CN107419343A - 用于制造膨体连续丝的系统和方法 - Google Patents

用于制造膨体连续丝的系统和方法 Download PDF

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Publication number
CN107419343A
CN107419343A CN201610974893.9A CN201610974893A CN107419343A CN 107419343 A CN107419343 A CN 107419343A CN 201610974893 A CN201610974893 A CN 201610974893A CN 107419343 A CN107419343 A CN 107419343A
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China
Prior art keywords
planetary
screw
screw extruder
extruder
polymer
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CN201610974893.9A
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CN107419343B (zh
Inventor
T.克拉克
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Aladdin Manufacturing Corp
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Mo Heke Industrial Group
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
    • B29C48/395—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders
    • B29C48/40—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die using screws surrounded by a cooperating barrel, e.g. single screw extruders using two or more parallel screws or at least two parallel non-intermeshing screws, e.g. twin screw extruders
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    • B29C48/44—Planetary screws
    • D—TEXTILES; PAPER
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/0095—Flat filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
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    • B29B17/02—Separating plastics from other materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
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    • B29B7/42—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with single shaft with screw or helix
    • B29B7/427—Mixing; Kneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with single shaft with screw or helix with independently driven screws rotating about the same axis, e.g. oscillating axially; with axially oscillating screws
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    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/145—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the particular extruding conditions, e.g. in a modified atmosphere or by using vibration at a venting zone
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C48/25—Component parts, details or accessories; Auxiliary operations
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    • B29C48/2552—Flow control means, e.g. valves provided in the feeding, melting, plasticising or pumping zone, e.g. screw, barrel, gear-pump or ram
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

一种制造膨体连续地毯丝的方法，在各种实施例中，该方法包括：(A)将回收PET瓶研磨成碎片组；(B)清洗碎片；(C)识别杂质，以及从该碎片组中移除杂质，包括不纯的碎片；(D)将该碎片组传送通过MRS挤出机，同时使MRS挤出机的MRS部分内的压力保持低于大约1.5毫巴；(E)将产生的聚合物熔体传送通过至少一个过滤器，过滤器具有小于大约50微米的过滤孔径；以及(F)使回收的聚合物形成基本由回收PET构成的膨体连续地毯丝。

Description

用于制造膨体连续丝的系统和方法
本申请是于2013年5月13日提交的已进入中国国家阶段的PCT专利申请(中国国家申请号为201380003461.8，国际申请号为PCT/US2013/040753，发明名称“用于制造膨体连续丝的系统和方法”)的分案申请。
与相关申请的交叉引用
本申请要求2012年12月20日提交的名称为“Systems and Methods forManufacturing Bulked Continuous Filament(用于制造膨体连续丝的系统和方法)”的美国申请No. 13/721,955的优先权，美国申请No. 13/721,955要求2012年5月31日提交的名称为“Systems and Methods for Manufacturing Bulked Continuous Fiber(用于制造膨体连续纤维的系统和方法)”的美国临时专利申请No. 61/654,016的优先权，它们通过引用而整体地结合在本文中。
背景技术
因为纯的原始PET聚合物比回收PET聚合物更贵，以及因为与使用回收聚合物相关联的环境益处的原因，能够用100%的回收PET聚合物(例如来自消费后的PET瓶的PET聚合物)来产生膨体连续地毯丝将是合乎需要的。
发明内容
根据特定实施例，一种制造膨体连续地毯丝的方法包括：(A)提供多螺杆挤出机；(B)使用压力调整系统来使多螺杆挤出机内的压力降低到低于大约1.8毫巴；(C)在使多螺杆挤出机内的压力保持低于大约1.8毫巴的同时，将包括回收聚合物的熔体传送通过多螺杆挤出机；以及(D)在将回收聚合物的熔体传送通过多螺杆挤出机的步骤之后，使回收聚合物形成膨体连续地毯丝。在各种实施例中，多螺杆挤出机包括：(i)第一行星螺杆挤出机，其包括第一行星螺杆，第一行星螺杆安装成围绕第一行星螺杆的中心轴线旋转；(ii)第二行星螺杆挤出机，其包括第二行星螺杆，第二行星螺杆安装成围绕第二行星螺杆的中心轴线旋转；以及(iii)压力调整系统，其适于使第一和第二行星螺杆挤出机内的压力保持低于大约1.8毫巴。在特定实施例中，当传送包括回收聚合物的熔体通过多螺杆挤出机时：(1)熔体的第一部分传送通过第一行星螺杆挤出机；以及(2)熔体的第二部分传送通过第二行星螺杆挤出机。
根据特定实施例，一种用于挤出聚合物熔体的挤出机包括：(1)第一行星螺杆挤出机，其包括第一行星螺杆，第一行星螺杆安装成围绕第一行星螺杆的中心轴线旋转；(2)第二行星螺杆挤出机，其包括第二行星螺杆，第二行星螺杆安装成围绕第二行星螺杆的中心轴线旋转；以及(3)压力调整系统，其适于在聚合物熔体传送通过第一和第二螺杆挤出机时，使第一和第二行星螺杆挤出机内的压力保持低于大约1.5毫巴的压力。
根据各种实施例，膨体连续地毯丝基本由回收聚合物构成。
根据特定实施例，一种制造地毯丝的方法包括以下步骤：(A)清洗一组聚合物碎片，以从碎片的表面移除一个或多个污染物的至少一部分，该组碎片包括基本由PET构成的第一多个碎片和基本不由PET构成的第二多个碎片；(B)在清洗第一多个碎片的步骤之后：(i)扫描经清洗的该碎片组，以识别第二多个碎片，以及(ii)分开第二多个碎片与第一多个碎片；(C)熔化第二多个碎片，以产生聚合物熔体；(D)提供挤出机，挤出机将材料挤出为多个不同的挤出流；(D)使挤出机内的压力降低到低于大约1.5毫巴；(F)在使挤出机内的压力保持低于大约1.5毫巴的同时，将聚合物熔体传送通过挤出机，使得聚合物熔体分成多个挤出流，各个挤出流具有低于大约1.5毫巴的压力；(G)在将聚合物熔体传送通过挤出机之后，通过至少一个过滤器来过滤聚合物熔体；以及(H)在将聚合物熔体传送通过过滤器之后，使回收聚合物形成膨体连续地毯丝。
附图说明
已经概括地描述了各种实施例，现在将参照附图，不必按比例制图，并且其中：
图1描绘根据特定实施例的用于制造膨体连续地毯丝的工艺流程。
图2是适合在图1的工艺中使用的MRS挤出机的透视图。
图3是图2的MRS挤出机的示例性MRS的横截面图。
图4描绘根据特定实施例的工艺流程，其描绘通过MRS挤出机和过滤系统的聚合物流。
图5是根据各种实施例的制造膨体连续地毯丝的方法的高级流程图。
具体实施方式
现在将更详细地描述各种实施例。应当理解，本发明可体现为许多不同的形式，并且不应将本发明理解为局限于本文阐述的实施例。而是提供这些实施例，以使得本公开将是详尽和完整的，并且这些实施例将对本领域技术人员全面地传达本发明的范围。相同标号在图中表示相同元件。
I. 综述
在下面描述一种用于用回收聚合物(例如回收PET聚合物)制作纤维的新工艺。在各种实施例中，这个新工艺：(1)比以前的从回收聚合物中移除污染物和水的工艺更有效；并且/或者(2)不需要像在以前的工艺中那样多次熔化和冷却聚合物。在至少一个实施例中，改进的工艺产生回收PET聚合物，它具有足够高的聚合物品质，使得PET聚合物可用来用100%的回收PET内容物(例如，100%的从之前使用过的PET瓶中获得的PET)产生膨体连续地毯丝。在特定实施例中，回收PET聚合物具有至少大约0.79 dL/g(例如介于大约0.79 dL/g和大约1.00 dL/g之前)的特性粘度。
II. 更详细的论述
根据特定实施例，BCF(膨体连续丝)制造工艺可大体分成三个步骤：(1)用消费后的瓶制备PET聚合物碎片，以在工艺中使用；(2)将碎片传送通过挤出机，挤出机使碎片熔化，并且纯化产生的PET聚合物；以及(3)将纯化的聚合物馈送到纺纱机中，纺纱机使聚合物变成丝，以用来制造地毯。在下面更详细地描述这三个步骤。
步骤1：用消费后的瓶制备PET聚合物碎片
在特定实施例中，用消费后的瓶制备PET聚合物碎片的步骤包括：(A)对消费后的PET瓶分类，并且将瓶研磨成碎片；(B)清洗碎片；以及(C)识别和移除任何杂质或不纯的碎片。
A. 对消费后的PET瓶分类，以及将瓶研磨成碎片
在特定实施例中，从各种回收设施获得的大量单色和彩色的回收的消费后(例如，“路边回收”)的PET瓶(或其它容器)构成用于在工艺中使用的消费后的PET容器。在其它实施例中，消费后的PET容器源可为归还的“押金”瓶(例如，PET瓶，其价格包括当顾客在消费完瓶的内容物之后归还瓶时退给顾客的押金)。路边回收或归还的“消费后”或“回收”容器可能包含少量非PET污染物。容器中的污染物可包括例如非PET聚合物污染物(例如，PVC、PLA、PP、PE、PS、PA等)、金属(例如含铁和非含铁金属)、纸、纸板、砂、玻璃，或者可能在收集回收PET时进入的其它不合需要的材料。例如，可通过下面描述的一个或多个各种工艺来从期望PET成分中移除非PET污染物。
在特定实施例中，通过旋转网从整个瓶移除较小的成分和碎屑(例如大小大于2英寸的成分和碎屑)。可将各种金属移除磁体和涡流系统结合到工艺中，以移除任何金属污染物。可利用近红外光学分类装备，诸如来自俄勒冈州尤金的Bulk Handling Systems公司的NRT多分类IR机，或者来自田纳西州纳什维尔的国家回收技术公司的Spyder IR机，来移除可混合在PET碎片中的任何松散的聚合物污染物(例如PVC、PLA、PP、PE、PS和PA)。另外，可利用自动化X光分类装备(诸如来自田纳西州纳什维尔的国家回收技术公司的VINYLCYCLE机器)来移除残留的PVC污染物。
在特定实施例中，使用配备有摄像检测系统的自动化颜色分类装备(例如来自田纳西州纳什维尔的国家回收技术公司的多分类ES机器)来实现透明材料与有色材料的二元分离。在各种实施例中，将人工分类器布置在流水线的各种点处，以移除未被分类器移除的污染物和任何有色瓶。在特定实施例中，对经分类的材料进行粒化步骤(例如，使用来自威斯康星州新柏林的Cumberland工程公司的50B制粒机)，以在大小上使瓶减小(例如研磨)到小于半英寸的大小。在各种实施例中，在进入清洗工艺之前，通过空气分离系统从产生的“脏碎片”(例如在粒化步骤期间形成的PET碎片)上移除瓶标签。
B. 清洗碎片
在特定实施例中，然后将“脏碎片”混合到一系列清洗箱中。作为清洗工艺的一部分，在各种实施例中，利用水相密度分离来分开烯烃瓶盖(例如，其可存在于“脏碎片”中，作为回收PET瓶的残余物)与比重较高的PET碎片。在特定实施例中，在被加热到大约190华氏度的腐蚀性浴槽中清洗碎片。在特定实施例中，使腐蚀性浴槽保持处于大约0.6%的氢氧化钠和大约1.2%的氢氧化钠之间的浓度。在各种实施例中，将肥皂表面活性剂和消泡剂添加到腐蚀性浴槽，例如，以便进一步提高碎片的分离和清洁。然后双冲洗系统从碎片中清洗掉腐蚀剂。
在各种实施例中，对碎片进行离心脱水，然后用热空气干燥碎片，以至少基本移除任何表面水分。然后通过静电分离系统(例如来自佛罗里达杰克逊维尔的Carpco公司的静电分离器)和碎片金属检测系统(例如MSS金属分类系统)来处理产生的“清洁的碎片”，以进一步移除残留在碎片中的任何金属污染物。在特定实施例中，空气分离步骤从清洁的碎片中移除任何残留标签。在各种实施例中，然后对碎片进行碎片颜色分类步骤(例如，使用来自爱尔兰唐道克的TSM控制系统公司的OPTIMIX机器)，以移除残留在碎片中的任何残留有色污染物。在各种实施例中，至少部分地基于Raman技术的光电碎片分类器(例如，德国卡尔斯鲁厄的Unisensor Sensorsysteme GmbH 公司的Powersort 200)执行最终聚合物分离，以移除残留在碎片中的任何非PET聚合物。这个步骤还可进一步移除任何剩余的金属污染物和有色污染物。
在各种实施例中，这些步骤的组合基本提供用于在下面描述的下游挤出工艺中使用的清洁的(例如清洁的)PET瓶碎片，它包括小于大约百万分之50的PVC(例如，25 ppmPVC)和小于大约百万分之15的金属。
C. 识别和移除杂质和不纯的碎片
在特定实施例中，在清洗碎片之后，沿着传送器馈送它们，并且用高速激光系统300扫描它们。在各种实施例中，构成高速激光系统300的特定激光器构造成检测特定污染物(例如，PVC或铝)的存在。可用空气射流将被识别成基本不含PET的碎片吹出主碎片流。在各种实施例中，产生的非PET碎片的水平小于25 ppm。
在各种实施例中，系统适于确保被处理成丝的PET聚合物基本不含水(例如完全不含水)。在特定实施例中，将碎片放到预调节器中达大约20至大约40分钟(例如大约30分钟)，在此期间预调节器从碎片上吹掉表面水。在特定实施例中，间隙(interstitial)水仍然在碎片内。在各种实施例中，这些“湿”碎片(例如，包括间隙水的碎片)然后可馈送到挤出机中(例如，如下面的步骤2中描述的那样)，挤出机包括真空装置，除了别的之外，真空装置设计成移除在上面描述的快速干燥工艺之后仍然在碎片中的间隙水。
步骤2：使用挤出系统来熔化和纯化PET碎片
在特定实施例中，使用挤出机将上面描述的湿碎片变成熔融的回收PET聚合物，以及执行多次纯化工艺来制备待变成地毯的BCF的聚合物。如上面提到的那样，在各种实施例中，在步骤1完成之后，回收PET聚合物碎片是湿的(例如，基本从碎片中移除(例如完全移除)表面水，但间隙水保留在碎片中)。在特定实施例中，将这些湿碎片馈送到多旋转螺杆(“MRS”)挤出机400中。在其它实施例中，将湿碎片馈送到任何其它适当的挤出机(例如双螺杆挤出机、多螺杆挤出机、行星挤出机或任何其它适当的挤出系统)中。在图2和3中显示示例性MRS挤出机400。在2005年3月3日公布的名称为“Extruder for Producing Molten PlasticMaterials(用于产生熔融塑料材料的挤出机)”的美国公布的专利申请2005/0047267中描述了这种MRS挤出机的特定示例，而且该申请通过引用而结合在本文中。
如可从这个图中理解的那样，在特定实施例中，MRS挤出机包括用于将材料馈送到MRS区段420中的第一单螺杆挤出机区段410，以及用于将从MRS区段中输送出材料的第二单螺杆挤出机区段440。
在各种实施例中，湿碎片在上面描述的清洗步骤之后基本立即(例如立刻)直接馈送到MRS挤出机400中(例如不干燥碎片或不允许干燥碎片)。在特定实施例中，在挤出之前使碎片基本完全预干燥的系统(例如，通过热空气传送到湿碎片上面达延长的一段时间来使碎片预干燥的系统)相比，在上面描述的清洗步骤之后基本立即(例如立刻)将湿碎片直接馈送到MRS挤出机400中的系统消耗的能量可少大约20%。在各种实施例中，在上面描述的清洗步骤之后基本立即(例如立刻)将湿碎片直接馈送到MRS挤出机400中的系统会避免需要等待使碎片完全干燥(例如从碎片上移除所有表面水和间隙水)大体所需的一段时间(例如高达八小时)。
图4描绘示出由特定实施例中的MRS挤出机400执行的各种工艺的工艺流程。在这个图中显示的实施例中，湿碎片首先馈送通过MRS挤出机的第一单螺杆挤出机区段410，第一单螺杆挤出机区段410例如可产生(例如通过剪切)足以至少基本熔化(例如熔化)湿碎片的热。
在各种实施例中，产生的聚合物熔体(例如包括熔融碎片)然后馈送到挤出机的MRS区段420中，其中，挤出机通过多个开放室使熔融流分成多个不同的流(例如4、6、8个或更多个流)。图3显示根据特定实施例的MRS区段420的详细剖面图。在特定实施例(诸如这个图中显示的实施例)中，MRS区段420使熔融流分成八个不同的流，后来它们被馈送通过八个行星螺杆425A-H。如可从图2理解的那样，在特定实施例中，这些行星螺杆基本彼此平行(例如平行)，以及平行于MRS机器400的主螺旋轴线。
在各种实施例中，在MRS区段420中，行星螺杆425例如可比在以前的系统中更快速地旋转(例如为大约四倍)。如图3中显示的那样，在特定实施例中：(1)行星螺杆425A-H布置在单螺杆鼓428内，单螺杆鼓428安装成围绕其中心轴线旋转；以及(2)行星螺杆425A-H构造成沿与单螺杆鼓428的旋转方向相反的方向旋转。在各种其它实施例中，行星螺杆425A-H和单螺杆鼓428沿相同的方向旋转。在特定实施例中，行星螺杆425A-H的旋转由环形齿轮驱动。而且，在各种实施例中，单螺杆鼓428的旋转速度为各个单独的行星螺杆425A-H的大约四倍。在某些实施例中，行星螺杆425A-H以基本类似的(例如相同)速度旋转。
在各种实施例中，如可从图4理解的那样，行星螺杆425A-H容纳在相应的挤出机筒内，挤出机筒可对MRS区段420的外部室开放例如大约30%。在特定实施例中，行星螺杆425A-H和单螺杆鼓428的旋转会增加聚合物熔体的表面交换(例如，与以前的系统相比，使熔融聚合物的更大表面积暴露于开放室)。在各种实施例中，与通过共同旋转的双螺杆挤出机所产生的熔体表面积相比，MRS区段420产生例如介于大约二十至大约三十倍的熔体表面积。在特定实施例中，与通过共同旋转的双螺杆挤出机所产生的熔体表面积相比，MRS区段420产生例如大约二十五倍的熔体表面积。
在各种实施例中，MRS挤出机的MRS区段420装配有真空泵430，真空泵430附连到MRS区段420的真空附连部分422上，使得真空泵430通过MRS区段的壳体中的适当的开口424而与MRS区段的内部连通。在另外的其它实施例中，MRS区段420装配有一系列真空泵。在特定实施例中，真空泵430构造成使MRS区段420的内部内的压力降低到介于大约0.5毫巴和大约5毫巴之间的压力。在特定实施例中，真空泵430构造成使MRS区段420中的压力降低到小于大约1.5毫巴(例如大约1毫巴或更低)。由MRS区段420中的真空泵430产生的低压真空可移除，例如：(1)在熔融聚合物传送通过MRS区段420时，存在于熔融聚合物中的挥发性有机物；以及/或者(2)当湿碎片进入MRS挤出机400时，存在于湿碎片中的任何间隙水的至少一部分。在各种实施例中，低压真空从聚合物流中移除基本所有(例如全部)水和污染物。
在特定示例中，真空泵430包括三个机械凸轮真空泵(例如串联布置)，以使室中的压力降低到适当的水平(例如大约1.0毫巴的压力)。在其它实施例中，不是上面论述的三个机械凸轮真空泵布置，而是真空泵430包括装配到MRS挤出机上的射流真空泵。在各种实施例中，射流真空泵构造成在MRS区段420的内部中实现大约1毫巴的压力，以及与上面关于聚合物熔体的最终特性粘度所描述的大约相同的结果。在各种实施例中，使用射流真空泵可为有利的，因为射流真空泵由蒸汽提供动力，并且因此基本是自清洁式的(例如自清洁)，从而与机械凸轮泵(例如它可能需要反复清洁，因为挥发物会出来，并且在凸轮上凝结)相比，需要的维护减少。在特定实施例中，真空泵430是德国贝格海姆的Arpuma GmbH公司制造的射流真空泵。
在特定实施例中，在熔融聚合物穿过多流MRS区段420之后，熔融聚合物流重新结合，并且流到MRS挤出机的第二单螺杆区段440中。在各种实施例中，单个熔融聚合物流接下来穿过过滤系统450，过滤系统450包括至少一个过滤器。在特定实施例中，过滤系统450包括两级过滤(例如，40微米筛网的过滤器，后面是25微米筛网的过滤器)。虽然在各种实施例中，在上面论述的真空工艺期间移除水和易挥发的有机杂质，但颗粒污染物，诸如例如铝微粒、砂、污垢和其它污染物可残留在聚合物熔体中。因而，这个过滤步骤对于移除颗粒污染物(例如在MRS区段420中未移除的颗粒污染物)可为有利的。
在特定实施例中，在熔融聚合物流传送通过过滤系统450之后，使用粘度传感器460(参见图4)来感测熔融聚合物流的熔融粘度。在各种实施例中，粘度传感器460例如通过测量流跨过已知区域的压降来测量流的熔融粘度。在特定实施例中，响应于测量到流的特性粘度低于预定水平(例如低于大约0.8 g/dL)，系统可：(1)丢弃一部分特性粘度低的流；以及/或者(2)降低MRS区段420中的压力，以便在聚合物熔体中实现较高的特性粘度。在特定实施例中，通过在具有真空区段430的计算机控制式反馈控制环中使用粘度传感器，来以基本自动化的方式(例如自动地)降低MRS区段420中的压力。
在特定实施例中，从聚合物中移除水和污染物会通过允许聚合物中的聚合物链重新连接以及延长链长度，来改进回收PET聚合物的特性粘度。在特定实施例中，在传送通过MRS区段420(它附连有真空泵430)之后，回收聚合物熔体具有至少大约0.79 dL/g的特性粘度(例如介于大约0.79 dL/g和大约1.00 dL/g之间)。在特定实施例中，传送通过低压MRS区段420会纯化回收聚合物熔体(例如通过移除污染物和间隙水)，以及使回收聚合物在结合上基本类似于(例如在结构上相同)纯的原始PET聚合物。在特定实施例中，通过真空而移除的水包括以下两者：来自如上面描述的那样用来清洁回收PET瓶的清洗水的水，以及来自由于在单螺杆加热器410中熔化PET聚合物而产生的未反应水的水(例如间隙水)。在特定实施例中，聚合物中存在的大部分水是清洗水，但一定百分比的水可为未反应水。
在特定实施例中，产生的聚合物是回收PET聚合物(例如100%从消费后的PET产品获得，诸如PET瓶或容器)，该回收PET聚合物具有适合在基本仅(例如仅仅)使用来自回收PET产品的PET来产生PET地毯丝时使用的聚合物品质。
步骤3：将纯化的PET聚合物馈送到纺纱机中，以使其变成地毯纱
在特定实施例中，在回收PET聚合物已经由上面描述的挤出工艺挤出和纯化之后，产生的熔融的回收PET聚合物直接馈送到BCF(或“纺纱”)机500中，BCF机500构造成使熔融聚合物变成膨体连续丝。例如，在各种实施例中， MRS挤出机400的输出基本直接(例如，直接)连接到纺纱机500的输入，使得来自挤出机的熔融聚合物直接馈送到纺纱机500中。这个工艺可为有利的，因为在某些实施例中，熔融聚合物可不必在挤出之后冷却成球粒(如果回收聚合物与原始PET聚合物混合的话就需要)。在特定实施例中，不将回收熔融聚合物冷却成球粒用来避免聚合物中有潜在的断链，断链可能会降低聚合物的特性粘度。
在特定实施例中，纺纱机500通过喷丝头中的小孔挤出熔融聚合物，以便用聚合物产生地毯纱丝。在特定实施例中，熔融的回收PET聚合物在离开喷丝头之后冷却。然后辊子卷取地毯纱，并且地毯纱最终变成用来产生地毯的丝。在各种实施例中，由纺纱机500产生的地毯纱可具有介于大约3克力每单位但尼尔(gf/den)和大约9 gf/den之间的韧度。在特定实施例中，产生的地毯纱具有至少大约3 gf/den的韧度。
在特定实施例中，上面描述的工艺中使用的纺纱机500是德国新明斯特的OerlikaNeumag公司制造的Sytec one纺纱机。Sytec one机器可尤其适合难以操作的纤维，诸如尼龙或纺染纤维，其中丝在处理期间易于断裂。在各种实施例中，Sytec one机器使喷丝头的下游的操作保持尽可能笔直，仅使用一个纺丝流水线，并且设计成在丝断裂时快速重新穿眼。
虽然上面描述的示例描述了使用Sytec one纺纱机来用聚合物产生地毯纱丝，但应当理解的是，可使用任何其它适当的纺纱机。这样的纺纱机可包括例如德国新明斯特的Oerlika Neumag公司或任何其它公司制造的任何适当的一纺丝流水线或三纺丝流水线纺纱机。
在各种实施例中，与使用纯的原始PET聚合物相比，使用以上工艺产生的回收PET聚合物的改进的强度允许它以更高的速度通过纺纱机500。与在使用原始PET聚合物时相比，这可允许有更高的处理速度。
示例性工艺的概述
图5提供制造上面描述的膨体连续的丝的方法的高度概述。如图中显示的那样，方法在步骤602处开始，其中，将回收PET瓶分成碎片组。接下来，在步骤604处，清洗该碎片组，以从碎片的相应的外表面移除污染物。接下来，在步骤606处，扫描该碎片组(例如，使用上面论述的一种或多种方法)，以识别杂质，包括不纯的碎片。然后从该碎片组中移除这些杂质和不纯的碎片。
接下来，在步骤608处，将碎片组传送通过MRS挤出机，同时使挤出机的MRS部分内的压力保持低于大约1.5毫巴。在步骤610处，将产生的聚合物熔体传送通过至少一个过滤器，过滤器具有小于大约50微米的过滤孔径(micron rating)。最后，在步骤612处，使回收聚合物形成膨体连续地毯丝，膨体连续地毯丝可用来产生地毯。然后方法在步骤614处结束。
备选实施例
在特定实施例中，系统可包括备选构件或执行备选工艺，以便用100%的回收PET或其它回收聚合物产生基本连续的BCF。在下面论述示例性备选方案。
非MRS挤出系统
在特定实施例中，工艺可利用上面描述的MRS挤出机之外的聚合物流挤出系统。备选挤出系统可包括例如双螺杆挤出机、多螺杆挤出机、行星挤出机或任何其它适当的挤出系统。在特定实施例中，工艺可包括任何适当的圆锥形螺杆挤出机的多个任何组合(例如四个双螺杆挤出机、三个多螺杆挤出机等)。
用100%的回收地毯制作地毯纱
在特定实施例中，上面描述的工艺可适于处理和准备旧地毯(或任何其它适当的消费后产品)，以产生包括100%的回收地毯的地毯纱。在这样的实施例中，工艺将通过研磨和清洗回收地毯而非回收PET瓶来开始。在旧地毯转换成包括100%的回收地毯的新地毯纱的各种实施例中，工艺可包括额外的步骤，来移除可能存在于回收地毯中但可能不存在于回收PET瓶中的额外的材料或杂质(例如地毯背衬、粘合剂等)。
其它回收PET源
在各种实施例中，上面描述的工艺适于处理来自任何适当的源(例如，除了回收瓶或地毯之外的源)的回收PET，以产生包括100%的回收PET的新地毯纱。
结论
与本发明有关的领域的受益于以上描述和相关联的图中介绍的教导的技术人员将想到本发明的许多修改和其它实施例。例如，虽然描述了上面论述的真空系统构造成使MRS挤出机的开放室中的压力保持为大约1毫巴，但在其它实施例中，真空系统可适于使MRS挤出机的开放室中的压力保持为大于或小于1毫巴的压力。例如，真空系统可适于使这个压力保持介于大约0.5毫巴和大约1.2毫巴之间。
类似地，虽然上面描述的系统的各种实施例可适于仅用基本回收PET来产生地毯丝(所以产生的地毯丝将包括回收PET，由回收PET构成和/或基本由回收PET构成)，但在其它实施例中，系统可适于用回收PET和原始PET的组合产生地毯丝。产生的地毯丝例如可包括介于大约80%和大约100%之间的回收PET和介于大约0%和大约20%之间的原始PET，由介于大约80%和大约100%之间的回收PET和介于大约0%和大约20%之间的原始PET构成，以及/或者基本由介于大约80%和大约100%之间的回收PET和介于大约0%和大约20%之间的原始PET构成。
而且，虽然上面关于用PET产生地毯丝来论述各种实施例，但可使用类似的技术，用其它聚合物产生地毯丝。类似地，虽然上面关于用PET产生地毯丝来论述各种实施例，但可使用类似的技术，用PET或其它聚合物产生其它产品。
另外，应当理解，各种实施例可省略上面描述的任何步骤或添加额外的步骤。
按照以上，要理解的是，本发明不局限于公开的特定实施例，而且修改和其它实施例意于包括在所附权利要求的范围内。虽然在本文采用了具体用语，但仅在一般和描述性的意义上使用它们，而且它们不是为了限制。

Claims (20)

1.一种制造膨体连续地毯丝的方法，所述方法包括：
(A)提供多螺杆挤出机，其包括：
(i)第一行星螺杆挤出机，所述第一行星螺杆挤出机包括第一行星螺杆，其安装成围绕所述第一行星螺杆的中心轴线旋转；
(ii)第二行星螺杆挤出机，所述第二行星螺杆挤出机包括第二行星螺杆，其安装成围绕所述第二行星螺杆的中心轴线旋转；
(iii)第三行星螺杆挤出机，所述第三行星螺杆挤出机包括第三行星螺杆，其安装成围绕所述第三行星螺杆的中心轴线旋转；
(iv)第四行星螺杆挤出机，所述第四行星螺杆挤出机包括第四行星螺杆，其安装成围绕所述第四行星螺杆的中心轴线旋转；以及
(v)压力调整系统，其适于使所述第一、第二、第三和第四行星螺杆挤出机内的压力保持在大约0毫巴和大约5毫巴之间；
(B)使用所述压力调整系统来使所述第一、第二、第三和第四行星螺杆挤出机内的压力降低到大约0毫巴和大约5毫巴之间；
(C)在使所述第一、第二、第三和第四行星螺杆挤出机内的所述压力保持在大约0毫巴和大约5毫巴之间的同时，将包括回收聚合物的熔体传送通过所述多螺杆挤出机，使得：(1)所述熔体的第一部分传送通过所述第一行星螺杆挤出机，(2)所述熔体的第二部分传送通过所述第二行星螺杆挤出机，(3)所述熔体的第三部分传送通过所述第三行星螺杆挤出机，以及(4)所述熔体的第四部分传送通过所述第四行星螺杆挤出机；以及
(D)在所述将回收聚合物的所述熔体传送通过所述多螺杆挤出机的步骤之后，使所述回收聚合物形成膨体连续地毯丝。
2.根据权利要求1所述的方法，其特征在于，所述多螺杆挤出机包括适于使所述第一、第二、第三和第四行星螺杆围绕主轴线旋转的行星螺杆挤出机支承系统，所述主轴线基本平行于：(a)所述第一行星螺杆的所述中心轴线；(b)所述第二行星螺杆的所述中心轴线；(c)所述第三行星螺杆的所述中心轴线；和(d)所述第四行星螺杆的所述中心轴线。
3.根据权利要求2所述的方法，其特征在于，在所述第一、第二、第三和第四行星螺杆挤出机围绕所述主轴线沿轨道旋转的同时，进行所述将回收聚合物的所述熔体传送通过所述多螺杆挤出机的步骤。
4.根据权利要求1所述的方法，其特征在于，所述回收聚合物基本由回收的聚乙烯对苯二酸酯构成。
5.根据权利要求4所述的方法，其特征在于，所述压力调整系统包括射流真空泵。
6.根据权利要求2所述的方法，其特征在于，
所述行星螺杆挤出机支承系统包括适于围绕所述主轴线旋转的鼓；
所述鼓限定第一螺杆筒，其具有基本平行于所述主轴线的中心轴线；
所述鼓限定第二螺杆筒，其具有基本平行于所述主轴线的中心轴线；
所述鼓限定第三螺杆筒，其具有基本平行于所述主轴线的中心轴线；
所述鼓限定第四螺杆筒，其具有基本平行于所述主轴线的中心轴线；
所述第一行星螺杆可旋转地安装在所述第一螺杆筒内；
所述第二行星螺杆可旋转地安装在所述第二螺杆筒内；
所述第三行星螺杆可旋转地安装在所述第三螺杆筒内；以及
所述第四行星螺杆可旋转地安装在所述第四螺杆筒内。
7.根据权利要求1所述的方法，其特征在于，
所述挤出机是第一挤出机；以及
所述方法进一步包括：
将回收PET的多个碎片传送通过第二挤出机；以及
在将所述多个碎片传送通过所述第二挤出机的同时，使用所述第二挤出机来将所述多个碎片加热到至少足以基本熔化所述多个碎片而形成所述聚合物熔体的温度。
8.根据权利要求7所述的方法，其特征在于，所述方法进一步包括：
在所述将所述多个碎片传送通过所述第二挤出机的步骤之前：
清洗所述多个碎片；
扫描经清洗的多个碎片，以识别所述多个碎片中的包括PET之外的材料的任何碎片；以及
移除包括PET之外的材料的识别出的碎片中的至少一个。
9.根据权利要求1所述的方法，其特征在于，在所述将回收聚合物的所述熔体传送通过所述多螺杆挤出机的步骤之后，所述聚合物熔体具有介于0.79 dL/g和1.00dL/g的特性粘度。
10.根据权利要求1所述的方法，其特征在于，进一步包括，在所述将回收聚合物的所述熔体传送通过所述多螺杆挤出机的步骤之后，将所述聚合物熔体传送通过至少一个过滤器，其具有小于大约25微米的过滤孔径。
11.根据权利要求1所述的方法，其特征在于，所述使所述回收聚合物形成膨体连续地毯丝的步骤包括对所述聚合物熔体进行纺纱而形成所述膨体连续地毯丝。
12.根据权利要求1所述的方法，其特征在于，进一步包括，在所述使所述回收聚合物形成膨体连续地毯丝的步骤之前：
使用粘度传感器来确定回收聚合物的至少一部分的特性粘度是否在预定范围内；以及
响应于确定所述特性粘度不在预定范围内而调节所述压力调整系统，以降低所述挤出机的内部压力。
13.一种制造膨体连续地毯丝的方法，所述方法包括：
(A)提供多螺杆挤出机，其包括：
至少六个行星螺杆挤出机，其中，所述至少六个行星螺杆挤出机中的每个包括行星螺杆，其安装成围绕所述至少六个行星螺杆挤出机中的每个的相应中心轴线旋转；以及
压力调整系统，其适于使所述至少六个行星螺杆挤出机内的压力保持在大约0毫巴和大约5毫巴之间；
(B)使用所述压力调整系统来使所述至少六个行星螺杆挤出机内的压力降低到大约0毫巴和大约5毫巴之间；
(C)在使所述至少六个行星螺杆挤出机内的所述压力保持在大约0毫巴和大约5毫巴之间的同时，将包括回收聚合物的熔体传送通过所述多螺杆挤出机，使得所述熔体的第一部分传送通过所述至少六个行星螺杆挤出机中的每个；以及
(D)在所述将回收聚合物的所述熔体传送通过所述多螺杆挤出机的步骤之后，使所述回收聚合物形成膨体连续地毯丝。
14.根据权利要求13所述的方法，其特征在于，所述多螺杆挤出机包括适于使所述至少六个行星螺杆挤出机围绕主轴线旋转的行星螺杆挤出机支承系统，所述主轴线基本平行于所述至少六个行星螺杆挤出机中的每个的所述相应中心轴线。
15.根据权利要求14所述的方法，其特征在于，在所述至少六个行星螺杆挤出机围绕所述主轴线沿轨道旋转的同时，进行所述将回收聚合物的所述熔体传送通过所述多螺杆挤出机的步骤。
16.根据权利要求15所述的方法，其特征在于，所述压力调整系统包括射流真空泵。
17.一种制造地毯丝的方法，包括以下步骤：
(A)清洗成组的聚合物碎片，以从所述碎片的表面移除一个或多个污染物的至少一部分，所述成组的聚合物碎片包括基本由PET构成的第一多个碎片，以及基本不由PET构成的第二多个碎片；
(B)在清洗所述第一多个碎片的步骤之后：
(i)扫描经清洗的碎片组，以识别所述第二多个碎片，
(ii)分开所述第二多个碎片与所述第一多个碎片；
(C)在分开所述第二多个碎片与所述第一多个碎片之后，使所述第二多个碎片熔化以产生聚合物熔体；
(D)提供挤出机，其将材料挤出为多个不同的挤出流；
(E)使所述挤出机内的压力降低到在大约0毫巴和大约5毫巴之间；
(F)在使所述挤出机内的所述压力保持在大约0毫巴和大约5毫巴之间的同时，将所述聚合物熔体传送通过所述挤出机，使得所述聚合物熔体分成多个挤出流，各个挤出流具有在大约0毫巴和大约5毫巴之间的压力；
(G)在将所述聚合物熔体传送通过所述挤出机之后，通过至少一个过滤器来过滤所述聚合物熔体；以及
(H)在将所述聚合物熔体传送通过所述过滤器之后，使所述回收聚合物形成膨体连续地毯丝。
18.根据权利要求17所述的方法，其特征在于，所述挤出机包括：
(A)第一行星螺杆挤出机，所述第一行星螺杆挤出机包括第一行星螺杆，其安装成围绕所述第一行星螺杆的中心轴线旋转；
(B)第二行星螺杆挤出机，所述第二行星螺杆挤出机包括第二行星螺杆，其安装成围绕所述第二行星螺杆的中心轴线旋转；
(C)压力调整系统，其适于在所述聚合物熔体传送通过所述第一和第二行星螺杆挤出机时，使所述第一和第二行星螺杆挤出机内的压力保持在大约0毫巴和大约5毫巴之间的压力；以及
(D)行星螺杆挤出机支承系统，其适于在所述聚合物熔体传送通过所述第一和第二行星螺杆挤出机时，使所述第一和第二行星螺杆围绕主轴线沿轨道旋转，所述主轴线基本平行于以下两者：(1)所述第一行星螺杆的所述中心轴线；以及(2)所述第二行星螺杆的所述中心轴线。
19.根据权利要求18所述的方法，其特征在于，所述挤出机包括：
(A)第三行星螺杆挤出机，所述第三行星螺杆挤出机包括第三行星螺杆，其安装成围绕所述第三行星螺杆的中心轴线旋转；和
(B)第四行星螺杆挤出机，所述第四行星螺杆挤出机包括第四行星螺杆，其安装成围绕所述第四行星螺杆的中心轴线旋转；
所述压力调整系统还适于在所述聚合物熔体传送通过所述第三和第四行星螺杆挤出机时，使所述第三和第四行星螺杆挤出机内的压力保持在大约0毫巴和大约5毫巴之间的压力；以及
所述行星螺杆挤出机支承系统还适于在所述聚合物熔体传送通过所述第三和第四行星螺杆挤出机时，使所述第三和第四行星螺杆围绕主轴线沿轨道旋转。
20.根据权利要求19所述的方法，其特征在于，所述至少一个过滤器包括：
具有小于50微米的过滤孔径的第一过滤器；以及
具有小于30微米的过滤孔径的第二过滤器。
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