Abstract: The present invention relates to a face spinneret and/or nylon face fiber having a certain shape and dimension which impart improved characteristics to the fiber, such a softer feel and a reduced sheen. In another embodiment, the invention is directed to a thatch spinneret and/or nylon thatch fiber having a certain shape and dimension which impart improved characteristics to the fiber, such a softer feel and a reduced sheen.

Abstract: An artificial grass product has 100% nylon face fabric which forms blades of grass when tufted. This grass shows a melt temperature exceeding 400 degrees Fahrenheit, at least about 100 degrees hotter than prior art materials. The thatch can be made of similar materials for at least some embodiments. When coupled with multiple yarns extending from common penetrations, quite durable and attractive products can be provided. Furthermore, resiliency in excess of 10% over prior art polyethylene or polypropylene grass products can be experienced with at least some embodiments.

Abstract: The processes of tufting, spraying coating on backing, and setting yarn been provided in a preferred embodiment as a part of a continuous process. The coating is preferably anhydrous with a tack free time of less than two minutes. The yarn setting station employed in many embodiment sets the yarn in a distance of less than about ten feet by injecting air into the yarn side of the tufted goods, preferably with an air knife while the yarns are spread apart.

Abstract: A texturizer is a base which provides a plurality of inlets directed to stations internal to the base. Each of the stations communicate internal to housings which have inserts therein. Receivers in the inserts receive air from the stations and direct the air towards distal ends of the housings through slots. Prior to reaching the distal ends of the inserts, passages through the inserts direct air to an internal bore in the insert and proximally out the insert bore. The insert bore extends all the way through the insert and through the housing so that yarn is pulled through the housing and crimped preferably at an impingement point in the insert.