The present disclosure is related to apparatuses, processes, and extrusion screws directed to process solid detergent compositions in shapes like billets, bars, tablets, noodles, and similar shapes produced from extruded synthetic detergents, soaps, and combinations thereof. The present disclosure describes an extrusion screw for processing synthetic detergents, soaps, and combinations thereof. The extrusion screw comprises a feed section, a metering section, and a compression section. Said compression section has a proximal channel depth adjacent to the feed section, and a distal channel depth adjacent to the metering section, and a compression ratio that may be between 2.2, and 4.1, for example, between 2.2, and 2.6. The extrusion screw may have a length to diameter ratio (L/D) that may be between 4.0, and 6.0. The present disclosure also describes an apparatus for processing synthetic detergents, soaps, and combinations thereof. The apparatus comprises a barrel and said extrusion screw. The present disclosure also describes a process for extruding solid synthetic detergents, soaps, and combinations thereof. The process comprises a step of providing a formulation that may be selected from synthetic detergent, and half-synthetic soap to said apparatus, and compressing said formulation at a temperature between 32° C., and 42° C. with a compression section of the extrusion screw. The screw rotation speed of the extrusion screw may be between 4, and 20 RPM. The formulation may be provided prewarmed. The screw rotation speed of the extrusion screw may be between 4, and 35 RPM (e.g., between 4 and 20 RPM).

Methods of manufacturing bulked continuous carpet filament which, in various embodiments, comprise: (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 (400) while maintaining the pressure within the MRS portion (420) of the MRS extruder (400) below about 25 millibars; (F) passing the resulting polymer melt through at least one filter (450) 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.

A method for manufacturing pellets from polymer, comprising: (1) melting polymer flakes in a first section of a melt processing unit to create a first single stream of polymer melt; (2) separating the first single stream of polymer melt into multiple streams of polymer melt by means of a separation element; (3) passing the multiple streams through a multiple stream section of said melt processing unit and exposing the multiple streams to a pressure within the multiple stream section of the melt processing unit as the multiple streams pass through the multiple stream section; (4) recombining the multiple streams into at least one combined stream of polymer melt; and (5) cooling the polymer melt and forming said pellets from the at least one combined stream. The intrinsic viscosity of the at least one combined stream may be determined and, in response, the chamber pressure within the multiple stream section adjusted.

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 25 millibars or another predetermined pressure; (5) recombining the streams; and (6) using the resulting purified polymer to produce bulked continuous carpet filament.

A method of fabricating a polymer composite material by mixing a polymer material with a planar material, depositing the mixture on a substrate, and stretching the resulting thin film, is described. Polymer composite materials produced using said method and ballistic resistant materials comprising said polymer composite materials are also described.

An assembly for performing an additive manufacturing process includes a first material feed for dispensing a first material, a second material feed for dispensing a second material, a material combiner chamber, a first entry channel fluidly connecting the first material feed and the material combiner chamber, and a second entry channel fluidly connecting the second material feed and the material combiner chamber. The assembly further includes a pen tip for dispensing a material in the additive manufacturing process, the material comprising the first material and the second material, a valve having a rod, a first seal between the material combiner and the pen tip, and a first actuator for moving the rod back and forth along a longitudinal axis to open and close the first seal.

An optical film formed of a resin C including a copolymer P containing a polymerization unit A and a polymerization unit B, wherein the optical film includes a phase separation structure that expresses structural birefringence, the phase separation structure includes a phase containing as a main component the polymerization unit A and a phase containing as a main component the polymerization unit B, and a value of Rth/d calculated from the thickness-direction retardation Rth (nm) and thickness d (nm) is 2.5×10-3 or more.

Provided by the present invention is a high melt strength styrene resin composition. The composition includes the following components proportioned according to certain parts by weight: a styrene resin or a styrene alloy, a tackifier, an antioxidant and a lubricant. Compared to the existing technology, the present invention has the following beneficial effects: 1. a random copolymer used as the tackifier in the present invention is thermodynamically compatible with the styrene resin and the alloy thereof, does not experience phase separation, and has excellent mechanical properties; 2. the random copolymer used as the tackifier in the present invention has a moderate molecular weight, and is more easily plasticized than a rubber powder, a SAN powder having a high molecular weight, a heat-resistant powder, and so on, thus having better processability, uniform thickness, and low shrinkage rate, and not frequently experiencing the problem of surface defects.

Method for manufacturing a composite material, comprising the following steps: a) plasticizing a binder in an extruder, wherein the binder comprises a polymer; b) providing a mixture of a cellulosic material and a hydrophobic agent dissolved and/or dispersed in a liquid carrier; c) mechanically shearing and drying the mixture in an extruder whereby liquid is at least partly extracted from the mixture or is not present in liquid form anymore; and d) blending the dried mixture with the plasticized binder.

Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) passing polymer flakes through a crystalliers; (2) melting the polymer to create a first single stream of polymer melt; (3) separating the first single stream of polymer melt into multiple streams of polymer melt; (4) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 25 millibars in a chamber; (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.