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.

The present invention pertains to a method for manufacturing a laminated textile product comprising providing a first intermediate product comprising a primary backing having a front surface and a back surface, and yarns stitched into the primary backing, the yarns extending from the front surface of the backing material, feeding the intermediate product along a body having a heated surface, the back surface being pressed against the said heated surface, to at least partly melt the yarns present in the intermediate product to bond the yarns to the backing, wherein the part of the back surface that is pressed against the heated surface has a relative speed with respect to the heated surface, so as to provide a second intermediate product having a calendered back surface, providing a dimensionally stable carrier sheet or secondary backing, and connecting the second intermediate product to the carrier sheet by providing a hot melt adhesive between the calendered surface and the sheet, and pressing the sheet to the second intermediate product to form the textile product.

A method for producing a textile product (I), (II), comprising at least two synthetic pile threads (P1), (P2) having a different pile height, so that a predetermined design is formed, in which the synthetic pile yarns (P1), (P2) are manufactured by extrusion from the same raw material, according to production processes which only differ from each other by a different setting of one or several process parameters of their respective extrusion processes, so that they have a different shrinking capability, and in which the textile product (I), (II) is subjected to a heat treatment which causes the pile yarns (P1), (P2) to shrink differently. Also such a method for producing synthetic textile yarns (P1), (P2) having a different shrinking capability.

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.

The invention relates to the light industry area, namely to material for production of the woven and knitted textiles, and can be used for the manual production of the carpets, runners, coverlets, blankets and other similar decorative objects. The object of this utility model consists in improvement of material for production of the woven and knitted textiles by way of the optimum combination of the material composition and texture (form) resulting in upgrading of its application characteristics, namely—getting softness, lightness, strength and elasticity in combination with the aesthetic and decorative properties. In addition, the diversification of products made of the applied material is present. Material for production of the woven and knitted textiles is composed of the tubular seamless knitted shell filled with a reinforcing filler, made of synthetic microfiber or of a mixture of synthetic and natural microfibers with a density of 0.010-0.030 g/cm.sup.3, and the shell is made of the cotton or wool added with a synthetic thread, at that the material diameter is not more than 8 cm, and the shell and the filler composition ratio are defined by the material functionality.

A pattern data processing system configured to determine and compensate for any points of entanglement between different yarns. A point of entanglement is defined as a point where the yarn from one needle crosses and traps the yarn from another needle on the back face of the backing medium. The pattern data processing system is configured to calculate the additional length of back stich caused by each point of entanglement by subtracting an ideal back stich length, calculated as the path which would have been taken by the yarn had it not been entangled in another yarn, from an actual yarn path, calculated as the actual length of the entangled yarn. A controller is configured to include in the amount of yarn fed by a respective yarn feed mechanism for each stitch an amount equivalent to the additional length of back stitch. The invention also includes a tufting machine and method of operating the tufting machine with the pattern data processing system.

A base paper (6), a picture pattern layer (7) provided on a surface (6a) side of the base paper (6), and foaming agents (8) arranged on a surface (7a) of the picture pattern layer (7) or in the picture pattern layer (7) are provided. In the foaming agents (8), the average particle diameter after foaming is set to 15 μm or more and 250 μm or less and the foaming start temperature is set to 100° C. or more and 220° C. or less.

A spacer fabric comprises a first and a second textile layer as well as spacer yarns that join the textile layers and is used to form an interior trim. The first textile layer is visible from outside on a surface of the interior trim, and the first textile layer and the spacer yarns are made entirely of polymeric multifilament yarns. At least the polymeric multifilament yarns of the first textile layer and of the spacer yarns are dyed.

A method of manufacturing bulked continuous carpet filament from polytrimethylene terephthalate (PTT) with polyethylene terephthalate (PET) comprises: (1) splitting the PTT stream extruded from the primary extruder into a number of polymer streams, each of the plurality of polymer streams having an associated spinning machine; (2) adding a colorant to each split polymer stream; (3) adding PET to the extruded polymer stream downstream of the primary extruder; (4) using one or more static mixing assemblies for each split polymer stream to substantially uniformly mix each split polymer stream and its respective colorant and PET; and (5) spinning each polymer stream with its substantially uniformly mixed colorant and any additives into BCF using the respective spinning machine.

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.