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The patent badge is an abbreviated version of the USPTO patent document. The patent badge does contain a link to the full patent document.

The patent badge is an abbreviated version of the USPTO patent document. The patent badge covers the following: Patent number, Date patent was issued, Date patent was filed, Title of the patent, Applicant, Inventor, Assignee, Attorney firm, Primary examiner, Assistant examiner, CPCs, and Abstract. The patent badge does contain a link to the full patent document (in Adobe Acrobat format, aka pdf). To download or print any patent click here.

Patent No.:

US 11724418 B1

PDFFull Text
Date of Patent:
Aug. 15, 2023

Filed:

Jun. 09, 2020

Methods for manufacturing bulked continuous carpet filament

Applicant:

Aladdin Manufacturing Corporation, Calhoun, GA (US);

Inventor:

Thomas R. Clark, Chattanooga, TN (US);

Assignee:

Aladdin Manufacturing Corporation, Calhoun, GA (US);

Attorney:

Brient IP Law, LLC

Primary Examiner:

Leo B Tentoni

Int. Cl.
CPC ...
B01J 19/18 (2006.01); C08G 63/78 (2006.01); C08G 63/80 (2006.01); D01D 13/00 (2006.01); D01D 13/02 (2006.01); D02G 3/24 (2006.01); F26B 3/30 (2006.01); B29B 17/02 (2006.01); D01D 1/10 (2006.01); B01D 29/00 (2006.01); C08J 11/06 (2006.01); B29B 17/00 (2006.01); D01D 5/00 (2006.01); D01F 6/62 (2006.01); C08J 11/04 (2006.01); B29C 48/425 (2019.01); B29C 48/385 (2019.01); B29C 48/92 (2019.01); B29C 48/38 (2019.01); B29C 48/05 (2019.01); B29D 99/00 (2010.01); B29C 48/43 (2019.01); B29C 48/44 (2019.01); B29C 48/70 (2019.01); B29C 48/255 (2019.01); D01D 5/08 (2006.01); B29C 37/00 (2006.01); B01J 3/00 (2006.01); D02G 3/44 (2006.01); B29B 13/00 (2006.01); B29K 105/26 (2006.01); B29K 105/00 (2006.01); B29K 67/00 (2006.01); B29C 48/76 (2019.01); B29C 48/435 (2019.01); B29C 48/14 (2019.01); B29C 35/08 (2006.01);
U.S. Cl.
CPC ...
B29B 17/02 (2013.01); B01D 29/0095 (2013.01); B01J 3/006 (2013.01); B29B 17/00 (2013.01); B29C 37/006 (2013.01); B29C 48/05 (2019.02); B29C 48/255 (2019.02); B29C 48/2552 (2019.02); B29C 48/38 (2019.02); B29C 48/385 (2019.02); B29C 48/425 (2019.02); B29C 48/43 (2019.02); B29C 48/44 (2019.02); B29C 48/70 (2019.02); B29C 48/92 (2019.02); B29D 99/0078 (2013.01); C08G 63/785 (2013.01); C08J 11/04 (2013.01); C08J 11/06 (2013.01); D01D 1/103 (2013.01); D01D 1/106 (2013.01); D01D 5/00 (2013.01); D01D 5/08 (2013.01); D01F 6/62 (2013.01); D02G 3/445 (2013.01); B29B 2013/002 (2013.01); B29B 2013/005 (2013.01); B29B 2017/0015 (2013.01); B29B 2017/0224 (2013.01); B29C 48/144 (2019.02); B29C 48/435 (2019.02); B29C 48/766 (2019.02); B29C 2035/0822 (2013.01); B29C 2948/922 (2019.02); B29C 2948/92514 (2019.02); B29C 2948/92876 (2019.02); B29K 2067/003 (2013.01); B29K 2105/0067 (2013.01); B29K 2105/26 (2013.01); C08J 2367/02 (2013.01); D10B 2503/04 (2013.01); H05K 999/99 (2013.01); Y02P 20/143 (2015.11); Y02W 30/62 (2015.05);
Abstract

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.

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