The present disclosure provides a polyamide 5X staple fiber, a preparation method and use thereof. The polyamide 5X staple fiber has a denier of 8.0-30.0D, a breaking strength of 2.0-6.0 cN/dtex, and an elongation at break of 30-100%. The polyamide 5X staple fiber has good mechanical properties and softness, and a blended wool yarn for manufacturing carpets with good mechanical properties, dyeability, and wear resistance can be obtained by using the polyamide 5X staple fiber.

The present disclosure provides combination yarns and carpets formed therefrom, in particular combination yarns comprising a first single primarily PET yarn and a second single primarily PTT yarn, wherein at least one of the first single yarn or the second single yarn includes one or more additives which increases dye uptake.

Various implementations include a method of forming a bulked continuous filament (BCF) yarn. The method includes providing N molten streams of polymer, providing M spinnerets, and spinning the N molten streams of polymer through the M spinnerets. At least a first group of filaments and a second group of filaments are spun through the M spinnerets. The first group of filaments each have a first average denier per filament along a length of the filaments and the second group of filaments each having a second average denier per filament along a length of the filaments, the first and second average denier per filament being different. The method further includes combining the filaments from the M spinnerets together and texturizing the spun filaments.

Disclosed herein, inter alia, is a flooring woven fabric. The flooring woven fabric includes a fabric layer including bulked continuous filaments (BCFs) having crimp and a polymer resin composition. The fabric layer includes a woven yarn of BCFs and the polymer resin composition is applied on the top portion of the fabric layer such that the polymer resin to form a coating layer. The polymer resin composition of the coating layer may penetrate between the BCFs and yarns made of BCFs. As such, the flooring woven fabric may have improved the wear resistance to strengthen the surface properties and positioning the coating layer to block the penetration of liquid contaminants at the same time, thereby improving the decontamination performance.

A carpet comprising a backing and pile comprising looped or cut tufts of pile yarn attached to and extending from the backing. The pile yarn comprises un-twisted, entangled filaments. The filaments are self-crimped and optionally textured multi-component filaments. A first component of the multi-component filament comprises a first thermoplastic polymer and a second component of the multi-component filaments comprises a second thermoplastic polymer. The first and the second thermoplastic polymer have different yield behavior, whereby the multi-component filaments are self-crimping.

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.

The present disclosure discloses a high resilience and stain resistant bulked continuous filament yarn. The yarn comprises a plurality of continuous filaments of polybutylene terephthalate (PBT), wherein the polybutylene terephthalate (PBT) has intrinsic viscosity in the range of 0.8 to 1.3. The yarn is obtained by a process comprising melt spinning of the plurality of continuous filaments of PBT; extrusion of the plurality of continuous filaments; quenching of the extruded filaments; drawing of the quenched filaments; texturizing of the drawn filaments; cooling of the texturized filaments, overfeeding of the cooled-texturized filaments; and winding of the overfeed filaments with or without tangling for obtaining the high resilience and stain resistant bulked continuous filament yarn. The high resilience and stain resistant bulked continuous filament yarn has a stain resistance rating of more than 3 and a hexapod rating of 2 or more after 12000 cycles.

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.

Systems for producing M bundles of filaments, wherein M≥1, include N extruders, M spin stations, and a processor, wherein N>1. Each extruder includes a thermoplastic polymer having a color, hue, and/or dyability characteristic, which are different from each other. Each spin station produces N bundles of filaments that form a yarn. Each spin station comprises N spinnerets through which filaments are spun from molten polymers streams received by the respective spin station and N spin pumps upstream of the N spinnerets for the respective spin station. Each spin pump is paired with one of the N extruders. The processor is in electrical communication with the N*M spin pumps and is configured to adjust the volumetric flow rate of the polymers pumped from each spin pump to achieve a ratio of the polymers to be included in the yarn from each spin station.

Systems and methods for producing BCF yarns include providing at least one color enhancement method for enhancing the color and/or hue of at least one of the N bundles of filaments. The color enhancement methods include tacking one or more of the bundles of spun filaments prior to and/or during drawing, texturizing one or more bundles of spun filaments individually from the other bundles of spun filaments, providing intermediate tacking of at least one bundle of texturized filaments and feeding the tacked and texturized filaments to a mixing cam for positioning tacked and texturized bundles relative one to the other before reaching the final tacking device, or combinations thereof.