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 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 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) adding one or more color concentrates to the flakes; (E) passing the group of flakes through an extrusion system while maintaining the pressure within the extrusion system below about 25 millibars; (F) passing the resulting polymer melt through at least one filter having a micron rating of less than about 50 microns; and (G) forming the recycled polymer into bulked continuous carpet filament that consists essentially of recycled PET.

An object of the present invention is to provide a method for efficiently manufacturing a protein crimped staple from protein filaments at a low cost. A manufacturing method for a protein crimped staple according to the present invention includes: a) preparing an artificial fibroin filament containing a modified fibroin; b) cutting the artificial fibroin filament to obtain an artificial fibroin staple; and c) performing crimping by bringing the artificial fibroin filament into contact with an aqueous medium to crimp the artificial fibroin filament before the cutting or bringing the artificial fibroin staple into contact with an aqueous medium to crimp the artificial fibroin staple after the cutting.

An object of the present invention is to provide a method for efficiently manufacturing a protein crimped staple from protein filaments at a low cost. A manufacturing method for a protein crimped staple according to the present invention includes: a) preparing an artificial fibroin filament containing a modified fibroin; b) cutting the artificial fibroin filament to obtain an artificial fibroin staple; and c) performing crimping by bringing the artificial fibroin filament into contact with an aqueous medium to crimp the artificial fibroin filament before the cutting or bringing the artificial fibroin staple into contact with an aqueous medium to crimp the artificial fibroin staple after the cutting.

Disclosed is a method for dyeing solution dyed bulk continuous filament (BCF) fibers. The BCF fibers are twisted together to form a 2 or more ply strand prior to dyeing. After twisting the fibers together, the fiber is preferably spaced dyed to provide a multi-colored pattern along the length of the strand. Following the space dyeing step, the strand is heat set.

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 reinforcing fiber bundle is a continuous reinforcing fiber bundle having a length of at least 1 m and is characterized by the number of monofilaments per unit width being at most 1,600/mm and the average number of fibers in the bundle being at most 1,000 in a region (I), and the drape level found in a region (II) being 120-240 mm. The continuous reinforcing fiber bundle has a length of at least 1 m and is characterized by the adhesion amount of a sizing agent (I) in the region (I) being 0.5-10% by weight and the drape level found in the region (II) being 120-240 mm. The continuous reinforcing fiber bundle has superior mechanical properties, formability into complex shapes, and continuous producibility.

A reinforcing fiber bundle is a continuous reinforcing fiber bundle having a length of at least 1 m and is characterized by the number of monofilaments per unit width being at most 1,600/mm and the average number of fibers in the bundle being at most 1,000 in a region (I), and the drape level found in a region (II) being 120-240 mm. The continuous reinforcing fiber bundle has a length of at least 1 m and is characterized by the adhesion amount of a sizing agent (I) in the region (I) being 0.5-10% by weight and the drape level found in the region (II) being 120-240 mm. The continuous reinforcing fiber bundle has superior mechanical properties, formability into complex shapes, and continuous producibility.

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.