Melt spun biocomponent filament and method for manufacturing a melt spun biocomponent filament

A method of manufacturing a plurality of bulked continuous filaments, comprising:

• providing a polymer melt;
• separating the polymer melt into a first portion and a second portion;
• treating the first portion to have a different rheological property than the second portion;
• combining the first and second portions;
• and
• melt spinning the combined portions into the plurality of bulked continuous filaments;
• wherein treating the first portion to have a different rheological property comprises adding an additive chosen from the group consisting of a flow aid, a molecular weight booster, a melt flow manipulating agent, a colorant, a plasticizer, a nucleating agent, or combinations thereof.

A plurality of bulked continuous filaments, comprising:

• a first polymer composition comprising a first additive and having a first and a second rheological properties and a second polymer composition comprising a second additive and having the first and the second rheological properties;
• wherein the first rheological property of the first polymer composition is different from the first rheological property of the second polymer composition;
• and
• wherein the second rheological property of the first polymer composition is different from the second rheological property of the second polymer composition;
• wherein the first additive is selected from the group consisting of a flow aid, a molecular weight booster, a melt flow manipulating agent, a colorant, a plasticizer, a nucleating agent, or combinations thereof;
• wherein the second additive is selected from the group consisting of a flow aid, a molecular weight booster, an intrinsic viscosity enhancer, a melt flow manipulating agent, a colorant, a plasticizer, a nucleating agent, or combinations thereof;
• and
• wherein the first rheological property is not the same as the second rheological property.