The invention is directed to a synthetic turf yarn, to a method of preparing said synthetic turf yarn, to artificial turf comprising said synthetic turf yarn, and to a method of preparing artificial turf.

The synthetic turf yarn of the invention comprises an aliphatic polyester and a copolyester of butanediol, terephthalic acid and a linear aliphatic dicarboxylic acid selected from the group consisting of succinic acid, adipic acid, and sebacic acid.

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 multipolymer fiber comprising a polyester phase formed from at least one polyester resin, present at between about 50 to about 95 percent by weight and a polyamide phase formed from at least one polyamide resin, present at between about 5 to about 50 percent by weight, wherein the polyamide phase is distinct from the polyester phase and comprises a plurality of polyamide fibrils dispersed in the polyester phase, and wherein the polyamide fibrils are separately distinguishable from each other.

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.

Carpet with self-twisted loop piles that has an appearance and aesthetics similar to cut pile construction with improved durability and methods for making the same are provided.

A method of tufting carpet using multiple yarns directed through at least one single needle, if not a plurality of such situations, whereby the needles tuft a carpet having unique specifications. Specifically, the yarns are pre-twisted together, and can be solution dyed and/or of have different twist characteristics, such as selected from the group of high twist, standard twist, low twist, no twist, flat yarns and/or pre-twisted flat yarns.

An artificial turf includes translucent thatch yarn fibers and opaque face yarn fibers that are integrated in a carrier.

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.

Wool-like, synthetic multifilament yarns may be produced with a plurality of primary yarns and at least one secondary yarn. Generally, the primary yarn and secondary yarn may be produced from polyamides. The wool-like multifilament yarns may be produced by: (1) melt-spinning the primary yarns and the secondary yarn; (2) drawing and texturizing the primary yarns and the secondary yarns; (3) entangling the texturized primary yarns and the texturized secondary yarn to form the inventive yarn; (4) optionally subjecting the inventive yarn to heat-setting or heat annealing; and (5) winding the yarn onto a package for distribution. The multifilament yarns may be used to produce floorcoverings.

A monofilament of a polyethylene terephthalate bulked continuous filament (BCF) has elongation of 5% or more at an initial stress of 1.0 g/d, elongation of 25 to 35% at a medium-term stress of 3.0 g/d, tensile strength of .0 to 6.0g/d, and elongation of 40 to 60%.