US 12,109,730 B2
Systems and methods for manufacturing bulked continuous filament
Thomas R. Clark, Hixon, TN (US)
Assigned to Aladdin Manufacturing Corporation, Calhoun, GA (US)
Filed by Aladdin Manufacturing Corporation, Calhoun, GA (US)
Filed on Feb. 2, 2022, as Appl. No. 17/591,447.
Application 16/557,076 is a division of application No. 16/432,579, filed on Jun. 5, 2019, granted, now 10,538,016, issued on Jan. 21, 2020.
Application 13/892,713 is a division of application No. 13/721,955, filed on Dec. 20, 2012, granted, now 8,597,553, issued on Dec. 3, 2013.
Application 17/591,447 is a continuation of application No. 16/816,409, filed on Mar. 12, 2020, granted, now 11,273,579.
Application 16/816,409 is a continuation of application No. 16/557,076, filed on Aug. 30, 2019, granted, now 11,179,868, issued on Nov. 23, 2021.
Application 16/432,579 is a continuation in part of application No. 16/220,733, filed on Dec. 14, 2018, granted, now 10,532,495, issued on Jan. 14, 2020.
Application 16/220,733 is a continuation in part of application No. 15/419,955, filed on Jan. 30, 2017, granted, now 10,487,422, issued on Nov. 26, 2019.
Application 15/419,955 is a continuation in part of application No. 15/396,143, filed on Dec. 30, 2016, granted, now 10,493,660, issued on Dec. 3, 2019.
Application 15/396,143 is a continuation of application No. 13/892,713, filed on May 13, 2013, granted, now 9,550,338, issued on Jan. 24, 2017.
Claims priority of provisional application 61/654,016, filed on May 31, 2012.
Prior Publication US 2022/0152879 A1, May 19, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B29B 7/46 (2006.01); B01D 29/00 (2006.01); B29B 7/72 (2006.01); B29B 9/06 (2006.01); B29B 17/00 (2006.01); B29B 17/02 (2006.01); B29C 48/00 (2019.01); B29C 48/05 (2019.01); B29C 48/14 (2019.01); B29C 48/255 (2019.01); B29C 48/38 (2019.01); B29C 48/385 (2019.01); B29C 48/425 (2019.01); B29C 48/43 (2019.01); B29C 48/44 (2019.01); B29C 48/70 (2019.01); B29C 48/76 (2019.01); B29C 48/80 (2019.01); B29C 48/88 (2019.01); B29C 48/92 (2019.01); B29C 69/00 (2006.01); B29D 99/00 (2010.01); C08J 11/04 (2006.01); C08J 11/06 (2006.01); D01D 1/10 (2006.01); D01D 5/00 (2006.01); D01D 5/08 (2006.01); D01F 6/62 (2006.01); B29B 13/00 (2006.01); B29C 48/435 (2019.01); B29K 67/00 (2006.01); B29K 105/00 (2006.01); B29K 105/26 (2006.01)
CPC B29B 17/02 (2013.01) [B01D 29/0095 (2013.01); B29B 7/726 (2013.01); B29B 9/065 (2013.01); B29B 17/00 (2013.01); B29C 48/0022 (2019.02); B29C 48/05 (2019.02); B29C 48/145 (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 48/765 (2019.02); B29C 48/767 (2019.02); B29C 48/802 (2019.02); B29C 48/92 (2019.02); B29C 69/001 (2013.01); B29D 99/0078 (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); 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 2791/006 (2013.01); B29C 2793/00 (2013.01); B29C 2948/922 (2019.02); B29C 2948/9238 (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); Y02P 20/143 (2015.11); Y02W 30/62 (2015.05)] 19 Claims
OG exemplary drawing
 
1. A method for manufacturing pellets from polymer, the method comprising:
melting a plurality of polymer flakes in a first section of a melt processing unit to create a first single stream of polymer melt;
separating the first single stream of polymer melt into multiple streams of polymer melt by means of a separation element;
passing the multiple streams of polymer melt through a multiple stream section of said melt processing unit and into a receiving section of the melt processing unit, and exposing the multiple streams of polymer melt to a pressure within the multiple stream section of the melt processing unit as the multiple streams of polymer melt pass through the multiple stream section of the melt processing unit, wherein a chamber pressure is maintained within the multiple stream section of the melt processing unit as the multiple streams of polymer pass through the multiple stream section, wherein the receiving section of the melt processing unit recombines the multiple streams of polymer melt into at least one combined stream of polymer melt;
cooling the polymer melt and forming said pellets from the at least one combined stream of polymer melt; and
wherein an intrinsic viscosity of the at least one combined stream is determined, and, in response to determining the intrinsic viscosity of the at least one combined stream of polymer melt, the chamber pressure within the multiple stream section of the melt processing unit is adjusted.