Fibers, woven fabrics including the fibers, and methods of manufacturing the same

A method of forming a twice-blended ultra-homogenous specialized yarn comprising:

• mixing a plurality of base material staple fibers, cleaning the base material staple fiber, carding the base material staple fiber and forming a cleaned base material staple sliver;
• mixing a plurality of dissolvable fibers, cleaning the dissolvable fiber, carding the dissolvable fiber and forming a cleaned dissolvable sliver, wherein the cleaned base material staple sliver and cleaned dissolvable sliver are produced independently on separate processing lines;
• combining the cleaned base material staple sliver and the cleaned dissolvable sliver for mixing in a blow room to produce a homogenous blend of base material staple fibers and dissolvable fibers;
• cleaning the homogenous blend of base material staple fibers and dissolvable fibers;
• carding the homogenous blend of base material staple fibers and dissolvable fibers;
• forming a homogenously-blended sliver comprising a homogenous blend of base material staple fibers and dissolvable fibers;
• drawing the homogenously-blended sliver on a draw frame;
• and
• spinning the homogenously-blended sliver to produce the twice-blended ultra-homogenous specialized yarn, the twice-blended ultra-homogenous specialized yarn comprising an ultra-homogenous blend of base material staple fibers and dissolvable fibers that are evenly and uniformly distributed throughout the cross section thereof, wherein the dissolvable fibers are positioned amongst the base material staple fibers such that the removal thereof defines a plurality of air voids, wherein when viewing the yarn's cross-section the plurality of air voids are positioned such that at least one air void path, defined between the central core of the yarn and the outer surface, is defined between about every 1-30 degrees around the entire 360 degree circumference of the specialized yarn.

A method of forming a twice-blended ultra-homogenous specialized yarn comprising:

• mixing a plurality of base material staple fibers in a first blow room, cleaning the base material staple fiber, carding the base material staple fiber and forming a cleaned base material staple web;
• providing a plurality of dissolvable fibers, wherein the dissolvable fibers of the specialized yarn are between about 10%-25% of the weight of the sum of the dissolvable fibers and the base material staple fibers;
• combining the cleaned base material staple web and the plurality of dissolvable fibers for mixing in a third blow room to produce a homogenous blend of base material staple fibers and dissolvable fibers;
• cleaning the homogenous blend of base material staple fibers and dissolvable fibers;
• carding the homogenous blend of base material staple fibers and dissolvable fibers;
• forming a homogenously-blended sliver comprising a homogenous blend of base material staple fibers and dissolvable fibers;
• drawing the homogenously-blended sliver on a draw frame to produce a twice-blended ultra-homogenous sliver;
• and
• spinning the twice-blended ultra-homogenous sliver to produce the twice-blended ultra-homogenous specialized yarn, the twice-blended ultra-homogenous specialized yarn comprising an ultra-homogenous blend of base material staple fibers and dissolvable fibers that are evenly and uniformly distributed throughout the cross section thereof, wherein the dissolvable fibers are positioned amongst the base insoluble fibers such that the removal thereof defines a plurality of air voids, wherein when viewing the yarn's cross-section the plurality of air voids are positioned such that at least one air void path, defined between the central core of the yarn and the outer surface, is defined between about every 0.5-15 degrees around the entire 360 degree circumference of the specialized yarn.