A method for manufacturing bulked continuous carpet filament, the method comprising: (1) reducing a chamber pressure within a chamber to below about 5 millibars; (2) after reducing the chamber pressure to below about 5 millibars, providing a polymer melt to the chamber; (3) separating the polymer melt into at least eight streams; (4) while the at least eight streams of the polymer melt are within the chamber, exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars; (5) after exposing the at least eight streams of the polymer melt to the chamber pressure of below about 5 millibars, recombining the at least eight streams into a single polymer stream; and (6) forming polymer from the single polymer stream into bulked continuous carpet filament.

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 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.

Polymer fiber or corresponding fabric including graphene and/or its derivative(s), wherein the graphene including polymer fabric is characterized by feature selected from the group consisting of anti-microbial, antistatic, wicking, thermal cooling, anti-odour, and ultraviolet protection, or any combination thereof. The graphene including polymer fiber or fabric shows several further beneficial properties including but not limited to good/excellent washing fastness, rubbing fastness, perspiration fastness, sublimation fastness, and light fastness. A process by which the graphene and/or its derivative(s) is incorporated in a polymer during its synthesis. The polymer is subsequently drawn into a fiber or fabric, and is capable of being converted into commercial products. A method to improve the aforementioned properties in a polymer fiber or fabric.

A carbon fiber bundle is characterized in that a ratio (n/N) of a number n of pairs wherein a flaw of 50 nm in size or more is present on at least one of the fracture surfaces forming the pair to a total number N of pairs of fiber fracture surfaces selected at random after performing a single fiber tensile test for a gauge length of 10 mm is 35% or less, and in that a single-fiber diameter d is 4.3 m or more.

A carbon fiber bundle is characterized in that a ratio (n/N) of a number n of pairs wherein a flaw of 50 nm in size or more is present on at least one of the fracture surfaces forming the pair to a total number N of pairs of fiber fracture surfaces selected at random after performing a single fiber tensile test for a gauge length of 10 mm is 35% or less, and in that a single-fiber diameter d is 4.3 m or more.

A method for manufacturing a nylon 66 hollow fiber includes steps as follows. A plurality of nylon 66 particles are provided. A melting step is provided, wherein the nylon 66 particles are melted so as to form a spun liquid. A fiber spitting step is provided, wherein the spun liquid goes through a hollow spinneret plate so as to form hollow nascent fibers. An evacuating step is provided, wherein the hollow nascent fibers are preliminarily solidified so as to form hollow half-solidified fibers. A cooling step is provided, wherein the hollow half-solidified fibers are cooled and solidified so as to form solidified fibers. A collecting and oiling step is provided. A drawing step is provided. A winding step is provided so as to obtain the nylon 66 hollow fiber.

An apparatus for making filaments has a spinneret plate having a row of holes from which emerge filaments. A manifold distributes a supplied plastic melt over a starting spinning width. A filter plate is downstream of the manifold. A pack of distributor plates is downstream of the filter plate. The distributor plates each have a plurality of distributor holes distributed over a manifold width. The distributor holes receive the plastic melt emerging from the filter plate. The spinneret plate is downstream of the distributor-plate pack and has a row of spinneret passages extending over a final spinning width aligned with the spinneret holes. An output face of the filter plate turned toward the distributor-plate pack and/or an inlet face of the spinneret plate turned toward the distributor-plate pack is curved or crowned at least in sections.

Disclosed are a high-elongation meta-aramid fiber, a preparation method and an apparatus. The high-elongation meta-aramid fiber is prepared by: adding isophthaloyl chloride to a m-phenylenediamine solution, reacting at a stirring speed of 20-30 r/min, and adjusting the pH of the achieved reaction liquid to obtain a first slurry; adding isophthaloyl chloride to a m-phenylenediamine solution, reacting at a stirring speed of 25-35 r/min, adjusting the pH of the achieved reaction liquid, filtering insoluble matter, adding an initiator and isophthaloyl chloride at a stirring speed of 25-35 r/min for reaction, and adjusting the pH of the achieved reaction liquid to obtain a second slurry; uniformly mixing and then de-foaming the two slurries, and producing the high-elongation meta-aramid fiber through a wet spinning process.

A method of manufacturing bulked continuous carpet filament which, in various embodiments, comprises: (A) grinding recycled PET bottles into a group of flakes; (B) washing the flakes; (C) identifying and removing impurities, including impure flakes, from the group of flakes; (D) passing the group of flakes through an expanded surface area extruder while maintaining a pressure within the expanded surface area extruder below about 25 millibars; (E) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (F) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.