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.

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.

A system and method are presented in which a flow of plastic is extruded to obtain nano-sized features by forming multiple laminated flow streams, flowing in parallel through the non-rotating extrusion system. Each of the parallel laminated flow streams are subjected to repeated steps in which the flows are compressed, divided, and overlapped to amplify the number of laminations. The parallel amplified laminated flows are rejoined to form a combined laminated output with nano-sized features. The die exit is formed to provide a tubular shape.

A fluid-flow-modification plate comprises a monolithic body, having an inlet-side surface, an outlet-side surface, a first passage, a second passage, a third passage, and a fourth passage. The first passage, second passage, third passage, and fourth passage each extend between the inlet-side surface and the outlet-side surface. The first passage and second passage intersect each other at a first intersection boundary. The third passage and fourth passage intersect each other at a second intersection boundary. The first passage and third passage do not intersect each other. The first passage and fourth passage do not intersect each other. The second passage and third passage do not intersect each other. The second passage and fourth passage do not intersect each other. The first-passage-inlet-opening perimeter boundary has single-point contact with the fourth-passage-inlet-opening perimeter boundary. The second-passage-outlet-opening perimeter boundary has single-point contact with the third-passage-outlet-opening perimeter boundary.

A fluid-flow-modification plate comprises a monolithic body, having an inlet-side surface and an outlet-side surface, a first passage, a second passage, a third passage, and a fourth passage. The first passage, the second passage, the third passage, and the fourth passage each extend between the inlet-side surface and the outlet-side surface. The first passage and the second passage intersect each other at a first intersection boundary. The third passage and the fourth passage intersect each other at a second intersection boundary. The first passage and the third passage do not intersect each other. The second passage and the fourth passage do not intersect each other. The first-passage-inlet-opening perimeter boundary has only two points of intersection with the fourth-passage-inlet-opening perimeter boundary. The second-passage-outlet-opening perimeter boundary has only two points of intersection with the third-passage-outlet-opening perimeter boundary.

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.

A single-cavity multi-runner applied to oriented arrangement extrusion molding equipment of graphene fibers includes a first extrusion cavity, the first extrusion cavity includes a first inlet and a first outlet arranged opposite to each other; a first molding cavity, the first molding cavity is arranged in an inclined manner, a second inlet is arranged at the high position end, a second outlet is arranged at the low position end of the first molding cavity, and the second inlet is connected to the first outlet; flow channels, the flow channels are formed by dividing the first molding cavity using baffle plates arranged horizontally and along the flowing direction of a heat-conducting mixture; a second molding cavity, the second molding cavity includes a third inlet and a third outlet arranged opposite to each other, the third inlet is connected to the outflow end of the flow channels.

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.

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 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.