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.

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.

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.

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.

An extrusion device including at least one extruder having a screw cylinder, a screw shaft rotatably supported in the screw cylinder and an extruder outlet, an injection mould having an outlet nozzle determining the cross-sectional contour of the extruder, and an extrusion head arranged between the extruder outlet of the at least one extruder and the outlet nozzle of the injection mould, wherein at least one perforated plate arranged in the extruder head is provided, which has a plurality of passage openings, wherein the passage openings are designed to dam up extrusion material conveyed from the at least one extruder through the passage openings of the perforated plate differently into at least one first region of the perforated plate and at least one second region of the perforated plate, in such a way that the extrusion material is partly diverted from its preferential direction within a central section of the perforated plate, specifically increasingly into at least one edge section of the perforated plate.

The present invention provides a spider for a die head and die tooling that utilizes curved flow guides to direct the flow of plastic through the die head and die tooling. The spider leg splits the stream of plastic flowing through the spider into two independent streams at the upstream end. The downstream end comprises two curved flow guides that are configured to direct the two streams of plastic towards a longitudinal center plane of the spider leg. The turbulence caused by the curved flow guides creates obtuse or acute angled welding lines between the two streams of plastic. These obtuse and acute angled welding lines provide stronger bonds than the known spider legs that create butt welding or right angled welding lines.

Provided are extrusion dies having entrance, orientation, merging (205), and exit (211) sections, which dies may be used to produce fibers having, e.g., oriented reinforcement materials (e.g., PTFE) dispersed within. The dies provide fibers having enhanced mechanical and processing properties. The orientation section comprises orientation channels (203) wherein a ratio of a cross-sectional area having of the channel inlet to a cross-sectional area of the channel outlet is between 2 and 45.

A multi-component extrusion die head for producing a composite tube comprises an extrusion nozzle, a main die head, and a melt flow distributor device. The main die head is configured to supply the extrusion nozzle with a first melt flow and a second melt flow, which are guided separately from one anther in the extrusion nozzle away from the main die head and toward a nozzle outlet of the extrusion nozzle. The melt flow distributor device is arranged in the extrusion nozzle outside of the main die head and is configured to split the first melt flow in a peripheral direction thereof, and to supply the second melt flow to the first melt flow such that at least one section of the second melt flow is arranged within the first melt flow in the peripheral direction.

A multi-component extrusion die head for producing a composite tube comprises an extrusion nozzle, a main die head, and a melt flow distributor device. The main die head is configured to supply the extrusion nozzle with a first melt flow and a second melt flow, which are guided separately from one anther in the extrusion nozzle away from the main die head and toward a nozzle outlet of the extrusion nozzle. The melt flow distributor device is arranged in the extrusion nozzle outside of the main die head and is configured to split the first melt flow in a peripheral direction thereof, and to supply the second melt flow to the first melt flow such that at least one section of the second melt flow is arranged within the first melt flow in the peripheral direction.

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.