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 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 laminate production method is provided which can sufficiently prevent the occurrence of blocking without causing deterioration in the outstanding characteristics of acrylic block copolymers such as adhesive performance, and can also ensure excellent processability during extrusion. The laminate production method includes a step (1) of bringing raw pellets of an acrylic block copolymer (A) into contact with an aqueous dispersion (C) containing acrylic resin particles (B) and no surfactants, the acrylic block copolymer (A) including at least one polymer block (a1) including acrylic acid alkyl ester units and at least one polymer block (a2) including methacrylic acid alkyl ester units, a step (2) of removing water attached to the pellets and thereby obtaining pellets (D), and a step (3) of preparing an adhesive composition using an adhesive feedstock including the pellets (D) from the step (2), and extruding the adhesive composition to form an adhesive layer and thereby producing a laminate including the adhesive layer and a substrate layer.

In particular embodiments, a process for producing bulked continuous carpet filament from recycled polymer utilizes two vacuum pumps (140A, 140B) in combination with a single extruder (100). In various embodiments, the dual vacuum arrangement (e.g., at least two vacuum pumps (140A, 140B)) operably coupled to the single extruder (e.g., MRS extruder (100)) may be configured to remove one or more impurities from recycled polymer as the recycled polymer passes through the extruder.

A multi-port single screw extruder combining a heated plastication barrel having a first entrance port and an exit port on opposing ends of the barrel and a second entrance port intermediately positioned therebetween; a first hopper positioned to deliver ingredients to the first entrance port of said barrel; a second hopper positioned to deliver ingredients to the second entrance port and a helical plastication screw rotatably carried within the barrel and running the length thereof between the first entrance port and exit port that is operable to rotate and transmit the ingredients along the length of the barrel; wherein the plastication screw includes a distributive mixing element located between at least one additional entrance port and the exit port, the minor diameter of the plastication screw is reduced in advance of each additional entrance port sufficient to reduce the barrel pressure at each entrance port to a level that permits the addition of ingredients to the barrel through the entrance port, and the ingredients include a thermoplastic polymer.

A polyphenylene sulfide resin composition includes a polyphenylene sulfide resin (A); an aromatic vinyl compound block copolymer (B) containing at least one functional group selected from the group consisting of a carboxyl group, an acid anhydride group, a hydroxyl group, an amino group, an epoxy group and an isocyanate group; and an alkoxysilane compound (C) containing at least one functional group selected from the group consisting of an epoxy group, an amino group and an isocyanate group; wherein a phase structure of the polyphenylene sulfide resin composition is a sea-island structure in which the polyphenylene sulfide resin (A) forms a sea phase, and the aromatic vinyl compound block copolymer (B) forms an island phase dispersed in a number average dispersed particle size of 1,000 nm or less.

A screw with a spiral blade for extruding a plastic elastomer while kneading the plastic elastomer, the screw includes a kneading region where the spiral blade is provided with cutout portions being configured to pass pins, and a plasticizing region being arranged on a downstream side in an extrusion direction of the kneading region. The plasticizing region includes a barrier extending between portions adjacently in the extrusion direction of the spiral blade.

The present disclosure relates to a facility for forming one of a graphene-polymer resin composite and a carbon material-polymer resin composite. According to the facility of the present disclosure, in a process of forming the composite, gas and water vapor contained in graphene, a carbon material, and a polymer resin are effectively removed resulting in an increase in coupling force between the polymer resin and one of the graphene and the carbon material, and the graphene and the carbon material is uniformly dispersed inside the polymer resin resulting in no degradation of physical properties of the composite, and also, the polymer resin may be prevented from carbonizing and solidifying because there is no stagnant section while molten liquid of the polymer resin and one of the graphene and the carbon material passes through each apparatus in the facility, and thus, physical properties of the composite are maintained constant.

The present disclosure relates to a facility for forming one of a graphene-polymer resin composite and a carbon material-polymer resin composite. According to the facility of the present disclosure, in a process of forming the composite, gas and water vapor contained in graphene, a carbon material, and a polymer resin are effectively removed resulting in an increase in coupling force between the polymer resin and one of the graphene and the carbon material, and the graphene and the carbon material is uniformly dispersed inside the polymer resin resulting in no degradation of physical properties of the composite, and also, the polymer resin may be prevented from carbonizing and solidifying because there is no stagnant section while molten liquid of the polymer resin and one of the graphene and the carbon material passes through each apparatus in the facility, and thus, physical properties of the composite are maintained constant.

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.