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.

Disclosed are the cut edges of an absorbent fabric comprising at least 45% and less than about 90% cellulosic or natural fibers, and a fusible component being stabilized by fusing the fusible component with an arrangement of spaced lines or spaced areas extending from the cut edges, and optionally over the entire absorbent fabric.

A knitting yarn used for forming a knitted product without using any knitting tools, such as crochet hooks or knitting needles. The knitting yarn includes a core thread having a length dimension and a plurality of loops affixed to the core thread, at least a first thread and at least a second thread having different structural and/or physical properties than each other; and the loops of the knitting yarn are made of the first thread, and the core thread is made of the second thread.

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 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 MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 1.5 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.

In particular embodiments, a process for producing bulked continuous carpet filament from recycled polymer utilizes two vacuum pumps (140A, 140B) in combination with a single extruder (100). In various embodiments, the dual vacuum arrangement (e.g., at least two vacuum pumps (140A, 140B)) operably coupled to the single extruder (e.g., MRS extruder (100)) may be configured to remove one or more impurities from recycled polymer as the recycled polymer passes through the extruder.

In one aspect, a textile component including bulking yarn is disclosed. In embodiments, the textile component is a knitted component. In one embodiment, an article of footwear includes a knitted component arch support configured to reduce the rate of pronation. A support structure may include a fusible yarn adjacent to an external surface of the arch support, a bulking yarn, and a nonfusible yarn. In certain embodiments, an arch support includes compartments and flex lines. In another aspect, an article having a knitted component includes a rigid material, a bulking yarn, and a flexible material. The rigid material may be fusible yarn. Methods for forming a textile component are provided. One embodiment involves knitting a first section comprising a fusible yarn, a second section comprising a bulking yarn, and a third section comprising a nonfusible yarn, and heating.

In one aspect, a textile component including bulking yarn is disclosed. In embodiments, the textile component is a knitted component. In one embodiment, an article of footwear includes a knitted component arch support configured to reduce the rate of pronation. A support structure may include a fusible yarn adjacent to an external surface of the arch support, a bulking yarn, and a nonfusible yarn. In certain embodiments, an arch support includes compartments and flex lines. In another aspect, an article having a knitted component includes a rigid material, a bulking yarn, and a flexible material. The rigid material may be fusible yarn. Methods for forming a textile component are provided. One embodiment involves knitting a first section comprising a fusible yarn, a second section comprising a bulking yarn, and a third section comprising a nonfusible yarn, and heating.

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.

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.