Yarn made of mixed filaments and multifilament capillary spinnerets

Abstract

The present invention relates to a yarn from a bundle of filaments having a soft hand-feel and good bulk. A yarn made with two filaments having different cross-sectional shapes at low denier has been found to have a softer hand-feel and greater bulk than a yarn of the same denier made from traditional methods. The yarn also has the same wear characteristics as a yarn made entirely with the more durable filament of the two filaments. The yarn may be made from a spinneret plate having single and multiple capillaries in fluid communication with each borehole or with a spinneret plate with grouped plurality of extrusion patterns.

Description

[0001] Yam made of mixed filaments and multifilament capillary spinnerets

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] The present application claims the benefit of priority to U.S. Patent Application No. 63 / 579,043 filed on 28 August 2023, and U.S. Patent Application No. 63 / 585,964 filed on 28 September 2023, the contents of which are hereby incorporated by reference for all purposes.

[0004] FIELD OF THE INVENTION

[0005] The present invention relates to a spinneret and a yam from a bundle of filaments having a soft hand-feel and good bulk. A yam made from a spinneret with the methods disclosed and taught herein has been found to have a softer hand-feel and greater bulk than a yam of the same denier made from traditional methods.

[0006] BACKGROUND

[0007] Carpets and mgs may be made from yams of natural fibers such as cotton and wool, or they may be made from yams of manufactured filaments such as bulk continuous filaments (BCF). Carpets and mgs made with natural fiber yarns have known characteristics such as hand-feel and bulk. In making carpets and mgs from natural fibers, manufacturers will create a yam having a yarn denier that balances hand-feel and bulk. In this, a yarn with a lower yam denier will exhibit a softer hand-feel but with a lower bulk, while a yarn with a higher yam denier will exhibit greater bulk but a coarser hand-feel.

[0008] Traditionally, the yams made from manufactured filaments have softer hand-feel when they are made from low denier per filament (dpf) filaments (or decitex per filament - dtpf). However, yarns made from low dpf filaments lack bulk. That is to say that a yam made with low dpf filaments will feel soft, but the pile will not stand up as well as a yarn made with higher dpf filaments, which will exhibit a coarser hand-feel.

[0009] Applicant has devised spinneret plates that contain two types of filament patterns to produce yams having soft hand-feel with unexpectedly good bulk characteristics. In an exemplary embodiment, a first pattern is configured to extrude a trilobal filament, while a second pattern is configured to extrude a ribbon filament. These patterns may be positioned on the extrusion side of the spinneret plate to produce a bundle of filaments, which may be the yam, or may be combined with other bundles extruded from other spinnerets to form a yam.

[0010] In these devised spinneret plates, the patterns may be configured to have the patterns located where the produced bundle has filaments produced from the first patterns that are generally between filaments produced from the second pattern. That is to say that in an exemplary and non-limiting embodiment, the trilobal patterns are located in the center of an oval-shaped spinneret plate with groups of ribbon patterns on the left and right sides of the trilobal patterns. Applicant tested that configuration by first producing and combining three bundles, where each bundle came from a separate spinneret. In that test, each spinneret was associated with its own spin pump and the extruded bundles were combined and texturized together.

[0011] In that exemplary test, a spinneret configured with trilobal patterns was located between spinnerets configured with ribbon patterns. In that exemplary test, all of the filament patterns were configured to extrude similarly weighted filaments. That is to say that the ribbon filaments extruded from the left and right spinnerets were configured to extrude 4 dpf (4.44 dtpf) ribbon filaments while the center spinneret was configured to extrude 4 dpf (4.44 dtpf) trilobal filaments. The spin pumps were controlled independently to maintain that all filaments were consistently 4 dpf (4.44 dtpf).

[0012] Applicant repeated the exemplary tests using left and right spinneret plates again configured with ribbon patterns to produce filaments of 2 dpf (2.22 dtpf). The configuration of the patterns was identical with an aspect ratio of 6:1, but the pressure from each spin pump to deliver molten polymer to the spinnerets was reduced as compared to the pressure needed to produce filaments of 4 dpf (4.44 dtpf).

[0013] This suggests that a desired bundle of filaments may be made by combining the three separate bundles produced from the three spinnerets. This was done using a single take up apparatus drawing all three bundles together before tacking and texturizing. As such Applicant has identified a need for a single spinneret plate that has multiple types of patterns where the extruded filaments from the different types of patterns may have different linear weights.

[0014] Spinneret plates having circular or oval faces are usually comprised of boreholes drilled from the non-extrusion face towards the extrusion face with the bottom of each of the boreholes ending at determined distance from the extrusion face. The capillaries are then cut between the extrusion face and the bottom of each of the boreholes. In most embodiments, there is one capillary for each borehole.

[0015] The pressure of the polymer melt at the non-extrusion face is controlled by the spin pumps and is generally applied equally over the non-extrusion face. That is to say that the polymer melt is forced into each borehole with the same pressure. The cross-sectional area of the capillary between the end of the borehole and the extrusion face determines the volume of polymer that may be extruded from each capillary. In many prior art spinneret plate designs with one capillary for each borehole, the cross-sectional areas have been kept generally consistent to extrude generally consistent filaments.

[0016] In some embodiments of the inventions disclosed and taught herein, Applicant has found it advantageous to chamfer the capillary at the extrusion face. The cross- sectional area described herein may be described as the minimal cross-sectional area between the extrusion face and the bottom of the borehole. That is to say that an outwardly chamfered cross-sectional area at the extrusion surface of the spinneret plate may not apply as much backpressure on the melt that may affect the extruded filament as a non-chamfered capillary.

[0017] In another embodiment, where it is desirable to have a mixture of filament sizes, the boreholes diameters may be configured to produce desirable filament sizes.

[0018] As a non-limiting exemplary embodiment where two filaments are to be produced with the first having a cross-sectional area that is twice the cross-sectional area of the second, the capillaries may be the same size, but the boreholes may have different diameters. The borehole with the smaller diameter will have lower pressure but the molten polymer flowing through it will have a greater velocity. With all other conditions being equal, filaments extruded from smaller boreholes will have lower cross-sectional areas than filaments extruded from larger boreholes.

[0019] While this intermediary outcome may be desirable, the process to retain the relative filament cross-sectional areas would require each filament to have separate drawing rates since the smaller cross-sectional area filament would be produced at a greater velocity than the larger cross-sectional area filament.

[0020] A person of skill in the art and in possession of the teachings and inventions disclosed herein may configure a spinneret plate having different borehole diameters to produce differently sized filaments that may be drawn at the same rate. This will entail a spinneret plate configured with different borehole sizes across the spinneret plate.

[0021] The linear weight of a filament may be measured in denier, which is the weight of a filament in grams per 9,000 meters. This is referenced as the denier per filament (dpf). The linear weight may also be measured in dtex, which is the weight of a kilometer of a yarn, filament, bundle, fiber, or other textile strand measured in tenths of a gram. For a filament, this may be referenced as the dtex per filament (dtpf). Conversion from denier to dtex and visa-versa may be performed using ASTM standard D-2260-03 (2018).

[0022] Throughout this specification, Applicant will refer to filaments having deniers of between 3 and 5 dpf (3.33 dtpf and 5.56 dtpf) as being “generally 4 dpf’. Applicant will refer to filaments having deniers of between 1.5 and 2.5 dpf (1.67 dtpf and 2.78 dtpf) as being “generally 2 dpf’.

[0023] Applicant will refer to embodiments of a bundle or a yarn having combinations of generally 4 dpf trilobal filaments and generally 2 dpf ribbon filaments as “generally 4-2 dpf’.

[0024] BRIEF SUMMARY

[0025] To this aim, the invention relates to creating a yarn from a single spinneret plate where the yarn has filaments of different cross-sectional shapes and areas, and different linear weights. This has been achieved through the methods and processes disclosed herein where a bundle of filaments may be produced comprised of different types of filaments with different cross-sectional areas and different linear weights from a single spinneret associated with a single spin pump.

[0026] In a first independent aspect, the invention relates to a yam, comprising: at least one bundle comprising a first plurality of filaments and a second plurality of filaments; wherein each filament of the first plurality of filaments has a first cross-sectional shape and each filament of the second plurality of filaments has a second cross- sectional shape; and wherein the first cross-sectional shape is different from the second cross-sectional shape.

[0027] In a second independent aspect, the invention relates to a spinneret plate, comprising: an extrusion face comprising a first plurality of extrusion patterns and a second plurality of extrusion patterns.

[0028] In a third independent aspect, the invention relates to a yam, comprising: at least one bundle comprising a first plurality of filaments and a second plurality of filaments; wherein each filament of the first plurality of filaments has a first cross- sectional shape and each filament of the second plurality of filaments has a second cross-sectional shape; and wherein the first cross-sectional shape is different from the second cross-sectional shape.

[0029] In a fourth independent aspect, the invention relates to a spinneret plate, comprising: a non-extrusion face comprising a plurality of boreholes; an extrusion face opposite the non-extrusion face comprising a first plurality of capillary patterns and a second plurality of capillary patterns.

[0030] In a fifth independent aspect, the invention relates to a spinneret plate, comprising: a non-extrusion face comprising a plurality of boreholes; an extrusion face opposite the non-extrusion face comprising a first plurality of capillary patterns and a second plurality of capillary patterns.

[0031] In a fifth independent aspect, the invention relates to a yam, comprising: a plurality of filaments comprising: M first filaments, wherein each of the M first filaments has a first cross-sectional shape, a first cross-sectional area, and a first linear weight; N second filaments, wherein each of the N second filaments has a second cross- sectional shape, a second cross-sectional area, and a second linear weight; wherein: the second cross-sectional shape is different from the first cross-sectional shape; N is a multiple of M such that N divided by M is a whole number X that is greater than 1; and the first linear weight is equal to the second linear weight multiplied by X.

[0032] In a sixth independent aspect, the invention relates to a spinneret plate, comprising: an extrusion face comprising: a first plurality of capillaries having a first capillary cross-section shape, and a first capillary cross-section area; and a second plurality of capillaries having a second capillary cross-section shape, and a second capillary cross-section area; wherein: the first capillary cross-section shape is different from the second capillary cross-section shape; and there are more of the second plurality of capillaries than there are of the first plurality of capillaries.

[0033] In a seventh independent aspect, the invention relates to a spinneret plate comprising: an extrusion face distal from and opposite a non-extrusion face; a plurality of boreholes on the non-extrusion face; a plurality of capillary patterns, wherein each capillary pattern comprises: at least one trilobal-shaped capillary having a modification ratio of between 5.50 and 5.60; a plurality of ribbon-shaped capillaries where each ribbon-shaped capillary has an aspect ratio of between 4: 1 and 10: 1; wherein: each of the at least one trilobal-shaped capillary is associated with only one borehole of the plurality of boreholes; and each of the plurality of ribbon-shaped capillaries shares a borehole with at least one other ribbon-shaped capillary.

[0034] Descriptions of these inventions will be defined in the appended independent claims, while preferred embodiments are defined in the dependent claims.

[0035] BRIEF DESCRIPTION OF THE DRAWINGS

[0036] With the intention of better showing the characteristics of the invention, herein after, as an example without any limitative character, some preferred embodiments are described, with reference to the accompanying drawings, wherein:

[0037] Figure 1 illustrates the results of hand-feel softness testing according to the inventions disclosed and taught herein.

[0038] Figure 2 illustrates the results of hand-feel bulk testing according to the inventions disclosed and taught herein.

[0039] Figure 3 illustrates an exemplary spinneret plate according to the inventions disclosed and taught herein.

[0040] Figure 4 illustrates a magnified bundle according to the inventions as disclosed and taught herein.

[0041] Figure 5 illustrates a spinneret plate according to the inventions disclosed and taught herein.

[0042] Figure 6 illustrates a close-up view of typical group of boreholes according to the inventions disclosed and taught herein.

[0043] Figure 7 illustrates a pattern of capillaries viewed from the extrusion face according to the inventions disclosed and taught herein. Figure 8 illustrates a pattern of boreholes according to the inventions as disclosed and taught herein.

[0044] The same reference signs refer to the same, similar or analogous elements in the different Figures.

[0045] Descriptions of these inventions will be defined in the appended independent claims, while preferred embodiments are defined in the dependent claims.

[0046] DETAILED DESCRPTION

[0047] Applicant has devised ways to combine different types of manufactured filaments into a yam such that it has unexpected and more desirable characteristics than yams made from manufactured filaments of the same types.

[0048] In a first illustrative embodiment, a yam may be made from a combination of trilobal and ribbon cross-sections.

[0049] A first set of trials were conducted where the characteristics of yarns made from trilobal filaments were compared against those of yams made of ribbon filaments.

[0050] In each of the first set of trials, a yam was made of filaments having a single cross- sectional configuration. That is to say that in a first set of trials, a griege product was made of yarns of BCF having a trilobal cross-section. In a second set of trials, a griege product was made of BCF filaments having a ribbon cross-section. In all trials, the yarn denier was 1,330 grams per 9,000 meters (1,478 dtex). Conversion from denier to dtex (also known as decitex) and visa-versa may be performed using ASTM standard D-2260-03 (2018).

[0051] In the trials of trilobal filaments, bundles, or ends, of filaments were extruded and texturized in the same way. In the different trials, the filaments were of 4, 6, and 11 dpf (4.44, 6.67, and 12.22 dtpf). The bundles of filaments were combined and tacked to produce a yarn. Each finished yarn had a denier of 1,330 grams per 9,000 meters (1,478 dtex). In this set of trials, trilobal filaments of different modification ratios were used. The modification ratios of the trilobal filaments that were used in the yams were between 1.4 and 2.7.

[0052] In the trials of ribbon filaments, bundles, or ends, or filaments were extruded and texturized in the same way. In the different trials, the filaments were made with filament deniers of 4, 6, and 11 dpf (4.44, 6.67, and 12.22 dtpf). The bundles of filaments were combined and tacked to produce a yarn. Each finished yarn had a denier of 1,330 grams per 9,000 meters (1,478 dtex). In this set of trials, ribbon filaments of different aspect ratios were used. The aspect ratios of the ribbon filaments that were used in the yams were 4: 1 and 6: 1. In extruding the BCF, different jet velocities were also used to produce the filaments for different yams. Those of ordinary skill in the art will understand the affect that different jet velocities will have on extruded filaments. These differences may be incorporated into produced yarn without deviating from the spirit of the inventions taught and disclosed herein.

[0053] Each yarn from each trial was tufted into two griege products. These products had face weight formats of 25 and 50 ounces per square yard (847.6 and 1,695.3 grams per square meter) independent of the primary backing, which was the same in all griege products made for the trials. In the hand-feel tests, a woven primary backing was consistently used. In subsequent productions, Applicant has found that the inventions disclosed and taught herein may be applied to both woven and nonwoven primary backings.

[0054] A similar set of greige products was developed of yarns made from combinations of filaments having the same denier per filament. Again, each trial yam was produced with a yarn denier of 1,330 grams per 9,000 meters (1,478 dtex).

[0055] The combinations of trilobal and ribbon filaments varied from 90% trilobal with 10% ribbon, to 90% ribbon with 10% trilobal, where the trilobal filaments had modification ratios of between 1.4 and 2.7 and the ribbon filaments has aspect ratios of 4: 1 and 6:1. The resulting bundles of filaments were treated as before, tacked into yarns, and tufted into primary backings with face weight formats of 25 and 50 ounces per square yard (847.6 and 1,695.3 grams per square meter) independent of the weight of the primary backing.

[0056] Test boards were developed where the griege products from the 4 and 6 dpf (4.44 and 6.67 dtpf) ribbon and trilobal filaments were randomly arranged for each face weight product. The griege products from the 11 dpf (12.22 dtpf) trilobal filaments were established for each board as a control. That is to say that a row of 25 ounce per square yard (847.6 grams per square meter) samples were randomly arranged with the griege product made from 11 dpf (12.22 dtpf) trilobal filaments identified as the control on a board. A similar board was developed for the 50 ounce per square yard (1,695.3 grams per square meter) samples.

[0057] A panel of over twenty-five people was instructed to feel each sample on each board. Each person was instructed to compare each sample against the control samples, where the control samples were given a hand-feel softness rating of 1, and a bulk rating of 10.

[0058] Each person was instructed to rate the hand-feel softness of the other samples with a value of between 1 and 10 where the least soft sample was the control sample, which had a rating of 1. Additionally, each person was instructed to rate the bulk of the other samples with a value of between 1 and 10 where the sample with the most bulk was the control sample, which had a rating of 10.

[0059] The results of these blind tests are generally illustrated in Figures 1 and 2.

[0060] Figure 1 illustrates the results of the softness testing of the griege products. The relative rating scale 110 varies from 1 to 10 for the hand-feel, with the yams made from 11 dpf (12.22 dtpf) trilobal filaments having a relative rating of 1. The x-axis 120 represents the filament denier that was used in the yarns.

[0061] The softness ratings of the griege products made from trilobal BCF are indicated by line 130. The softness rating of the griege products from yams made with higher denier filaments were rated as coarser - closer to 1 - than the softness ratings of the griege products from yarns made from the lowest denier filaments, which were closer to a value of around 8. The softness ratings of the griege products made from ribbon BCF are indicated by line 140. The softness rating of the griege products from yams made from higher denier yams were rated as coarser than the softness ratings of the griege products from yams made from the lowest denier filaments. Overall, the griege products made from ribbon filaments were rated as softer than the products made from trilobal filaments. The softness ratings 130, 140 were similar for both the 25 and 50 ounce per square yard products (847.6 and 1,695.3 grams per square meter).

[0062] The average softness ratings of the griege products made from yarn of combinations of trilobal and ribbon BCF are indicated by line 150. This indicates that the handfeel softness of griege products made from yam combinations of trilobal and ribbon BCF fell between the softness ratings of griege products made with only trilobal or with only ribbon filaments for yams made with 4 and 6 dpf (4.44 and 6.67 dtpf). Griege products made with 90% ribbon filaments were closer to the softness ratings of griege products made with all ribbon filaments, and griege products made with 90% trilobal filaments were closer to the softness ratings of griege products made with all trilobal filaments.

[0063] Figure 2 illustrates the results of the hand-feel bulk testing of the griege products. The relative rating scale 210 varies from 1 to 10 for the hand-feel, with the griege products made from yams having 11 dpf (12.22 dtpf) trilobal filaments having a relative rating of 1. The x-axis 220 represents the filament denier that was used in the yams.

[0064] The bulk ratings of the griege products made from trilobal BCF are indicated by line 230. The bulk rating of the griege products from yarns made with higher denier filaments were rated as bulkier - closer to 10 - than the bulk ratings of the griege products from yams made from the lowest denier filaments, which were closer to a value of around 5. The bulk ratings of the griege products made from ribbon BCF are indicated by line 240. The bulk rating of the of the griege products from yarns made from higher denier filaments were rated as having less bulk than the bulk ratings of the griege products from yams made from the lowest denier filaments. Overall, the griege products made from ribbon filaments were rated as having less bulk than the products made from trilobal filaments. The bulk ratings 230, 240 were similar for both the 25 and 50 ounce per square yard products (847.6 and 1,695.3 grams per square meter).

[0065] The average bulk ratings of the griege products made from yarn of combinations of trilobal and ribbon BCF are indicated by line 251 for the 25 ounce per square yard product (847.6 grams per square meter) and line 252 for the 50 ounce per square yard product (1,695.3 grams per square meter). This indicates that the bulk ratings of griege products made from yam combinations of trilobal and ribbon BCF fell outside the bulk ratings of griege products made with only trilobal or with only ribbon filaments for yarns made with filaments of generally 4 dpf (4.44 dtpf).

[0066] Applicant’s inventions disclosed and taught herein are not limited to the illustrative embodiments of products made of yarns comprising trilobal and ribbon filaments. Other embodiments using other combinations of filaments having different crosssections are also expected to provide results similar to those disclosed herein. For example, other multilobal filaments may be combined with ribbon filaments or other types of filaments including, but not limited to, round, oval, and square filaments to produce similar results. Additionally, filaments having hollow cores (both multilobal and ribbon, round, oval, or square) made be combined in the ways disclosed and taught herein without departing from the spirit of the inventions claimed.

[0067] Also, Applicant’s inventions disclosed and taught herein are not limited to single types of polymers. That is to say that the two types of filaments as disclosed herein do not need to be made of the same polymer. As a non-limiting example, one type of filament may be made from a polyolefin while the other may be either a polyester or a polyamide. Along those lines, each extruded filament may be combinations of polymers. In one way, this may be that a first extruded filament may be comprised of PET and PTT. In another way, it may be that a multilobal filament may have a core of one type of polymer and lobes of another type. In another way, a filament may have a core of one polymer and a sheath of another polymer. Combinations of all of these are also envisioned and do not depart from the spirit of the inventions disclosed and taught herein.

[0068] In another envisioned embodiment, a bundle of filaments as disclosed and taught herein may be combined with one or more bundles of filaments that do not have filaments with different cross-sections to make a yarn. That is to say that a first bundle of filaments may have trilobal and ribbon filaments in it, and that bundle is combined with a bundle of filaments having round cross-sections.

[0069] Further testing has provided some preferred embodiments for combinations of generally 4 dpf solid core trilobal and solid ribbon filaments. In a first embodiment, yarn may be made from 60-80% ribbon filaments with 20-40% trilobal filaments.

[0070] A more preferred embodiment is a yam made from 65%-75% ribbon filaments with 25-35% trilobal filaments. An even more preferred embodiment is a yam made from 70% ribbon filaments with 30% trilobal filaments.

[0071] Table 1 lists some of the ratios of the types of filaments having trilobal and ribbon cross-section that comprise a yarn using all generally 4 dpf filaments as disclosed and taught herein.

[0072]

[0073] Table 1

[0074] In these preferred embodiments of generally 4 dpf filaments, a filament denier of between 3 and 5 dpf (3.33 dtpf and 5.56 dtpf) may be used. In a more preferred embodiment, a filament denier of between 3.5 and 4.5 dpf (3.89 and 5.00 dtpf) may be used.

[0075] A yarn denier of 1,330 grams per 9,000 meters (1,478 dtex) was used for all yarns to provide a consistent testing environment. Applicant’s inventions disclosed and taught herein are not limited to a yam of that denier. Any yarn weight may be used with the inventions disclosed and taught herein.

[0076] In an embodiment of generally 4 dpf filaments using trilobal and ribbon filaments, a preferred embodiment of a trilobal filament may have a modification ratio of between 1.4 and 2.7. A preferred spinneret pattern to make trilobal filaments having those modification ratios is a trilobal pattern having a modification ratio of 5.56 while using a jet velocity to achieve a finished trilobal filament having a modification ratio of between 1.4 and 2.7. A preferred embodiment for a spinneret pattern for ribbon filaments has an aspect ratio of 6: 1.

[0077] Applicant’s embodiments of generally 4 dpf filaments used for testing combined ribbon and trilobal filaments manually. That is to say that in one embodiment, a group of ribbon filaments and a group of trilobal filaments may be drawn and texturized together to form a yarn or a bundle that may be combined with other bundles to form a yarn. A preferred embodiment is to extrude a plurality of trilobal and ribbon filaments from a single spinneret plate to form either a bundle or a yarn.

[0078] In a preferred embodiment of generally 4 dpf filaments, a spinneret plate may comprise 60-80% ribbon filament patterns with 20-40% trilobal filament patterns. A more preferred embodiment is a spinneret plate having 65%-75% ribbon filament patterns with 25-35% trilobal filament patterns. An even more preferred embodiment is a spinneret plate with 342 filament patterns comprised of 256 ribbon filament patterns and 86 trilobal filament patterns. In this, the patterns are the shape of the capillaries on the extrusion face of the spinneret plate. While this embodiment of a spinneret plate has a ratio of 256:86 ribbon filament patterns to trilobal filament patters, other ratios disclosed and taught herein may be used.

[0079] In one embodiment, the spinneret plate may be configured to have each trilobal pattern configured with a modification ratio of between 5.00 and 6.00. In a preferred embodiment, each trilobal pattern may be configured with a modification ratio of between 5.50 and 5.60. In a more preferred embodiment, each trilobal pattern may be configured with a modification ratio of 5.56.

[0080] In one embodiment of generally 4 dpf filaments, the spinneret plate may be configured to have each ribbon pattern configured with an aspect ratio of between 4: 1 and 8: 1. In another embodiment, the spinneret plate may be configured to have some ribbon patterns configured with an aspect ratio of 4: 1 and others with an aspect ratio of 6: 1. In a preferred embodiment all ribbon patterns may be configured to have an aspect ratio of 6: 1. In one of several embodiments of a spinneret plate for extruding generally 4 dpf filaments in accordance with the inventions disclosed and taught herein, each pattern may be configured to extrude a filament having a denier of between 3 and 5 dpf (3.33 dtpf and 5.56 dtpf). In a preferred embodiment for this spinneret configuration, each pattern may be configured to extrude a filament having a denier of between 3.5 and 4.5 dpf (3.89 and 5.00 dtpf).

[0081] In a preferred embodiment a spinneret plate of this configuration to extrude generally 4 dpf filaments, the trilobal patterns may be grouped within the center of the spinneret plate with the ribbon patterns surrounding them. Having this arrangement of patterns may aid in quenching the extruded filaments since air or another cooling fluid may move more easily between the ribbon filaments than between trilobal filaments. This pattern arrangement may also be preferred as it may limit the movement of the individual filaments within the bundle or the yam.

[0082] Figure 3 illustrates an exemplary spinneret plate 300 with trilobal patterns 392 and ribbon patterns 391 on its extrusion face 390. In this, the capillaries may be entirely perpendicular to the plane of the extrusion face 390, or they may be flared at the edges near the extrusion face 390. In a preferred embodiment the capillaries may be flared outwardly from the capillary at an angle of between 50° and 75° from the axial direction of the capillary running through the spinneret plate 300. That is to say that tracing one side of the capillary wall as it runs through the spinneret plate towards the extrusion face will start with a line perpendicular to the extrusion face within the extrusion plate, and will flare outward by an angle of between 25° and 37.5° as it approaches the extrusion face. The capillary wall opposite will have the same angle of flare in the opposite direction as it approaches the extrusion face so that the combination of the two flared portions results in an angle of between 50° and 75° from the axial direction of the capillary running through the spinneret plate.

[0083] In a preferred embodiment of extruding a bundle of filaments through a spinneret plate, a quenching fluid may be propelled across the filaments as they are being extruded. In some embodiments, the quenching fluid may be air controlled to be at a temperature and a humidity. In other embodiments, the quenching fluid may be other gases or liquids. In these, a preferred embodiment is to have the quenching fluid cross the filaments as they are being extruded in the direction of the quench fluid 380, which is perpendicular to the long axis of the spinneret plate 300.

[0084] In a preferred embodiment, the ribbon patterns 391 may be oriented such that the long axis of each ribbon pattern 391 is parallel to the direction of the quench fluid 380. In this, the quenching fluid will laminarly flow across the major axes of the ribbon filaments as they are being extruded.

[0085] In a preferred embodiment, the trilobal patterns 392 may be oriented such that an apex of the trilobal filament is facing the direction of the quench fluid 380. In this, a lobe that is parallel to the direction of the quench fluid 380 may have its distal end downwind of the direction of the quench fluid 380.

[0086] Figure 3 illustrates an embodiment of a spinneret plate face 390 where the extrusion patterns 391, 392 are arranged symmetrically. The inventions taught and disclosed herein are not limited to that arrangement. In other embodiments, the extrusion patters may be arranged in staggered order, where the staggering may be in the rows along the minor axis, or in the columns along the major axis, or both.

[0087] Figure 4 illustrates a magnified bundle 400 as disclosed and taught herein. The bundle 400 contains filaments having trilobal cross-sections 492, and filaments having ribbon cross-sections 491. The bundle 400 comprises about 70% ribbon filaments and about 30% trilobal filaments.

[0088] In this magnified bundle 400, it may be seen that the texturizing actions performed on the bundle has mixed together the ribbon filaments 491 and the trilobal filaments 492.

[0089] The bundle 400 may comprise a yarn by itself, of may be combined with other bundles to make a yarn.

[0090] In another illustrative embodiment of a spinneret plate, a bundle of filaments may be made from a combination of trilobal and ribbon cross-sections where the trilobal filaments have a first linear weight, where the ribbon filaments have a second linear weight, and where all of the filaments are produced from a single spinneret associated with a single spin pump.

[0091] Figure 5 illustrates a spinneret plate 500 according to the inventions disclosed and taught herein. The non-extrusion face 501 of the spinneret plate 500 has been configured with boreholes 510, which all have the same diameter within the tolerances of manufacture. In this exemplary embodiment, each borehole 510 may be aligned horizontally along the long axis of the spinneret plate 500, and staggered from the next adjacent borehole 510 along the short axis. This may be done to maximize the number of boreholes 510 in the area of the non-extrusion face 501. That is to say that having the boreholes 510 staggered in their alignment may produce a higher density of boreholes 510 on the non-extrusion face 501, than if the boreholes had been strictly aligned in a center-to-center arrangement in both the long and short axes of the non-extrusion face of the spinneret plate.

[0092] While the figures show the details of the boreholes and capillaries, it must be noted that they may not be show in their correct proportions. In many cases, the borehole is relatively much larger than the outer dimensions of the capillary or capillaries contained therein.

[0093] In the illustrative embodiment of Figure 5, a quenching fluid may be blown across the extruded filaments in the general direction of the arrow 512.

[0094] A close-up view of typical group of boreholes 520 is illustrated in Figure 6. In this illustrative embodiment, capillaries have been configured within each borehole 510. In this illustrative embodiment, some of the boreholes 510 have been configured with trilobal capillaries 630 and some with ribbon capillaries 640.

[0095] In each borehole 510 with a trilobal capillary 630, each trilobal capillary 630 has been configured to extrude a generally 4 dpf trilobal filament. That is to say that under a configured pressure of polymer melt exerted by the spin pump associated with the spinneret plate, the cross-sectional area of each trilobal capillary 630 has been configured to extrude a filament of generally 4 dpf. In each borehole 510 with a ribbon capillary 640, each ribbon capillary 640 has been configured to extrude four ribbon filaments where the combined linear density of the four ribbon filaments is generally 4 dpf. That is to say that under a configured pressure of polymer melt exerted by the spin pump associated with the spinneret plate, the cross-sectional area of the four ribbon capillaries 640 has been configured to extrude four filaments, that when combined have a linear weight of generally 4 dpf

[0096] In the illustrated embodiment the capillaries may be arranged to form desired patterns when the filaments are extruded. However, this need not always be the case.

[0097] Figure 7 illustrates a pattern of capillaries viewed from the extrusion face of the spinneret plate. A repeating pattern 750 may be seen where each trilobal filament is surrounded by four ribbon filaments where each of the four ribbon filaments has been extruded from a separate borehole.

[0098] One way of describing this exemplary embodiment is that the mass of polymer flowing through each borehole is substantially the same as that flowing through the adjacent boreholes. As disclosed, this may be accomplished by configuring the sum of cross-sectional areas for the capillaries in each borehole to be substantially the same. When this is done with the boreholes having the same diameters and depths, the filaments extruded will be drawn and texturized together and will retain proportional linear weights.

[0099] In an envisioned embodiment, the masses of polymer being extruded from each capillary may be configured to be different by having different cross-sectional areas for the capillaries in different boreholes. That is to say that a first borehole may have a trilobal capillary configured to extrude a generally 4 dpf filament, while a second borehole may have three circular capillaries such that each circular capillary is configured to extrude a generally 4 dpf filament, which results in the three capillaries delivering approximately 12 dpf of filament. As noted previously, the pressure of the polymer melt traveling through the borehole with a larger egress cross-sectional area will be less than the pressure of the polymer melt traveling through the borehole with the smaller egress cross-sectional area. This will result in a faster jet velocity of polymer from the trilobal capillary. When these are drawn and texturized together, the trilobal filament with a greater jet velocity will not be reduced in its overall proportion as much as each of the circular filaments. Depending upon the draw rate of these filaments, the circular filaments may be greatly reduced in cross-sectional area as compared to the reduction of the cross- sectional area of the trilobal filament.

[0100] The inventions disclosed and taught herein are not limited to having a single capillary in some of the boreholes. Nor are the inventions limited to uniformity throughout the spinneret plate.

[0101] Figure 8 illustrates a preferred embodiment of the inventions disclosed and taught herein for the production of a generally 4-2 dpf bundle of filaments where the trilobal filament is generally 4 dpf and two associated ribbon filaments are each generally 2 dpf, and where the ratio of generally 2 dpf ribbon filament to generally 4 dpf trilobal filament is approximately 18:4. Figure 8 illustrates sets of arrangements 860 of trilobal 830 and ribbon 840 capillaries in boreholes 810 that will provide this ratio. Other arrangements may be made that produce this ratio without deviating from the spirit of the inventions disclosed and taught herein.

[0102] In this illustrative embodiment, the resulting bundle of filaments will have a dispersion of generally 2 dpf ribbon filaments interspersed among generally 4 dpf trilobal filaments. A spinneret using this pattern, or a similar pattern with this ratio, may have 342 boreholes with 105 of them producing generally 4 dpf trilobal filaments and 237 of them producing two generally 2 dpf ribbon filaments. This produces 105 trilobal filaments and 474 ribbon filaments. The yarn produced from this spinneret would then comprise about 18% trilobal filaments and 82% ribbon filaments.

[0103] While the arrangements 860 are illustrated as being linear, which would fit a spinneret non-extrusion face 501 as illustrated in Figure 5, embodiments are not limited to that. For example, the arrangements may be circular or spiral so as to fit a round spinneret plate.

[0104] While the preferred embodiments disclosed and taught herein describe trilobal and ribbon filaments, the inventions are not limited to those. Alternative embodiments include all filament cross-sectional shapes with single or multiple capillaries in each borehole. For example, a first borehole may contain two trilobal capillaries while an adjacent borehole may contain three square capillaries.

[0105] In one embodiment, the spinneret plate may be configured to have each trilobal pattern configured with a modification ratio of between 5.00 and 6.00. In a preferred embodiment, each trilobal pattern may be configured with a modification ratio of between 5.50 and 5.60. In a more preferred embodiment, each trilobal pattern may be configured with a modification ratio of 5.56.

[0106] In one embodiment of generally 2 dpf ribbon filaments, the spinneret plate may be configured to have each ribbon pattern configured with an aspect ratio of between 4:1 and 10: 1. In another embodiment, the spinneret plate may be configured to have some ribbon patterns configured with an aspect ratio of 4: 1 and others with an aspect ratio of 6: 1. In a preferred embodiment all ribbon patterns may be configured to have an aspect ratio of 6: 1.

[0107] In a preferred embodiment, the capillaries in the exemplary spinneret may be entirely perpendicular to the plane of the extrusion face 790, or they may be flared at the edges near the extrusion face 790. In a preferred embodiment the capillaries may be flared outwardly from the capillary at an angle of between 50° and 75° from the axial direction of the capillary running through the spinneret plate 700. That is to say that tracing one side of the capillary wall as it runs through the spinneret plate towards the extrusion face will start with a line perpendicular to the extrusion face within the extrusion plate, and will flare outward by an angle of between 25° and 37.5° as it approaches the extrusion face. The capillary wall opposite will have the same angle of flare in the opposite direction as it approaches the extrusion face so that the combination of the two flared portions results in an angle of between 50° and 75° from the axial direction of the capillary running through the spinneret plate.

[0108] In a preferred embodiment of extruding a bundle of filaments through a spinneret plate, a quenching fluid may be propelled across the filaments as they are being extruded. In some embodiments, the quenching fluid may be air controlled to be at a temperature and a humidity. In other embodiments, the quenching fluid may be other gases or liquids. In these, a preferred embodiment is to have the quenching fluid cross the filaments as they are being extruded in the direction of the quench fluid 512, which is perpendicular to the long axis of the spinneret plate 500.

[0109] In a preferred embodiment, the ribbon patterns 640, 840 may be oriented such that the long axis of each ribbon pattern is parallel to the direction of the quench fluid 512. In this, the quenching fluid will laminarly flow across the major axes of the ribbon filaments as they are being extruded.

[0110] In a preferred embodiment, the trilobal patterns 630, 830 may be oriented such that an apex of the trilobal filament is facing the direction of the quench fluid 512. In this, a lobe that is parallel to the direction of the quench fluid 512 may have its distal end downwind of the direction of the quench fluid 512.

[0111] In another embodiment of a yarn that has a soft hand-feel and good bulk, Applicant has made a yarn composed of generally 2 dpf (2.22 dtpf) ribbon filament with generally 4 dpf trilobal filament. Throughout this specification, Applicant will refer to filaments having deniers of between 1.5 and 2.5 dpf (1.67 dtpf and 2.78 dtpf) as being “generally 2 dpf’. Also, Applicant will refer to embodiments of yarn having combinations of generally 4 dpf trilobal filaments and generally 2 dpf ribbon filaments as “generally 4-2 dpf’.

[0112] As compared to the generally 4 dpf filament embodiments that consist of ribbon and trilobal filaments each having generally 4 dpf filaments, a generally 4-2 dpf yarn may have twice as many filaments of ribbon filaments with the same number of trilobal filaments. The ribbon filaments may have aspect ratios of between 4: 1 and 10:1 and the trilobal filaments may have modification ratios of between 1.4 and 2.7. A preferred aspect ratio of the ribbon filaments in this embodiment is 6:1.

[0113] In a first embodiment, a yam may be made from 11-25% trilobal filaments of generally 4 dpf with 75-89% ribbon filaments of generally 2 dpf. A more preferred embodiment is a yarn made from 18% trilobal filaments of generally 4 dpf with 82% ribbon filaments of generally 2 dpf.

[0114] Table 2 lists some of the ratios of the types of filaments having trilobal and ribbon cross-section that comprise a yam using generally 4-2 dpf filaments as disclosed and taught herein. Table 2

[0115] Many other combinations of filaments may be made using all of the processes disclosed and taught herein without departing from the spirit of the inventions claimed to create a bundle or a yarn having the characteristics of softness and bulk as claimed herein. For example, filaments having a ribbon cross-sectional shape throughout the range of between 1.5 dpf and 5 dpf (1.67 dtpf and 5.56 dtpf) may be combined with filaments having a trilobal cross-sectional shape throughout the range of between 1.5 dpf and 5 dpf (1.67 dtpf and 5.56 dtpf).

[0116] In the embodiments described, when the yam is comprised of ribbon being generally 2 dpf (between 1.5 and 2.5 dpf - 1.67 dtpf and 2.78 dtpf) and trilobal filaments being generally 4 dpf (between 3 and 5 dpf - 3.33 dtpf and 5.56 dtpf), then the percentages of ribbon to trilobal filaments may be from about 89% ribbon with about 11% trilobal to about 75% ribbon with about 25% trilobal. Those of skill in the art and in possession of the teachings of this disclosure will be able to envision other embodiments of combinations of different cross-sectioned filaments of different filament deniers in similar proportions without departing from the inventions claimed.

[0117] Quantitative testing was performed on several griege products produced using the processes disclosed and taught herein.

[0118] Griege products were creating using all ribbon filaments, all trilobal filaments, and combinations of ribbon and trilobal filaments. To quantitatively compare results, all yams used to make the griege products were kept at a consistent denier of 1,900 grams per 9,000 meters (2,111 dtex). The griege products were tested using the Carpet and Rug Institute (CRI) Test Methodology 101, Assessment of Carpet Surface Appearance Change using the CRI Reference Scales - Revision 5-27-2003 (CRI TM-101). The test griege products were prepared in accordance with ASTM D-1776M-20 as required by this procedure and were rated using the CRI-4 scale for Cut Pile Commercial Plush. The hexapod used was the 8.4 lb. (3.81 kg) Commercial Hexapod Tester with 12,000 rotations. In conformance with ASTM D- 5252(98a), the carpet was vacuumed after every 2,000 revolutions with a dual motor, top loading, upright vacuum clear with rotating brush.

[0119] The summary of results of the CRI TM-101 tests are reported in Table 3 and show that the griege products using yarn combinations of trilobal and ribbon filaments wore much better than products made with only ribbon filaments. In all tests, they unexpectedly wore the same as griege products made entirely with trilobal products.

[0120] Table 3

[0121] Even with large amounts of ribbon filaments in the yarns, the griege products having a combination of ribbon and trilobal filaments behaved the same as griege products having yarn made entirely of trilobal filaments. That is to say that the griege products having a combination of ribbon and trilobal filaments exhibits the same wear characteristics as a griege product made entirely of trilobal filaments of the same denier. On the other hand, griege products made from yam of entirely ribbon filaments failed the CRI TM-101 tests.

[0122] These results are consistent with the hand-feel tests. The softness hand-feel test results of products made with yarns of combinations of different filament crosssections were between the results from products made from yarns of one crosssection shape or the other as is shown in Figure 1. However, the hand-feel tests for bulk for products made of low denier per filament yam made of combinations of different filament cross-section shapes were higher than the results of yam made entirely of one cross-section shape or the other. A person of skill in the art seeing the results of CRI TM-101 tests of griege products made of yarn having entirely ribbon filaments and griege products made of yam having entirely trilobal filaments would assume that a CRI TM-101 test of griege products made of yam having combinations of ribbon and trilobal filaments would yield results having an average between the two. Unexpectedly, however, the results of CRI TM-101 testing of griege products having filaments of primarily ribbon filaments are that of the more wear-resistant products having yam made entirely of trilobal filaments.

[0123] CONCLUSION

[0124] The present invention is in no way limited to the herein above-described embodiments. On the contrary many such products may be made using yams comprised of combinations of filaments having different cross-sections.

[0125] Applicant’s inventions disclosed and taught herein are not limited to the illustrative embodiments of products made of yarns comprising trilobal and ribbon filaments. Other embodiments using other combinations of filaments having different crosssections are also expected to provide results similar to those disclosed herein. For example, other multilobal filaments may be combined with ribbon filaments or other types of filaments including, but not limited to, round, oval, and square filaments to produce similar results. Additionally, filaments having hollow cores (both multilobal and ribbon, round, oval, or square) made be combined in the ways disclosed and taught herein without departing from the spirit of the inventions claimed.

[0126] Also, Applicant’s inventions disclosed and taught herein are not limited to single types of polymers. That is to say that the two types of filaments as disclosed herein do not need to be made of the same polymer. As a non-limiting example, one type of filament may be made from a polyolefin while the other may be either a polyester or a polyamide. Along those lines, each extruded filament may be combinations of polymers. In one way, this may be that a first extruded filament may be comprised of PET and PTT. In another way, it may be that a multilobal filament may have a core of one type of polymer and lobes of another type. In another way, a filament may have a core of one polymer and a sheath of another polymer. Combinations of all of these are also envisioned and do not depart from the spirit of the inventions disclosed and taught herein.

[0127] In another envisioned embodiment, a bundle of filaments as disclosed and taught herein may be combined with one or more bundles of filaments that do not have filaments with different cross-sections to make a yarn. That is to say that a first bundle of filaments may have trilobal and ribbon filaments in it, and that bundle is combined with a bundle of filaments having round cross-sections.

Claims

CLAIMS1. A yarn, comprising: at least one bundle comprising a first plurality of filaments and a second plurality of filaments; wherein each filament of the first plurality of filaments has a first cross-sectional shape and each filament of the second plurality of filaments has a second cross- sectional shape; and wherein the first cross-sectional shape is different from the second cross-sectional shape.

2. The yarn according to claim 1, wherein the filaments of the first plurality of filaments have a first denier and the filaments of the second plurality of filaments have a second denier; and wherein the first denier is between 1.5 dpf and 5.0 dpf (1.67 and 5.56 dtpf) and the second denier is between 3.0 dpf and 5.0 dpf (3.33 and 5.56 dtpf).

3. The yarn according to either claim 1 or claim 2, wherein: the first plurality of filaments has a first number of filaments and the second plurality of filaments has a second number of filaments; and wherein the ratio of the first number of filaments to the second number of filaments is between 160:20 and 120:40.

4. The yarn according to any previous claim 1-3, wherein the first filament cross-sectional shape is a ribbon and the second filament cross-sectional shape is a trilobal.

5. The yarn according to claim 4, wherein the first filament cross-sectional shape has an aspect ratio of between 4: 1 and 10: 1.

6. The yarn according to either of claims 4 or 5, wherein the second filament cross-sectional shape has a modification ratio of between 1.4 and 2.7.

7. A griege product tufted with the yam of any proceeding claim 1-6, wherein the griege product passes a CRI TM-101 test whereas a griege good tufted entirely with only filaments of the ribbon cross-sectional shape will fail the CRI TM-101 test.

8. A griege product tufted with the yam of any proceeding claim 1-6, wherein the griege product passes a CRI TM-101 test at a same rating as a griege good tufted entirely with only filaments of the trilobal cross-sectional shape.

9. A spinneret plate, comprising: an extrusion face comprising a first plurality of extrusion patterns and a second plurality of extrusion patterns.

10. The spinneret plate according to claim 9, wherein the first plurality of extrusion patterns is comprised of a first portion and a second portion, and wherein the first and second portions of the first plurality of extrusion patterns are apart from each other and are separated by the second plurality of extrusion patterns.

11. The spinneret plate according to either of claims 9 or 10, wherein the spinneret plate has a major axis and a minor axis, and the second plurality of extrusion patterns is grouped in the center of the major axis and the first portion of the second plurality of extrusion patterns is grouped towards a first end of the major axis.

12. The spinneret plate according to any proceeding claim 9-11, wherein each pattern in the first plurality of extrusion patterns has a ribbon cross-sectional shape and each pattern in the second plurality of extrusion patterns has a trilobal cross- sectional shape.

13. The spinneret plate according to claim 12, wherein the ribbon cross- sectional shape has an aspect ratio of 6: 1 and the trilobal cross-sectional shape has a modification ratio of 5.56.

14. The spinneret plate according to claim 13, wherein each extrusion pattern in the first and second pluralities of extrusion patterns comprises a capillary and wherein all of the capillaries are flared outwards at the extrusion face.

15. A method of using the spinneret plate according to any proceeding claim 9- 11 to make a bundle of filaments, comprising: extruding a polymer through the spinneret plate to produce filaments.

16. The method of making a bundle of filaments according to claim 15, wherein each of the filaments produced from the first plurality of extrusion patterns has a ribbon cross-sectional shape and each of the filaments produced from the second plurality of extrusion patterns has a trilobal cross-sectional shape.

17. The method of making a bundle of filaments according to claim 16, wherein the trilobal filaments extruded have a modification ratio of between 1.4 and 2.7.

18. The method of using the spinneret plate according to any preceding claim 13-14 to make a bundle of filaments, comprising: extruding a polymer through the spinneret plate to produce filaments.

19. The method of making a bundle of filaments according to claim 18 wherein the trilobal filaments extruded have an aspect ratio of between 1.4 and 2.7.

20. A yarn comprising at least one bundle of filaments produced from the method according to any preceding claims 15-19.

21. A griege product comprising at least one bundle of filaments produced from the method according to any preceding claim 15-20 tufted into a primary backing.

22. The griege product according to claim 21 wherein the primary backing is a woven or non-woven.

23. A yarn, comprising: at least one bundle comprising a first plurality of filaments and a second plurality of filaments; wherein each filament of the first plurality of filaments has a first cross-sectional shape and each filament of the second plurality of filaments has a second cross- sectional shape; and wherein the first cross-sectional shape is different from the second cross-sectional shape.

24. The yam of claim 23, wherein the filaments of the first plurality of filaments have a first denier and the filaments of the second plurality of filaments have a second denier; and wherein the first denier is between 1.5 dpf and 5.0 dpf (1.67 and 5.56 dtpf) and the second denier is between 3.0 dpf and 5.0 dpf (3.33 and 5.56 dtpf).

25. The yarn of claim 24, wherein: the first plurality of filaments has a first number of filaments and the second plurality of filaments has a second number of filaments; and wherein the ratio of the first number of filaments to the second number of filaments is between 160:20 and 120:40.

26. The yarn of claim 25, wherein the first filament cross-sectional shape is a ribbon and the second filament cross-sectional shape is a trilobal.

27. The yarn of claim 26, wherein the first filament cross-sectional shape has an aspect ratio of between 4: 1 and 10: 1.

28. The yarn of claim 27, wherein the second filament cross-sectional shape has a modification ratio of between 1.4 and 2.7.

29. A griege product tufted with the yarn of claim 27, wherein the griege product passes a CRI TM-101 test whereas a griege good tufted entirely with only filaments of the ribbon cross-sectional shape will fail the CRI TM-101 test.

30. Agriege product tufted with the yarn of claim 27, wherein the griege product passes a CRI TM-101 test at a same rating as a griege good tufted entirely with only filaments of the trilobal cross-sectional shape.

31. A spinneret plate, comprising: a non-extrusion face comprising a plurality of boreholes; an extrusion face opposite the non-extrusion face comprising a first plurality of capillary patterns and a second plurality of capillary patterns.

32. The spinneret plate according to claim 31, wherein the first plurality of capillary patterns comprises two ribbon-shaped capillaries and the second plurality of capillary patterns comprises a trilobal-shaped capillaries.

33. The spinneret plate according to claim 32, wherein the ribbon-shaped capillaries have an aspect ratio of 6: 1 and the trilobal-shaped capillaries have a modification ratio of 5.56.

34. The spinneret plate according to claim 33, wherein at least one of the capillaries is flared outwards at the extrusion face.

35. The spinneret plate according to claim 32, wherein the spinneret plate is configured to extrude about 82% ribbon filaments and about 18% trilobal filaments.

36. The spinneret plate according to claim 35, wherein each capillary pattern is in fluid communication with a borehole, and the ratio of boreholes in fluid communications with the first plurality of capillary patterns to the boreholes in fluid communication with the second plurality of capillary patterns is about 9:4.

37. A method of using the spinneret plate of claim 33 to make a bundle of filaments, comprising: extruding a polymer through the spinneret plate to produce filaments.

38. The method of making a bundle of filaments of claim 37, wherein each of the filaments produced from the first plurality of extrusion patterns has a ribbon cross-sectional shape and each of the filaments produced from the second plurality of extrusion patterns has a trilobal cross-sectional shape.

39. The method of making a bundle of filaments of claim 38, wherein the trilobal filaments extruded have an aspect ratio of between 1.4 and 2.7.

40. The method of using the spinneret plate of claim 35 to make a bundle of filaments, comprising: extruding a polymer through the spinneret plate to produce filaments.

41. The method of making a bundle of filaments of claim 40 wherein the trilobal filaments extruded have an aspect ratio of between 1.4 and 2.7.

42. A griege product comprising at least one bundle of filaments produced from the method of claim 40.

43. A spinneret plate, comprising:a non-extrusion face comprising a plurality of boreholes; an extrusion face opposite the non-extrusion face comprising a first plurality of capillary patterns and a second plurality of capillary patterns.

44. The spinneret plate according to claim 43, wherein the first plurality of capillary patterns comprises two ribbon-shaped capillaries and the second plurality of capillary patterns comprises a trilobal-shaped capillaries.

45. The spinneret plate according to claim 44, wherein the ribbon-shaped capillaries have an aspect ratio of 6: 1 and the trilobal-shaped capillaries have a modification ratio of 5.56.

46. The spinneret plate according to claim 45, wherein at least one of the capillaries is flared outwards at the extrusion face.

47. The spinneret plate according to any previous claim 43-46, wherein the spinneret plate is configured to extrude about 82% ribbon filaments and about 18% trilobal filaments.

48. The spinneret plate according to any previous claim 43-47, wherein each capillary pattern is in fluid communication with a borehole, and the ratio of boreholes in fluid communications with the first plurality of capillary patterns to the boreholes in fluid communication with the second plurality of capillary patterns is about 9:4.

49. A method of using the spinneret plate according to any proceeding claim 43-48 to make a bundle of filaments, comprising: extruding a polymer through the spinneret plate to produce filaments.

50. The method of making a bundle of filaments according to claim 49, wherein each of the filaments produced from the first plurality of extrusion patterns has aribbon cross-sectional shape and each of the filaments produced from the second plurality of extrusion patterns has a trilobal cross-sectional shape.

51. The method of making a bundle of filaments according to claim 50, wherein the trilobal filaments extruded have a modification ratio of between 1.4 and 2.7.

52. The method of using the spinneret plate according to any preceding claim 43-48 to make a bundle of filaments, comprising: extruding a polymer through the spinneret plate to produce filaments.

53. The method of making a bundle of filaments according to claim 52 wherein the trilobal filaments extruded have a modification ratio of between 1.4 and 2.7.

54. A yarn comprising at least one bundle of filaments produced from the method according to any preceding claims 49-53.

55. Agriege product comprising at least one bundle of filaments produced from the method according to any preceding claim 49-54 tufted into a primary backing.

56. The griege product according to claim 55 wherein the primary backing is a woven or non-woven.

57. A yarn, comprising: a plurality of filaments comprising:M first filaments, wherein each of the M first filaments has a first cross-sectional shape, a first cross-sectional area, and a first linear weight;N second filaments, wherein each of the N second filaments has a second cross-sectional shape, a second cross-sectional area, and a second linear weight; wherein:the second cross-sectional shape is different from the first cross- sectional shape;N is a multiple of M such that N divided by M is a whole number X that is greater than 1 ; and the first linear weight is equal to the second linear weight multiplied by X.

58. The yarn of claim 57, wherein the first cross-sectional area is equal to the second cross-sectional area multiplied by X.

59. The yarn of claim 57, wherein the first cross-sectional shape is multilobal.

60. The yarn of claim 57, wherein the second cross-sectional shape is selected from the group consisting of round, oval, and square.

61. The yarn of claim 57, wherein either the first or the second filament comprises a core and sheath.

62. The yarn of claim 57, wherein the whole number X is selected from the group consisting of 2, 3, and 4.

63. The yarn of claim 62, wherein a total number of filaments of the first filaments in the yam is between about 11% and about 30% of a total number of filaments of the plurality of filaments in the yam.

64. The yarn of claim 63, wherein the first cross-sectional shape is trilobal and the second cross sectional shape is ribbon.

65. The yarn of claim 64, wherein the first linear length is between 3 and 5 dpf (3.33 dtpf and 5.56 dtpf).

66. A griege product made with the yarn of claim 65.

67. A carpet or rug made from the griege product of claim 66.

68. A spinneret plate, comprising: an extrusion face comprising: a first plurality of capillaries having a first capillary cross-section shape, and a first capillary cross-section area; and a second plurality of capillaries having a second capillary crosssection shape, and a second capillary cross-section area; wherein: the first capillary cross-section shape is different from the second capillary cross-section shape; and there are more of the second plurality of capillaries than there are of the first plurality of capillaries.

69. The spinneret plate of claim 68, wherein: the spinneret plate has a major axis and a minor axis, wherein the major axis has a center, a first end, and a second end; the first plurality of capillaries is grouped proximal the center; a first portion of the second plurality of capillaries is grouped proximal the first end; a second portion of the second plurality of capillaries is grouped proximal the second end; the first portion of the second plurality of capillaries is separated from the second portion of the second plurality of capillaries by the first plurality of capillaries; and the first cross-section shape is multilobal and the second cross-section shape is ribbon.

70. The spinneret plate of claim 69, wherein each capillary of the first plurality of capillaries is configured with a modification ratio of 5.56, each capillary of the second plurality of capillaries is configured with an aspect ratio of 6: 1, and wherein each capillary of the first and second pluralities of capillaries is flared outwards proximal the extrusion face.

71. The spinneret plate of claim 68, wherein: the first capillary cross-section shape is trilobal and has a modification ratio of between 5.00 and 6.00; the second capillary cross-section shape is ribbon and has an aspect ratio of between 4: 1 and 10: 1.

72. The spinneret plate of claim 68, wherein: the first capillary cross-section shape is trilobal and has a modification ratio of between 5.50 and 5.60; the second capillary cross-section shape is ribbon and has an aspect ratio of 6: 1.

73. The spinneret plate of claim 71, wherein the first plurality of capillaries and the second plurality of capillaries are arranged on the extrusion face in a repeated pattern such that each capillary of the first plurality of capillaries is interspersed within a group of capillaries of the second plurality of capillaries.

74. The spinneret plate of claim 73, wherein the number of the first plurality of capillaries is between 11% and 25% and the sum of the total number of the first and the second pluralities of capillaries.

75. A spinneret plate comprising: an extrusion face distal from and opposite a non-extrusion face; a plurality of boreholes on the non-extrusion face; a plurality of capillary patterns, wherein each capillary pattern comprises:at least one trilobal-shaped capillary having a modification ratio of between 5.50 and 5.60; a plurality of ribbon-shaped capillaries where each ribbon-shaped capillary has an aspect ratio of between 4: 1 and 10: 1; wherein: each of the at least one trilobal-shaped capillary is associated with only one borehole of the plurality of boreholes; and each of the plurality of ribbon-shaped capillaries shares a borehole with at least one other ribbon-shaped capillary.

76. The spinneret plate of claim 75, wherein each trilobal capillary is interspersed within at least two ribbon-shaped capillaries.

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