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.

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.

A method of creating a soft and lofty continuous fiber nonwoven web is provided. The method includes providing molten polymer to a spinneret defining a plurality of orifices, and flowing a fluid intermediate the spinneret and a moving porous member. The moving porous member is positioned below the spinneret. The method includes using the fluid to draw or push the molten polymer, in a direction that is toward the moving porous member, through at least some of the plurality of orifices to form a plurality of individual continuous fiber strands. The method includes depositing the continuous fiber strands on the moving porous member at a first location to create an intermediate continuous fiber nonwoven web, and removing and/or diverting some of the fluid proximate to the first location to maintain loft and softness in the deposited intermediate continuous fiber nonwoven web.

An airlaid substrate includes at least one bicomponent fiber having a first region and a second region. The first region includes polypropylene and the second includes a blend of an ethylene-base polymer and an ethylene acid copolymer. The ethylene-base polymer has a density from 0.920 g/cm.sup.3 to 0.970 g/cm.sup.3 and a melt index (I.sub.2) from 0.5 g/10 min to 150 g/10 min. The ethylene acid copolymer includes the polymerized reaction product of from 60 wt % to 99 wt % ethylene monomer and from 1 wt % to 40 wt % unsaturated dicarboxylic acid comonomer, based on the total weight of the monomers in the ethylene acid copolymer. The ethylene acid copolymer having a melt index (I.sub.2) from 0.5 g/10 min to 500 g/10 min.

A ball-shaped light heat generating fiber aggregate and a method for producing the same include a light heat generating material that is sprayed and applied to any one filament or a mixture of two or more filaments selected from the group consisting of a polyamide-based filament, a polyester-based filament, and a polypropylene-based filament, opening and mixing the same to separate the filaments, and producing a ball-shaped fiber aggregate.

A ball-shaped light heat generating fiber aggregate and a method for producing the same include a light heat generating material that is sprayed and applied to any one filament or a mixture of two or more filaments selected from the group consisting of a polyamide-based filament, a polyester-based filament, and a polypropylene-based filament, opening and mixing the same to separate the filaments, and producing a ball-shaped fiber aggregate.

This long-fiber woven fabric comprises long fibers formed by two-component conjugate spinning from poly(ethylene terephthalate) and a copolyester, and has an apparent density of 0.1-0.25 g/cc and a recovery from 50% elongation of 55% or greater.

Various aspects disclosed relate to structures such as a textile, a garment, a garment component, footwear, or a footwear component. The present disclosure includes the structure having a first region having one of more first fibers. An individual first fiber includes co-extruded first and second filaments, the first filament formed of a first thermoplastic polymeric material. Due to expansion or contraction of the one or more first fibers, the first region contracts or expands on a change in relative humidity, relative to an equilibrium state of the first region prior to the change in relative humidity.

Various aspects disclosed relate to structures such as a textile, a garment, a garment component, footwear, or a footwear component. The present disclosure includes the structure having a first region having one of more first fibers. An individual first fiber includes co-extruded first and second filaments, the first filament formed of a first thermoplastic polymeric material. Due to expansion or contraction of the one or more first fibers, the first region contracts or expands on a change in relative humidity, relative to an equilibrium state of the first region prior to the change in relative humidity.

A system for preparing a polylactic acid (PLA) spunbond nonwoven fabric is provided. In particular, the system includes a first PLA source configured to provide a stream of molten or semi-molten PLA resin; a spin beam in fluid communication with the first PLA source, the spin beam configured to extrude and draw a plurality of PLA continuous filaments; a collection surface disposed below an outlet of the spin beam onto which the PLA continuous filaments are deposited to form the PLA spunbond nonwoven fabric; a first ionization source positioned and arranged to expose the PLA continuous filaments to ions; and a calender positioned downstream of the first ionization source.