A yarn disclosed that is formed of a blend of polyester fibers customized by three parameters (1) a combination of polyester staple fibers with staple lengths of 1.5 inches, 1.25 inches, 1.0 inch and 0.75 inch; (2) a combination of polyester staple fibers with staple deniers (tex, fineness) of 1.0 dpf, 1.2 dpf, and 1.5 dpf; and (3) a combination of polyester staple fibers with at least two different staple cross sections.

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.

Method for manufacturing yarn, wherein said yarn comprises a plurality of continuous filaments, wherein said method comprises at least the following steps: the step of spinning, preferably melt spinning, a plurality of continuous filaments; andthe step of treating said plurality of continuous filaments by means of a pressurized fluid supplied by two or more nozzles, and wherein one or more of said nozzles deliver said fluid at a varying pressure and/or rate and/or temperature.

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.

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 flakes through a PET crystallizer; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 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.

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 flakes through a PET crystallizer; (E) passing the group of flakes through an MRS extruder while maintaining the pressure within the MRS portion of the MRS extruder below about 18 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.

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.

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.