Systems and methods can be used to produce fibers with external corrugations, internal corrugations, or both. These fibers can be used, for example, in hollow fiber membrane modules.

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 method of recycling a PET-containing material comprises: (1) providing a polymer crystallizer comprising at least one heating element, and at least one blower; (2) providing an MRS extruder having an MRS section comprising a plurality of satellite screws; (3) providing a vacuum pump in fluid communication with the MRS section; (4) grinding and washing the PET-containing material; (5) heating the PET-containing material in the crystallizer to at least partially dry the PET-containing material; (6) shearing the PET-containing material in the MRS extruder to produce a PET-containing melt; (7) increasing a surface area of the PET-containing melt by distributing the PET-containing melt across a plurality of satellite screws in the MRS extruder; (8) drawing off vapors from the PET-containing melt by reducing the pressure in the MRS section with the vacuum pump; (9) collating the PET-containing melt in the MRS extruder; and (10) extruding a recycled PET-containing material.

A method of manufacturing a mixture PTFE thread using a mixture PTFE powder consisting of PTFE: 73-95 wt %, MoS.sub.2: 3-25 wt %, Al.sub.2O.sub.3: 1-5 wt %, and Al(OH).sub.3: 1-5 wt % comprises heat-retaining step for adding 18-25 wt % kerosene of a solvent to the mixture PTFE powder and keeping it warm at 30-50° C. for 40 to 50 hours, extruding the heat-retained mixture PTFE powder into a rod shape with a circular or elliptical cross section at the cylinder temperature of 70-90° C., rolling the extrusion at 100-150° C. into a 0.3-0.7 mm thick sheet shape, multiple-folding the sheet and passing the sheet through an oven at 250-270° C. at the rate of 10-40 cm/s, and stretching the folded sheet with a stretch ratio of 200-600% in multiple stages after heating the sheet at 450-500° C.

A method of forming an array of aligned, uniform-length carbon nanotubes on a planar surface of a substrate employing a composite catalyst layer of iron and cobalt. The carbon nanotubes have visible length and are useful for producing spun threads of carbon nanotubes having improved spinability and mechanical and electrical properties.

The present invention is directed to articles of manufacture, including fibers and films, and methods of making thereof. In accordance with the present invention, the article includes a binder impregnated with or encapsulating a filler. The binder is a polyvinyl alcohol (PVOH), cellulose nanofibrils, or a combination of the PVOH and cellulose nanofibrils. The filler is deinking waste solids comprising ash and cellulose fines.

The present invention is directed to an article of manufacture, which can be a fiber and or a film. In one aspect, the fiber or the film comprises a polyvinyl alcohol (PVOH) and an inorganic filler comprising particles having an average diameter of less than about 20 micrometers. The PVOH has a degree of hydrolysis of greater than about 95% and is present in a range between about 20 wt. % and about 99 wt. % based on the total fiber weight. Methods of making the fibers and films are also disclosed.

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.

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.

An ultrafine fiber production device has a first heating unit, a nozzle unit, a hot air heating unit, a hot air blowing unit, a second heating unit, and a fiber collecting unit. The first heating unit melts a thermoplastic resin. The nozzle unit discharges the thermoplastic resin melted by the first heating unit. The hot air blowing unit performs fiber forming by blowing high-temperature gas produced by the hot air heating unit to the melted thermoplastic resin discharged by the nozzle unit and by extending the thermoplastic resin. The second heating unit further heats, extends, and fines produced fibers. The fiber collecting unit collects the thermoplastic resin in a fibrous form which is fined by the second heating unit.