A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 25 millibars, or another predetermined pressure. The streams are recombined into a single polymer stream. Polymer from the polymer stream is then formed into bulked continuous carpet filament.

A method of manufacturing bulked continuous carpet filament from recycled polymer. In various embodiments, the method includes: (1) reducing recycled polymer material into polymer flakes; (2) cleansing the polymer flakes; (3) melting the flakes into a polymer melt; (4) removing water and contaminants from the polymer melt by dividing the polymer melt into a plurality of polymer streams and exposing those streams to pressures below 25 millibars or another predetermined pressure; (5) recombining the streams; and (6) using the resulting purified polymer to produce bulked continuous carpet filament.

A method for producing fibers with improved color and anti-microbial properties is described. One embodiment includes a method for generating a halogen stable antimicrobial synthetic fiber, the method comprising creating a mixture that includes a polymer, an anti-microbial agent, and a non-halogen pigment, and extruding the mixture to form an anti-microbial synthetic fiber.

A multifunctional fiber with full-spectrum infrared radiation, flame retardant and antibacterial functions, including a composite masterbatch having a water content of 30-50 ppm and accounting for 10-12% by weight, polyethylene terephthalate having a water content of 25-30 ppm or polycaprolactam high polymer having a water content of 50-70 ppm and accounting for 88-90% by weight; the fiber and its fabric possess multiple functions such as spectral heating, flame retardancy, anti-bacteria and anti-virus; after being illuminated for 5-10 minutes, the temperature difference of the fiber fabric of the present invention is higher than 15-20? C., the far-infrared emissivity is greater than 98%, the radiation temperature rise is greater than 3.0? C., the CLO value is greater than 0.5, the heat transfer coefficient is greater than 18.0w/(m.sup.2k), and the thermal resistance is less than 0.05 (m.sup.2k)/w. The antibacterial rate against Escherichia coli, Staphylococcus aureus, Candida albicans and pneumobacillus is greater than 99.0%.

A multifunctional fiber with full-spectrum infrared radiation, flame retardant and antibacterial functions, including a composite masterbatch having a water content of 30-50 ppm and accounting for 10-12% by weight, polyethylene terephthalate having a water content of 25-30 ppm or polycaprolactam high polymer having a water content of 50-70 ppm and accounting for 88-90% by weight; the fiber and its fabric possess multiple functions such as spectral heating, flame retardancy, anti-bacteria and anti-virus; after being illuminated for 5-10 minutes, the temperature difference of the fiber fabric of the present invention is higher than 15-20? C., the far-infrared emissivity is greater than 98%, the radiation temperature rise is greater than 3.0? C., the CLO value is greater than 0.5, the heat transfer coefficient is greater than 18.0w/(m.sup.2k), and the thermal resistance is less than 0.05 (m.sup.2k)/w. The antibacterial rate against Escherichia coli, Staphylococcus aureus, Candida albicans and pneumobacillus is greater than 99.0%.

The invention discloses a starch-based multi-channel airflow unit and a preparation method and an application thereof. The preparation method of the present invention comprises the following steps: melting a polylactic acid, wherein a temperature of a first temperature control zone is 135 C. to 145 C., a temperature of a second temperature control zone is 175 C. to 185 C., a temperature of a third temperature control zone is 190 C. to 200 C., and a temperature of a fourth temperature control zone is 175 C. to 185 C.; gelatinizing a starch-based material, adding the starch-based material in the third temperature control zone and fully mixing the mixture; adding a polyol in the third temperature control zone, and fully mixing the mixture; and extruding out the mixed material through twin screws, sizing in vacuum, cooling and sizing, and winding and cutting to obtain the starch-based multi-channel airflow unit.

A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 25 millibars, or another predetermined pressure. The streams are recombined into a single polymer stream. Polymer from the polymer stream is then formed into bulked continuous carpet filament.

A method for producing an artificial turf fiber, comprising: preparing a core polymer mixture from a core polymer and a thread polymer forming beads within the core polymer; coextruding the core polymer mixture with a cladding polymer component into a monofilament, the core polymer mixture forming a cylindrical core, The cladding polymer component forming a cladding encompassing the core with a non-circular profile; quenching the monofilament; reheating the quenched monofilament; stretching the reheated monofilament to deform the beads into threadlike regions; and providing one or more of the stretched monofilaments as the artificial turf fiber.

A system comprising: (1) a grinding unit configured to receive and grind recycled PET bottles into a group of polymer flakes comprising up to about ten percent colored polymer flakes and balance substantially clear polymer flakes; (2) a washing unit configured to wash the group of polymer flakes; and (3) an extruder configured to extrude material in a plurality of different extrusion streams. The extruder may be further configured to: (1) receive a concentrate-polymer mixture comprising a mixture of the polymer flakes and a color concentrate; (2) melt the concentrate-polymer mixture to produce a polymer melt; (3) reduce a pressure within the extruder; and (4) pass the polymer melt through the extruder so that the polymer melt is divided into the plurality of extrusion streams. The system may then filter the polymer melt through at least one filter and form the polymer melt into bulked continuous carpet filament.

A system comprising: (1) a grinding unit configured to receive and grind recycled PET bottles into a group of polymer flakes comprising up to about ten percent colored polymer flakes and balance substantially clear polymer flakes; (2) a washing unit configured to wash the group of polymer flakes; and (3) an extruder configured to extrude material in a plurality of different extrusion streams. The extruder may be further configured to: (1) receive a concentrate-polymer mixture comprising a mixture of the polymer flakes and a color concentrate; (2) melt the concentrate-polymer mixture to produce a polymer melt; (3) reduce a pressure within the extruder; and (4) pass the polymer melt through the extruder so that the polymer melt is divided into the plurality of extrusion streams. The system may then filter the polymer melt through at least one filter and form the polymer melt into bulked continuous carpet filament.