Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) melting polymer (e.g., derived from post-consumer PET bottles) to create a first single stream of polymer melt; (2) separating the first single stream of polymer melt into multiple streams of polymer melt; (3) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 5 millibars; (4) allowing the multiple streams of polymer melt to fall into a receiving section of a melt processing unit; (5) recombining the multiple streams of polymer melt into a second single stream of polymer melt; and (6) providing the second single stream of polymer melt to one or more spinning machines that are configured to form the second single stream of polymer melt into bulked continuous carpet filament.

A method and a facility produce polylactide (PLA) by polymerization, in which a lactide mixture is mixed with at least one catalyst, is introduced into a modular planetary roller extruder and the finished PLA is then removed. The lactide mixture continuously passes through segments of the extruder. The course of the reaction is measured and controlled in the segments in a targeted manner such that the temperature can be set by heating and/or cooling. The pressure can be variably set depending on pressure values to be checked by a controllable gas extraction and/or a controllable extruder speed and/or static variability of the planetary rollers and/or a variable metering speed of the lactide mixture and/or a variable mixing ratio of the lactide mixture. Flammable gas is removed in an explosion-protected zone in a partial region of the extruder. Additives are introduced into the extruder during the rolling process.

The present invention relates to an improved process for manufacturing an extruded composite product comprising natural fibers and a thermoplastic polymer. According to the present invention, mixing as well as crosslinking takes place inside an extruder. The natural fibers may be provided for example in the form of pulp or wood particles.

The present invention relates to an extrusion die and a method for extruding a sheet using the same, and according to one aspect of the present invention, there is provided an extrusion die comprising a storage part configured to hold a raw material, the storage part defining a first width, a pressure part configured to move the raw material through the storage part, a first die defining a second width less than the first width, such that a flow width of the raw material becomes narrower, a second die in fluid communication with the first die, the second die defining a width that increases from the second width to a third width, such that the flow width of the raw material passing through the first die becomes wider and a flow thickness becomes smaller, and a heating part configured to heat the raw material passing through the second die.

In the manufacture of double-walled corrugated extruded pipe it is desirable to form an integral connecting cuff that is of a single wall thickness and typically of a large diameter. The mold blocks and process parameters for forming of the cuff as part of an otherwise double-walled pipe requires a transition as the cuff moves past the die outlets. The present invention allows for accurate sensing and control of air pressure and temperature as the cuff moves past the die outlets. Improvements in both the die tooling and the method of manufacture are disclosed.

A film that comprises a thermoplastic composition that contains a continuous phase that includes a polyolefin matrix polymer and a nanoinclusion additive dispersed within the continuous phase in the form of discrete domains is provided. The film is biaxially stretched in a machine direction and cross-machine direction to form a porous network in the composition. The porous network contains nanopores having a maximum cross-sectional dimension of about 800 nanometers or less. At least a portion of the nanopores are oriented in the cross-machine direction so that the axial dimension generally extends in the cross-machine direction and the cross-sectional dimension generally extends in the machine direction.

Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) melting polymer (e.g., derived from post-consumer PET bottles) to create a first single stream of polymer melt; (2) separating the first single stream of polymer melt into multiple streams of polymer melt; (3) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 5 millibars; (4) allowing the multiple streams of polymer melt to fall into a receiving section of a melt processing unit; (5) recombining the multiple streams of polymer melt into a second single stream of polymer melt; and (6) providing the second single stream of polymer melt to one or more spinning machines that are configured to form the second single stream of polymer melt into bulked continuous carpet filament.

A system for depositing a composite filler material into a channel of a composite structure includes an end-effector configured to extrude a bead of the filler material into the channel. The filler material can comprise a first group of relatively long fibers, a second group of relatively short fibers and a resin. A drive system is configured to move the end-effector relative to the channel, and a position sensor is configured to detect the position of the bead relative to the channel. A controller is configured to operate the drive system in response to the detected position and to operate the end-effector to heat and compress the filler material so as to orient the longer fibers in a substantially longitudinal direction relative to the channel and the shorter fibers in substantially random directions relative to the channel when the bead is extruded into the channel.

A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 25 millibars, or another predetermined pressure. The streams are recombined into a single polymer stream. Polymer from the polymer stream is then formed into bulked continuous carpet filament.

Provided is a method for producing a resin molded article, capable of reducing deterioration of resin during melt extrusion. The method includes passing a resin fed from a hopper for resin through a molding machine provided with the hopper, an extruder, and a pressure control device in this order, to produce a resin molded article, the resin pressure between a tip of the extruder and an inlet port for resin of the pressure control device being 15.0 MPa or lower.