A method of manufacturing bulked continuous carpet filament from polytrimethylene terephthalate (PTT) with polyethylene terephthalate (PET) comprises: (1) splitting the PTT stream extruded from the primary extruder into a number of polymer streams, each of the plurality of polymer streams having an associated spinning machine; (2) adding a colorant to each split polymer stream; (3) adding PET to the extruded polymer stream downstream of the primary extruder; (4) using one or more static mixing assemblies for each split polymer stream to substantially uniformly mix each split polymer stream and its respective colorant and PET; and (5) spinning each polymer stream with its substantially uniformly mixed colorant and any additives into BCF using the respective spinning machine.

A co-rotating self-cleaning two-screw extruder with a gradual number of threads and through self-cleaning function, and a processing method using the same, are disclosed. The screw assembly in the extruder includes a first screw (3) and a second screw (4) that co-rotate at the same speed in engagement; the first screw (3) includes a first single threaded element, a first transition element, a multiple threaded element, a second transition element and a second single threaded element that are connected in sequence; and the second screw (4) includes a first single threaded element, a third transition element, a multiple threaded element, a fourth transition element and a second single threaded element that are connected in sequence. The materials are transferred by rotation of the first (3) and second screws (4), and get their respective compositions mixed based on the structure of a gradual number of threads; with the flow passage expanded, contracted and re-expanded in shape in sequence, the materials undergo the single-to-multiple threaded, multiple-to-single threaded and again single-to-multiple threaded chaotic mixing in sequence; and the first and second screws achieve the self-cleaning effect by wiping each other.

One embodiment provides a twin-screw extruder which is used to knead materials and has excellent productivity. The twin-screw extruder includes screws. The screws include double thread screws in which first screw portions engage with each other. Ratio D1/C of external diameter D1 of the first screw portion to a shaft distance C ranges from 1.25 to 1.40. The screws further include triple thread screws in which third screw portions engage with each other. Ratio D3/C of external diameter D3 of the third screw portion to the shaft distance C ranges from 1.05 to 1.10. External diameter D2 of a second screw portion decreases gradually from the first screw portion toward the third screw portion.

A twin-screw extrusion kneader includes: two rotating shafts provided side by side in an internal space; a rotational driving portion configured to rotationally drive the rotating shafts; and paddles provided in the rotating shafts and configured to rotate along with the rotating shafts so as to knead a kneading material. Further, the twin-screw extrusion kneader includes movable portions provided as members constituting a part of the housing, the part of the housing including an inner wall surface of the housing, the inner wall surface being opposed to radially outer peripheral surfaces of the paddles. The movable portions can be moved in a direction to approach the paddles and in a direction to be distanced from the paddles. The twin-screw extrusion kneader can control the viscosity of electrode paste by moving the movable portions.

A planetary extruder for producing and processing polymers includes a degassing section. The extruder includes a housing and a bushing arranged therein. The bushing has an internal toothing with a pitch diameter and a root circle. An externally toothed central spindle is arranged within the housing. Planetary spindles rotate about the central spindle between the central spindle and the bushing. A heat transfer fluid is guided through fluid channels which extend helically along an outer surface of the bushing and guide the heat transfer fluid axially. A degassing opening is provided to which a negative pressure is applied for degassing. A minimum radial thickness (t) of the bushing between the root circle of the internal toothing on an inside of the bushing and a bottom of the fluid channels on an outside of the bushing is selected based on the pitch diameter (d) of the internal toothing.

A screw extruder for extruding a kneaded material, includes: a screw; and a casing housing the screw and having a material supply port on an upstream side. The screw has a shaft portion and a helical flight portion provided on an outer peripheral surface of the shaft portion. Regarding a clearance between a top portion of the flight portion and an inner wall surface of the casing, the clearance at a downstream side end of the flight portion is larger than the clearance at a downstream side end of the supply port. No area where the clearance decreases from the upstream side toward the downstream side is present between the downstream side end of the supply port and the downstream side end of the flight portion.

A multi-screw kneader that exhibits an extensional flow function before and behind small holes of a disk-shaped segment having the small holes and a method for producing a nano-composite using the multi-screw kneader and a disk-shaped segment to be used therein. The multi-screw kneader includes a plurality of kneading screws and a disk-shaped segment in a barrel. The disk-shaped segment partitions the inside of the barrel downstream a part for charging a kneading material and includes a plurality of shaft penetrating parts through which rotating shafts of the kneading screws rotatably pass and a large number of small holes punched in a periphery of these shaft penetrating parts and serving as flow channels of the kneading material. The nano-composite production includes charging nanoparticles as a resin additive using the multi-screw kneader. The disk-shaped segment includes the shaft penetrating parts and the large number of the small holes.

A multi-screw kneader is configured to exhibit an extensional flow function before and behind holes of a disk-shaped segment and a method for producing a nano-composite uses the multi-screw kneader. The multi-screw kneader includes a plurality of kneading screws and the disk-shaped segment in a barrel. The disk-shaped segment partitions the inside of the barrel downstream of a part for supplying a kneading material and includes shaft receiving parts through which rotating shafts of the kneading screws are to rotatably pass and the holes are defined in a periphery of the shaft penetrating parts and are configured to serve as flow channels of the kneading material. The method for producing the nano-composite includes charging nanoparticles as a resin additive using the multi-screw kneader.

A method of manufacturing bulked continuous carpet filament from polytrimethylene terephthalate (PTT) with polyethylene terephthalate (PET) comprises: (1) splitting the PTT stream extruded from the primary extruder into a number of polymer streams, each of the plurality of polymer streams having an associated spinning machine; (2) adding a colorant to each split polymer stream; (3) adding PET to the extruded polymer stream downstream of the primary extruder; (4) using one or more static mixing assemblies for each split polymer stream to substantially uniformly mix each split polymer stream and its respective colorant and PET; and (5) spinning each polymer stream with its substantially uniformly mixed colorant and any additives into BCF using the respective spinning machine.

A method of manufacturing bulked continuous carpet filament from a plurality of polymer flakes comprises: (1) providing an extruder; (2) melting and purifying the plurality of polymer flakes into a polymer stream using the extruder; (3) providing a static mixing assembly downstream of the extruder; (4) adding a first liquid colorant to a center of the polymer stream at a first location before the static mixing assembly or along a length of the static mixing assembly; (5) adding a second liquid colorant to the polymer stream at a second location before the static mixing assembly or along a length of the static mixing assembly; (6) using the static mixing assembly to mix the polymer stream with the first and second liquid colorant to create a colored polymer stream; and (7) forming the colored polymer stream into bulked continuous carpet filament.