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.

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.

Disclosed is an artificial turf. In the present disclosure, 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 handfeed, wear resistance, anti-aging performance, grass fiber resilience, trampling resistance and grass uprightness.

A fibre for use in artificial turf has an elongate cross-sectional shape defining a first face and a second face that meet at side edges of the fibre. The first and second faces having respective first and second ridges that are offset with respect to each other, such that the cross-sectional shape is 2-fold rotationally symmetric with no reflectional symmetry. The fibre may be an extruded monofilament and shows improved resilience over symmetrical fibres of similar dimensions.

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 from a plurality of polymer flakes comprises: (1) providing an extruder; (2) melting and purifying the plurality of polymer flakes into a polymer stream using the extruder; (3) providing a static mixing assembly downstream of the extruder; (4) adding a first liquid colorant to a center of the polymer stream at a first location before the static mixing assembly or along a length of the static mixing assembly; (5) adding a second liquid colorant to the polymer stream at a second location before the static mixing assembly or along a length of the static mixing assembly; (6) using the static mixing assembly to mix the polymer stream with the first and second liquid colorant to create a colored polymer stream; and (7) forming the colored polymer stream into bulked continuous carpet filament.

Implementations herein describe an artificial turf having a backing layer and a plurality of rows of individual tufts tufted into the backing layer. Each tuft comprises at least three yarns per tuft and each one of the at least three yarns varies in at least one of material, color, texture, denier and cross-section. Each row of individual tufts is substantially similar to each adjacent tufted row and adjacent tufts on a given row are spaced apart at a predetermined gauge.

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.

Yarns are described herein which, in some embodiments, comprise plies or single strands dyed with at least one vat dyestuff yielding a tweed or heathered appearance. In one aspect, a yarn comprises a first ply and a second ply each dyed with at least one vat dyestuff, wherein a difference in color depth (DL*) between the dyed first single strand and the dyed second single strand has an absolute value of at least 2 when the vat dyestuff is in an oxidized state. As described further herein, the first ply and the second ply are dyed in the same dyebath. In another aspect, a yarn comprises a first ply and a second ply each dyed with at least one vat dyestuff, wherein a reflectance ration between the second ply and the first ply ranges from 0.05 to 0.95.

A fibre for use in artificial turf has an elongate cross-sectional shape defining a first face and a second face that meet at side edges of the fibre. The first and second faces having respective first and second ridges that are offset with respect to each other, such that the cross-sectional shape is 2-fold rotationally symmetric with no reflectional symmetry. The fibre may be an extruded monofilament and shows improved resilience over symmetrical fibres of similar dimensions.