer or polymer mixture introduced by way of the feed section into the barrel is devolatilized in at least one vacuum devolatilization region downstream of the feed section and upstream of the melting region in the barrel.