Abstract:
A method for producing terylene fiber using polyester waste is disclosed. Firstly, dried polyester waste is sent into a screw extruder, then is melt and extruded to be polyester melt. Whereafter, the melt is filtrated twice to remove impurities. Then macromolecule polymerization reaction is taken place in the polyester melt to homogenize the molecular weight of macromoleclar polymer and to increase the viscosity of the polyester. Then the melt with increased viscosity is finely filtrated using melt precision filter. Whereafter, the melt is sent into a spinning box to execute metering spinning, then is cooled and solidified to be filaments. Finally, the filaments are wound according to various process requirements. The method can increase the quality of regenerated polyester spinning melt. The regenerated polyester melt has less impurities and homogenous viscosity after multiple filtrating. The fiber product has advantages of less end breakage rate, high full-bobbin rate, high finished product rate and less wastage.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a method for producing foam from bottles with polyester waste, and more particularly to a method for producing terylene fiber using polyester waste. 
         [0003]    2. Description of Related Art 
         [0004]    A conventional nozzle for producing foam comprises a press cover, a revolving cover and a cylinder. The revolving cover is mounted on the opening of a bottle or a container. The press cover is able to move upwardly/downwardly relative to the revolving cover. The cylinder is extended into the bottle or the container. 
         [0005]    The cylinder has an unidirectional flow mechanism. The unidirectional flow mechanism comprises a connection tube, a needle valve, a piston, a spring, and a one-way valve . . . etc. The connecting tube has a channel for the piston to move downward when the piston is pressed. The one-way valve is placed on the bottom of the cylinder, in which the one-way valve allows the fluid to flow up from the container into the cylinder under the air pressure, and prevents the fluid to flow reversely. 
         [0006]    When the cylinder is full of fluid and a user presses the press cover, the channel of the connecting tube is communicated with the cylinder. Thus, the fluid flows out of the press cover via connecting tube when the press cover is pressed by the user. In contrast, when the user releases the press cover, the connecting tube moves upward by the spring&#39;s recovering force. Simultaneously, the volume of the cylinder is expanded by the air, in which the air pushes the fluid back into the bottle or container for recycling. 
         [0007]    The publication CN2632010Y further discloses a nozzle for producing foam. The nozzle has a chamber to mix the liquid and the air together, and at least one filter is used to adjust the dimension of the foam, so that the foam is not too dense or too dilute. Unfortunately, there are two shortcomings in the publication CN2632010Y: 
         [0008]    First of all, the metallic spring is often submerged in the liquid and it makes the spring get broken easily; 
         [0009]    Secondly, between each connecting element has an unfilled space, in which the air can flow into or out. Thus, the unfilled space makes the airtight condition get worse. 
         [0010]    The present invention has arisen to mitigate and/or obviate the disadvantages of the conventional. 
       SUMMARY OF THE INVENTION 
       [0011]    The main objective of the present invention is to provide an improved a method for producing foam from bottles with polyester waste. 
         [0012]    To achieve the objective, a method for producing terylene fiber using polyester waste is achieved by a nozzle assembled to a bottle, the nozzle comprises a press cover, a revolving cover, and a cylinder to construct the appearance of the nozzle, the press cover having a first tube extending therefrom, a first channel defined in the first tube for melting substances or liquid to flow through, the revolving cover being screwed on an opening of the bottle for sealing the bottle, the cylinder having an upper chamber and a lower chamber, the upper chamber abutting against the inner wall of the opening of the bottle, a first melt precision filter, a spinning box, a connecting tube, a first piston, a spring, a second piston, a needle valve and an unidirectional valve being assembled into the nozzle, the first melt precision filer having a second tube defined therethrough, a first filtrated mesh being set on the bottom of the second tube, a net being set on the top of the second tube, the spinning box formed by a fourth tube, an annular fringe extended from the fourth tube and around the fourth tube, a second filtrated mesh being set on the top of the fourth tube, the bottom of the fourth tube being opened for the melting substances or liquid to flow into, the annular fringe having an annular groove defined therein; when the press cover is pressed down, the bottom of the first tube is abutted against the annular fringe; the top of the connecting tube extending into the spinning box, the connecting tube having a second channel, the second channel communicating with the first channel of the press cover, a sealing member assembled between the spinning box and the connecting tube, the sealing member formed by a seventh tube, a sealing fringe extruded along the bottom periphery of the seventh tube, a plurality of ribs radially formed on the outer periphery of the seventh tube, a plurality of air paths defined between each of two neighbor ribs, the sealing fringe having a taper portion formed thereon; the first piston assembled into the upper chamber of the cylinder, the first piston comprising a first inner tube, a first outer tube, a first connecting portion formed between the first inner tube and the first outer tube for integrating the first piston, the first inner tube surrounding the middle of the connecting tube, an up-sealing groove defined on the top of the first connecting portion of the first piston, a plurality of air holes defined between the up-sealing groove and the first inner tube; when the spinning box is assembled to the first piston, the annular groove of the spinning box is received in the up-sealing groove of the first piston and sealing with each other; a taper recess defined on the bottom periphery of the first inner tube; when the sealing member is assembled to the first piston, the taper portion is engaged with the taper recess for sealing, the second piston assembled into the lower chamber of the cylinder, the second piston comprising a second inner tube, a second outer tube, a second connecting portion formed between the second inner tube and the second outer tube for integrating the second piston, a tapered section defined on the bottom periphery of the second inner tube of the second piston; when the connecting tube is moving downward, the bottom of the connecting tube is abutted against the second connecting portion of the second piston; one end of the spring abutted against the sealing member, another end of the spring abutted against the lower chamber of the cylinder, the needle valve formed by a rod, the rod having a disk at the bottom, a sealing section extended from the disk and surrounding the bottom of the rod; when the needle valve is upwardly passing through the second inner tube of the second piston and entering into the second channel of the connecting tube, the top of the needle valve is received in a necking portion and positioned by the necking portion, a fluid channel formed between the needle valve and the second inner tube of the second piston for the melting substances or liquid to flow into, the tapered section of the second piston engaged with the sealing section of the needle valve for sealing, the unidirectional valve placed in the lower chamber of the cylinder and near an entrance of the cylinder. 
         [0013]    The first filtrated mesh and the second filtrated mesh both have a top layer and a bottom layer, a plurality of diamond holes alternately defined on the top layer and bottom layer, a middle space formed between the top layer and the bottom layer, the diamond holes on the top layer and bottom layer communicated with the middle space. 
         [0014]    The first tube has two rectangular edges defined in the left and right sides of the inner wall of the first tube, two cutting edges respectively defined at the left and right sides of the outer periphery of the second tube of the first melt precision filter, the cutting edges engaged with the rectangular edges for stably connecting the first melt precision filter into the first tube of the press cover, a curved recess defined on the outer periphery of the fourth tube of the spinning box, the spinning box positioned in the first tube by an engagement between the rectangular edge and the curved recess. 
         [0015]    A plurality of fourth teeth is formed on the bottom peripheral of the fourth tube, a plurality of fourth gaps defined between each of two neighbor fourth teeth, the fourth tube having a plurality of fourth ribs formed on the inner wall of the fourth tube, a plurality of air channel defined between each of two neighbor fourth ribs. 
         [0016]    The top of the connecting tube has an enlarging portion, a plurality of sixth teeth formed on the top periphery of the enlarging portion, a plurality of sixth gaps defined between each of two neighbor sixth teeth, the spinning box communicated with the second channel of the connecting tube via the sixth gaps. 
         [0017]    The middle of the second channel is necked to form the necking portion, the top of the needle valve received in the necking portion and positioned by the necking portion, a plurality of protrusions axially formed on the periphery of the rod, a plurality of unfilled space defined between each of two neighbor protrusions. 
         [0018]    An annular recess is defined at the bottom of the sealing fringe of the sealing member, one end of the spring fixing in the annular recess of the sealing member. 
         [0019]    The lower chamber has a spring room for receiving the spring, the lower chamber and the upper chamber separated by the second piston, another end of the spring receiving into the spring room of the cylinder. 
         [0020]    The upper chamber has a vent defined thereon, the first piston assembled into the upper chamber of the cylinder and near the vent, the inner space of the cylinder isolated by the first piston. 
         [0021]    An annular pad is assembled between the top of the upper chamber of the cylinder and the opening of the bottle for further sealing the bottle. 
         [0022]    Further benefits and advantages of the present invention will become apparent after a careful reading of the detailed description with appropriate reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0023]      FIG. 1  is an exploded view of a nozzle in accordance with the present invention; 
           [0024]      FIG. 2  is a cross-sectional view for showing the nozzle in the initial state; 
           [0025]      FIG. 3  is a cross-sectional view for showing the nozzle to be slightly pressed; 
           [0026]      FIG. 4  is a cross-sectional view for showing the nozzle to be completely pressed; 
           [0027]      FIG. 5  is a cross-sectional view of a press cover in accordance with the present invention; 
           [0028]      FIG. 6  is a perspective view of the press cover in accordance with the present invention; 
           [0029]      FIG. 7  is a cross-sectional view of a first melt precision filter in accordance with the present invention; 
           [0030]      FIG. 8  is a top side view of the first melt precision filter in accordance with the present invention; 
           [0031]      FIG. 9  is a perspective view of the first melt precision filter in accordance with the present invention; 
           [0032]      FIG. 10  is a cross-sectional view of a revolving cover in accordance with the present invention; 
           [0033]      FIG. 11  is a cross-sectional view of a spinning box in accordance with the present invention; 
           [0034]      FIG. 12  is a partial enlarged view of the spinning box for showing a second filtrated mesh; 
           [0035]      FIG. 13  is a top side view of the spinning box in accordance with the present invention; 
           [0036]      FIG. 14  is a perspective view of the spinning box in accordance with the present invention; 
           [0037]      FIG. 15  is a cross-sectional view of a first piston in accordance with the present invention; 
           [0038]      FIG. 16  is a perspective view of the first piston in accordance with the present invention; 
           [0039]      FIG. 17  is a cross-sectional view of a connecting tube in accordance with the present invention; 
           [0040]      FIG. 18  is a top side view of the connecting tube in accordance with the present invention; 
           [0041]      FIG. 19  is a perspective of the connecting tube in accordance with the present invention; 
           [0042]      FIG. 20  is a cross-sectional view of a sealing member in accordance with the present invention; 
           [0043]      FIG. 21  is a perspective view of the sealing member in accordance with the present invention; 
           [0044]      FIG. 22  is a cross-sectional view of a second piston in accordance with the present invention; 
           [0045]      FIG. 23  is a perspective view of the second piston in accordance with the present invention; 
           [0046]      FIG. 24  is a cross-sectional view of a needle valve in accordance with the present invention; and 
           [0047]      FIG. 25  is a perspective view of the needle valve in accordance with the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0048]    Referring to  FIG. 1 , a method for producing terylene fiber using polyester waste is achieved by a nozzle assembled to a bottle (not shown), wherein the nozzle comprises a press cover  1 , a revolving cover  3 , and a cylinder  14  to construct the appearance of the nozzle. A first melt precision filter  2 , a spinning box  4 , a connecting tube  6 , a first piston  5 , a spring  10 , a second piston  8 , a needle valve  9  and a unidirectional valve  13  are assembled into the nozzle. 
         [0049]    Referring to  FIGS. 5-6 , the press cover  1  has a first tube  11  extended therefrom. A first channel  12  is defined in the first tube  11  for melting substances or liquid to flow through. The first tube  11  has two rectangular edges  13 ,  13 ′ defined in the left and right sides of the inner wall. 
         [0050]    Referring to  FIG. 10 , the revolving cover  3  is screwed on an opening of the bottle for sealing the bottle. 
         [0051]    Referring to  FIG. 26 , the cylinder  14  has an upper chamber  141  and a lower chamber  142 . The upper chamber  141  is abutted against the inner wall of the opening of the bottle. The upper chamber  141  has a vent  1411  defined thereon. The lower chamber  142  has a spring room  1421  for receiving the spring  10  and an entrance  1422  for the melting substances or liquid to flow into. 
         [0052]    Referring to  FIG. 2-4 , an annular pad  15  is assembled between the top of the upper chamber  141  of the cylinder  14  and the opening of the bottle for further sealing the bottle. Thus, the air cannot flow into or out of the bottle. 
         [0053]    Referring to  FIGS. 7-9 , the first melt precision filer  2  has a second tube  22  defined therethrough. A first filtrated mesh  21  is set on the bottom of the second tube  22 . A net  23  is set on the top of the second tube  22 . Two cutting edges  221 ,  222  are respectively defined at the left and right sides of the outer periphery of the second tube  22 . The cutting edges  221 ,  222  are engaged with the rectangular edges  13 ,  13 ′ for stably connecting the first melt precision filter  2  into the first tube  11  of the press cover  1 . 
         [0054]    The first filtrated mesh  21  has a first top layer  211  and a first bottom layer  212 . A plurality of diamond holes is alternately defined on the first top layer  211  and first bottom layer  212  (as shown in  FIG. 7 ). A first middle space  213  is formed between the first top layer  211  and the first bottom layer  212 . The diamond holes on the first top layer  211  and first bottom layer  212  are communicated with the first middle space  213  so that the melting substances or liquid can pass through the first filtrated mesh  21 . 
         [0055]    Referring to  FIGS. 11-14 , the spinning box  4  is formed by a fourth tube  42 . An annular fringe  43  is extended from the fourth tube  42  and around the fourth tube  42 . A second filtrated mesh  41  is set on the top of the fourth tube  42 . The bottom of the fourth tube  42  is opened for the melting substances or liquid to flow into. A curved recess  425  is defined on the outer periphery of the fourth tube  42 . The diameter of the fourth tube  42  and the diameter of the first channel  12  of the press cover  1  are the same. The spinning box  4  is positioned in the first tube  11  by an engagement between the rectangular edge ( 13  or  13 ′) and the curved recess  425 . 
         [0056]    The fourth tube  42  has a plurality of fourth ribs  423  formed on the inner wall of the fourth tube  42 . A plurality of air channel  424  is defined between each of two neighbor fourth ribs  423 . 
         [0057]    A plurality of fourth teeth  421  is formed on the bottom peripheral of the fourth tube  42 . A plurality of fourth gaps  422  is defined between each of two neighbor fourth teeth  421 . 
         [0058]    When the press cover  1  is pressed down, the bottom of the first tube  11  is abutted against the annular fringe  43 . The annular fringe  43  has an annular groove  431  defined therein. 
         [0059]    The second filtrated mesh  41  has a second top layer  411  and a second bottom layer  412 . A plurality of diamond holes is alternately defined on the second top layer  411  and second bottom layer  412 . A second middle space  413  is formed between the second top layer  411  and the second bottom layer  412 . The diamond holes on the second top layer  411  and second bottom layer  412  are communicated with the second middle space  413  so that the melting substances or liquid can pass through the second filtrated mesh  41 . 
         [0060]    Referring to  FIGS. 17-19 , the connecting tube  6  has a second channel  61 . The second channel  61  is communicated with the first channel  12  of the press cover  1 . The middle of the second channel  61  is necked to form a necking portion  611 . The top of the connecting tube  6  is selectively connected to the spinning box  4 . The top of the connecting tube  6  has an enlarging portion  62 . A plurality of sixth teeth  621  is formed on the top periphery of the enlarging portion  62 . A plurality of sixth gaps  622  is defined between each of two neighbor sixth teeth  621 . The spinning box  4  is communicated with the second channel  61  of the connecting tube  6  via the sixth gaps  622 , so that the liquid and the air are mixed here to form foam. 
         [0061]    Referring to  FIGS. 20-21 , a sealing member  7  is assembled between the spinning box  4  and the connecting tube  6 . The sealing member  7  is formed by a seventh tube  71 . A sealing fringe  72  is extruded along the bottom periphery of the seventh tube  71 . A plurality of ribs  711  is radially formed on the outer periphery of the seventh tube  71 . A plurality of air paths  712  is defined between each of two neighbor ribs  711 . The sealing fringe  72  has a taper portion  721  formed thereon. An annular recess  722  is defined at the bottom of the sealing fringe  72 . 
         [0062]    Referring to  FIGS. 15-16 , the first piston  5  is assembled into the upper chamber  141  of the cylinder  14  and near the vent  1411 . The inner space of the cylinder  14  is isolated by the first piston  5 . The first piston  5  comprises a first inner tube  51 , a first outer tube  52 . A first connecting portion  53  is formed between the first inner tube  51  and the first outer tube  52  for integrating the first piston  5 . The first inner tube  51  is surrounding the middle of the connecting tube  6 . An up-sealing groove  531  is defined on the top of the first connecting portion  53  of the first piston  5 . A plurality of air holes  532  is defined between the up-sealing groove  531  and the first inner tube  51 . When the spinning box  4  is assembled to the first piston  5 , the annular groove  431  of the spinning box  4  is received in the up-sealing groove  531  of the first piston  5  and sealing with each other. A taper recess  511  is defined on the bottom periphery of the first inner tube  51 . When the sealing member  7  is assembled to the first piston  5 , the taper portion  721  is engaged with the taper recess  511  for sealing. 
         [0063]    Referring to  FIGS. 22-23 , the second piston  8  is assembled into the lower chamber  142  of the cylinder  14 . The second piston  8  comprises a second inner tube  81 , a second outer tube  82 . A second connecting portion  83  is formed between the second inner tube  81  and the second outer tube  82  for integrating the second piston  8 . When the connecting tube  6  is moving downward, the bottom of the connecting tube  6  is abutted against the second connecting portion  83  of the second piston  8 . A tapered section  811  is defined on the bottom periphery of the second inner tube  81  of the second piston  8 . 
         [0064]    Referring to  FIGS. 24-25 , the needle valve  9  is formed by a rod  91 . The rod  91  has a disk  92  at the bottom. A sealing section  93  is extended from the disk  92  and surrounding the bottom of the rod  91 . The tapered section  811  of the second piston  8  is engaged with the sealing section  93  of the needle valve  9  for sealing. 
         [0065]    The needle valve  9  is upwardly passing through the second inner tube  81  of the second piston  8  and entering into the second channel  61  of the connecting tube  6 . The top of the needle valve  9  is received in the necking portion  611  and positioned by the necking portion  611 . A plurality of protrusions  911  is axially formed on the periphery of the rod  91 . A plurality of unfilled space is defined between each of two neighbor protrusions  911 . A fluid channel formed between the needle valve  9  and the second inner tube  81  of the second piston  8  for the melting substances or liquid to flow into. One end of the spring  10  is fixed in the annular recess  722  of the sealing member  7 . Another end of the spring  10  is received into the spring room  1421  of the cylinder  14 . The spring room  1421 , the lower chamber  142  and the upper chamber  141  are separated by the second piston  8 , so that the melting substances or liquid in the lower chamber  142  cannot flow to the spring  10 . 
         [0066]    The unidirectional valve  13  is placed in the lower chamber  142  of the cylinder  14  and near the entrance  1422 . 
         [0067]    To use the nozzle assembled to a bottle for producing terylene fiber using polyester waste is illustrated as following: 
         [0068]    In the beginning, the lower chamber  142  of the cylinder  14  is filled with the melting substances or liquid, such as the polyester waste; and the upper chamber  141  of the cylinder  14  is filled with the air. The vent  1411  of the upper chamber  141  is closed by the first piston  5  so that the inner side of the cylinder  14  is isolated. 
         [0069]    Specifically, the annular groove  431  of the spinning box  4  is separated from the up-sealing groove  531  of the first piston  5  and the upper chamber  141  is divided into two parts by the first piston  5 . The two parts of the upper chamber  141  are communicated with each other by the air holes  532 . In contrast, the taper portion  721  of the sealing member  7  is tightly engaged with the taper recess  511  of the first piston  5 . Thus, the air in the upper chamber  141  cannot flow into the spinning box  4 . Furthermore, the sealing section  93  of the needle valve  9  is tightly engaged with the tapered section  811  of the second piston  8 . Thus, the melting substances or the liquid in the lower chamber  142  cannot flow into the second channel  61  of the connecting tube  6 . 
         [0070]    Referring to  FIG. 3 , when the user slightly presses the press cover  1  (said press cover moves around 2 mm downward), the bottom of the first tube  11  of the press cover  1  is abutted against the annular fringe  43  of the spinning box  4  and the press cover  1  presses the spinning box  4  down. At the same time, the first piston  5  and the second piston  8  stay at the original locations. The annular groove  431  of the spinning box  4  is received into the up-sealing groove  531  of the first piston  5  and the two parts are isolated by the first piston  5 . The spinning box  4  pushes the sealing member  7  to move downward and the taper portion  721  of the sealing member  7  is disconnected with the taper recess  511  of the first piston  5 . Simultaneously, the air in the upper chamber  141  and under the first piston  5  is flowing into the spinning box  4 . The second filtrated mesh  41  of the spinning box  4  pushes the connecting tube  6  and the needle valve  9  to move down. Consequently, the sealing section  93  of the needle valve  9  is disconnected to the tapered section  811  of the second piston  8 , and the melting substances or liquid in the lower chamber  142  can flow into the second channel  61  of the connecting tube  6 . 
         [0071]    When one part above the first piston  5  is expanded in the upper chamber  141 , the first piston  5  leaves from the vent  1411 , so that the air flows into the upper chamber  141 . In addition, the up-sealing groove  531  of the first piston  5  is sealed by the annular groove  431  of the spinning box  4 . Thus, the air form the vent  1411  cannot flow into another part below the first piston  5 . The original air below the first piston  5  is pushed into the spinning box  4  to mix with the melting substances or liquid when the press cover  1  is gradually pressed down. 
         [0072]    Referring to  FIG. 4 , when the user keeps pressing the press cover  1 , the annular groove  431  of the spinning box  4  is abutted against the first connecting portion  53  of the first piston  5  and the spinning box  4  presses the first piston  5  down. The bottom of the connecting tube  6  is abutted against the second connecting portion  83  of the second piston  8  and the connecting tube  6  presses the second piston  8  down. The another part below the first piston  5  in the upper chamber  141  is compressed gradually, and the air is flowing into the spinning box  4  via the air channel  424  of the spinning box  4  and the sealing member  7 . In addition, the space of the lower chamber  142  of the cylinder  14  is also compressed gradually, and the melting substances or the liquid are flowing into the second channel  61  of the connecting tube  6  and the spinning box  4  via the needle valve  9  and the second inner tube  81  of the second piston  8 . The melting substances or liquid are mixed with the air in the spinning box  4  and in the second channel  61 . Thereafter, the mixtures pass through the second filtrated mesh  41  of the spinning box  4  and the first filtrated mesh  21  of the first melt precision filter  2  to form a plurality of uniform foam, and the foam is expelled out from the first channel  12  of the press cover  1 . 
         [0073]    After the user sprays enough foam, the user releases the press cover  1 . The sealing member  7  and the spinning box  4  are moved up by the recovering force form the spring  10 . The taper portion  721  of the sealing member  7  is engaged with the taper recess  511  of the first piston  5  again, and the annular groove  431  of the spinning box  4  is separated from the up-sealing groove  531  of the first piston  5  again. The air holes  532  are opened again and the air is flowing into another part which is below the first piston  5  via the air holes  532 . Thus, the first piston  5  moves back to the original position. In addition, the sealing member  7  pushes the enlarging portion  62  of the connecting tube  6  to make the connecting tube  6  and the needle valve  9  moving up. The sealing section  93  of the needle valve  9  is engaged with the tapered section  811  of the second piston  8  again. The disk  92  of the needle valve  9  moves the second piston  8  back to the original position. 
         [0074]    Furthermore, the annular groove  431  of the spinning box  4  is separated from the up-sealing groove  531  of the first piston  5  to make the air flow downward via the air holes  532 . Consequently, the space of the part which is above the first piston  5  is decreasing and the space of another part which is below the first piston  5  is increasing. Finally, the first piston  5  moves back to close the vent  1411 . The user can press the nozzle again to spray the foam. 
         [0075]    Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.