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Mohawk Industries (MHK)

Utility
Systems and methods for manufacturing bulked continuous filament
5 Apr 22
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.
Thomas R. Clark
Filed: 22 Jul 19
Utility
Method of manufacturing bulked continuous carpet filament
22 Mar 22
In particular embodiments, a process for producing bulked continuous carpet filament from recycled polymer utilizes two vacuum pumps (140A, 140B) in combination with a single extruder (100).
Thomas R. Clark
Filed: 2 Mar 18
Utility
Systems and methods for manufacturing bulked continuous filament
15 Mar 22
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.
Thomas R. Clark
Filed: 12 Mar 20
Utility
Low weight modular carpet components and methods of making the same
1 Mar 22
A low-weight carpet tile and process for making the same, wherein the carpet tile comprises a facecloth having a plurality of face yarns tufted through a primary backing, an extruded polymer secondary backing layer, and a reinforcing scrim layer partially embedded within the extruded polymer secondary backing layer.
Mike Gallman, Mike Bell
Filed: 13 Sep 17
Utility
Floor Mats and Methods of Producing the Same
24 Feb 22
Various implementations include a mat having a lower surface and first and second edge portions that define at least a portion of a perimeter of the mat.
Craig TRIMBLE, Joey JENKINS, Shawn EDWARDS, Anthony LAWSON, Franco SANCHEZ-CAMARILLO, Andrew BROWN
Filed: 12 Nov 19
Utility
Floor Board and Method for Manufacturing Such Floor Boards
24 Feb 22
A floor board including a decorative surface layer applied to a substrate, where the substrate has MDF or HDF material at a side edge thereof, where the side edge is treated both with an impregnation agent and/or a sealing agent based on a superabsorbing material.
Dieter D'HONDT, Aaron SHAW
Filed: 4 Nov 21
Utility
a Method to Provide Multifilament Bundles of Melt Spun Polymer Filaments
10 Feb 22
A method for providing a multifilament bundle of melt spun polymer filaments, the that includes providing a spinning device including at least M extruders for melting M polymers, M groups of spinning stations, each group comprising N spinning stations, each spinning station comprising and a spin pack coupled to a spin pump which receives molten polymer from one of the M extruders and spins a strand of filaments by pushing said polymer through the coupled spin pack, and N transformation stations for bundling M strands of filaments.
Anthony CASCIO
Filed: 22 Nov 19
Utility
Bulked continuous carpet filament manufacturing from polytrimethylene terephthalate
8 Feb 22
A method of manufacturing bulked continuous carpet filament from polytrimethylene terephthalate (PTT) with polyethylene terephthalate (PET) comprises: (1) splitting the PTT stream extruded from the primary extruder into a number of polymer streams, each of the plurality of polymer streams having an associated spinning machine; (2) adding a colorant to each split polymer stream; (3) adding PET to the extruded polymer stream downstream of the primary extruder; (4) using one or more static mixing assemblies for each split polymer stream to substantially uniformly mix each split polymer stream and its respective colorant and PET; and (5) spinning each polymer stream with its substantially uniformly mixed colorant and any additives into BCF using the respective spinning machine.
Thomas R. Clark
Filed: 17 Jul 19
Utility
Floor Board and Method for Manufacturing Such Floor Boards
3 Feb 22
A floor board including a decorative surface layer applied to a substrate, where the substrate has MDF or HDF material at a side edge thereof, where the side edge is treated both with an impregnation agent and/or a sealing agent based on a superabsorbing material.
Dieter D'HONDT, Aaron SHAW
Filed: 19 Oct 21
Utility
Floor Board and Method for Manufacturing Such Floor Boards
3 Feb 22
A floor board including a decorative surface layer applied to a substrate, where the substrate has MDF or HDF material at a side edge thereof, where the side edge is treated both with an impregnation agent and/or a sealing agent based on a superabsorbing material.
Dieter D'HONDT, Aaron SHAW
Filed: 19 Oct 21
Utility
Polyester Yarn Cushioned Rugs and Methods of Manufacturing Same
27 Jan 22
The invention relates to cushioned rugs comprising polyester yarn, particularly polyethylene terephthalate (PET) yarn, comprising a crystallinity-reducing modifier in the polyester yarn, such as a branched polyester modifier.
Mack Brindle, Jacqueline Killings, Melissa North, Christina Maria Hooker, Alfred Scroggins
Filed: 8 Nov 19
Utility
Composition and Flooring Product Comprising Such Composition
13 Jan 22
A hot-melt composition is provided.
Rajeev Bhatia
Filed: 22 Oct 19
Utility
Systems and Methods for Producing a Bundle of Filaments And/or a Yarn
16 Dec 21
Systems for producing M yarns, wherein M≥1, include N extruders, M spin stations, and a processor, wherein N>1.
Anthony Cascio, James Mason, Daniel Amos, Lucinda Jones
Filed: 16 Jun 21
Utility
Systems and Methods to Provide Color Enhanced Yarns
16 Dec 21
Systems and methods for producing BCF yarns include providing at least one color enhancement method for enhancing the color and/or hue of at least one of the N bundles of filaments.
Anthony Cascio, James Mason, Lucinda Jones
Filed: 16 Jun 21
Utility
Systems and Methods for Producing a Bundle of Filaments And/or a Yarn
16 Dec 21
Systems for producing M bundles of filaments, wherein M≥1, include N extruders, M spin stations, and a processor, wherein N>1.
Anthony Cascio, James Mason, Daniel Amos, Lucinda Jones
Filed: 16 Jun 21
Utility
Roof Tile for Forming a Roof Covering, Method for Manufacturing a Roof Tile and Method for Installing Roof Tiles
2 Dec 21
A method for manufacturing a roof tile, wherein the roof tile comprises a ceramic body, which is made of porcelain, and is provided with at least one hole, which is present in at least said ceramic body; wherein the method comprises at least the steps of providing a body composition; pressing the body composition; and firing the pressed body composition, and wherein, for forming said at least one hole, before said step of firing, a recess is formed in the body in the form of a blind hole or a through hole.
Rahul Patki, Terry Adams, Raul Rodriguez, Claudio Caselli
Filed: 21 Jul 21
Utility
Tube Holder for Line Dispensing
25 Nov 21
A tube holder supports a spool of flexible line wrapped onto the outer surface of a tube.
John T. Schuler
Filed: 24 Jan 19
Utility
Systems and methods for manufacturing bulked continuous filament
23 Nov 21
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.
Thomas R. Clark
Filed: 30 Aug 19
Utility
Floor Element for Forming a Floor Covering, a Floor Covering, and a Method for Manufacturing a Floor Element
11 Nov 21
A floor element for forming a floor covering, wherein the floor element comprises a decorative layer made of a ceramic material and a support layer arranged below this decorative layer, wherein the support layer comprises edges provided with coupling elements configured to realize a mechanical coupling with coupling elements of an adjacent floor element and wherein the floor element comprises an intermediate layer having a resin material and wherein said resin material comprises a modulus of elasticity greater than 0.1 GPa, preferably greater than 0.5 GPa, even more preferably greater than 1 GPa.
Claudio Caselli, Rahul Patki
Filed: 7 May 20
Utility
Floor Board and Method for Manufacturing Such Floor Boards
4 Nov 21
A floor board including a decorative surface layer applied to a substrate, where the substrate has MDF or HDF material at a side edge thereof, where the side edge is treated both with an impregnation agent and/or a sealing agent based on a super absorbing material.
Dieter D'HONDT, Aaron SHAW
Filed: 13 Jul 21
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