Abstract: 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) passing the flakes through a PET crystallizer; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 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.

Abstract: 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) passing the group of flakes through an expanded surface area extruder while maintaining a pressure within the expanded surface area extruder below about 25 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

Abstract: 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) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 5 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

Abstract: A method of recycling PET into PET nurdles, 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) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into PET nurdles. In various embodiments, the polymer melt is formed into PET nurdles using any suitable technique such as, for example, any suitable strand pelletizing or melt pelletizing techniques.

Abstract: 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) passing the flakes through a PET crystallizer; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 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.

Abstract: 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) passing the group of flakes through an expanded surface area extruder while maintaining a pressure within the expanded surface area extruder below about 25 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

Abstract: A method of recycling polymers and other plastics comprises: (A) grinding recycled PET bottles (or other suitable recycled polymer) into a group of flakes; (B) washing the flakes; (C) identifying and removing impurities, including impure flakes, from the group of flakes; (D) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 5 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) preparing the polymer melt for recycling into a new product. In various embodiments, the above process may be utilized in the recycling of, for example, polytrimethylene terephthalate (PTT), polypropylene, polyvinyl chloride (PVC), high-density polyethylene (HDPE), polystyrene (PS), expanded polystyrene (EPS), or any other suitable polymer or plastic.

Abstract: 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) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 1.5 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

Abstract: 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) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 5 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

Abstract: Various embodiments of the present invention are directed to a cushioned mat configured for use in environments where water may come into contact with the cushioned mat, such as in a household bathroom. According to various embodiments, the cushioned mat includes a foam layer configured to act as a cushioning material. To improve the drying performance of the mat, the foam layer is apertured. In addition, various embodiments of the cushioned mat may be provided with a surface layer of face fabric and a backing layer configured for reducing slippage of the mat against a support surface.

Abstract: 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) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 1.5 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

Abstract: 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) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 1.5 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

Abstract: A system and method for producing multi-colored carpets using a tufting machine. The present invention features a system and method for: providing a multi-colored pattern which is analyzed for validity with reference to a particular tufting machine; collecting parameters concerning a particular tufting machine; determining the colors of yarn to load with each needle of the particular tufting machine; and generating a report including a palette of colors used within the pattern, a chart indicating which color of yarns are used within each needle position, and a summary of the number of yarn cones needed to create a carpet of a predetermined size with the particular tufting machine.

Abstract: A system for forming a carpet seam including source and take-up carpet roller assemblies and a seaming support having a work surface upon which two carpet sections can be aligned. The seaming support includes a roller and an electric current source for providing an electric current to electrically self-heating thermoplastic bonding tape. The method of the present invention includes the steps of cutting out a defective section of carpet on the seaming support work surface, aligning the leading edge of the resulting front carpet section with trailing edge of the rear carpet section, applying a strip of electrically self-heating thermoplastic bonding tape to the backing side of the carpet, applying an electric current to the tape, and rolling the rejoined carpet onto the take-up roller assembly.

Abstract: An adapter is provided for use in venting a coal or wood burning stove through the flue of a fireplace. The adapter includes a fireproof board and a metal pressure plate, each formed with a central opening to receive the exhaust end of stove pipe from the stove. The board and plate are fitted into the fireplace flue and held there by means of a pair of longitudinally adjustable legs, the lower ends of which press against the floor of the fireplace. The pressure plate is provided with studs to receive the upper ends of the legs and tabs are provided on the plate at the sides of the stove pipe hole for fastening with the stove pipe.

Abstract: A draft tube in a wood burning stove is provided with a nozzle at the lower end thereof for directing a portion of the draft air downwardly against the charge of burning wood, coal, etc. and deflects a portion thereof sideways into a zone above the fuel to provide a more complete combustion of the rising volatiles. The nozzle may be integral with the draft tube or may be attached thereto as an accessory. The nozzle includes a tube having an outside diameter somewhat smaller than the inside diameter of the draft tube to define an annular passage therewith when the nozzle is installed. An annular radial flange is mounted on the outside and at the lower end of the nozzle and in line with the annular clearance whereby the major portion of the air and draft will flow directly downwardly through the nozzle tube while a portion passing through the annular passage will strike the flange and be deflected perpendicularly to the flow of the draft.