The present invention relates to an artificial turf. In the present invention, nylon is used as the main material. Through selecting straight fibers and curve fibers with certain cross-sectional shapes, lengths and widths and using the straight fiber and curve fiber together, the obtained grass fibers not only have relatively good temperature resistance, but also good handfeel, wear resistance, anti-aging performance, grass fiber resilience, trampling resistance and grass uprightness.

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 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 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.

Different combining techniques are employed for directing multiple denier yarns to be tufted adjacently in a carpet by a tufting machine. Different aesthetic appearances be achieved which provide for many new design opportunities in the marketplace.

Various implementations include a melt-spun filament (or fiber), a spinneret plate for producing the melt-spun filaments, and methods of making the melt-spun filaments. The melt-spun filaments have a similar soft hand feel as natural cotton fibers and are more resilient, less absorbent, and easier to clean, according to some implementations. In addition, according to some implementations, the melt-spun filaments produce a softer and bulkier yarn than traditional trilobal shaped filaments having the same denier per filament.

This application is directed to polymer blends of polyethylene naphthalate, polytrimethylene terephthalate, and polyethylene naphthalate, for use in fibers, such as carpet fibers, and other applications. This application is also directed to methods of producing such polymer blends and fibers.

A multi-step process is disclosed for heat setting twisted, bulk continuous filament (BCF) yarn comprising the steps of developing crimp in the yarn under hot atmospheric air and heat setting the yarn by saturated steam treatment.

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.