A method of continuously manufacturing a cured membrane includes continuously compounding and mixing a vulcanizable rubber composition in a mixing extruder while continuously removing gasses from the vulcanizable rubber composition during mixing with a vacuum. The vulcanizable rubber composition may be continuously extruded to form an extrudate, which may be continuously calendered to form a green membrane. The green membrane may be continuously cured, such as by a hot air conveyor curing system, to form a cured membrane.

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 co-rotating self-cleaning multi-screw extruder with a speed ratio of 2.5 and an extruding method therefor are disclosed. The screw mechanism includes a center screw and peripheral screws which rotate in the same direction. The peripheral screws are each of a double threaded structure, and the center screw is of a quintuple threaded structure. The rotation speed of the peripheral screws is 2.5 times that of the center screw, and the peripheral screws are always meshed with the center screw, whereas the adjacent peripheral screws are intermittently meshed with each other. The extruding method therefor is as follows: there is a periodically open space between adjacent peripheral screws, providing the periodical and intermittent mixing action, so that material from different thread grooves is mixed with each other. Meanwhile, the topological chaos action, by which the material is cut into two portions, is formed between the center screw and the peripheral screws, and the chaos mixing is caused by the random motion which is generated from the periodical changes of the channel, so that a periodical action of “compression-expansion” is achieved. Furthermore, due to the tensile force field action caused by the differences in rotation speed between the center screw and the peripheral screws, the compression preheating and dispersion mixing of the material are achieved. The co-rotating self-cleaning multi-screw extruder effectively improves the efficiency of conveying and mixing of materials.

A co-rotating self-cleaning multi-screw extruder with a speed ratio of 2.5 and an extruding method therefor are disclosed. The screw mechanism includes a center screw and peripheral screws which rotate in the same direction. The peripheral screws are each of a double threaded structure, and the center screw is of a quintuple threaded structure. The rotation speed of the peripheral screws is 2.5 times that of the center screw, and the peripheral screws are always meshed with the center screw, whereas the adjacent peripheral screws are intermittently meshed with each other. The extruding method therefor is as follows: there is a periodically open space between adjacent peripheral screws, providing the periodical and intermittent mixing action, so that material from different thread grooves is mixed with each other. Meanwhile, the topological chaos action, by which the material is cut into two portions, is formed between the center screw and the peripheral screws, and the chaos mixing is caused by the random motion which is generated from the periodical changes of the channel, so that a periodical action of “compression-expansion” is achieved. Furthermore, due to the tensile force field action caused by the differences in rotation speed between the center screw and the peripheral screws, the compression preheating and dispersion mixing of the material are achieved. The co-rotating self-cleaning multi-screw extruder effectively improves the efficiency of conveying and mixing of materials.

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 processing solid polymer particles of a poly condensate by a multi-rotation system. Polymer particles are melted in a first extruder section having an extruder screw that rotates. The partly molten polymer mass containing between 5% by volume and 50% by volume of unmolten polymer particles is passed into a second extruder section with a poly-rotation unit and multiple satellite screws that rotate therein. A diameter of the poly-rotation unit is increased compared to the screw diameter of the first extruder section and a transition cone is formed between the extruder sections and a conical gap is formed with respect to the housing. Ambient pressure plastification of the remaining polymer particles is performed by passage through a drive zone. The polymer mass is guided completely molten in the drive zone onward through a venting zone under reduced pressure.

A method of processing solid polymer particles of a poly condensate by a multi-rotation system. Polymer particles are melted in a first extruder section having an extruder screw that rotates. The partly molten polymer mass containing between 5% by volume and 50% by volume of unmolten polymer particles is passed into a second extruder section with a poly-rotation unit and multiple satellite screws that rotate therein. A diameter of the poly-rotation unit is increased compared to the screw diameter of the first extruder section and a transition cone is formed between the extruder sections and a conical gap is formed with respect to the housing. Ambient pressure plastification of the remaining polymer particles is performed by passage through a drive zone. The polymer mass is guided completely molten in the drive zone onward through a venting zone under reduced pressure.

A method of continuously manufacturing a cured membrane includes continuously compounding and mixing a vulcanizable rubber composition in a mixing extruder while continuously removing gasses from the vulcanizable rubber composition during mixing with a vacuum. The vulcanizable rubber composition may be continuously extruded to form an extrudate, which may be continuously calendered to form a green membrane. The green membrane may be continuously cured, such as by a hot air conveyor curing system, to form a cured membrane.