Apparatus and methods for converting granular plastic resin into colored finished or semi-finished plastic parts include a process machine having a barrel with a vertically opening feed throat, a rotatable screw inside the barrel, and a color feed conduit assembly positioned at least partially within the process machine and extending into the barrel for passage of liquid color downwardly through the color feed conduit assembly into proximity with the screw.

A co-injection extrusion apparatus and method. The first extruder cooperates with a first material delivery channel for delivering a first material to a die. The second extruder cooperates with a second material delivery channel for delivering a second material to a die. A first plunger is positioned in the first material delivery channel and a second plunger is positioned in the second material delivery channel. The plungers are movable between a first position in which to the plunger is extended in a respective material delivery channel toward the die, and a second position in which the plunger is retracted in the respective material delivery channel away from the die.

The present invention relates to an overturning device (10) for overturning a molten material (200) in a melt channel (110) comprising a melt inlet (20) and a melt outlet (30), wherein between the melt inlet (20) and the melt outlet (30) at least a melt guiding means (40) is assembled for a rearrangement of the molten material (200) from the centre (22) of the melt inlet (20) to the edge (34) of the melt outlet (30) and for a rearrangement of the molten material (200) from the edge (24) of the melt inlet (20) into the centre (32) of the melt outlet (30).

The present invention relates to an overturning device (10) for overturning a molten material (200) in a melt channel (110) comprising a melt inlet (20) and a melt outlet (30), wherein between the melt inlet (20) and the melt outlet (30) at least a melt guidance means (40) is assembled for a rearrangement of molten material (200) from the centre (22) of the melt inlet (20) at the edge (34) of the melt outlet (30) and for a rearrangement of molten material (200) from the edge (24) of the melt inlet (20) in the centre (32) of the melt outlet (30).

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.

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 from recycled polymer. In various embodiments, the method includes: (1) reducing recycled polymer material into polymer flakes; (2) cleansing the polymer flakes; (3) melting the flakes into a polymer melt; (4) removing water and contaminants from the polymer melt by dividing the polymer melt into a plurality of polymer streams and exposing those streams to pressures below 5 millibars; (5) recombining the streams; and (6) using the resulting purified polymer to produce bulked continuous carpet filament.

A method is disclosed for die coating a moving substrate with a high viscosity material such as a polymer. The method includes heating and mixing ingredients to form a homogenous mixture, pumping the mixture around a circulation loop with a first pump, maintaining a predetermined pressure of the mixture within the circulation loop, drawing mixture from the circulation loop with a second pump, delivering the mixture using the second pump to an extrusion die adjacent the moving substrate to coat the substrate, and controlling the second pump as a function of at least the speed of the moving substrate to maintain predetermined characteristics of the coating mixture applied to the moving substrate. An apparatus for carrying out the method also is disclosed.

A molding apparatus comprises a first extruder and a second extruder and conduit fluidically connecting the extruders with a common mold wherein the at least one conduit has a conduit axis. The longitudinal axis of the first and second extruders extend at an angle of about 90° to a direction of flow in the conduit.

Composites containing one or more synthetic plastics, such as thermoplastics, one or more natural materials, such as plant/tree fibers, and biochar and/or torrefied material are described herein. The composite can contain additional additives, such as reinforcing agents and/or fibers, compatibilizers, etc. The composites have improved mechanical and/or physical properties, such as strength, impact strength, rigidity/modulus, heat deflection temperature, moldability/melt flow index, renewability, and lower cost compared to composites that do not contain the biochar and/or torrefied material. The presence of the biochar and/or torrefied material also serves to remove the odor often associated with natural fibers and other additives.