A method and an extrusion device for producing a foamed body. A plastics melt is produced inside the casing of a first extruder. The plastics melt is conveyed to an outlet die of a second extruder. The conveyed plastics melt has a foaming agent and expands after being fed through the outlet die. Before the plastics melt is fed through the outlet die, variations in temperature between different radial positions over the cross-section of the plastics melt are reduced by an extruder screw device which has a number of screw spindles distributed around the periphery. The plastics melt which is thus thermally homogeneous is fed through the outlet die.

A method and an extrusion device for producing a foamed body. A plastics melt is produced inside the casing of a first extruder. The plastics melt is conveyed to an outlet die of a second extruder. The conveyed plastics melt has a foaming agent and expands after being fed through the outlet die. Before the plastics melt is fed through the outlet die, variations in temperature between different radial positions over the cross-section of the plastics melt are reduced by an extruder screw device which has a number of screw spindles distributed around the periphery. The plastics melt which is thus thermally homogeneous is fed through the outlet die.

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.

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 25 millibars or another predetermined pressure; (5) recombining the streams; and (6) using the resulting purified polymer to produce bulked continuous carpet filament.

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 25 millibars or another predetermined pressure; (5) recombining the streams; and (6) using the resulting purified polymer to produce bulked continuous carpet filament.

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 of manufacturing a plurality of colors of bulked continuous carpet filament from a single multi-screw extruder which, in various embodiments, comprises: (A) passing PET through an extruder that melts the PET and purifies the resulting PET polymer melt; (B) splitting the extruded polymer melt into a plurality of melt streams and adding a colorant to each of the plurality of melt streams; (C) using one or more static mixers (e.g., thirty six static mixers) to substantially uniformly mix (e.g., homogeneously mix) each of the plurality of melt streams with its respective added colorant; and (D) feed each of the uniformly mixed and colored plurality of melt streams into a respective spinning machines that turns the polymer into filament for use in manufacturing carpet, rugs, and other products.