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) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an extrusion system while maintaining the pressure within the extrusion system below about 25 millibars; (F) passing the resulting polymer melt through at least one filter 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 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) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 25 millibars; (F) passing the resulting polymer melt through at least one filter 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 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) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 25 millibars; (F) passing the resulting polymer melt through at least one filter 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.

An insulation module for a floor of a motor vehicle includes a panel of a molded and bound fiber material. The panel extends along a longitudinal axis (X). At least one notch is formed in the thickness direction (D) of the panel and extends at an angle between 0 and 30 to the longitudinal axis (X). At least one incision is formed in an outer edge of the panel and extends at an angle between 80 and 100 to the longitudinal axis (X) of the panel.

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 planetary roller extruder section forms a feed part of an extruder. The planetary roller extruder has an internally toothed housing and an externally toothed central spindle disposed centrally within and at a distance from the housing. Planetary spindles are arranged to rotate in a void between the central spindle and the housing. Each planetary spindle has an external toothing meshing with both the housing and the central spindle. At least one planetary spindle has two axially spaced areas with less than a full set of teeth. Those axially spaced areas include a first area having a first number of teeth and a second area having a second number of teeth. The second number of teeth is less than a full set of teeth and more than the first number of teeth.

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.

The disclosure relates to various measures for increasing the cooling effect on a planetary roller extruder section/module. Those measures include a choke being arranged at an outlet of the planetary roller extruder section or module, a distance between centerlines of adjacent planetary spindles being at least equal to an outer diameter of the planetary spindles, providing a pressurized melt supply, having a cooling section composed of several sections/modules, providing at least one section/module in which a flow, during melt supply is converse to the conveying direction of the extruder, and providing cooling tubes arranged within the central spindle.

The disclosure relates to various measures for increasing the cooling effect on a planetary roller extruder section/module. Those measures include a choke being arranged at an outlet of the planetary roller extruder section or module, a distance between centerlines of adjacent planetary spindles being at least equal to an outer diameter of the planetary spindles, providing a pressurized melt supply, having a cooling section composed of several sections/modules, providing at least one section/module in which a flow, during melt supply is converse to the conveying direction of the extruder, and providing cooling tubes arranged within the central spindle.

A system for manufacturing bulked continuous carpet filament that is adapted for providing a polymer melt and dividing the polymer melt into a plurality of streams (e.g., at least six or eight streams) to increase a surface area of the polymer melt. The plurality of streams is then exposed to a pressure that is below approximately 5 millibars. The streams are then recombined into a single polymer stream and formed into bulked continuous carpet filament. In various embodiments, an extruder, such as a multi-screw extruder, is used to divide the polymer melt into the plurality of streams.