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1. 发明申请

US20220356321A1 METHODS FOR MANUFACTURING BULKED CONTINUOUS FILAMENT 有权
公开(公告)号：US20220356321A1
公开(公告)日：2022-11-10
申请号：US17871145
申请日：2022-07-22
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： C08J11/04 , B29D99/00 , B29C48/435 , B29C48/05 , B29C48/00 , B29C48/38 , B29C48/92 , B29C48/14 , B29C48/385 , D01D1/10 , D01F6/62 , B29B17/00 , B29C48/76 , B29C48/255 , B29C48/44 , B29C48/43 , B29C48/525 , B29C48/40 , B29C48/425 , D02G3/24 , B29B13/06 , B29B17/02 , B29B17/04 , D01D5/08
摘要： A method of recycling a PET-containing material comprises: (1) providing an MRS extruder having an MRS section comprising a plurality of satellite screws and an outlet; (2) providing a vacuum pump in communication with the MRS section; (3) providing a spinning machine comprising an inlet, wherein the inlet is directly coupled to the outlet of the MRS extruder; (4) heating a plurality of PET-containing flakes in the MRS extruder to form a PET-containing melt; (5) increasing a surface area of the PET-containing melt by distributing the PET-containing melt across the plurality of satellite screws in the MRS extruder; (6) drawing off vapors from the PET-containing melt by reducing the pressure in the MRS section with the vacuum pump; (7) collating the PET-containing melt in the MRS extruder; and (8) extruding the PET-containing melt through the outlet of the MRS extruder into the inlet of the spinning machine.

2. 发明申请

US20220355526A1 METHODS FOR MANUFACTURING BULKED CONTINUOUS FILAMENT 有权
公开(公告)号：US20220355526A1
公开(公告)日：2022-11-10
申请号：US17871102
申请日：2022-07-22
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： B29C48/05 , D01D1/10 , B29C48/38 , B29C48/92 , B29C48/385 , B29C48/435 , C08J11/04 , D01F6/62 , B29D99/00 , B29B17/00 , B29B17/02 , B29C48/40 , B29C48/43 , B29C48/69 , B29C48/44 , B29C48/425 , D02G3/24 , B29C37/00 , B29C48/70 , B29B13/06 , B29B17/04 , D01D5/08
摘要： A method of recycling a PET-containing material comprises: (1) providing a polymer crystallizer comprising at least one heating element, and at least one blower; (2) providing an MRS extruder having an MRS section comprising a plurality of satellite screws; (3) providing a vacuum pump in fluid communication with the MRS section; (4) grinding and washing the PET-containing material; (5) heating the PET-containing material in the crystallizer to at least partially dry the PET-containing material; (6) shearing the PET-containing material in the MRS extruder to produce a PET-containing melt; (7) increasing a surface area of the PET-containing melt by distributing the PET-containing melt across a plurality of satellite screws in the MRS extruder; (8) drawing off vapors from the PET-containing melt by reducing the pressure in the MRS section with the vacuum pump; (9) collating the PET-containing melt in the MRS extruder; and (10) extruding a recycled PET-containing material.

3. 发明申请

US20220152879A1 SYSTEMS AND METHODS FOR MANUFACTURING BULKED CONTINUOUS FILAMENT 有权
公开(公告)号：US20220152879A1
公开(公告)日：2022-05-19
申请号：US17591447
申请日：2022-02-02
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： B29B17/02 , D01D5/00 , B29C48/38 , D01D1/10 , D01F6/62 , B29B17/00 , B29C48/92 , B29C48/425 , C08J11/06 , B29D99/00 , B01D29/00 , D01D5/08 , B29C48/385 , B29C48/05 , C08J11/04 , B29C48/255 , B29C48/70 , B29C48/44 , B29C48/43
摘要： A method for manufacturing pellets from polymer, comprising: (1) melting polymer flakes in a first section of a melt processing unit to create a first single stream of polymer melt; (2) separating the first single stream of polymer melt into multiple streams of polymer melt by means of a separation element; (3) passing the multiple streams through a multiple stream section of said melt processing unit and exposing the multiple streams to a pressure within the multiple stream section of the melt processing unit as the multiple streams pass through the multiple stream section; (4) recombining the multiple streams into at least one combined stream of polymer melt; and (5) cooling the polymer melt and forming said pellets from the at least one combined stream. The intrinsic viscosity of the at least one combined stream may be determined and, in response, the chamber pressure within the multiple stream section adjusted.

4. 发明授权

US11273579B2 Systems and methods for manufacturing bulked continuous filament 有权
公开(公告)号：US11273579B2
公开(公告)日：2022-03-15
申请号：US16816409
申请日：2020-03-12
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： B29B17/02 , D01D5/00 , B29C48/38 , D01D1/10 , D01F6/62 , B29B17/00 , B29C48/92 , B29C48/425 , C08J11/06 , B29D99/00 , B01D29/00 , D01D5/08 , B29C48/385 , B29C48/05 , C08J11/04 , B29C48/255 , B29C48/70 , B29C48/44 , B29C48/43 , B29C48/76 , B29K67/00 , B29K105/26 , B29K105/00 , B29C48/435 , B29C48/14 , B29B13/00
摘要： 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.

5. 发明授权

US10767281B2 Polyester fiber blends and methods of manufacturing same 有权
公开(公告)号：US10767281B2
公开(公告)日：2020-09-08
申请号：US15469025
申请日：2017-03-24
申请人： Aladdin Manufacturing Corporation
发明人： James L. Williams , Mark G. Dye , Jonathan Skelley , Thomas R. Clark
IPC分类号： D01F6/92 , C08L67/02 , C08J11/16 , B29C48/18 , B29C48/40 , B29C48/425 , B29B17/00 , B29B7/74 , B29B7/42 , B29B7/48 , D02G3/44 , B29B7/86 , B29K67/00 , B29L31/00
摘要： 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.

6. 发明申请

US20200172327A1 SILO 审中-公开
公开(公告)号：US20200172327A1
公开(公告)日：2020-06-04
申请号：US16698941
申请日：2019-11-27
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： B65D88/54
摘要： A silo for storing bulk material, the silo comprising: a container defining an inner space, at least one supply opening for receiving bulk material, an insert located in said inner space, the insert having the shape of a capped cone, the bottom rim of the insert being mechanically coupled to the inner surface of the container, the insert having one or more openings, along its bottom rim for allowing bulk material to pass from the upper inner space to the lower inner space, a first group of discharge openings near or at the lower side of the container in the surface of the container for discharging bulk material from the lower inner space, the top rim is provided with a second group of discharge openings comprising at least one discharge opening for discharging bulk material from the upper inner space, a recirculation system coupled to the discharge openings of one of the first and second group of discharge openings, for transporting bulk material from said discharge openings to said supply opening, and an extraction system being coupled to the discharge openings of the other of the first and second group of discharge openings for extracting bulk material towards the exterior of the silo.

7. 发明申请

US20190381699A1 SYSTEMS AND METHODS FOR MANUFACTURING BULKED CONTINUOUS FILAMENT 审中-公开
公开(公告)号：US20190381699A1
公开(公告)日：2019-12-19
申请号：US16557076
申请日：2019-08-30
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： B29B17/02 , D01D1/10 , B29D99/00 , D01D5/00 , B29C48/05 , C08J11/06 , D01D5/08 , B29C48/92 , C08J11/04 , D01F6/62 , B29B17/00 , B01D29/00 , B29C48/385 , B29C48/425 , B29C48/38
摘要： 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.

8. 发明授权

US10493664B2 Methods for manufacturing bulked continuous carpet filament 有权
公开(公告)号：US10493664B2
公开(公告)日：2019-12-03
申请号：US16432579
申请日：2019-06-05
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： D02G3/24 , B29B17/02 , D01D5/00 , B29C48/38 , D01D1/10 , D01F6/62 , B29B17/00 , B29C48/92 , B29C48/425 , C08J11/06 , B29D99/00 , B01D29/00 , D01D5/08 , B29C48/385 , B29C48/05 , C08J11/04 , B29C48/255 , B29C48/70 , B29C48/44 , B29C48/43 , B29C48/76 , B29K67/00 , B29K105/26 , B29K105/00 , B29C48/435 , B29C48/14 , B29B13/00
摘要： 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 5 millibars; (5) recombining the streams; and (6) using the resulting purified polymer to produce bulked continuous carpet filament.

9. 发明授权

US10428442B2 Methods for manufacturing bulked continuous filament from colored recycled pet 有权
公开(公告)号：US10428442B2
公开(公告)日：2019-10-01
申请号：US15419955
申请日：2017-01-30
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： D02G3/24 , D01D5/08 , D01F6/62 , D01D1/10 , B29B17/00 , B29B17/02 , C08J11/04 , C08J11/06 , D01D1/04 , D01D1/06 , B29C48/92 , B29C48/05 , B29C48/29 , B29C48/275 , B29C48/285 , B29C48/425 , B29C48/435 , B29C48/38 , B29B13/00 , B29K105/00 , B29K67/00 , B29K105/26 , D01F1/06 , D01F6/92 , B29C48/14 , B29C48/17 , B29C48/25 , B29C48/385 , B29C48/76
摘要： A method of manufacturing bulked continuous carpet filament which, in various embodiments, comprises: (A) grinding recycled PET bottles into a group of flakes; (B) washing the flakes; (C) identifying and removing impurities, including impure flakes, from the group of flakes; (D) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 25 millibars; (F) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (G) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

10. 发明授权

US10427328B2 Methods for manufacturing bulked continuous filament from recycled PET 有权
公开(公告)号：US10427328B2
公开(公告)日：2019-10-01
申请号：US16220733
申请日：2018-12-14
申请人： Aladdin Manufacturing Corporation
发明人： Thomas R. Clark
IPC分类号： D01F1/06 , D02G3/24 , B29B17/02 , C08J11/06 , D01D5/00 , C08J11/04 , D01D1/10 , D01F6/62 , B29B17/00 , B01D29/00 , D01D5/08 , B29D99/00 , B29C48/05 , B29C48/38 , B29C48/92 , B29C48/14 , B29C48/385 , B29C48/425 , B29C48/435 , B29C48/76 , B29C48/255 , B29C48/43 , B29C48/70 , B29C48/44 , B29K67/00 , B29K105/26 , B29K105/00 , B29B13/00
摘要： 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 5 millibars. The streams are recombined into a single polymer stream and formed into bulked continuous carpet filament.

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