COMPOSITIONS OF RECYCLED POLYETHYLENE TEREPHTHALATE, FIBERS AND ARTICLES PRODUCED THEREOF, AND METHODS FOR PRODUCING THEM

Abstract

In one aspect, the invention relates to compositions of recycled polyethylene terephthalate, fibers and articles produced therefrom, and methods for producing them. In a further aspect, the invention relates to homogenized polyethylene terephthalate derived from consumer products. In a further aspect, the invention relates to extruded polymer compositions, polymer blends, fibers, and / or bulky continuous filament fibers comprising polyethylene terephthalate derived from consumer products. In a further aspect, the invention relates to processes for preparing compositions of recycled polyethylene terephthalate.

Description

COMPOSITIONS OF RECYCLED POLYETHYLENE TEREPHTHALATE, FIBERS AND ARTICLES PRODUCED THEREOF, AND METHODS FOR PRODUCING THEM FIELD OF INVENTION The present invention relates to compositions of recycled polyethylene terephthalate, fibers and articles produced therefrom, and methods for producing them. In a further aspect, the invention relates to homogenized polyethylene terephthalate derived from consumer products. In a further aspect, the invention relates to extruded polymer compositions, polymer blends, fibers, and / or bulky continuous filament fibers comprising polyethylene terephthalate derived from consumer products. In a further aspect, the invention relates to processes for preparing compositions of recycled polyethylene terephthalate. BACKGROUND OF THE INVENTION Polyethylene terephthalate (PET) resins exhibit hardness, transparency, good barrier properties, light weight, design flexibility, chemical resistance, and good shelf life performance. Consequently, PET is widely used in the packaging industry, for example, in the manufacture of beverage bottles. Furthermore, PET is environmentally friendly, as it is recyclable. Conventional recycling processes for consumer PET (PCPET), however, typically do not yield satisfactory materials for extrusion into a fiber, such as bulk continuous filament (BCF), especially compared to virgin PET (VPET). For example, recycled polyethylene terephthalate (RPET) produced by conventional recycling techniques may exhibit unsatisfactory graining when used in carpet applications and may break down during processing. Therefore, there remains a need for methods and compositions that overcome these deficiencies and effectively provide recycled polyethylene terephthalate compositions, fibers, and articles. SUMMARY OF THE INVENTION In accordance with the purpose(s) of the invention, as represented and described in full herein, the invention, in one aspect, relates to recycled polyethylene terephthalate compositions, fibers and articles produced therefrom, and methods for producing them. Extruded polymer compositions comprising polyethylene terephthalate, present as up to about 100% by weight of consumer-sourced polyethylene terephthalate collected from curbside deposits, and equilibrium virgin polyethylene terephthalate, are disclosed. Also disclosed are polymer blends comprising polyethylene terephthalate, qr Lnnn / zznz / E / Yi present as up to about 100% by weight of homogeneous polyethylene terephthalate sourced from consumption, collected from curbside deposits, and equilibrium virgin polyethylene terephthalate. Also disclosed are extruded fibers made from polyethylene terephthalate, present as up to about 100% by weight of polyethylene terephthalate sourced from consumption, collected from curbside deposits, and equilibrium virgin polyethylene terephthalate. Also disclosed are bulky continuous filament extruded fibers comprising a polymer composition of polyethylene terephthalate, present as up to about 100% by weight of consumer-sourced polyethylene terephthalate collected from curbside deposits, and equilibrium virgin polyethylene terephthalate. Also disclosed are bulky continuous filament fibers extruded from a polymer composition comprising polyethylene terephthalate, present as up to about 100% by weight of consumer-sourced polyethylene terephthalate collected from curbside deposits, and equilibrium virgin polyethylene terephthalate. Homogenized polyethylene terephthalate from consumer waste, collected from sidewalk deposits, is also reported. Processes for preparing recycled polyethylene terephthalate compositions are also disclosed, which include the stage of combining polyethylene terephthalate from consumption, collected from deposits on sidewalks, until homogenized, before mixing with virgin polyethylene terephthalate. Processes for preparing recycled polyethylene terephthalate compositions are also disclosed, comprising the step of mixing homogeneous polyethylene terephthalate from consumption, collected from sidewalk deposits, with virgin polyethylene terephthalate, before extruding the mixture. Processes for preparing a recycled polyethylene terephthalate composition are also disclosed, comprising the step of extruding a homogeneous mixture of polyethylene terephthalate from consumption, collected from curbside deposits, and virgin polyethylene terephthalate. Processes for preparing recycled polyethylene terephthalate compositions are also disclosed, which include the stage of combining polyethylene terephthalate from consumption, collected from deposits on sidewalks, until it is homogenized, before extrusion. Processes for preparing recycled polyethylene terephthalate compositions are also disclosed, comprising the steps of combining polyethylene terephthalate from consumer waste, collected from sidewalk deposits, until homogenized; optionally, crystallizing the homogeneous polyethylene terephthalate from consumer waste, collected from sidewalk deposits; drying the homogeneous polyethylene terephthalate from consumer waste, collected from sidewalk deposits; mixing the homogeneous polyethylene terephthalate from consumer waste, collected from sidewalk deposits, with virgin polyethylene terephthalate; and extruding the mixture. The products of the processes described are also made public. qr Lnnn / zznz / B / Yi Although aspects of the present invention may be described and claimed in a particular statutory class, such as the statutory class of systems, this is for convenience only, and a person skilled in the art will understand that each aspect of the present invention may be described and claimed in any statutory class. Unless expressly stated otherwise, no method or aspect set forth herein is intended to be interpreted as requiring its steps to be performed in a specific order. Accordingly, where a claim of the method does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, no order is intended to be inferred in any way.This is stated for any possible non-explicit grounds for interpretation, including matters of logic regarding stage arrangement or operational flow, ordinary meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification. BRIEF DESCRIPTION OF THE FIGURES The supplementary figures, which are incorporated into and form part of this specification, illustrate various aspects and, together with the description, serve to explain the principles of the invention. Figure 1 is a flow diagram showing an exemplary method for processing bulky continuous filaments (BCF) of consumer polyethylene terephthalate (PET). Figure 2 is a schematic representation showing side and cross-section views of barrier-type extrusion screws that may be useful in the processes disclosed. Additional advantages of the invention will be partly set forth in the following description, and partly will be obvious from the description, or can be learned through the practice of the invention. The advantages of the invention will be realized and achieved by means of the elements and combinations particularly highlighted in the appended claims. It is to be understood that the preceding general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. DETAILED DESCRIPTION OF THE INVENTION The present invention can be more easily understood by reference to the following detailed description of the invention and the Examples included therein. Before the present compounds, compositions, articles, systems, devices, and / or methods are disclosed and described, it should be understood that they are not limited to specific synthetic methods, unless otherwise specified, or to particular reagents, unless otherwise specified, since, as such, they may, of course, vary. It should also be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. Although any similar or equivalent methods and materials to those described herein may be used in the practice or testing of the present invention, example methods and materials are described herein. All publications mentioned herein are incorporated herein for reference, to disclose and describe the methods and / or materials in relation to which the publications are cited. The publications discussed herein are provided solely for descriptive purposes prior to the filing date of this application. Nothing herein should be construed as an admission that the present invention is not entitled to precede such publication by virtue of the prior invention. Furthermore, the publication dates provided herein may differ from the actual publication dates, which may require independent confirmation. A. DEFINITIONS As used in the specification and accompanying claims, the singular forms “a,” “an,” and “the” include plural referents, unless the context clearly dictates otherwise. Thus, for example, a reference to “a composition,” “a fiber,” or “a stage” includes mixtures of two or more compositions, fibers, stages, and the like. Intervals may be expressed in this document as “from around” a particular value, and / or “to around” another particular value. When such an interval is expressed, “another aspect” includes “from” a particular value and / or “to” the other particular value. Similarly, when values ​​are expressed as approximations, the antecedent “around” will be understood to mean that the particular value forms another aspect. It will further be understood that the endpoints of each interval are meaningful in relation to, and independently of, the other endpoint. It is also understood that there are a number of values ​​disclosed in this document, and that each value is also disclosed in this document as “around” that particular value, in addition to the value itself. For example, if the value “10” is disclosed, then “around 10” is also disclosed. It is further understood that every unit between any two particular units is also disclosed.For example, if 10 and 15 are revealed, then 11, 12, 13, and 14 are also revealed. As used in this document, the terms “optional” or “Optionally” mean that the event or circumstance described below may or may not occur, and that the description includes cases where such event or circumstance occurs and cases where it does not. As used in this document, the term “residue” refers to a portion that is the resulting product of the chemical species in a particular reaction scheme, formulation, or subsequent chemical product, regardless of whether the portion is actually obtained from the chemical species. Thus, an ethylene glycol residue in a polyester refers to one or more -OCH2CH2O- units in the polyester, regardless of whether ethylene glycol was used to prepare the polyester. Similarly, a sebacic acid residue in a polyester refers to one or more -CO(CH2)8CO- portions in the polyester, regardless of whether the residue is obtained by reacting sebacic acid or an ester thereof to obtain the polyester. qr Lnnn / zznz / E / Yi As used in this document, the term “polymer” refers to an organic compound, natural or synthetic, of relatively high molecular weight, whose structure can be represented by a small repeating unit, the monomer (e.g., polyethylene, rubber, cellulose). Synthetic polymers are typically formed by addition or condensation polymerization of monomers. Homopolymers (i.e., a single repeating unit) and copolymers (i.e., more than one repeating unit) are two categories of polymers. As used in this document, the term “copolymer” refers to a polymer formed from two or more different repeating units (monomer residues). By way of example and without limitation, a copolymer may be a staggered copolymer, a random copolymer, a block copolymer, or a graft copolymer. It is also contemplated that, in certain respects, various block segments of a block copolymer may itself comprise copolymers. As used in this document, the term “molecular weight” (MW) refers to the mass of a molecule of that substance, relative to the unified atomic mass unit u (equal to 1 / 12 the mass of a carbon-12 atom). As used in this document, the term “number-average molecular weight” (Mn) refers to the common arithmetic mean of the molecular weights of the individual polymers. Mn can be determined by measuring the molecular weight of n polymer molecules, summing the weights, and dividing by n. Mn is calculated by: qr Lnnn / zznz / E / Yi where N¡ is the number of molecules of molecular weight M¡. The number average molecular weight of a polymer can be determined by gel diffusion chromatography, viscometry (Mark-Houwink equation), light scattering, analytical ultracentrifugation, vapor pressure osmometry, titration of end groups, and colligative properties. As used in this document, the term “weighted average molecular weight” (Mw) refers to an alternative measure of the molecular weight of a polymer. Mw is calculated by: AA,· where N¡ is the number of molecules of molecular weight M¡. Intuitively, if the weighted average molecular weight is w, and a random monomer is selected, then the polymer to which it belongs will have a weight of w, on average. The weighted average molecular weight can be determined by light scattering, small-angle neutron scattering (SANS), X-ray scattering, and sedimentation rate. As used in this document, the terms “polydispersity” and “polydispersity index” refer to the ratio of average weight to average number (Mw / Mn). As used in this document, the terms “polyethylene terephthalate” and “PET” refer to a thermoplastic polyester resin that can exist as an amorphous (transparent) material and as a semicrystalline (opaque and white) material. PET can also exist as a transparent semicrystalline material, as used in the sidewalls of PET bottles. In such forms, the crystals are smaller than the wavelength of visible light and thus do not make the material opaque and white. PET can be represented by the following structural formula: n qr Lnnn / zznz / E / Yi PET can be used in synthetic fibers; containers for beverages, food, and other liquids; thermoforming applications; and engineering resins, often in conjunction with fiberglass. Its monomer can be synthesized by the esterification reaction between terephthalic acid and ethylene glycol with water as a byproduct, or by the transesterification reaction between ethylene glycol and dimethyl terephthalate with methanol as a byproduct. Polymerization can occur through a polycondensation reaction of the monomers with ethylene glycol as a byproduct. The terms “polyethylene terephthalate” and “PET” include PET polymers and copolymers. For example, PET may be supplied as a copolymer that has, in addition to terephthalic acid residues and ethylene glycol residues, additional isophthalic acid residues and / or cyclohexanedimethanol residues. It is also understood that the PET polymer and / or copolymer may be supplied as part of a polymer blend. As used in this document, the terms “new” and “virgin”, when used in relation to polymeric material, refer to polymeric material that is not consumer-sourced (or industrial-sourced) polymeric material. As used in this document, the term “consumer-sourced,” when used in relation to polymeric material, refers to polymeric material collected from the end consumer of a material stream. Consumer-sourced (or industrial-sourced) polymeric material, in contrast to virgin polymeric material, typically may contain impurities resulting from its use in consumer (or industrial) products before being recovered for recycling. As used in this document, the term “crystallized”, when used in relation to polyethylene terephthalate, refers to a polymer that has been subjected to crystallization conditions (e.g., heat at a temperature above the glass transition temperature (Tg) of polyethylene terephthalate) sufficient to minimize or eliminate sticking during a subsequent processing stage, e.g., a drying stage. As used in this document, the term “homogeneous”, when used in relation to polymeric material, refers to a material mechanically blended to a uniform state sufficient to minimize or eliminate streaking in textiles such as carpet and / or breakage of extruded material during a subsequent processing stage, e.g., an extrusion, braiding, or tufting stage. As used in this document, the term “deposit,” when used in relation to consumer-sourced polymer material, refers to consumer-sourced polymer material that is deposit-grade. Deposit-grade is the highest quality consumer-sourced packaged polymer, for example, PET. Deposit polymer primarily comes from PET soda bottles collected in one of about nine U.S. states where a bottle deposit system encourages their return. Deposit materials command a premium price on the market. As used in this document, the term “curbside dump collection,” when used in connection with consumer polymer material, refers to consumer polymer material that is generally lower-grade, packaged consumer polymer, such as PET. Curbside dump polymer primarily comes from PET soda, water, and custom bottles, which usually include other types of resins. Sand, glass, PVC, and dirt are common contaminants. As used in this document, the term “granule”, when used in relation to consumer-sourced polymer material, refers to consumer-sourced polymer material supplied in granular form, similar to the form of commercial virgin polymer. As used in this document, the term “flake”, when used in relation to consumer-sourced polymer material, refers to consumer-sourced polymer material supplied in the form of irregular flakes, typically of mechanically shredded polymer material. As used in this document, the term “staple fiber” refers to relatively short lengths of fiber, typically cut from a continuous filament into lengths of 10.16 cm to 19.05 cm (4” to 7 1 / 2”). These lengths can be spun together to create strands of yarn. As used in this document, the term “bulky continuous filament fiber” refers to continuous strands of synthetic fiber formed into yarn bundles of a given number of filaments and typically textured to increase bulk and coverage. The components to be used to prepare the compositions of the invention, as well as the compositions themselves for use within the methods disclosed herein, are disclosed. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc., of these materials are disclosed, although the specific reference to each of the various individual and collective combinations and permutations of these compounds may not be explicitly disclosed, each is specifically contemplated and described herein. For example, if a particular compound is disclosed and discussed, and a number of modifications that can be made to a number of molecules qr Lnnn / zznz / E / Yi, including the compounds, are discussed, each and every combination and permutation of the compound and the modifications that are possible are specifically contemplated, unless specifically stated otherwise.Thus, if a class of molecules A, B, and C is disclosed, as well as a class of molecules D, E, and F, and an example of a combination molecule, AD, is disclosed, then even if each is not listed individually, each is considered individually and collectively, meaning that the combinations AE, AF, BD, BE, BF, CD, CE, and CF are considered disclosed. Likewise, any subset or combination thereof is also disclosed. Thus, for example, the subgroup of AE, BF, and CE may be considered disclosed. This concept applies to all aspects of this application, including, but not limited to, steps in methods for preparing and using the compositions of the invention. Thus, if there are a variety of additional steps that can be performed, it is understood that each of these additional steps can be performed using any specific modality or combination of modalities of the methods of the invention. It is understood that the compositions described in this document have specific functions. This document outlines certain structural requirements for performing these functions, and it is understood that a variety of structures can perform the same function as those described, and that these structures will typically achieve the same result. B. RECYCLED POLYETHYLENE TEREPHTHALATE In one aspect, the invention relates to recycled polymer compositions prepared from consumer-grade polyethylene terephthalate. For example, a recycled polymer composition can be prepared from homogenized consumer-grade polyethylene terephthalate collected from curbside deposits, which may be in granular form, flake form, or a combination thereof. As further examples, the recycled polymer compositions can be provided as polymer blends, extruded polymer compositions, fibers, and / or bulky continuous filament fibers. In one respect, a composition of recycled consumer polymers (e.g., consumer polyethylene terephthalate collected from curbside deposits) can be extruded to provide a bulky continuous filament fiber. It is understood that the compositions, mixtures, and fibers disclosed may be used in connection with the fibers, methods, and uses disclosed. 1. MIXTURES AND COMPOSITIONS In one aspect, the invention relates to polymer mixtures comprising polyethylene terephthalate, present as up to about 100% by weight of homogeneous polyethylene terephthalate from consumption, collected from sidewalk deposits, and equilibrium virgin polyethylene terephthalate. In an additional aspect, the invention relates to extruded polymer compositions that comprise polyethylene terephthalate, present as up to about 100% by weight of polyethylene terephthalate from consumption, collected from sidewalk deposits, and equilibrium virgin polyethylene terephthalate. 2. FIBERS In a further aspect, the invention relates to fibers extruded from polyethylene terephthalate, present as up to approximately 100% by weight of polyethylene terephthalate derived from consumer waste, collected from sidewalk deposits, and virgin equilibrium polyethylene terephthalate. For example, the fiber may be a bulky continuous filament extruded fiber comprising a polymer composition of polyethylene terephthalate, present as up to approximately 100% by weight of polyethylene terephthalate derived from consumer waste, collected from sidewalk deposits, and virgin equilibrium polyethylene terephthalate.As a further example, the fiber can be a bulky continuous filament fiber extruded from a polymer composition comprising polyethylene terephthalate, present as up to about 100% by weight of consumer-sourced polyethylene terephthalate collected from curbside deposits, and equilibrium virgin polyethylene terephthalate. 3. CONTENT FROM CONSUMPTION qr Lnnn / zznz / E / Yi In one aspect, at least a portion of the disclosed compositions comprises consumer-derived polyethylene terephthalate. In one aspect, the consumer-derived polyethylene terephthalate is collected from curbside deposits. In one aspect, the balance of the composition may be virgin polyethylene terephthalate. In an additional aspect, polyethylene terephthalate is presented as at least about 5%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80%, at least about 85%, at least about 90%, or at least about 95% by weight of polyethylene terephthalate from consumption, collected from curbside deposits. In an additional aspect, polyethylene terephthalate is presented as up to about 5%, up to about 10%, up to about 30%, up to about 50%, up to about 70%, up to about 15%, up to about 35%, up to about 55%, up to about 75%, up to about 20%, up to about 40%, up to about 60%, up to about 80%, up to about 25%, up to about 45%, up to about 65%, up to about 85%, up to about 90%, or up to about 95% by weight of polyethylene terephthalate from consumption, collected from curbside deposits. In additional aspects, polyethylene terephthalate may be present as approximately 100% by weight of polyethylene terephthalate from consumption, collected from curbside deposits, or virgin polyethylene terephthalate may be absent. 4. RAW MATERIALS In one respect, raw materials can be selected for compatibility with the disclosed processes. For example, polyethylene terephthalate from household waste, collected from curbside deposits, can be in granular form, flake form, or a mixture of both. As a further example, consumer-grade polyethylene terephthalate flakes collected from curbside deposits may be selected for one or more of the following specifications: Bulk density (kg / m3 (lb / ft3)) of 320.4-432.54 (20-27); Moisture content (%) of < 1.0%; Floating contamination (ppm) of < 25; PVC contamination (ppm) of < 150; Metal contamination (ppm) of < 10; Other non-melted particles (ppm) of < 50; Green PET contamination (ppm) of < 5000; Light blue contamination (ppm) of < 75,000; Low melting point material (PETG) (ppm) of < 50; Black PET (ppm) of < 50; Pressure increase (kPa per kilogram (psi per pound)) of < 1139 kPa / kg (75 psi / lb); b color values, when measured by a HunterLabs Spectrophotometer, of 0-3 units, and / or L color values, when measured by a HunterLabs Spectrophotometer, of more than 50 units. As an additional example, consumer-grade polyethylene terephthalate granules collected from curbside deposits may be selected for one or more of the following specifications: bulk density greater than about 720.9 kg / m3 (45 lb / ft3); pressure rise less than about 531.534 kPa / kg (35 psi / lb) with solution viscosity IV greater than 0.70; and granule count of about 50-70 granules / gram; Hunter color L value (crystallized granule) greater than about 60; and color B value less than about 6. Commercial suppliers of suitable consumer polyethylene terephthalate flake / granule materials can be found in the Consumer Plastics Recyclers Association directory. 5. IMPURITIES Consumer-grade polyethylene terephthalate (PET), such as PET collected from curbside dumps, can contain various impurities, including sand, glass, dyes, paper, other polymers (such as PVC and PETG), metals, adhesives, syrups, fillers, and dirt. These impurities in consumer-grade PET may include one or more of the following: floatable contaminants; PVC contamination; metal contamination; other unmelted particles; green PET contamination; light blue PET contamination; low-melting-point material (such as PETG); and black PET contamination. In contrast, such impurities are typically substantially absent from virgin PET. Additionally, one or more impurities may be present at concentrations of up to approximately 10 ppm, 25 ppm, 50 ppm, 100 ppm, 500 ppm, 1000 ppm, 5000 ppm, 1%, 2%, 3%, 5%, 7.5%, or 10% by weight. Furthermore, the total impurity content may be up to approximately 10 ppm, 25 ppm, 50 ppm, 100 ppm, 500 ppm, 1000 ppm, 5000 ppm, 1%, 2%, 3%, 5%, 7.5%, or 10% by weight. Additionally, one or more impurities may be present at concentrations of less than approximately 10 ppm, approximately 25 ppm, approximately 50 ppm, approximately 100 ppm, approximately 500 ppm, approximately 1000 ppm, approximately 5000 ppm, approximately 1%, approximately 2%, approximately 3%, approximately 5%, approximately 7.5%, or approximately 10% by weight. Furthermore, the total impurity content may be up to approximately 10 ppm, approximately 25 ppm, approximately 50 ppm, approximately 100 ppm, approximately 500 ppm, approximately 1000 ppm, approximately 5000 ppm, approximately 1%, approximately 2%, approximately 3%, approximately 5%, approximately 7.5%, or approximately 10% by weight. 6. ADDITIVES The disclosed compositions may also include one or more additives known to those skilled in the art. That is, a skilled person can easily modify one or more properties of the disclosed compositions by selecting and including one or more additives. For example, one or more additives may be selected from plasticizers, opacifiers, nucleating agents, colorants, dyes, lighteners, thinners, and / or fillers. In various aspects, one or more additives may be present as up to about 0.5%, up to about 1%, up to about 2%, up to about 3%, up to about 4%, up to about 5%, or up to about 10% by weight of the composition. In various respects, one or more additives may be present as less than around 0.5%, less than around 1%, less than around 2%, less than around 3%, less than around 4%, less than around 5%, or less than around 10% by weight of the composition. c. USES The disclosed compositions are useful in various articles commonly manufactured from polymer compositions, particularly polyethylene terephthalate compositions. In one aspect, the compositions can be provided as fibers, for example, as bulky continuous filament fibers. These fibers can be used in textile articles, including carpets. Thus, in one aspect, the invention relates to a carpet comprising a disclosed polymer composition or a disclosed fiber. In a further aspect, the invention relates to a carpet comprising a product of a disclosed process. It is understood that the uses disclosed may be employed in relation to the fibers, compositions, methods, and mixtures disclosed. D. PROCESSES TO PREPARE RECYCLED POLYETHYLENE TEREPHTHALATE In one aspect, the invention relates to a process for preparing a recycled polyethylene terephthalate composition comprising the step of homogenizing polyethylene terephthalate from consumer waste, collected from sidewalk deposits, before blending it with virgin polyethylene terephthalate. In a further aspect, the invention relates to a process for preparing a recycled polyethylene terephthalate composition comprising the step of blending homogeneous polyethylene terephthalate from consumer waste, collected from sidewalk deposits, with virgin polyethylene terephthalate before extruding the blend.In a further process, the invention relates to a process for preparing a recycled polyethylene terephthalate composition comprising the step of extruding a homogeneous mixture of polyethylene terephthalate derived from consumer waste, collected from sidewalk deposits, and virgin polyethylene terephthalate. In a further process, the invention relates to a process for preparing a recycled polyethylene terephthalate composition comprising the step of homogenizing polyethylene terephthalate derived from consumer waste, collected from sidewalk deposits, prior to extrusion. It is understood that the processes disclosed may be employed in relation to the fibers, compositions, mixtures, and uses disclosed. 1. SYSTEM COMPONENTS As illustrated in Figure 1, the method for processing PET from consumer use may, for example, include at least one of the following: at least one combining means, at least one crystallizer, at least one drying means, at least one extruder, and at least one spinneret. Additionally, at least one filtration means and / or at least one mixing means may be included. In one aspect, at least one combining means 2 may comprise at least one conventional active mixer with an auger, configured to increase the uniformity of the PET flakes and / or granules from the consumer contained therein. In another aspect, at least one combining means may further comprise at least one conventional combining silo 4, 5 configured to further improve the uniformity of the blended flakes and / or granules. In one aspect, at least one combining silo may include a recirculation means and at least one flow channel to improve uniformity, as known in the art. In another aspect, at least one combining silo may be sized to process batch sizes of PET flakes and / or granules from the consumer of up to 226,796.19 kilograms (500,000 pounds).For example, in one respect, at least one combination silo 4, 5 can be scaled up to process batch sizes of flakes and / or pellets of approximately 113,398.09 kilograms (250,000 pounds). A non-limiting example of a suitable combination silo is a Directed Flow Channel (DFC) mixer commercially available from Columbian TecTank, 5400 Kansas Avenue, Kansas City, KS 66106. Another non-limiting example is the Sprout Waldron (Muncy, PA, USA) 42.475 cubic meter (1500 cu. ft.) batch mixer. At least one combining means, in one aspect, may further comprise at least one bulk bag unloading means 1 configured to permit the direct mixing of a plurality of feed batches in at least one combining silo. In another aspect, at least one bulk bag unloading means may be configured to permit the direct mixing of up to four different feed batches in at least one combining silo. In a further aspect, this direct mixing means may be tailored to enable optimal mixing, if desired. In another aspect, at least one bulk bag unloading means 1 may be a commercially available, conventional bulk bag unloader. In one respect, at least one crystallizer 6 can be a conventional, commercially available crystallizer configured to crystallize virgin PET and / or PET from consumption. In another aspect, the drying medium 8 may comprise a commercially available, conventional drying system configured to dry virgin PET and / or PET from consumption. At least one extruder 9 may comprise an extruder screw and an extruder mixing element 10. One embodiment of the extruder screw is illustrated in Figure 2. In one aspect, the extruder screw 20 may comprise a conventional barrier screw 22 configured such that pressure and / or temperature fluctuations are minimized during the fiber extrusion process. In another aspect, the extruder screw may comprise a barrier fillet 24 inserted in a transition section between the feed zone 26, where the material to be processed is fed into the extruder screw, and a metering zone 28, where the material to be processed is fed into a filtration medium. The barrier fillet may define two channels, a molten polymer channel 30 and a solids channel 32, and may have clearance between a tip of the barrier fillet and a wall of the cylinder containing the screw.This clearance allows virgin PET and / or PET from melted consumer products to pass from the solids channel to the molten polymer channel. An example of such an extruder screw is the commercially available DSB-1 barrier screw from Davis-Standard LLC, #1 Extrusion Drive, Pawcatuck, CT 06379. Suitable models of the DSB-1 include a Moderate Duty Barrier Screw with a 30:1 Length-to-Diameter ratio and deep feed, and a Moderate / Minimum Duty Barrier Screw with a 34:1 L / D ratio. In one respect, compared to extruding virgin PET, extruding a blend of recycled PET and virgin PET may require one or more modifications to the extruder screw feed section, the use of a mixing screw with a barrier fillet, and increased power availability in the extruder drive system. In another respect, an extrusion profile is used that minimizes heat generation along the barrel length (while still ensuring adequate heat input to melt the different variants of recycled PET flakes). The mixing element of the extruder 10 may comprise a conventional mixing unit with checkweighing having at least one hopper mounted adjacent to at least one extruder 9. Two examples of such an extruder mixing element are the commercially available XGGCYUMFFK01 or XLGCYYUMKLXOls mixers from Process Control Corporation. At least one hopper may comprise a mixing means for introducing virgin PET and / or PET from consumption into the extruder screw. At least one filtration medium 12 may comprise a conventional plastic molten polymer filtration unit comprising an automatic back-discharge filtration system qr Lnnn / zznz / E / Yi configured to minimize extruder downtime. In one aspect, at least one filtration medium may be capable of processing at least 453.592 kilograms (1,000 pounds) of PET from hourly consumption per filter. In another aspect, at least one filtration medium preferably may process at least 453.592 kilograms (1,000 pounds) of PET from hourly consumption per filter. For example, about 453.592 kilograms (1,000 pounds) of PET from hourly consumption per filter, about 1,133.981 kilograms (2,500 pounds) of PET from hourly consumption per filter, about 2,267.962 kilograms (5,000 pounds) of PET from hourly consumption per filter, or about 4,535.924 kilograms (10,000 pounds) of PET per hour per filter. In another aspect, at least one filter medium can remove particles as small as approximately 50 microns from the molten stream. However, it is envisaged that at least one filter medium can remove from the molten stream, for example, particles that are approximately 10 microns in size, approximately 25 microns in size, approximately 50 microns in size, or approximately 100 microns in size. An example of a suitable filter medium is a Gneuss RSF60 Rotary Filtration System, which is commercially available from Gneuss Inc., 10820-G, Independence Pointe Parkway, Matthews, NC 28105. At least one spinner may be a conventional spinner comprising at least one molten polymer pump configured to pump virgin PET and / or PET from molten consumer sources to at least one spinner, to produce the fiber. 2. ASSEMBLY AND USEWith reference to Figure 1, a system for processing PET from the consumer can be assembled to comprise any or all of the components described above. In one aspect, at least one bulk bag discharge means 1 can be operatively coupled to the combining means 2, so that a plurality of feed batches can introduce PET from the consumer into the combining means. Optionally, virgin PET can be introduced into the combining means, either alone or in conjunction with the PET from the consumer. In another aspect, the combining means, which can comprise at least one active mixer and / or at least one combining silo 4, at least one crystallizer 6, at least one drying means 8, and at least one extruder 9, can be operatively coupled in series.In this way, virgin PET granules and / or flakes and / or PET from consumer sources can be conveyed from at least one bulk bag unloading device to at least one combining device, from at least one combining device to at least one crystallizer, from at least one crystallizer to at least one drying device, and from at least one drying device to at least one extruder. As can be seen by someone skilled in the art, the granules and / or flakes can be conveyed pneumatically, carried on a conveyor belt, gravity-fed, and / or transported by other means. In another aspect, at least one filtration medium 12 can be attached to at least one extruder to filter contaminants from the molten stream, before it enters the spinneret for fiber production. qr Lnnn / zznz / B / Yi As can also be seen by an expert in the technique, the components that process virgin PET and / or PET from molten consumer use can be in fluid communication with each other, for example, through at least one tube. In its use, in one aspect, PET granules and / or flakes from consumer products in bulk bags can be discharged by at least one bulk bag discharge means 1 into at least one combining means 2, such as at least one active mixer. In another aspect, at least one active mixer can have an auger for combining the PET granules and / or flakes from consumer products. In another aspect, the PET granules and / or flakes from consumer products can be conveyed from at least one active mixer to at least one combining silo 4.5 until a homogeneous mixture of PET from consumer products is formed in the silo. In yet another aspect, the PET granules and / or flakes from consumer products can be diverted to a plurality of combining silos 4.5 so that a greater quantity of material can be processed at any given time.On another note, the amount of time required for a homogeneous mix to occur can vary depending on the model of active mixer and / or mixing silo used, and this information can be provided by the respective equipment manufacturer. In some cases, a homogeneous mix can be achieved in approximately 2 hours. In others, it can take approximately 36 hours. And in still others, it can take approximately 48 hours. In one aspect, to test the homogeneity of a blend, a known quantity of PET of a known color can be introduced into at least one active mixer and / or at least one blending silo. A known quantity of an exogenous tracer can also be introduced into at least one active mixer and / or at least one blending silo. The exogenous tracer can be provided with a known property (e.g., color, fluorescence, etc.) that can be easily measured in samples taken from the blend. The PET of known color and the exogenous tracer can be blended together, and the resulting blend can be periodically checked for tracer distribution levels. Blending can continue until the percentage of tracer in a sample is substantially equal to the percentage of tracer in at least one active mixer and / or at least one blending silo. In an additional aspect, the homogenized mixture of consumer PET can then be conveyed to at least one crystallizer 6. The crystallizer manufacturer can provide a temperature and time required to crystallize the consumer PET, which can prevent the consumer PET from sticking together within the system. After crystallization, in yet another aspect, the granules and / or flakes of consumer PET can enter at least one drying medium 8 for moisture removal from the consumer PET. Again, the manufacturer of the respective drying medium can provide a required drying time. Alternatively, a moisture sensor can be used to determine whether the consumer PET is sufficiently dry for further processing. In one aspect, the qr Lnnn / zznz / E / Yi Consumer PET can be dried to a moisture level of approximately 25–200 ppm. Alternatively, consumer PET can be dried to a moisture level of approximately 50–100 ppm. The residence time of consumer PET in the drying medium can be at least five hours. Furthermore, the dew point in the drying medium can be -28.889°C (-20°F). In an additional aspect, upon exiting at least one drying medium, the PET granules and / or flakes from the consumer may enter at least one hopper of the extruder's mixing element, 9. At this point, in one aspect, virgin PET may also be added to another hopper of the extruder's mixing element. At least one hopper may feed the mixed consumer PET and virgin PET to the extruder in the desired mixing ratio, following the instructions of the extruder's mixing element manufacturer.In another aspect, the percentage of PET from consumption, present in the mixture of PET from consumption and virgin PET that is fed to the extruder, can be at least around 5%, at least around 10%, at least around 15%, at least around 20%, at least around 25%, at least around 30%, at least around 35%, at least around 40%, at least around 45%, at least around 50%, at least around 55%, at least around 60%, at least around 65%, at least around 70%, at least around 75%, at least around 80%, at least around 85%, at least around 90%, or at least around 95% by weight of PET from consumption.On another note, the percentage of PET from consumption, present in the mixture of PET from consumption and virgin PET that is fed to the extruder, can be up to around 5%, up to around 10%, up to around 15%, up to around 20%, up to around 25%, up to around 30%, up to around 35%, up to around 40%, up to around 45%, up to around 50%, up to around 55%, up to around 60%, up to around 65%, up to around 70%, up to around 75%, up to around 80%, up to around 85%, up to around 90%, or up to around 95% by weight of PET from consumption. In one aspect, the virgin PET / PET blend from the consumer can enter the feed zone 26 of the barrier screw 22 of at least one extruder 9. The barrier screw can rotate, propelling the blend into a barrier zone, where the virgin PET / PET blend from the consumer can be melted into a liquid that can enter the molten polymer channel 30 of the barrier screw. The molten blend can then be propelled into the metering zone 28 of the barrier screw, configured to feed the molten blend, at an appropriate pressure, to at least one filtration medium. In one aspect, the extruder profile of at least one extruder can be adjusted to temperatures between approximately 250-350°C. In another aspect, the extruder profile can be adjusted to temperatures between approximately 280-305°C. In yet another aspect, the extruder profile can be adjusted to produce a melting temperature between approximately 275-325°C at the extruder end. And in yet another aspect, the extruder profile can be adjusted to produce a melting temperature between approximately 285-300°C at the extruder end. In one respect, the extruder control pressure can be adjusted to a pressure that provides an adequate supply of polymer to the metering pumps of the spinneret with at least one row. In another respect, injection pressure variations related to the filtration equipment must be kept below 2,500 kPa (25 bar) to minimize variations in the temperature of the molten polymer. In another aspect, the filter medium can remove any unmelted particles and / or other contaminants from the molten smelt. This can, in one way, help prevent weak spots from forming in the fiber. The filtered molten smelt can then be fed into the spinneret, where it is forced through a die to form a fiber. The fiber can then be cooled and wound onto a reel for further processing. In one respect, at least one spinneret may have a polymer spinning pump speed that varies less than 5% from the target setting along the line. In another respect, at least one spinneret may have a polymer spinning pump speed that varies less than 1% from the target setting along the line. In another respect, the texturizing system spin speeds of at least one spinneret may be controlled to + / - 4 m / min, and the texturizing system spin temperatures may be controlled to be within + / - 4°C. In another respect, the texturizing system spin speeds of at least one spinneret may be controlled to + / - 2 m / min, and the texturizing system spin temperatures may be controlled to be within + / - 2°C. In yet another respect, the yarn draw ratio of at least one spinneret may be between 3.0 and 5.5.In one aspect, the yarn draw ratio of at least one spinneret may be between 3.7 and 4.4. In one aspect, the texturizer jet pressures and temperatures of at least one spinneret may be controlled within a range of + / - 4°C and less than 100 kPa (1.0 bar). In another aspect, the texturizer jet pressures and temperatures of at least one spinneret may be controlled within a range of + / - 2°C and less than 50 kPa (0.5 bar). The system and steering pressure may be controlled to be within a range of 100 kPa (1.0 bar), according to one aspect. In another aspect, the system and steering pressure may be controlled to be within a range of 50 kPa (0.5 bar). In one aspect, the fiber formed from the virgin PET / consumer PET blend, referred to as individual yarns, can be processed, for example, into yarn by stranding, as is commonly known in the techniques. In another aspect, the individual yarns produced can be wound to a tension of approximately 100-300 grams. In another aspect, finishing oil can be added as a weight percentage of approximately 1.0-1.5%. In yet another aspect, substantially all the individual yarns of the stranded yarn can be formed from the virgin PET / consumer PET blend. In another aspect, at least one of the individual yarns of the stranded yarn can be formed from the virgin PET / consumer PET blend. In yet another aspect, any number of individual yarns of the stranded yarn can be formed from the virgin PET / consumer PET blend. In one respect, the braided yarn containing at least one individual yarn produced from the virgin PET / consumer PET blend can be woven into a carpet, as is also commonly known in the techniques. In another respect, substantially all of the braided yarn in the carpet can be formed from individual yarns formed from the virgin PET / consumer PET blend. In yet another respect, at least one of the braided yarns in the carpet can be formed from individual yarns formed from the virgin PET / consumer PET blend. In yet another respect, any number of the braided yarns in the carpet can be formed from individual yarns formed from the virgin PET / consumer PET blend. 3. SELECTION OF RAW MATERIALS In one respect, consumer PET collected from curbside deposits may be selected so that it meets or exceeds at least one of the following specifications: Bulk density (kg / m3 (lb / ft3)) of 320.4-432.54 (20-27); Moisture content (%) of < 1.0%; Floating contamination (ppm) of <25; PVC contamination (ppm) of <150; Metal contamination (ppm) of <10; Other non-melted particles (ppm) of < 50; Green PET contamination (ppm) of < 5000; Light blue contamination (ppm) of < 75,000; Low melting point material (PETG) (ppm) of < 50; Black PET (ppm) of <50; Pressure increase (kPa per kilogram (psi per pound)) of < 1139 kPa / kg (75 psi / lb); b color values, when measured by a HunterLabs Spectrophotometer, of 0-3 units, and / or L color values, when measured by a HunterLabs Spectrophotometer, of more than 50 units. 4. COMBINATION In one aspect, the disclosed processes may include a blending stage to homogenize the feed profile of PET from the consumer to the extruder. For example, at least one blending silo may comprise a recirculation line to recirculate, and thus blend, PET from the consumer. In another example, at least one blending silo may comprise multiple flow channels to aid in blending PET from the consumer. The blending stage, in one aspect, may reduce particle size variation, color variation, copolymer content, and contamination to provide a more homogeneous feed of PET from the consumer to the extruder. In another aspect, the blending stage may comprise blending the PET from the consumer in the blending silo until a desired level of homogenization is achieved.In another aspect, the blending stage may involve combining the PET from consumption in the blending silo for a specific period of time to homogenize the mixture. For example, 2 hours, 4 hours, 8 hours, 12 hours, 16 hours, 24 hours, 36 hours, or 72 hours. qr Lnnn / zznz / E / Yi 5. CRYSTALLIZATION In one aspect, the disclosed process may include a crystallization step. For example, PET granules and / or flakes from consumer products may be heated to an elevated temperature while being constantly stirred and / or agitated for a period of time. In another aspect, the crystallization step may take place in a crystallizer, which comprises a heated vessel with a series of paddles or agitators. In other aspects, the crystallization step may take place in a crystallizer comprising a heated fluidized bed to keep the granules and / or flakes separated. Crystallization may be achieved using commercially available equipment known to those skilled in the art. 6. DRYING In one respect, the disclosed processes may include a drying stage. For example, consumer PET granules and / or flakes may be dried in a conventional PET dryer. In another respect, the consumer PET granules and / or flakes may be dried to a specific moisture level. In a further respect, the consumer PET granules and / or flakes may be dried for a period of time. The drying may be carried out, for example, to achieve a moisture level of less than approximately 5%, less than approximately 4%, less than approximately 3%, less than approximately 2%, less than approximately 1%, less than approximately 0.5%, less than approximately 0.25%, less than approximately 1000 ppm, less than approximately 500 ppm, or less than approximately 100 ppm. In a further respect, the moisture levels may be reduced from approximately 50 ppm to approximately 100 ppm.In an additional aspect, humidity levels can be reduced to a level sufficient to minimize or eliminate the effect of humidity during subsequent processing stages. 7. MIXING In one respect, the processes disclosed may include a mixing stage. For example, PET granules and / or flakes from consumer sources may be mixed with virgin PET granules and / or flakes to create a consumer PET / virgin PET blend. In one respect, the percentage of PET from consumption in the mix can be at least around 5%, at least around 10%, at least around 15%, at least around 20%, at least around 25%, at least around 30%, at least around 35%, at least around 40%, at least around 45%, at least around 50%, at least around 55%, at least around 60%, at least around 65%, at least around 70%, at least around 75%, at least around 80%, at least around 85%, at least around 90%, or at least around 95% by weight of PET from consumption.In another aspect, the percentage of PET from consumption present in the mixture of PET from consumption and / or virgin PET that is fed to the extruder can be up to around 5%, up to around 10%, up to around 15%, up to around 20%, up to around 25%, up to around 30%, up to around 35%, up to around 40%, up to around 45%, up to around 50%, up to around 55%, up to around 60%, up to around 65%, up to around 70%, up to around 75%, up to around 80%, up to around 85%, up to around 90%, or up to around 95% by weight of PET from consumption. In a further aspect, the mixing stage may occur in a mixer. In one aspect, the mixer may be a mixing element of the extruder comprising at least one hopper, which feeds the extrusion medium. At least one hopper may comprise a mixing means for introducing virgin PET and / or PET from consumption into the extruder screw in a specified ratio. In a further aspect, the mixer may be a mixing means within the extruder. The mixing element of the extruder 10 may comprise a conventional mixing unit with checkweighing having at least one hopper mounted adjacent to at least one extruder 9. Two examples of such an extruder mixing element are the commercially available XGGCYUMFFK01 or XLGCYYUMKLX01 mixers from Process Control Corporation. At least one hopper may comprise a mixing means for introducing virgin PET and / or PET from consumption into the extruder screw. 8. EXTRUSION In one respect, the processes disclosed may include an extrusion stage. For example, a blend of recycled PET and virgin PET may be extruded to produce fiber. In one respect, the extrusion stage may take place in an extruder comprising a screw (e.g., a barrier screw), a filter medium, and / or a die. Extrusion may be achieved using commercially available equipment familiar to those skilled in the field. 9. ADDITIVES In one respect, the disclosed processes may include the addition of additives to the combination of recycled PET and / or the blend of recycled PET and virgin PET. By way of example, and without limitation, additives may include dyes, colorants, UV absorbers, plasticizers, opacifiers, nucleating agents, brighteners, thinners, and / or fillers. Additives may be added, for example, at the same time as blending. E. EXPERIMENTAL PART The following examples are intended to provide those skilled in the art with a complete disclosure and description of how the compounds, compositions, articles, devices, and / or methods claimed herein are prepared and evaluated. They are intended to be purely illustrative of the invention and are not intended to limit the scope of what the inventors consider to be their invention. Every effort has been made to ensure accuracy with respect to numbers (e.g., quantities, temperature, etc.), but some errors and deviations should be expected. Unless otherwise stated, parts are parts by weight, temperature is in °C or ambient temperature, and pressure is at or near atmospheric pressure. In the examples presented, the braiding and heat-hardening, tufting, and dyeing and finishing processes were performed to the same specifications, regardless of the percentage of PET sourced from consumption being processed. Thus, all samples of PET sourced from consumption were processed under the same specifications for braiding and heat-hardening, tufting, and dyeing and finishing as the 100% virgin PET control. Although these conditions were used to produce the compositions and articles presented, it is understood that, unless otherwise stated, these conditions are not limiting and may be modified to meet other manufacturing requirements. 1. PREPARATION OF YARN AND CARPET FROM FIBER FORMED FROM FLAKES, COLLECTED FROM DEPOSITS ON SIDEWALKS, OF CONSUMER PET The fiber containing 50% consumer PET, 65% consumer PET, 85% consumer PET, and 100% RPET was formed, as described above, from curbside collection-grade flakes. As illustrated in Table 1, tests were conducted with uncombined (i.e., unhomogenized) flakes collected from curbside deposits from two suppliers. The tests were repeated with co-blended flakes collected from curbside deposits from the two suppliers. All tests were successfully processed with no significant differences in performance or product physical characteristics, except for a change in color in the compositions (e.g., fibers) produced from the curbside collection flakes. The results of the experiments, compared to a control lot containing 0% consumer PET, are illustrated in Tables 2-8. qr Lnnn / zznz / E / Yi Table 1: Description of the qr tests Lnnn / zznz / E / Yi Test # Raw Material Supplier # RPET Insertion Rate Mixed 1 Flake collected from sidewalk deposits C1 50% No 2 Flake collected from sidewalk deposits C1 65% No 3 Flake collected from sidewalk deposits C1 85% No 4 Flake collected from sidewalk deposits C1 100% No 5 Flake collected from sidewalk deposits C2 50% No 6 Flake collected from sidewalk deposits 02 65% No 7 Flake collected from sidewalk deposits C2 85% No 8 Flake collected from sidewalk deposits 02 100% No 9 Flake collected from sidewalk deposits 01 / 02 50% Yes 10 Flake collected from sidewalk deposits 01 / 02 65% Yes 11 Flake collected from sidewalk deposits 01 / 02 85% If 12 Scale collected from deposits on sidewalks 01 / 02 100% If Control 0% N / A This fiber was processed into yarn, as is commonly known in the techniques, and compared to a sample of yarn containing 0% consumer-sourced PET. The results of this comparison are tabulated in Tables 2, 3, 4, and 5. Yarn produced from fiber containing 50%, 65%, 85%, and 100% consumer-sourced PET was woven into a carpet and compared to a sample of carpet containing 0% consumer-sourced PET. The resulting comparison is illustrated in Tables 6–8. The test results for the individual yarns formed are illustrated in Table 2. Denier, Yarn Finish (“FOY”), Modification Ratio (“MR”), Peak Load Tenacity, Peak Load Elongation, Knots per Meter, Crimp, Volume, and Solution Viscosity IV are conventional industrial measurements used to define a yarn. As can be seen by someone skilled in the techniques, and as illustrated in Table 2, there was no significant difference observed between the control sample and the consumer PET samples with respect to these physical properties. However, drying times and / or temperatures were adjusted to minimize any impact that the increasing content of consumer PET flakes (for both blended and unblended samples) might have on the Modification Ratio and VI. Yarn color was measured using a HunterLabs Spectrophotometer.As illustrated in Table 2, as the percentage of PET from consumption in the yarn increased, the Db also increased, indicating that the yarn became more yellow as the percentage of PET from consumption increased. Note also that the standard deviation of Db for blended yarn was lower than for the unblended samples. The average Db standard deviation of yarn formed from uncombined flakes, collected from sidewalk deposits, supplied by the first supplier (Tests 1-4) was 0.28, and the average Db standard deviation of yarn formed from uncombined flakes, collected from sidewalk deposits, supplied by the second supplier (Tests 5-8) was 0.20. The average Db standard deviation of yarn formed from flakes collected from sidewalk deposits, supplied by the first and second suppliers, and mixed together (Tests 9-12) was 0.17. qr Lnnn / zznz / E / Yi Table 2: Data in % of individual threads of PET flakes from sidewalk deposits originating from consumption Desv. Est. Db 0.13 0.37 0.17 co 0.12 gold 0 23 0.37 0.15 0.15 0.21 0.16 Db 0.71 1.34 2.60 3.17 0.54 0.48 frg 0 2.01 0.8 1.18 2.24 1.90 Viscosity Sol. IV 0.6305 0.6677 0.6534 CJ oo oo Ώ 3689 0 0.6513 6Δ99Ό 0.6641 0.6782 so 0069Ό 0.6812 % Volumen 29.7 30.1 34.6 34.7 31.5 32.5 34 33.9 32.2 30.8 29.3 29.7 23.6 % Rizado 10.3 10.3 10.3 10.9 10.6 9.56 10.6 10.6 9.72 9.90 9.18 9.39 9.22 Nodos / m cQ 25 27 Cb cQ 'O 25 27 25 Cb Cb 25 Elong Prom 42.825 42.65 41.475 % Elong 39.4 Γ-Ί 45.3 44 44.4 44.3 39.2 42.7 43.3 45.5 36.4 40.7 37.8 Tenacidad Prom 2.1125 2.2425 2.2975 Tenacity (g / d) 1.95 2.17 2.23 2.20 2.44 2.15 2.18 2.28 2.33 2.28 2.30 2.48 MR JO 2.91 r-··] oo 2.79 2.64 2.78 2.69 2.72 2.75 2.91 2.84 OO oo 2.78 FOY % OWF 1.42 1.41 1.42 1.49 1.39 1.32 1.26 1.24 1.42 1.41 1.34 1.35 1.38 Demer so CJ 1265 1258 £1246 1269 1264 1259 1248 1247 1243 1260 1252 Prueba # 1 rj OI k-ί so O OO Cb 1 CJ Control qr Lnnn / zznz / E / YiAi Individual filaments were removed from the individual yarns and tested. These results are illustrated in Table 3. Excluded pulls were excluded from the tests because these filaments had a tenacity and / or elongation less than 20% of the average, according to ASTM standards. These samples illustrate that there were average improvements in tenacity, elongation, and their standard deviations with the combined samples. Additionally, the combined sample had a lower number of excluded pulls. Increasing levels of PET flakes from consumer sources, although impacting color, did not have a significant impact on tenacity and elongation, particularly for the combined samples, and combining the flakes resulted in less variability in molecular composition. The standard deviation of the average elongation of the yarn formed from uncombined flakes, collected from sidewalk deposits, supplied by the first supplier (Tests 1-4) was 11.42, and the standard deviation of the average tenacity of this yarn was 0.777. The standard deviation of the average elongation of the yarn formed from uncombined flakes, collected from sidewalk deposits, supplied by the second supplier (Tests 5-8) was 10.58, and the standard deviation of the average tenacity of this yarn was 0.629. The standard deviation of the average elongation of the yarn formed from flakes collected from sidewalk deposits, supplied by the first and second suppliers, and mixed together (Tests 9-12) was 7.79, and the standard deviation of the average tenacity of the yarn formed from these flakes was 0.423. qr Lnnn / zznz / E / Yi Table 3: % of individual PET flake filaments from consumer waste collected from sidewalk deposits qr Lnnn / zznz / E / Yi Test # Tenacity Excl. Tenacity @ Break (g / dn) Std. Dev. of Tenacity Elongation @ Break Dev. Est. of Elongation 1 7 2.540 0.723 31.580 11.344 2 4 2.688 0.850 32.873 11.437 3 N / A 4 5 2.064 0.759 25.999 11.472 5 0 3.233 0.286 36.844 7.813 6 2 3.023 0.596 34.827 8.109 7 7 2.545 0.749 32.092 12.650 8 7 2.562 0.884 34.616 13.731 9 0 3.200 0.342 40.612 6.974 10 4 3.001 0.346 41.116 7.972 11 5 2.472 0.625 31.987 9.679 12 1 3.186 0.380 36.866 6.533 Control 0 3.160 0.427 36,363 7,730 The individual yarns were each braided with at least one other similar yarn (i.e., if a yarn was made from 50% PET sourced from Supplier 1, it was braided with at least one other yarn made from 50% PET sourced from Supplier 1) and heat-hardened, as is commonly known in the techniques, and compared to a sample of braided yarn containing 0% PET sourced from Supplier 1. The results of this comparison are tabulated in Tables 4 and 5. As can be seen by someone skilled in the technique, and as illustrated in Table 4, there were color differences between the samples, with the combined samples (test numbers 8-12) having less average variation in b* (blue / yellow) and Db* (blue / yellow) in the heat-hardened samples from the beginning and end of the heat-hardening operation, when measured by a HunterLabs Spectrophotometer. Also, the average b* and Db* values ​​for the combined samples were between those of the uncombined C1 and C2 samples. The positive impact of combining the samples is shown in the reduced color variation for the samples from the beginning and end of each test and in the average color of the different flakes supplied. The average b* value of the yarn formed from uncombined flakes, collected from sidewalk deposits, supplied by the first supplier (Tests 1-4) was 3.31, and the average Db* value of this yarn was 1.95. The average b* value of the yarn formed from uncombined flakes, collected from sidewalk deposits, supplied by the second supplier (Tests 5-8) was 2.43, and the average Db* value of this yarn was 1.06. The average b* value of the yarn formed from flakes collected from sidewalk deposits, supplied by the first and second suppliers, and mixed together (Tests 9-12) was 3.16, and the average Db* value of the yarn formed from these flakes was 1.79. There was an average b* difference of 0.36 and an average Db* difference of 0.47 for the yarn made from uncombined flakes collected from sidewalk deposits supplied by the first and second suppliers (Tests 1-8). This average b* difference decreased to 0.22 and the average Db* difference decreased to 0.38 when the yarn was formed from flakes collected from sidewalk deposits supplied by the first and second suppliers and blended together (Tests 9-12). The reduction in color variation for the beginning and end samples of each test, and the average of contaminants and copolymer content of the different supplied flakes, makes the yarn less variable over time with changes in sources. qr Lnnn / zznz / E / Yi Table 4: % Color of heat-hardened yarn from PET flakes collected from curbside deposits originating from consumption qr Lnnn / zznz / E / Yi Test # Position b* Avg. b* Diff. b* start and finish Db* Avg. Db* Diff. Db* start and finish 1 Start HS 1.69 0.16 1 Finish HS 2.00 1.85 0.31 0.80 0.48 0.64 2 Start HS 2.22 0.68 2 Finish HS 2.64 2.43 0.42 1.44 1.06 0.76 3 Start HS 4.43 2.89 3 Finish HS 4.08 4.26 0.35 2.88 2.89 0.01 4 Start HS 4.36 2.83 5 Finish HS 5.09 4.73 0.73 3.89 3.36 1.06 5 Start HS 1.87 0.33 5 End HS 1.82 1.85 0.05 0.61 0.47 0.28 6 Start HS 1.44 -0.10 6 End HS 1.34 1.39 0.10 0.13 0.02 0.23 7 Start HS 3.07 1.54 7 End HS 2.23 2.65 0.84 1.03 1.29 0.51 8 Start HS 3.85 2.32 8 End HS 3.79 3.82 0.06 2.59 2.46 0.27 9 Start HS 2.13 0.59 9 End HS 2.28 2.21 0.15 1.07 0.83 0.48 10 Start HS 2.66 1.12 10 End HS 3.04 2.85 0.38 1.83 1.48 0.71 11 Start HS 3.98 2.45 11 End HS 3.90 3.94 0.08 2.70 2.58 0.25 12 Start HS 3.78 2.24 12 End HS 3.51 3.65 0.27 2.31 2.28 0.07 Control 0.00 0.00 Table 5 illustrates the average tenacity and elongation of the heat-hardened yarns. As can be seen, the yarns formed from combined consumer PET flakes collected from curbside deposits had improved tenacity and elongation compared to similar uncombined yarns. As can be seen by someone skilled in the techniques, the average tenacity and elongation for all samples was only marginally lower than the control and has no impact on the carpet formed from them. Table 5: Tenacity and elongation of heat-hardened yarns from PET flakes collected from sidewalk deposits originating from consumption qr Lnnn / zznz / E / Yi Test # Avg. HS Tenacity Avg. HS Elongation 1 2.483 48.888 2 2.544 44.015 3 2.535 51.351 4 2.455 44.307 5 2.572 44.087 6 2.520 46.110 7 2.461 50.394 8 2.444 49.361 9 2.600 48.291 10 2.545 51.828 11 2.537 53.664 12 2.516 48.999 Control 2.623 56.249 The yarn produced from the tests was woven into carpets and compared to a carpet sample containing 0% consumer PET. For example, Carpet Test 1 was produced only from yarn made of 50% consumer PET flakes collected from curbside deposits, which were not blended to homogenization. Carpet Test 12 was produced only from yarn made of 100% consumer PET flakes collected from curbside deposits, supplied by two vendors and blended together. Each carpet was tested against a control containing 0% consumer-collected curbside flakes. Tables 6–8 tabulate the results. Table 6 illustrates that there were no significant differences between the combined samples, the uncombined samples, and the control with respect to stain resistance. In each test, various industry-standard colorants, such as mustard, coffee, red wine, Red #40, and povidone-iodine, were applied to the samples. A score between 1 and 10 was given to each sample to indicate the carpets' resistance to the colorants. Table 6: Test data on flake carpets collected from sidewalk deposits of PET from consumption qr Lnnn / zznz / E / Yi Test # Red 40 Mustard Povidone-iodine Coffee Red wine 1 10.0 10.0 9.0 10.0 10.0 2 10.0 10.0 10.0 10.0 10.0 3 10.0 10.0 10.0 10.0 10.0 4 10.0 10.0 9.0 10.0 10.0 5 10.0 10.0 10.0 10.0 10.0 6 10.0 10.0 9.0 10.0 10.0 7 10.0 10.0 9.0 10.0 10.0 8 10.0 10.0 9.0 10.0 10.0 9 10.0 10.0 9.0 10.0 10.0 10 10.0 10.0 9.0 10.0 10.0 11 10.0 10.0 9.0 10.0 10.0 12 10.0 10.0 8.0 10.0 10.0 Control 10.0 10.0 9.0 10.0 10.0 As shown in Table 7, the carpets were evaluated using a variety of conventional industrial tests. Xenon, Ozone, Stain Removal, and NOx are conventional tests related to color, measured on a scale of 1 to 5, with 5 representing an invisible change from the control and 3 representing a transient change. DE (CMC) and Gray Scale are conventional measures of a carpet's soil resistance. Hexapod is a conventional measure of carpet wearability, while the Pili test is a conventional measure of flammability. As can be seen in Table 7, there were no significant differences between the blended samples, the unblended samples, and the control with respect to these tests. Stitching, pile height, and pile weight are conventional industry measurements of carpet construction. As illustrated in Table 8, there were no significant differences among the blended samples, unblended samples, and control with respect to carpet construction. Grain, tips, hand, and finish are conventional industry measurements of carpet appearance. Although all carpet samples containing consumer PET were rated inferior to the control for grain, carpets made from blended samples had less grain than those made from unblended samples. Overall, carpets containing consumer PET had better hand, less texture, and were coarser as the percentage of PET increased.However, based on improvements in yarn color homogeneity in extruded quality and improved yarn grain indices, the overall process and system components were shown to be effective. Table 7: Test data on carpet flakes of PET deposits on sidewalks from consumption Prueba Pili oo M oo DO OO M oo M oo M OO M 8 ¡ 8 8 / 8 8 / 8 oo Μ 8 / 8 oo M 8 / 8 * O Q. tí XOX tí '2 'u tí OS o Cu Γ-J en en en OO c^i CJ en σ·. CN CD ΓΜ co O·. C^í Γ-] oo 'o '= oo rj =1 M CJ OO Cd <=i oo c--i co cd =1 CZi OO c--i CD <D •o 5 en en en en en OO Γ-J en en 1=1 en 1=1 en ι=ι en 1= en i= en en en cz O * g u z CO en en en i= en i= en en =i ι= i= i= CZ * O Q । o N | (Μ O l en Wl 1=1 Mn en en 1= 1= 1= Mn * o 3 tí -tí O tí s <z¡ O Q o o 1 O & vr o *3 <D g K <=i CD CD CD =1 <=i <=i CZI CZI CZI CZi <=i CD CZ 44 2 c O Ό § X CD CD CD CD = <=i CD en co = = = Suciedad Acelerada (Z 1) <Z ó CJ O tí tí o z w * tí ‘οα CD CD = -r -r = = = = = = CD * tí ‘o tí UQ en O CD en en en CZi CZI CD co co co CD θ' 2 o, uí Q tí ü <i oo ό o r-j 1 l cg oo ch ti θ', os i>O C--J s tí 'o tí UQ Ch co l 1 ÚO r·-] OX en l——1 Cd rj cd en c--i M C--J οχ Ό Γ-] Cd 1= Ox tí 43 O tí CU —-H Γ-J en kí-Ί Ό Γ- OO οχ co '—1 CJ c T® qa Lnnn / zznz / E / YiAi Table 8: Construction data and removal of deposits in PET containers coming from consumption Plush Weight (kg(oz)) 1.236 (43.61) 1.236 (43.60) 1.243 (43.85) 1.242 (43.82) 1.243 (43.86) 1.245 (43.90) 1.239 (43.70) 1.237 (43.63) 1.241 (43.76) 1.241 (43.78) 1.244(43.87) 1.239(43.70) 1.246 (43.95) Seam 2 62.5 62.5 Ό 62.5 in rj G 62 64 G in 62 Plush Height (cm(in)) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) 2.46 (31 / 32) Average Finish 5.75 5.88 6.00 Finish 6.00 5.75 5.75 5.50 in in '•O '•O 5.50 5.50 6.42 5.92 6.00 £ 7.00 Average Tips 6.19 6.19 6.15 Tips 6.33 6.17 6.17 6.08 6.50 ej] '•O 6.00 5.83 6.50 '•O 6.17 5.75 7.00 Hand Avg 6.19 6.27 6.10 Hand 6.42 o 6.08 6.08 6.25 6.17 6.08 6.08 5.83 5.92 7.00 Vein Avg 00 9 6.00 co Vein in Plush 5.50 6.50 6.50 5.50 6.00 6.50 6.00 5.50 6.50 6.50 6.00 7.00 Test # 1 eJ in Γ- oo Ch '—1 Γ-] Control qr Lnnn / zznz / E / YiAi In other experiments, fiber containing 25% consumer PET, as described above, was formed from flakes collected from curbside deposits. The flake batch was premixed and precrystallized and dried on a fiber line. The test was successfully processed with no significant differences in performance or product physical characteristics, except for a change in color (approximately 1.5 units of yellow). The results of the experiment, compared to a control batch containing 0% consumer PET, are illustrated in Tables 9 and 10. The color was stable throughout the batch of 25% consumer PET flakes collected from curbside deposits. Table 9: Data on flake threads collected from PET deposits on sidewalks originating from consumption qr Lnnn / zznz / E / Yi Lot Denier Tenacity Elongation NPM Volume FOY 0% PET from consumption 1255 2.20 41.26 24.69 9.7 1.29 25% PET flakes collected from curbside deposits from consumption 1258 2.23 44.56 1.14 Table 10: Color data of flakes collected from sidewalk deposits of PET from consumption Lot DL Da Db DE 0% PET from consumption .0133 .035 -.23 .3267 25% PET flakes collected from curbside deposits from consumption -.5325 -.310 1.5425 2.2313 The batch of 25% consumer-grade PET flakes, collected from curbside dumps, was processed with little to no variation in physical properties compared to the standard, except for color, as noted above. As expected by someone skilled in the art, the curbside flakes required increased backflushing of the filter medium due to the additional contaminants present in the curbside-grade material. In this experiment, the initial pressure across the filter medium with new (clean) sieves in place was 17,500 kPa (175 bar). The backflushing pressure was set to 18,500 kPa (185 bar). With this setup, the curbside flakes were backflushed approximately every two hours. 2. DISCUSSION OF RESULTS As can be seen in the tables above, which reflect the tests performed on yarn and fiber carpet made from PET flakes collected from sidewalk litter, the combined PET flakes performed better as a control than the uncombined flakes. Furthermore, the combined PET flakes from multiple sources performed better as a control than the uncombined flakes. It is understood that blending PET flakes sourced from consumer sources reduces the percentage of any impurities in a given sample of those flakes. For example, if a first batch of PET flakes sourced from a supplier has light blue contamination, it is still within specifications. However, a second batch of PET flakes sourced from a different supplier is unlikely to have the same level of light blue contamination, and the blended product will have some degree of light blue contamination between the two batches. In this way, the blended product will have an improved level of light blue contamination compared to the first batch. In one respect, it is considered that if suppliers of PET flakes sourced from consumer use are geographically separated, then it is more likely that the flakes will have different contaminant and copolymer content depending on the bottle source and their respective bottle cleaning technologies. Also, producers of virgin PET resin, used to manufacture bottles, have their own specific PET formulations. Therefore, after combining flakes from geographically separated suppliers, any contaminants and copolymer differences present may occur in a more uniform and / or smaller percentage than in an uncombined batch from a single supplier. In another aspect, having contaminants present in a more uniform and / or smaller percentage will produce a more consistent fiber. This fiber, in turn, can be used to produce more consistent articles from it, such as, for example, and without limitation, carpeting. Thus, in one aspect, the invention relates to a polymer mixture comprising polyethylene terephthalate, present as up to about 100% by weight of homogeneous polyethylene terephthalate from consumption, collected from sidewalk deposits, and equilibrium virgin polyethylene terephthalate, wherein the polyethylene terephthalate materials from consumption, collected from sidewalk deposits, are supplied by two or more suppliers. It will be apparent to those skilled in the art that various modifications and variations may be made to the present invention without departing from the scope or spirit of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. The specification and examples are intended to be considered as illustrative only, with the true scope and spirit of the invention being indicated by the following claims.

Claims

1. An extruded polymer composition consisting essentially of a polyethylene terephthalate polymer composition, wherein the polyethylene terephthalate polymer composition has more than 10% by weight to approximately 100% by weight of homogenized polyethylene terephthalate from collected curbside deposit consumption and equilibrium virgin polyethylene terephthalate.

2. The composition according to claim 1, wherein the polyethylene terephthalate polymer composition has at least approximately 25% by weight of polyethylene terephthalate from homogenized curbside waste collected.

3. The composition according to claim 1, wherein the polyethylene terephthalate polymer composition has at least approximately 50% by weight of polyethylene terephthalate from homogenized curbside waste collected.

4. The composition according to claim 1, wherein the homogenized polyethylene terephthalate from collected sidewalk waste comprises at least one impurity absent in virgin polyethylene terephthalate.

5. The composition according to claim 4, wherein the at least one impurity comprises floating contamination in an amount less than 25 ppm, PVC contamination in an amount less than 150 ppm, or a combination thereof.

6. A polymer blend consisting essentially of a polyethylene terephthalate polymer composition, wherein the polyethylene terephthalate polymer composition has more than 10% by weight to approximately 100% by weight of homogenized polyethylene terephthalate from collected curbside deposit consumption and equilibrium virgin polyethylene terephthalate.

7. The mixture according to claim 6, wherein the polyethylene terephthalate polymer composition has at least approximately 25% by weight of homogenized polyethylene terephthalate from collected curbside waste.

8. The mixture according to claim 6, wherein the polyethylene terephthalate polymer composition has at least approximately 50% by weight of homogenized polyethylene terephthalate from collected consumption from curbside deposits.

9. The mixture according to claim 6, wherein the homogenized polyethylene terephthalate from consumption collected from sidewalk deposits comprises at least one impurity absent in virgin polyethylene terephthalate.

10. The mixture according to claim 9, wherein the at least one impurity comprises floating contamination in an amount less than 25 ppm, PVC contamination in an amount less than 150 ppm, or a combination thereof.

11. A carpet comprising a fiber consisting essentially of a polyethylene terephthalate polymer composition, wherein the polyethylene terephthalate polymer composition qr Lnnn / zznz / B / Yi has greater than 10% by weight to approximately 100% by weight of consumption polyethylene terephthalate collected from homogenized sidewalk deposits and balance virgin polyethylene terephthalate.

12. The carpet according to claim 12, wherein the polyethylene terephthalate polymer composition has at least approximately 25% by weight of polyethylene terephthalate from homogenized sidewalk waste collected from deposits.

13. The carpet according to claim 12, wherein the polyethylene terephthalate polymer composition has at least approximately 50% by weight of polyethylene terephthalate derived from homogenized collected sidewalk waste. 10 14. The folder according to claim 12, wherein the homogenized polyethylene terephthalate derived from collected sidewalk waste comprises at least one impurity absent in virgin polyethylene terephthalate.

15. The carpet according to claim 15, wherein the at least one impurity comprises airborne contamination in an amount less than 25 ppm, PVC contamination in an amount less than 150 ppm, or a combination thereof.

16. The carpet according to claim 16, wherein the waste polyethylene terephthalate exhibits an apparent density in the range of 320.4-432.54kg / m3 (20-27 lb / ft3); a moisture content of less than 1.0% and a pressure rise of less than 1139 kPa / kg (75 psi / lb).