Method and system for manufacturing bulked continuous filament having tonal coloring from PET comprising: an extruder (202); a static mixing assembly (208) coupled to the extruder and comprising a housing and one or more individual static mixing elements disposed within the housing; the method and system further comprising a plurality of colorant ports along a length of the static mixing assembly such that each of the plurality of colorant ports is configured to provide colorant (204) to a polymer stream at a different location along the length of the static mixing assembly, and one or more spinning machines (212) positioned downstream of the static mixing assembly and coupled to the static mixing assembly to receive the colored polymer stream. The spinning machine(s) may be configured to form the colored polymer stream into bulked continuous carpet filament having a tonal color effect.

Method and system for manufacturing bulked continuous filament having tonal coloring from PET comprising: an extruder (202); a static mixing assembly (208) coupled to the extruder and comprising a housing and one or more individual static mixing elements disposed within the housing; the method and system further comprising a plurality of colorant ports along a length of the static mixing assembly such that each of the plurality of colorant ports is configured to provide colorant (204) to a polymer stream at a different location along the length of the static mixing assembly, and one or more spinning machines (212) positioned downstream of the static mixing assembly and coupled to the static mixing assembly to receive the colored polymer stream. The spinning machine(s) may be configured to form the colored polymer stream into bulked continuous carpet filament having a tonal color effect.

A multiple screw extruder (50) combines application of vacuum to a vacuum vent (62) positioned between material feed locations (70, 72) of the extruder and use of specially configured extruder screws (58) to extract gases, primarily air, out of the extruder to densify the materials introduced into it and to extract unwanted fluid from material introduced for mixture with molten polymeric material flowing through the extruder. The multiple screw extruder is operationally versatile in that it is capable of carrying out the material densification and fluid extraction processes either separately or simultaneously. Implementation of the disclosed vacuum feed technology provides an increase in rate of extrudate throughput as compared with that achievable by implementation of atmospheric venting (16) in a conventionally configured extruder (10a, 10b).

The present invention provides a method for manufacturing a molded foam product which can reduce or prevent blisters and crinkles on the surface even in the case of manufacturing a molded product designed to have a small thickness, thereby giving a molded foam product having excellent heat insulation while avoiding an increase in the amounts of materials used. The method for manufacturing a molded foam product according to the present invention includes the steps of: injecting, during injection molding, a molten resin containing a supercritical fluid or a chemical foaming agent into a cavity formed in a mold that includes a movable portion; and moving the movable portion to increase the volume of the cavity before the molten resin injected into the cavity completely solidifies, the mold alternately including, in a direction from a resin injection port to the periphery of the cavity, first linear portions each giving a large gap size in the cavity and second linear portions each giving a small gap size in the cavity.

Disclosed is an asymmetric co-rotating multi-screw extrusion device, an extruder, and a processing method thereof. The barrel is provided with a feed port located at one end of the screw mechanism and a discharge port located at the other end of the screw mechanism, and the barrel comprises a conveying section, a melting section, an exhaust section, and a mixing extrusion section sequentially arranged from a side thereof where the feed port is located, wherein the exhaust section is provided with an exhaust hole. The screw mechanism comprises at least a first screw and a second screw arranged parallel to the first screw, wherein at least one of the first screw and the second screw has a cross-sectional profile comprising an arc forming a radial step between a root and a crest thereof, and the first screw and the second screw are asymmetrically inter-meshed and co-rotated at the same speed.

This application is directed to polymer blends of polyethylene naphthalate, polytrimethylene terephthalate, and polyethylene naphthalate, for use in fibers, such as carpet fibers, and other applications. This application is also directed to methods of producing such polymer blends and fibers.

This application is directed to polymer blends of polyethylene naphthalate, polytrimethylene terephthalate, and polyethylene naphthalate, for use in fibers, such as carpet fibers, and other applications. This application is also directed to methods of producing such polymer blends and fibers.

A method for manufacturing bulked continuous carpet filament, the method comprising: (1) reducing a chamber pressure within a chamber to below about 5 millibars; (2) after reducing the chamber pressure to below about 5 millibars, providing a polymer melt to the chamber; (3) separating the polymer melt into at least eight streams; (4) while the at least eight streams of the polymer melt are within the chamber, exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars; (5) after exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars, recombining the at least eight streams into a single polymer stream; and (6) forming polymer from the single polymer stream into bulked continuous carpet filament.

A method for manufacturing bulked continuous carpet filament, the method comprising: (1) reducing a chamber pressure within a chamber to below about 5 millibars; (2) after reducing the chamber pressure to below about 5 millibars, providing a polymer melt to the chamber; (3) separating the polymer melt into at least eight streams; (4) while the at least eight streams of the polymer melt are within the chamber, exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars; (5) after exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars, recombining the at least eight streams into a single polymer stream; and (6) forming polymer from the single polymer stream into bulked continuous carpet filament.

The disclosure discloses a co-rotating dual speed multi-screw extruder and a processing method thereof, the co-rotating dual speed multi-screw extruder enables a first screw and a second screw with the same outer diameter to co-rotate at different speed in a barrel, and the two screws wipe with each other, to achieve self-cleaning in processing; and circular arcs meshed with each other are respectively arranged between root diameters and top diameters of the two screws to form a first step structure and a second step structure, thus breaking an axial symmetry of a cross-sectional contour of the screws, and moreover, the first step structure and the second step structure are periodically meshed in a meshing zone in a staggered manner, so that a flow channel in the meshing zone is changed in a topological way, a strong elongation action and a strong disturbance action are effectively introduced in the meshing zone.