Disclosed is a method for the manufacture of fibrous yarn including the steps, where an aqueous suspension including fibers and at least one rheology modifier is provided, followed by directing the suspension through at least one nozzle, to form at least one yarn, and then dewatering the yarn.

Disclosed is a method for the manufacture of fibrous yarn including the steps, where an aqueous suspension including fibers and at least one rheology modifier is provided, followed by directing the suspension through at least one nozzle, to form at least one yarn, and then dewatering the yarn.

A process for the preparation of plexifilamentary film-fibril strands of polymer. The process includes the steps of generating a spin fluid containing (a) 5 to 30 wt. % containing one or more polymer types, (b) a primary spin agent selected from the group consisting of dichloromethane, cis-1,2-dichloroethylene and trans-1,2-dichloroethylene, and (c) a co-spin agent comprising 1H,6H-perfluorohexane or 1H-perfluorohexane or 1H-perfluoroheptane. The spin fluid is flash-spun at a pressure that is greater than the autogenous pressure of the spin fluid into a region of lower pressure to form plexifilamentary film-fibril strands of the polymer. The co-spin agent is present in the spin fluid in an amount sufficient to form an azeotrope-like composition with the primary spin agent in the presence of the one or more polymer types. The polymer may be selected from the group consisting of high density polyethylene, polypropylene, polybutene-1, polymethylpentene, polyvinylidene fluoride, poly (ethylene tetrafluoroethylene), and blends of the foregoing.

A process for the preparation of plexifilamentary film-fibril strands of polymer. The process includes the steps of generating a spin fluid containing (a) 5 to 30 wt. % containing one or more polymer types, (b) a primary spin agent selected from the group consisting of dichloromethane, cis-1,2-dichloroethylene and trans-1,2-dichloroethylene, and (c) a co-spin agent comprising 1H,6H-perfluorohexane or 1H-perfluorohexane or 1H-perfluoroheptane. The spin fluid is flash-spun at a pressure that is greater than the autogenous pressure of the spin fluid into a region of lower pressure to form plexifilamentary film-fibril strands of the polymer. The co-spin agent is present in the spin fluid in an amount sufficient to form an azeotrope-like composition with the primary spin agent in the presence of the one or more polymer types. The polymer may be selected from the group consisting of high density polyethylene, polypropylene, polybutene-1, polymethylpentene, polyvinylidene fluoride, poly (ethylene tetrafluoroethylene), and blends of the foregoing.

A process for the preparation of plexifilamentary film-fibril strands of polymer. The process includes the steps of generating a spin fluid containing (a) 5 to 30 wt. % containing one or more polymer types, (b) a primary spin agent selected from the group consisting of dichloromethane, cis-1,2-dichloroethylene and trans-1,2-dichloroethylene, and (c) a co-spin agent comprising 1H,6H-perfluorohexane or 1H-perfluorohexane or 1H-perfluoroheptane. The spin fluid is flash-spun at a pressure that is greater than the autogenous pressure of the spin fluid into a region of lower pressure to form plexifilamentary film-fibril strands of the polymer. The co-spin agent is present in the spin fluid in an amount sufficient to form an azeotrope-like composition with the primary spin agent in the presence of the one or more polymer types. The polymer may be selected from the group consisting of high density polyethylene, polypropylene, polybutene-1, polymethylpentene, polyvinylidene fluoride, poly (ethylene tetrafluoroethylene), and blends of the foregoing.

A process for the preparation of plexifilamentary film-fibril strands of polymer. The process includes the steps of generating a spin fluid containing (a) 5 to 30 wt. % containing one or more polymer types, (b) a primary spin agent selected from the group consisting of dichloromethane, cis-1,2-dichloroethylene and trans-1,2-dichloroethylene, and (c) a co-spin agent comprising 1H,6H-perfluorohexane or 1H-perfluorohexane or 1H-perfluoroheptane. The spin fluid is flash-spun at a pressure that is greater than the autogenous pressure of the spin fluid into a region of lower pressure to form plexifilamentary film-fibril strands of the polymer. The co-spin agent is present in the spin fluid in an amount sufficient to form an azeotrope-like composition with the primary spin agent in the presence of the one or more polymer types. The polymer may be selected from the group consisting of high density polyethylene, polypropylene, polybutene-1, polymethylpentene, polyvinylidene fluoride, poly (ethylene tetrafluoroethylene), and blends of the foregoing.

Fibers, yarns, woven fabric including the yarns and fibers, and methods of manufacturing the same are disclosed. Fibers can include base material staple fibers and dissolvable or water-soluble fibers. At least the base material staple fiber is mixed and cleaned to form a base material web or sliver. The clean base material web or sliver is then intimately mixed with the dissolvable fibers in a blow room to form a homogenously-mixed base material/dissolvable material sliver. The homogenously-mixed base material/dissolvable material sliver is then blended again during drawing so as to produce a twice-mixed, ultra-homogenous yarn comprising base material and dissolvable material. A processing step can allow for removal of the dissolvable fibers to produce a yarn defining a plurality of pores that are uniformly distributed throughout the structure of the yarn.

Fibers, yarns, woven fabric including the yarns and fibers, and methods of manufacturing the same are disclosed. Fibers can include base material staple fibers and dissolvable or water-soluble fibers that are mixed together to define an ultra-homogenous yarn comprising base material and dissolvable material, which is provided in at least the warp direction to form a woven fabric having a 7-end, 8-end or 10-end sateen weave. A processing step provides for the removal of the dissolvable fibers to produce a yarn defining a plurality of pores that are uniformly distributed throughout the structure of the yarn. The woven fabric has a thread count between 450-1200. The woven fabric is thermally-insulative, breathable and moisture-wicking.

Fibers, yarns, woven fabric including the yarns and fibers, and methods of manufacturing the same are disclosed. Fibers can include base material staple fibers and dissolvable or water-soluble fibers that are mixed together to define an ultra-homogenous yarn comprising base material and dissolvable material, which is provided in at least the warp direction to form a woven fabric having a 7-end, 8-end or 10-end sateen weave. A processing step provides for the removal of the dissolvable fibers to produce a yarn defining a plurality of pores that are uniformly distributed throughout the structure of the yarn. The woven fabric has a thread count between 450-1200. The woven fabric is thermally-insulative, breathable and moisture-wicking.

A sheet comprising a plexifilamentary film-fibril network consisting essentially of high density polyethylene in an overlapping multi-directional configuration, the sheet, as-produced from a spin cell, having a normalized Frazier air permeability of between 0.002 and 0.2 m.sup.3/m.sup.2.Math.minute at 50 gsm, a BET surface area of between 9 and 20 m.sup.2/gm, and a normalized hydrohead of between 150 and 250 cm at 50 gsm, wherein the plexifilamentary film-fibril network in an overlapping multi-directional configuration is flash-spun from a spin fluid comprising polymer and spin agent, the spin fluid temperature being 190° C. or greater, the spin agent comprising dichloromethane, the spin fluid having a polymer concentration of 12 to 14 weight percent.