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.

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 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.

Disclosure provides a twisted and heat-set Bulked Continuous side-by-side bi-component Filament (BCF) yarn including a plurality of side-by-side bi-component filaments, each includes first and second polymer components. The first polymer component forms a first side of the side-by-side bi-component filaments, and includes polybutylene terephthalate (PBT) in at least 25 and up to 75 volume percent of the filament in the BCF yarn. Further, the second polymer component forms a second side of the side-by-side bi-component filaments, and includes one of polyethylene terephthalate (PET) or polylactic acid (PLA) in at most 75 and down to 25 volume percent of the filament in the BCF yarn. The twisted and heat-set BCF yarn is obtained by a single-step continuous process, and subsequently followed by steps of twisting and/or cabling and heat-setting. The twisted and heat-set BCF yarn as obtained exhibits an elongation to break in a range of 40% to 65%, and floor covering manufactured from the yarn exhibits a Hexapod rating after 12000 cycles of more than 2.

An object of the present invention is to provide a carpet exhibiting excellent antifouling property against both dry soil and wet soil. The carpet is a carpet including a pile yarn having a coated pile single yarn, in which the coated pile single yarn is a pile single yarn to which a layer A containing organopolysiloxane and a fluorine-based compound is attached, a fineness of the coated pile single yarn is 8 to 40 dtex, a crimp elongation of the pile yarn is 10% to 30%, a carpet staining degree (ΔE) in an antifouling dry test is 30 or less, and a carpet staining degree (ΔE) in an antifouling wet test is 30 or less.

Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) passing polymer flakes through a crystalliers; (2) melting the polymer to create a first single stream of polymer melt; (3) separating the first single stream of polymer melt into multiple streams of polymer melt; (4) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 25 millibars in a chamber; (5) recombining the multiple streams of polymer melt into a second single stream of polymer melt; and (6) providing the second single stream of polymer melt to one or more spinning machines that are configured to form the second single stream of polymer melt 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.

An artificial turf filament has a cross-section that includes a body having a center juncture having a first width and a first and second wing member arranged in diverging orientation from the center juncture. Each wing member having a plurality of legs and a plurality of leg junctures positioned between respective legs of the plurality of legs. Moving from the center juncture to a distal end of each wing member, the minimal cross-sectional widths of the respective legs of the plurality of legs decrease and the maximal cross-sectional widths of the respective leg junctures of the plurality of leg junctures decrease.

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 healthier carpet employing UV light-transmitting threads, which facilitate UV light transmittance down from the surface of the carpet, through the interior of the carpet, and into the primary backing of the carpet. The UV light can destroy bacteria, molds, viruses, yeast, and other microorganisms, which are present in the carpet. An external UV light source, with UV wavelengths from 100-400 nm, can be passed over the carpet for effective sanitization.