Composite textile and method of manufacturing the same

Abstract

A composite fabric may include various layers, such as a nonwoven layer and a waterproof and breathable membrane. The composite fabric may include various properties, such as water resistance and water repellency. Furthermore, the composite fabric can be manufactured using various technologies that can be configured to impart desired properties. The composite fabric is suitable for forming articles designed for harsh weather conditions.

Description

Technical Field

[0001] This specification describes a waterproof and breathable non-woven fabric for a product and a method of manufacturing the same. Background Art

[0002] Conventional products (e.g., wearable products, bags, etc.) designed for harsh weather conditions (e.g., precipitation) are typically formed from knitted or woven fabrics. In some cases, the knitted or woven fabric can be combined with a waterproof and breathable membrane. However, knitted and / or woven fabrics are typically manufactured using processes that are less sustainable and / or consume a relatively high amount of energy (e.g., knitting, weaving, dyeing, etc.). Summary of the Invention

[0003] A composite fabric can include various layers, such as a non-woven layer and a waterproof and breathable membrane. The composite fabric can include various properties, such as water resistance, water repellency, etc. In addition, the composite fabric can be manufactured using various techniques that can be configured to impart desired properties. The composite fabric can be suitable for forming products designed for harsh weather. Brief Description of the Drawings

[0004] The subject matter of the present disclosure relates to a waterproof and breathable non-woven fabric and is described in detail below with reference to the drawings: [FIG. 1] illustrates an example life cycle of an example first composite fabric in accordance with various aspects herein. [FIG. 2] illustrates a first non-woven fabric layer of the first composite fabric for [FIG. 1] in accordance with various aspects herein. [FIG. 3] illustrates a waterproof and breathable membrane of the first composite fabric for [FIG. 1] in accordance with various aspects herein. [FIG. 4] illustrates an optional second non-woven fabric layer of the first composite fabric for [FIG. 1] in accordance with various aspects herein. [FIG. 5] illustrates a first side of the first composite fabric of [FIG. 1] in accordance with various aspects herein. [FIG. 6] illustrates a relative second side of the first composite fabric of [FIG. 1] in accordance with various aspects herein. [FIG. 7] illustrates a first example manufacturing process for forming the first composite fabric of [FIG. 1] in accordance with various aspects herein. [FIG. 8] illustrates a second example manufacturing process for forming the first composite fabric of [FIG. 1] in accordance with various aspects herein. [FIG. 9] illustrates a third example manufacturing process for forming the first composite fabric of [FIG. 1] in accordance with various aspects herein. [Figure 10] illustrates a waterproof and breathable membrane for an exemplary second composite fabric according to various aspects herein. [Figure 11] illustrates a non-woven fabric layer for a second composite fabric according to various aspects herein. [Figure 12] illustrates a first side of a second composite fabric according to various aspects herein. [Figure 13] illustrates an opposite second side of a second composite fabric according to various aspects herein. [Figure 14] illustrates an exemplary manufacturing process for forming a second composite fabric according to various aspects herein. [Figures 15A] through [Figure 15B] illustrate a front view and a rear view, respectively, of a first exemplary clothing article for the upper body formed from a first composite fabric and / or a second composite fabric according to various aspects herein. [Figures 16A] through [Figure 16B] illustrate a front view and a rear view, respectively, of a second exemplary clothing article for the lower body formed from a first composite fabric and / or a second composite fabric according to various aspects herein. Embodiments

[0005] [Cross-Reference to Related Applications]

[0006] This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 525,482, filed on July 7, 2023, which is hereby incorporated by reference in its entirety.

[0007] This specification describes waterproof and breathable non-woven fabrics and methods of manufacturing the same. In at least some instances, the waterproof and breathable non-woven fabrics can be intended for use in products (such as wearable products, bags, etc.) used in adverse weather (such as precipitation). In the examples of the present disclosure, one or more non-woven fabric layers can be combined with a waterproof and breathable membrane. For example, the one or more non-woven fabric layers can include a spunlace layer, entangled fibers (such as needle-entangled staple fibers), and / or other types of non-woven fabrics, such as spunbond fabrics, meltblown fabrics, etc. In addition to being waterproof, the one or more non-woven fabric layers can also include additional properties, such as water repellency, color properties (such as via dyes applied or impregnated by various means (such as sublimation or as a supercritical fluid in a CO2 medium)), breathability, pilling resistance, etc. Compared to conventional waterproof fabrics, the subject matter of the present disclosure can be more sustainable (such as by using fewer resources to manufacture, by facilitating the manufacture with recycled materials (including shredded products), by being more easily recycled into future products, etc.). These and other examples associated with the present disclosure are described in more detail below.

[0008] Contrary to the present disclosure, some conventional fabrics designed for harsh conditions (e.g., precipitation) are typically formed from knitted or woven fabrics (to which a durable water repellent coating is applied). In another example, a waterproof breathable membrane can be sandwiched between or positioned between knitted and / or woven fabrics. Knitted and / or woven fabrics are typically manufactured using processes (e.g., knitting or weaving) that are less sustainable and / or consume more energy compared to other fabric manufacturing processes. Additionally, the coloring processes used to finish knitted and / or woven fabrics typically consume a large amount of energy. For example, typical dyeing processes for knitted and / or woven fabrics include a water dyeing process as well as a drying process. Both water consumption and the energy used to dry the fabric increase the fabric's carbon footprint. Additionally, the structure of conventional knitted and / or woven fabrics is generally not conducive to incorporating fibers derived from different categories of recyclable and / or recycled items (including shredded products), which may limit sustainability.

[0009] As indicated, examples of the present disclosure can include composite fabrics incorporating one or more non-woven fabric layers and sustainable processes for forming the composite fabrics, where the composite fabrics are suitable for forming articles designed for inclement weather (such as rain, sleet, or snow). Due to the spaces between the entangled fibers, the non-woven fabric itself can be porous. In some cases, these spaces can allow water to pass through the fabric and / or sometimes can trap water and / or moisture, and thus, non-woven fabrics have not traditionally been used for articles designed for inclement weather. Examples of the present disclosure envision combining one or more non-woven fabric layers with a waterproof breathable membrane and / or a durable water repellent deposit to impart waterproof and / or water repellent characteristics to the composite fabric.

[0010] Additionally, some examples of the present disclosure can include waterproof and / or water repellent non-woven fabrics having printed components. In an example, the printed component is a deposit or application of any functional material (e.g., a fluid, such as in liquid form, gas form, supercritical form, etc.) on the composite fabric (e.g., on the fibers or in the fibers). The deposit can be via any of a variety of application processes (e.g., a printing process), such as screen printing, print heads, padding (e.g., print padding, solution padding (in a bath), etc.), gravure printing, sublimation printing, extrusion, CO2 dyeing, etc. The material of the printed component can be configured to perform one or more functions, such as coloring or forming a pattern, reducing pilling, water repellency (e.g., water or solvent-based durable water repellent (DWR)), waterproofing, water vapor control, anti-adhesion, breathability balance, surface roughness or smoothness, etc.

[0011] Typically, in contrast to conventional non-woven fabrics (e.g., fabrics including knitted, braided, and / or woven structures), the composite fabrics disclosed herein are sustainable and / or sustainably produced. For example, the non-woven fabric layer can incorporate fibers from completely different recycled fiber sources, which provides additional utilization options for various end-of-life products. In contrast, conventional fabrics and systems may limit the sources from which they accept recycled fibers and do not provide non-landfill disposal options for various types of goods. Additionally, the composite fabrics described herein can be part of a closed-loop or semi-closed-loop that uses raw materials (e.g., polymeric materials) to produce clothing products and repeatedly uses the same raw materials (e.g., the same polymeric materials) to produce subsequent generations of clothing products. Beyond this, these aspects contribute to sustainability by using and reusing materials that might otherwise be discarded in landfills.

[0012] Consistent with this, aspects herein contemplate that the composite fabric and the clothing products formed from the composite fabric are fully recyclable. In other words, the non-woven fabric layer and the waterproof breathable membrane in the composite fabric can be from the same or similar polymer classes that facilitate the full recyclability and ease of recycling of the fabric and / or clothing (e.g., without the need to separate or classify the components of the composite fabric before recycling or shredding). For example, the fibers (i.e., fibers or filaments) selected to form the non-woven fabric layer can include recycled materials, and the recycled materials include recycled polyethylene terephthalate (PET) fibers commonly known as polyester fibers. Additionally, the materials selected to form the waterproof breathable membrane can include recycled materials, and the recycled materials can be from the same or similar polymer classes as the fibers in the non-woven fabric layer. Because the fibers and materials used to form the waterproof breathable membrane are from the same or similar polymer classes, it is generally not necessary to separate the components of the composite fabric before recycling. Moreover, the use of recycled fibers and materials reduces the carbon footprint of the composite fabric.

[0013] In one example, the composite fabric can include a first non-woven fabric layer bonded to a waterproof breathable membrane. The first non-woven fabric layer includes a durable water repellent deposit. When the first composite fabric is formed into a product (e.g., a wearable product, a bag, etc.), the first non-woven fabric layer can form the outward-facing surface of the product. Thus, due to the durable water repellent deposit, the outward-facing surface of the product generally repels water. Additionally, the use of the waterproof breathable membrane creates an additional barrier against water penetration while still allowing water vapor (e.g., the wet vapor generated by the wearer) to escape to the external environment, which contributes to the comfort of the wearer.

[0014] In an example, the first composite fabric may optionally include a second layer on an opposite side of the waterproof breathable membrane as compared to the first nonwoven layer. When the composite fabric is formed into a product, the second layer may form the inward-facing surface of the garment product. The second layer may be of various different materials or forms, such as a nonwoven fabric layer, a knitted layer, a woven layer, a printed layer, etc.

[0015] In at least one instance, the second layer includes a second nonwoven fabric layer that is also bonded to the waterproof breathable membrane such that the membrane is positioned between the two nonwoven fabric layers. When the composite fabric is formed into a product, the second nonwoven fabric layer may form the inward-facing surface of the garment product. In an example, using the second nonwoven fabric layer not only increases the durability of the composite fabric but also creates a soft handfeel on the inward-facing surface of the product, which further contributes to the comfort of the wearer. In some instances, the first nonwoven fabric and the second nonwoven fabric may include the same type of nonwoven fabric (e.g., both may include spunlace nonwoven fabric). In some instances, the first nonwoven fabric and the second nonwoven fabric may include different types of nonwovens as compared to each other. For example, one of the nonwoven fabrics may include a spunlace fabric (e.g., the first nonwoven layer), while the other of the nonwoven fabrics may include a different type of nonwoven fabric, such as a spunbond fabric (e.g., the second nonwoven layer).

[0016] As described above, nonwoven fabrics are generally prone to pilling. Aspects herein contemplate applying a chemical binder to the first nonwoven fabric layer to create multiple chemical bonding sites. One or more fibers adhere together at the chemical bonding sites, which reduces the tendency of fiber ends to migrate and entangle to form pills. In an example, the chemical binder is applied only to the first nonwoven fabric layer because this layer is more prone to pilling due to abrasion with objects in the external environment as compared to the second nonwoven fabric layer. Additionally, in an example, the chemical binder is not applied to the second nonwoven fabric layer or a lesser amount of the chemical binder is applied to the second nonwoven fabric layer to maintain the drape and / or handfeel of the composite fabric.

[0017] Aspects herein also contemplate that the first nonwoven fabric layer may include a printed component such that the resulting composite fabric has a pleasing color and / or pattern aesthetic. Different from traditional dyeing processes and subsequent drying processes for knitted and / or woven fabrics that include a water bath to dye the fabric, aspects herein contemplate applying a colorant (e.g., applied using a screen gravure printing process) to the first nonwoven fabric layer and / or applying a sublimation dye using a sublimation printing process.

[0018] In some instances, printing components can be added or applied to a non-woven fabric (e.g., a first non-woven fabric layer and / or a second non-woven fabric layer) via CO₂ as a medium instead of water. For example, CO₂ can be transformed into a supercritical state (SC-CO₂), in which CO₂ can have a very high solubility capacity, allowing dyes to dissolve easily. Due to the high permeability, the dyes can be easily and deeply transported into the fibers (e.g., fiber impregnation), which can contribute to vivid colors. In some cases, these processes can use less energy than other dyeing processes (e.g., typically associated with knitted and / or woven fabrics) and can reduce the overall carbon footprint of the composite fabric.

[0019] In some cases, the order of applying a durable water repellent, a chemical linker, and a printing component to the first non-woven fabric layer can be selected to improve the performance, operation, and function of each deposit. For example, the printing component can be applied before bonding the first non-woven fabric layer to a waterproof breathable membrane, whether applied via a colorant or via a sublimation printing process or a CO₂ process. In an exemplary aspect, this can be done because the typical higher temperatures associated with applying a color or dye (e.g., from about 140 degrees Celsius to about 160 degrees Celsius) may affect the structural integrity of the waterproof breathable membrane, which can have a melting point of, for example, approximately 150 degrees Celsius to 160 degrees Celsius. When applying a colorant to the first non-woven fabric layer using, for example, a screen gravure printing process, the chemical linker can be applied simultaneously with the colorant, which reduces the number of processing steps. In the aspect of applying a printing component to the first non-woven fabric layer using sublimation printing, the chemical linker can be applied after bonding the first non-woven fabric layer to the waterproof breathable membrane. In some instances, these processes can be performed in any sequence, and / or the steps can be rearranged.

[0020] After bonding the first non-woven fabric layer to the waterproof breathable membrane, a durable water repellent can be applied to the first non-woven fabric layer by, for example, a padding process. In an exemplary aspect, this order of operations can reduce the likelihood that the durable water repellent affects the adhesive used to bond the first non-woven fabric layer to the waterproof breathable membrane. For example, in various aspects, a polyurethane reactive (PUR) adhesive film can be used to bond the two layers. As used herein, the terms "adhesive layer" and "adhesive film" can be used synonymously and / or they can refer to the same feature. PUR adhesives typically crosslink when exposed to moisture, which helps to form a strong bond between the waterproof breathable membrane and the first non-woven fabric layer and reduces the likelihood of delamination. Applying the durable water repellent to the first non-woven fabric layer prior to the bonding step may interfere with the crosslinking step, resulting in a weaker bond between the layers and an increased likelihood of delamination. When applying a printed component to the first non-woven fabric layer using sublimation printing, the durable water repellent can be applied after the chemical linking agent so that the durable water repellent does not affect the ability of the chemical linking agent to adhere the fibers together at the chemical bonding sites. This can be at least partially mitigated by selecting a water-based durable water repellent and a water-based chemical linking agent such that the durable water repellent and the chemical linking agent are somewhat compatible. In some cases, the DWR can be applied prior to the bonding (e.g., laminating) step. In some cases, the choice of materials and adhesives can allow these steps to be performed in various different orders or sequences.

[0021] In an example, after applying the durable water repellent, the second non-woven fabric layer (in use) can be bonded to the waterproof breathable membrane using, for example, an additional adhesive film. Since the second non-woven fabric layer (in some cases) is not treated with a durable water repellent, there may be less concern about the crosslinking issues mentioned above.

[0022] Various aspects herein contemplate an exemplary second composite fabric having at least waterproof and breathable properties. In this example, a waterproof breathable membrane is bonded to a non-woven fabric layer. When the resulting composite fabric is formed into a product, the waterproof breathable membrane can form the outward-facing surface of the product, and the non-woven fabric layer can form the inward-facing surface of a garment product, where the soft feel of the garment product can contribute to the comfort of the wearer. In this aspect, the waterproof breathable membrane can optionally include a durable water repellent deposit, but various aspects herein contemplate that a durable water repellent may not be used, such that the composite fabric may be more suitable for light rain conditions.

[0023] Regarding the second composite fabric, the waterproof breathable membrane can be selected to have a desired color, eliminating the need to apply printed components to the composite fabric. Additionally, since the outward-facing surface of the garment product includes the waterproof breathable membrane, chemical binders are typically not used because pilling is not a problem. Eliminating these steps can improve the manufacturing efficiency associated with the second composite fabric. Further, compared to other fabrics designed for use in inclement weather (such as for water resistance), the fabric can generally provide a relatively light weight (e.g., basis weight).

[0024] As used herein, the term "garment product" is intended to encompass products worn by a wearer, and products worn by a wearer may also be referred to as a garment product or a "wearable product". Wearable products can include upper body clothing (e.g., tops, t-shirts, sweaters, hoodies, jackets, coats, etc.); lower body clothing (e.g., pants, shorts, tights, capris, full body leotards, etc.); headgear; gloves and mittens; sleeves (arm warmers, leg warmers); footwear products (e.g., the upper of a shoe), etc. Aspects herein contemplate embodiments in which the composite fabric, and / or the wearable product, and / or the garment product do not include any knitted, crocheted, and / or woven structures. As used herein, the term "finished product" can include a garment product or a wearable product, equipment (such as a bag), furniture, and other such items. As used herein, the term "web" can include, for example, a roll of fabric, waste or remnants left after cutting pieces from the roll, etc.

[0025] The term "inward-facing surface", when referring to a wearable product, means the surface configured to face the wearer's body surface (or away from the external environment), and the term "outward-facing surface" means the surface configured to face the surface opposite the inward-facing surface, away from the wearer's body surface and towards the external environment. The term "innermost-facing surface" or "innermost surface" means the surface closest to the wearer's body surface relative to the other layers of the wearable product, and the term "outermost-facing surface" or "outermost surface" means the surface positioned furthest from the wearer's body surface relative to the other layers of the wearable product.

[0026] As used herein, the term "nonwoven fabric" refers to fibers and / or filaments that are held together by mechanical and / or chemical interactions and do not take the form of a knitted, woven, braided structure, or other structured form. The terms "fiber" and "filament" generally refer to materials having a high ratio of length to cross-sectional area. Fibers (including "staple fibers") can differ from filaments in that fibers are generally shorter based on their natural state (e.g., wool, cotton, etc.), based on their method of manufacture (e.g., cut into a desired staple fiber length), and / or based on the fiber source (e.g., shredded product fibers that can have different lengths or variable lengths). On the other hand, filaments can generally be longer than fibers and generally have an indefinite length based on the manufacturing method. However, in some cases, filaments can have a length shorter than that of fibers. Aspects herein contemplate that fibers and / or filaments can be used to form nonwoven fabric layers. When referring to fibers, the same description can also refer to or describe filaments, and vice versa.

[0027] In a specific aspect, the nonwoven fabric includes a collection of fibers (i.e., fibers and / or filaments) that are mechanically manipulated to form a mat-like material. In other words, the nonwoven fabric is made directly from fibers and / or filaments. The nonwoven fabric can include different fiber webs formed into a cohesive structure, where the different fiber webs can have different or similar fiber compositions and / or different properties. Examples of nonwoven fabrics can include fiber webs formed from staple fibers or shredded fibers, spunbond fabrics, hydroentangled fabrics, meltblown fabrics, etc., and any and all combinations thereof.

[0028] In an exemplary aspect, the mechanical manipulation contemplated herein can include needle entanglement (i.e., needling) and / or fluid entanglement (i.e., hydroentanglement). Needling typically uses barbed or spiked needles to reorient a proportion of the fibers or filaments from a generally horizontal orientation (an orientation extending along the x, y plane) to a generally vertical orientation (a z-direction orientation). Hydroentanglement typically uses a fine, high-pressure water jet that penetrates the fiber and / or filament web, and the fiber and / or filament web can be carded and / or cross-lapped such that the fibers and / or filaments are entangled. An exemplary nonwoven fabric produced using hydroentanglement is generally referred to as a hydroentangled fabric. Hydroentangled nonwoven fabrics are generally commercially available, inexpensive, and lightweight.

[0029] The fibers (i.e., fibers and / or filaments) contemplated herein can be formed from a variety of different materials (e.g., cotton, nylon, etc.), including polyesters such as polyethylene terephthalate (PET). The fibers can include virgin material fibers (fibers that have not been recycled) and / or recycled material fibers. Recycled fibers include “chopped product fibers” and / or “regranulated polymer fibers”. As used herein, chopped product fibers include fibers that are a direct by-product of chopped fiber-containing products (e.g., knitted, woven, non-woven, etc.). In some examples, chopped product fibers can be obtained through a less energy-consuming process without granulation and extrusion, and thus fabrics incorporating chopped product fibers can have a lower carbon footprint. Generally, due to the chopping process, chopped product fibers typically have varying lengths relative to each other. Regranulated polymer fibers include fibers extruded from granulated or chopped by-products derived from polymer-containing sources (e.g., polymer-containing bottles or containers; knitted, woven, non-woven polymer fiber products; rolls; fabric manufacturing waste; fiber webs at various stages of carding, lapping, pre-needling, and needling, etc.). Generally, regranulated polymer fibers typically have a uniform length.

[0030] When referring to the composite fabrics described herein, the composite fabric can include a first side and an opposite second side, both the first side and the second side facing outward relative to the interior of the composite fabric and including the outermost surfaces of the composite fabric. Thus, when observing the composite fabric, the first side and the second side are each fully visible. Both the first side and the second side can extend along an x, y plane, the x, y planes generally being parallel to each other and offset from each other. For example, the first side can be oriented in a first x, y plane, and the second side can be oriented in a second x, y plane, the second x, y plane being generally parallel to the first x, y plane and offset from the first x, y plane.

[0031] As used herein, the term “waterproof breathable membrane” refers to a layer that exhibits waterproof characteristics (e.g., water impermeability) and breathability (e.g., the ability to transport wet vapor away from the wearer's body to the external environment). These characteristics can be obtained, for example, through micropores in the membrane. In another example, the membrane can be hydrophilic such that the membrane attracts water molecules from the wet vapor and transports the molecules through the membrane to the external environment. Aspects herein also contemplate that the waterproof breathable membrane can have stretch and recovery characteristics (i.e., elastic resilience) along at least one axis of orientation, the waterproof breathable membrane including membranes having stretch and recovery characteristics along a single axis of orientation and membranes having stretch and recovery characteristics along multiple axes of orientation. Examples of axes of orientation include the length direction, the width direction, the x direction, the y direction, and any direction that is angularly offset from the length direction, the width direction, the x direction, and the y direction.

[0032] Some example materials for forming the waterproof breathable membranes contemplated herein include polymers. In some instances, the polymer can include olefins. In some instances, the olefins can include polyolefins. In an instance, the polyolefins can include polyethylene, polypropylene, or a combination thereof. In some instances, the polymer can include polyurethane. In some instances, the polymer can include thermoplastic polymers. In some instances, the polymer can include thermoplastic elastomers. In some instances, the polymer can include recycled polymers. In some instances, the polymer can include recycled polyurethane (rPU), thermoplastic polyurethane (TPU), recycled TPU (rTPU), thermoplastic polyether ester elastomer (TPEE), recycled TPEE (rTPEE), polytetrafluoroethylene (PTFE), recycled PTFE (rPTFE), etc.

[0033] Aspects herein refer to printed components that typically include color or color characteristics. As used herein, the term "color" or "color characteristic" refers to the observable color of the fibers (i.e., fibers and / or filaments) that form the composite fabric. Such aspects contemplate that the color can be any color that can be provided to the fibers using dyes, pigments, and / or colorants known in the art. Thus, the fibers can be configured to have a color, including but not limited to red, orange, yellow, green, blue, indigo, purple, white, black, and their chromaticities. In one example aspect, the color can be imparted to the fibers during fiber formation (commonly referred to as solution dyeing). In solution dyeing, the color is added to the fibers as they are extruded such that the color is integrated with the fibers and no color is added to the fibers in a post-formation step. In other aspects described herein, the color can be added to the fibers after fiber formation and incorporation into a nonwoven fabric layer. This can be accomplished by applying a colorant using, for example, a screen gravure printing process, sublimation printing, padding, spraying, etc.

[0034] Aspects related to color also contemplate determining whether one color is different from another color. In these aspects, the color can include digital color values that can be determined by using an instrument that objectively measures and / or calculates the color value of an object's color by standardizing and / or quantifying factors that can affect color perception. Such instruments include but are not limited to spectroradiometers, spectrophotometers, etc. Thus, aspects herein contemplate that the "color" of a fabric provided by fibers and / or filaments can include digital color values measured and / or calculated using a spectroradiometer and / or spectrophotometer. Additionally, the digital color values can be associated with a color space or color model, which is a specific color organization of the color representation that provides the digital color values, and thus, each digital color value corresponds to a single color represented in the color space or color model.

[0035] In these respects, if the digital color values of each color are different, one color can be determined to be different from another color. Such determination can be carried out as follows: measuring and / or calculating, for example, the digital color value of a first fabric having a first color with a spectroradiometer or a spectrophotometer, measuring and / or calculating the digital color value of a second fabric having a second color with the same instrument (i.e., if the spectrophotometer is used to measure the digital color value of the first color, then the spectrophotometer is used to measure the digital color value of the second color), and comparing the digital color value of the first color with the digital color value of the second color. In another example, the determination can be carried out by measuring and / or calculating the digital color value of a first region of a fabric with a spectroradiometer or a spectrophotometer, measuring and / or calculating the digital color value of a second region of a fabric having a second color with the same instrument, and comparing the digital color value of the first color with the digital color value of the second color. If the digital color values are not equal, then the first color or the first color characteristic is different from the second color or the second color characteristic, and vice versa.

[0036] In addition, it can be envisaged that the visual difference between two colors can be related to the percentage difference between the digital color value of the first color and the digital color value of the second color, and as the percentage difference between the color values increases, the visual difference will be greater. In addition, the visual difference can be based on a comparison between the color representations of the color values in a color space or model. For example, when the first color has a digital color value corresponding to a represented color that is black or dark blue, and the second color has a digital color value corresponding to a represented color that is red or yellow, the visual difference between the first color and the second color is greater than the visual difference between the first color with a represented color of red and the second color with a represented color of yellow.

[0037] As used herein, the term "pill" or "pilling" refers to small balls formed by fiber ends (i.e., fiber ends and / or filament ends) on the front surface of a composite fabric. The pills can extend away from the surface plane of the face. Typically, during normal washing and abrasion, due to forces (e.g., abrasion forces), the fiber ends migrate through the face of the non-woven fabric and become entangled with other fiber ends, thereby forming pills. The pilling resistance of a fabric can be measured using standardized tests such as Random Tumble and Martindale Pilling tests.

[0038] As used herein, the term "chemical bonding" refers to the use of a chemical linking agent (e.g., an adhesive material) that is used to hold fibers together, hold filaments together, and / or hold fibers and filaments together. Generally, the chemical linking agent joins fibers together, joins filaments together, and / or joins fibers and filaments together at regions where the fibers and / or filaments intersect (e.g., cross each other) and creates a bond. In one exemplary aspect, the chemical linking agent can form an adhesive film that bonds the fibers and / or filaments together at, for example, fiber-fiber, filament-filament, and / or fiber-filament intersections. Because the fibers and / or filaments adhere to each other, the ends of the fibers and / or filaments are less likely to migrate and pill, and the overall pilling resistance of the composite fabric is improved.

[0039] Suitable chemical linking agents can include those that comprise polymers and can include vinyl polymers and copolymers, acrylate polymers and copolymers, rubbers and synthetic rubbers, and natural agents such as starches. The chemical linking agent can be applied in the form of an aqueous dispersion (i.e., water-based), an oil-based dispersion (or solvent-based), a foam dispersion, etc. As used herein, the term "chemical bonding site" refers to the location of chemical bonding and also refers to the chemical linking agent itself applied at the chemical bonding site to, for example, a nonwoven fabric layer. Aspects herein contemplate that the chemical linking agent can be transparent in color so as not to affect the color characteristics of the printed component.

[0040] As used herein, the term "deposit" generally means a physical material applied to a substrate in a continuous or discontinuous manner. When used herein, the term "finishing agent" generally refers to a material that imparts a certain property (e.g., color, water repellency, adhesion between fibers and / or filaments, wicking, etc.) to a substrate. In this context, the finishing agent is applied to the substrate as a deposit (continuous or discontinuous).

[0041] This document can provide various measurements regarding non-woven fabric layers and the resulting composite fabrics. Thickness can be measured using a precision thickness gauge. To measure the thickness, for example, the composite fabric, non-woven fabric layer, and / or waterproof breathable membrane can be positioned on a flat anvil, and the pressure foot can be pressed onto the composite fabric, non-woven fabric layer, and / or waterproof breathable membrane from the upper surface under a standard fixed load. The dial indicator on the precision thickness gauge gives a thickness indication in millimeters (mm), micrometers (µm), etc. The basis weight is measured using the ISO3801, Method 5 (1977) test standard and is in grams per square meter (gsm). The fabric stiffness, which generally corresponds to drape, is measured using a pneumatic actuator and a digital meter with a 25 Kgf capacity, using the ASTM D4032 (2008) test standard, and is in kilogram-force (Kgf). The water penetration resistance of the composite fabric is measured using ISO811 (1981) (commonly known as the hydrostatic pressure test) and is in mm. In an example, as used herein, the term "waterproof" means that the waterproof breathable membrane and / or composite fabric can resist water penetration of at least 450 mm of water column. The resistance to vapor transport (RET) of the composite fabric is measured using a 10-inch plate with ISO11092 (2014), and RET indirectly measures the ease of wet vapor passing through the composite fabric. In an example, as used herein, the term "breathable" means that the composite fabric has a RET ranging from about 15 RET to about 60 RET. The surface wet resistance of the composite fabric is measured using ISO4920 (2012), and the surface wet resistance is a measure of water repellency. Regarding surface wetting, the washing conditions are NAL.TM.0020V3.2, SDL Vortex M6 washer, machine washing for 16 ± 1 minutes at 40 degrees Celsius ± 3 degrees Celsius with an EC detergent of 1.0 ±.01 g / L. During the last washing cycle, washing is carried out without detergent, followed by tumble drying.

[0042] Unless otherwise specified, all measurements provided herein are taken at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar), where the composite fabric is in a stationary (unstretched) state.

[0043] As used herein, unless otherwise specified, the term "about" generally means within ±10% of the indicated value.

[0044] FIG. 1 is a schematic diagram of an exemplary life cycle of a composite fabric contemplated herein. Depicted is a first composite fabric, but the following description may also apply to a second composite fabric or other composite fabrics described herein. Elemental symbol 100 generally indicates a first non-woven fabric layer 110, a waterproof breathable membrane 112, and an optional second non-woven fabric layer 114 in a stacked configuration prior to bonding. In an exemplary aspect, the fibers (i.e., fibers and / or filaments) used to form the first non-woven fabric layer 110 and the second non-woven fabric layer 114 may include recycled fibers and / or filaments, and particularly recycled polyester (e.g., PET) fibers and / or filaments. Additionally, in an exemplary aspect, the waterproof breathable membrane 112 may be formed from recyclable materials. Arrow 118 schematically represents a bonding step of bonding the first non-woven fabric layer 110 and the second non-woven fabric layer 114 to the waterproof breathable membrane 112 to form a first composite fabric 120. In this aspect, the waterproof breathable membrane 112 is positioned between the first non-woven fabric layer 110 and the second non-woven fabric layer 114. Arrow 122 schematically represents a processing step of forming the first composite fabric 120 into a garment article 124. Although the garment article 124 is shown as an upper body garment, it is contemplated herein that the garment article 124 may take other forms, such as lower body garments, uppers of shoes, hats, gloves, sleeves, etc. At the end of the life of the garment article 124, it is contemplated that the wearer may return the garment article 124 to, for example, a manufacturer / retailer, where the garment article 124 may be fully recycled as indicated by arrow 126 to form shredded product fibers and / or regranulated polymer fibers and / or filaments, and the shredded product fibers and / or regranulated polymer fibers and / or filaments are used to form fiber and / or filament webs, such as the first non-woven fabric layer 110 and the second non-woven fabric layer 114 and possibly a waterproof breathable membrane (such as the waterproof breathable membrane 112), thereby forming a self-sustaining cycle. This self-sustaining cycle reduces the carbon impact typically associated with making garment articles (including knitted, woven, and non-woven garment articles).

[0045] FIG. 2 depicts a schematic diagram of a first non-woven fabric layer 110 formed of entangled fibers and / or filaments such as fibers and / or filaments 205 (schematically depicted). The first non-woven fabric layer 110 includes a first side 210 and an opposite second side 212. When the first non-woven fabric layer 110 is incorporated into the composite fabric 120, the first side 210 forms a first side of the composite fabric 120. When the composite fabric 120 is formed into a garment article, it is contemplated that the first side forms an outward-facing surface of the garment article and, in some aspects, forms the outermost-facing surface of the garment article.

[0046] In an example aspect, the properties of the first non-woven fabric layer 110, such as basis weight, thickness, type of fibers and / or filaments, etc., can be selected to achieve the desired final properties of the composite fabric 120. Since the first non-woven fabric layer 110 forms the outward-facing surface of the resulting garment product, the desired properties can include durability, coverage, and abrasion resistance. Additional factors to consider include a relatively low basis weight to reduce the overall weight of the resulting garment product. In one example aspect, the first non-woven fabric layer 110 can include a tangled fiber web (i.e., a needle-tangled web) that is formed by needling and has a basis weight ranging from about 50 gsm to about 100 gsm, from about 60 gsm to about 90 gsm, from about 65 gsm to about 85 gsm, or from about 70 gsm to about 80 gsm.

[0047] In another example aspect, the first non-woven fabric layer 110 can include a spunlace fabric having a basis weight ranging from about 30 gsm to about 125 gsm, from about 35 gsm to about 100 gsm, or about 40 gsm. Setting the basis weight of the spunlace fabric forming the first non-woven fabric layer 110 within this range provides a resulting composite fabric 120 having a basis weight within the desired range after combination with the waterproof breathable membrane 112 and the optional second non-woven fabric layer 114. Additionally, setting the basis weight of the spunlace fabric forming the first non-woven fabric layer 110 within this range provides a stable substrate (i.e., a substrate that is not easily torn or wrinkled) for printing (including sublimation printing).

[0048] In an example aspect, the fibers and / or filaments 205 used to form the first non-woven fabric layer 110 can include polyester (e.g., PET) fibers (recycled or virgin), but other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also contemplated herein. In one example aspect, the fibers and / or filaments 205 can include 100 weight% recycled fibers, such as 100 weight% recycled polyester fibers. However, in other aspects, the fibers and / or filaments 205 can include 100 weight% virgin fibers, or other combinations of virgin and recycled fibers, as needed. In some instances, the fibers 205 can include a blend of fibers.

[0049] In some instances, the fibers 205 can be continuous, such as when formed by a meltblown process and / or a spunbond process. In some instances, the fibers 205 can include a uniform length, such as when the fibers are formed from virgin extruded polyester or regranulated polyester and cut to a defined length. In other aspects, the fibers 205 can include variations in staple fiber length, such as when the fibers 205 are derived from a shredded product fiber source. In an example, the fibers 205 can include from about 10% to about 100% fibers derived from a shredded product fiber source, from about 20% to about 90% fibers derived from a shredded product fiber source, from about 30% to about 80% fibers derived from a shredded product fiber source, from about 40% to about 70% fibers derived from a shredded product fiber source, or from about 50% to about 60% fibers derived from a shredded product fiber source. Any and all aspects and any variations thereof are contemplated to be within the aspects herein.

[0050] Figure 3 depicts a schematic diagram of the waterproof breathable membrane 112. The waterproof breathable membrane 112 can include a spunbond layer, a meltblown layer, a film, and the like. In an example aspect, the waterproof breathable membrane can have a thickness from about 10 µm to about 30 µm, from about 15 µm to about 25 µm, or about 20 µm or about 18 µm. In an example aspect, the waterproof breathable membrane 112 can have a basis weight from about 10 gsm to about 30 gsm, from about 15 gsm to about 25 gsm, or about 16 gsm or about 20 gsm. In at least some instances, a lighter and thinner membrane 112 (e.g., 18 µm thickness and 16 gsm basis weight) can contribute to a better handfeel of the composite fabric as compared to a composite fabric including a heavier and / or thicker membrane. The waterproof breathable membrane 112 can include a PU, rPU, TPU, rTPEE, or rPTFE material, or any other material described in the present disclosure associated with the waterproof breathable membrane 112.

[0051] When formed from recycled materials, aspects herein contemplate the waterproof breathable membrane 112 to include at least about 50% recycled materials, about 60% recycled materials, about 70% recycled materials, about 80% recycled materials, about 90% recycled materials, or about 100% recycled materials. The waterproof breathable membrane 112 can be selected to have a low basis weight to maintain a low basis weight of the resulting garment product, to be waterproof, to be breathable (which contributes to the comfort characteristics of the garment article formed from the composite fabric 120), and to be flexible to reduce the stiffness of the composite fabric 120.

[0052] FIG. 4 depicts a schematic view of an optional second non-woven fabric layer 114 formed of entangled fibers and / or filaments such as fibers and / or filaments 405 (schematically depicted). The second non-woven fabric layer 114 includes a first side 410 and an opposite second side 412. When the second non-woven fabric layer 114 is incorporated into the composite fabric 120, the first side 410 forms the second side of the composite fabric 120. When the composite fabric 120 is formed into a garment article, it is contemplated that the second side forms the inward-facing surface of the garment article and, in some aspects, the innermost-facing surface of the garment article. In an exemplary aspect, the use of the second non-woven fabric layer 114 in the composite fabric 120 contributes to the durability of the composite fabric 120 and also imparts a soft hand to the second surface of the composite fabric 120.

[0053] In an exemplary aspect, the properties of the second non-woven fabric layer 114, such as basis weight, thickness, type of fibers and / or filaments, etc., can be selected to achieve the desired final properties of the composite fabric 120. Since the second non-woven fabric layer 114 forms the inward-facing surface of the resulting garment article, the desired properties can include, for example, a soft hand. Additional factors to consider include a relatively low basis weight to reduce the overall weight of the resulting garment article.

[0054] In one exemplary aspect, the second non-woven fabric layer 114 can include a felted fiber web (i.e., a needle-felted web) that is formed by needling and has a basis weight ranging from about 50 gsm to about 100 gsm, from about 60 gsm to about 90 gsm, from about 65 gsm to about 85 gsm, or from about 70 gsm to about 80 gsm.

[0055] In another exemplary aspect, the second non-woven fabric layer 114 can include a spunlace fabric having a basis weight ranging from about 30 gsm to about 125 gsm, from about 35 gsm to about 100 gsm, or about 40 gsm. Setting the basis weight of the spunlace fabric that will form the second non-woven fabric layer 114 within this range provides a resulting composite fabric 120 having a basis weight within the desired range after combination with the waterproof breathable membrane 112 and the first non-woven fabric layer 110.

[0056] In another example aspect, the second non-woven fabric layer 114 can include a spunbond fabric having a low basis weight from about 8 gsm to about 16 gsm, from about 10 gsm to about 14 gsm, or about 12 gsm. In an example, the spunbond fabric can include a scrim. Setting the basis weight of the spunbond fabric forming the second non-woven fabric layer 114 within this range can provide a resulting composite fabric 120 having a basis weight within the desired range after the combination of the second non-woven fabric layer 114, the waterproof breathable membrane 112, and the first non-woven fabric layer 110.

[0057] In an example aspect, the fibers and / or filaments 405 used to form the second non-woven fabric layer 114 can include polyester fibers (recycled or virgin PET), but other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are contemplated herein. In one example aspect, the fibers and / or filaments 405 can include 100 weight % recycled fibers, such as 100 weight % recycled polyester fibers. However, in other aspects, the fibers and / or filaments 405 can include 100 weight % virgin fibers, or other combinations of virgin and recycled fibers as needed.

[0058] In some examples, the fibers 405 can be continuous, such as when formed by a meltblown process or a spunbond process. In some examples, the fibers 405 can include a uniform length, such as when the fibers are formed from virgin extruded material or regranulated polymeric material and cut to a defined length. In other aspects, the fibers 405 can include variations in staple fiber lengths, such as when the fibers 405 are derived from a shredded product fiber source. In one example aspect, the fibers 405 can include from about 10% to about 100% of the fibers derived from a shredded product fiber source, from about 20% to about 90% of the fibers derived from a shredded product fiber source, from about 30% to about 80% of the fibers derived from a shredded product fiber source, from about 40% to about 70% of the fibers derived from a shredded product fiber source, or from about 50% to about 60% of the fibers derived from a shredded product fiber source. Any and all aspects and any variations thereof are contemplated to be within the aspects herein.

[0059] In at least some examples, as opposed to the second non-woven layer, the second layer can include some other fabric layer, such as a knitted fabric layer, a woven fabric layer, a film, etc.

[0060] FIG. 5 depicts a schematic view of the composite fabric 120 after being processed to include, for example, one or more deposits such as a durable water repellent deposit (e.g., water-based or solvent-based), printed components, and / or chemical linkers. In an exemplary aspect, the composite fabric 120 can be processed to include three deposits, including a durable water repellent deposit, printed components, and a chemical linker. In other exemplary aspects, the composite fabric 120 can be processed to include two deposits, such as a durable water repellent deposit and printed components, a durable water repellent deposit and a chemical linker, or printed components and a chemical linker. In still other exemplary aspects, the composite fabric 120 can be processed to include only one deposit, such as only a durable water repellent deposit, only printed components, or only a chemical linker. The composite fabric 120 includes a first non-woven fabric layer 110, a waterproof breathable membrane 112, and an optional second non-woven fabric layer 114, wherein the waterproof breathable membrane 112 is positioned between the first non-woven fabric layer 110 and the second non-woven fabric layer 114. The composite fabric 120 has a first side 510 formed by the first side 210 of the first non-woven fabric layer 110 and a second side 512 formed by the first side 410 of the second non-woven fabric layer 114; the first side 510 is mainly visible in FIG. 5.

[0061] Aspects herein contemplate a variety of different combinations of spunlace webs and needle-punched webs for the composite fabric 120. For example, one combination includes a spunlace fabric for the first non-woven fabric layer 110, an rTPEE material or an rPU material for the waterproof breathable membrane 112, and a spunlace fabric for the second non-woven fabric layer 114.

[0062] A second combination includes a spunlace fabric for the first non-woven fabric layer 110, an rTPEE or rPU material for the waterproof breathable membrane 112, and a needle-punched web for the second non-woven fabric layer 114.

[0063] A third combination includes a needle-punched web for the first non-woven fabric layer 110, an rTPEE or rPU material for the waterproof breathable membrane 112, and a needle-punched web for the second non-woven fabric layer 114.

[0064] Additional combinations include a needle-punched web for the first non-woven fabric layer 110, an rTPEE or rPU material for the waterproof breathable membrane, and a spunlace material for the second non-woven fabric layer 114.

[0065] Aspects herein also contemplate additional types of non-woven materials for the first non-woven fabric layer 110 and the second non-woven fabric layer 114, including, for example, spunbond materials and / or meltblown materials. For example, additional combinations for the composite fabric include a spunlace fabric for the first non-woven fabric layer 110, an rTPEE material or an rPU material for the waterproof breathable membrane 112, and a spunbond fabric (e.g., from about 10 gsm to about 14 gsm; or a very low basis weight of about 12 gsm). Aspects herein also contemplate using different materials for the waterproof breathable membrane 112, such as rPU, TPU, rPTFE, etc. Any and all aspects and any combinations thereof are contemplated to be within the aspects herein.

[0066] After processing, the composite fabric 120 includes one or more deposits, such as a durable water repellent deposit (not shown), a printed component 514 (depicted using a diagonal line), and / or a chemical linker (depicted as multiple chemical bonding sites 516 in the enlarged view of FIG. 5). In one example aspect, these deposits are applied only to the first non-woven fabric layer 110 and not to the second non-woven fabric layer 114. The durable water repellent deposit is applied only to the first non-woven fabric layer 110 because this layer forms the outward-facing surface of the garment product formed by the composite fabric 120. Similarly, the printed component 514 is applied only to the first non-woven fabric layer 110 because this layer is visible when the resulting garment product is worn. The chemical bonding sites 516 are present only on the first non-woven fabric layer 110 to maintain the feel and drape of the composite fabric 120. In an example aspect, the amount of the surface area of the first non-woven fabric layer 110 occupied by the chemical bonding sites 516 can be from about 10% to about 70%, or from about 40% to about 60%, to produce a pilling resistance of 2 or greater based on the Martindale pilling test while still maintaining the desired drape, feel, and growth and recovery characteristics. Another example herein contemplates that when the resulting garment product is reversible, the durable water repellent, printed component, and / or chemical linker can also be applied to the second non-woven fabric layer 114.

[0067] FIG. 6 depicts the composite fabric 120 and primarily depicts the second side 512 of the composite fabric 120. In one example aspect, and as depicted in the figure, the second side 512 of the composite fabric 120 does not include a printed component, a durable water repellent deposit, or chemical bonding sites.

[0068] In at least some instances, the inner surface of the composite fabric 120 (e.g., the surface configured to face the wearer or be oriented towards the wearer when the apparel product is worn as intended) can include material deposits (e.g., inks or other solutions). In some instances, the material deposits can impart various characteristics, such as color, aesthetic pattern structure, anti-adhesion, etc. Various techniques can be used to apply the material deposits, such as by gravure printing, spraying, screen printing, inkjet, etc. In some instances, the material deposits can be applied to a second fabric layer (e.g., a second non-woven layer).

[0069] In at least some instances, the material deposits can be applied to the inner surface of the waterproof breathable membrane 112, such as where the second fabric layer is omitted. Thus, an exemplary composite fabric of the present disclosure can include a first non-woven layer 110 (e.g., as the outermost layer of the composite fabric), a waterproof breathable membrane 112, and a material deposit layer (e.g., a printed layer) located on the inner surface of the waterproof breathable membrane 112, the material deposit layer being positioned on the opposite side of the waterproof breathable membrane 112 as compared to the first non-woven layer 110. In such instances, the membrane 112 can include a PU or rPU membrane that includes micropores and is a hydrophobic membrane. Additionally, the membrane 112 can include a basis weight of from about 18 gsm to about 26 gsm; or about 22 gsm. In at least some instances, the membrane 112 can include a thickness of from about 60 µm to about 80 µm; or about 70 µm.

[0070] The first composite fabric 120 can exhibit characteristics that make it suitable for use in harsh weather conditions. For example, when the first composite fabric 120 includes: a spunlace material formed of 100% recycled polyester for the first non-woven fabric layer 110 and the second non-woven fabric layer 114, and an rTPEE or rPU film for the waterproof breathable membrane 112, the composite fabric 120 can be lighter in weight, having a basis weight ranging from about 110 gsm to about 150 gsm, from about 115 gsm to about 145 gsm, from about 120 gsm to about 140 gsm, or about 130 gsm. The composite fabric 120 can exhibit a water resistance ranging from about 8,000 mm to about 12,000 mm, from about 9,500 mm to about 10,500 mm, or about 10,000 mm. The composite fabric 120 can have a RET (i.e., water vapor transport resistance) ranging from about 15 RET to about 22 RET, from about 16 RET to about 20 RET, from about 17 RET to about 19 RET, or about 18 RET. The composite fabric 120 can have a surface wet resistance ranging from about 2.5 to about 6, or from about 4 to about 5 before washing, after three washes, and after 20 washes. In this example, the composite fabric 120 can have a pilling resistance ranging from about 2 to about 5, from about 2.5 to about 4.75, or from about 3 to about 4.5 as measured using the Martindale pilling test. When compared to the formation of a composite fabric including a waterproof breathable membrane positioned between two woven layers, the formation of the composite fabric 120 can exhibit a reduction in energy cost (i.e., carbon) from about 60% to about 70%.

[0071] Figure 7 depicts a schematic diagram of a first exemplary process for forming the first composite fabric 120. Generally, the process for constructing the composite fabric 120 can include various steps, including but not limited to coloring one or more of the material layers (e.g., by CO2 coloring, sublimation, etc.), applying a pilling resistance coating, applying a DWR coating, printing, and laminating. These steps can be performed in various sequences, and Figure 7 depicts an example of an operating sequence.

[0072] In at least one example, at step 710, a screen gravure printing system 705 is used to simultaneously apply a colorant 712 and a chemical linking agent 714 to a first side 210 of a first nonwoven fabric layer 110 to impart a printed component 514 to the first nonwoven fabric layer 110 and to reduce the formation of pills on at least a first side 510 of the resulting composite fabric 120 by creating a plurality of chemical bonding sites 516. The components depicted in association with the screen gravure printing system 705 are illustrative and are intended to convey the general concepts associated with the screen gravure printing system 705. System 705 may include additional components or fewer components, and these components may have configurations different from the configurations shown. Other application methods known in the art are contemplated herein, including additional types of gravure printing systems.

[0073] The screen gravure printing system 705 includes a screen roller 716 adapted to rotate along a first direction 718. The screen roller 716 has a plurality of openings, such as opening 715. In one exemplary aspect, the screen roller 716 may have, for example, from about 30 openings per linear inch to about 80 openings per linear inch, from about 35 openings per linear inch to about 70 openings per linear inch, or from about 40 openings per linear inch to about 60 openings per linear inch. The number of openings per linear inch may be selected to achieve a desired coverage amount of the colorant 712 and the chemical linking agent 714 while still maintaining the hand and drape of the first nonwoven fabric layer 110.

[0074] In an example aspect, the screen roller 716 supplies the colorant 712 and the chemical linker 714. In one instance, the colorant 712 and the chemical linker 714 can be mixed together such that the screen roller 716 applies the colorant 712 and the chemical linker 714 simultaneously. Aspects herein also contemplate separately supplying the colorant 712 and the chemical linker 714 such that the screen roller 716 first applies the colorant 712 and then applies the chemical linker 714, or vice versa. When the screen roller 716 rotates in a first direction 718, the colorant 712 and the chemical linker 714 are deposited onto the first side 210 of the first nonwoven fabric layer 110 at a density corresponding to the number of openings per linear inch. In other words, aspects herein contemplate discontinuously applying the colorant 712 and the chemical linker 714 to create multiple discrete colorant sites and multiple discrete chemical bonding sites (e.g., chemical bonding sites 516). In an example aspect, when the colorant 712 and the chemical linker 714 are supplied together, the multiple discrete colorant sites and the multiple discrete chemical bonding sites can occupy substantially the same positions on the first side 210 of the first nonwoven fabric layer 110. In an example aspect, when the colorant 712 and the chemical linker 714 are supplied separately, the multiple discrete colorant sites and the multiple discrete chemical bonding sites can occupy different positions, can partially overlap each other on the first side 210 of the first nonwoven fabric layer 110, or can completely overlap. In an example aspect, the viscosities of the colorant 712 and the chemical linker 714 before application can be selected to achieve a desired level of penetration into the first nonwoven fabric layer 110 after applying the colorant 712 and the chemical linker 714 to, for example, the first side 210 of the first nonwoven fabric layer 110.

[0075] The screen roller 716 can be adapted to apply a certain amount of pressure and heat to the first nonwoven fabric layer 110. For example, the application temperature can be from about 140 degrees Celsius to about 180 degrees Celsius, from about 150 degrees Celsius to about 170 degrees Celsius, or about 160 degrees Celsius. The amount of pressure supplied by the screen roller 716 is generally sufficient to ensure that the entire first side 210 is in contact with the screen roller 716 such that a uniform coverage of the colorant 712 and the chemical linker 714 is applied to the first side 210 in a pattern corresponding to the number of openings per linear inch of the screen roller 716.

[0076] Although the screen gravure printing system 705 is depicted as applying only the colorant 712 and the chemical linker 714 to the first side 210, aspects herein contemplate that the colorant 712 and the chemical linker 714 may also be applied to the second side 212 of the first non-woven fabric layer 110. For example, after applying the colorant 712 and the chemical linker 714 to the first side 210, the first non-woven fabric layer 110 may be passed back through the screen gravure printing system 705 such that the second side 212 contacts the screen roller 716.

[0077] As described above, the chemical linker 714 acts as an adhesive to help hold the fibers and / or filaments together in the area where it is applied. Because the fibers and / or filaments adhere together, for example, the ends of the fibers and / or filaments are less likely to pill, and the overall pilling resistance of at least the first side 210 of the first non-woven fabric layer 110 is improved. For example, in a Martindale pilling test, the pilling resistance can be about 2, 2.5, 3, 4.5, 4.75, or 5. As previously mentioned, in an exemplary aspect, when the resulting composite fabric 120 is incorporated into a garment article, the first side 510 corresponding to the first side 210 of the first non-woven fabric layer 110 forms the outward-facing surface of the article. Thus, the application of the chemical linker 714 helps improve the pilling resistance of the outward-facing surface of the article, which may be more prone to wear than, for example, the inward-facing surface of the article.

[0078] In step 720, the first non-woven fabric layer 110 is bonded to the waterproof breathable membrane 112. In an exemplary aspect, the bonding can be achieved by using a first adhesive film 724 positioned between the second side 212 of the first non-woven fabric layer 110 and the waterproof breathable membrane 112. In an exemplary aspect, the first adhesive film 724 includes a PUR reactive adhesive film, but other types of adhesive films are contemplated herein. Other aspects herein also contemplate the use of non-film adhesives. For example, prior to the bonding step 720, a liquid adhesive can be applied to one or more of the first non-woven fabric layer 110 and / or the waterproof breathable membrane 112. Regarding the first adhesive film 724 in the form of a PUR reactive adhesive, one or more of heat and pressure 722 are applied to the first non-woven fabric layer 110 and / or the waterproof breathable membrane 112 to activate the first adhesive film 724 such that the first adhesive film 724 melts. In an exemplary aspect, the application temperature can be from about 80 degrees Celsius to about 105 degrees Celsius, from about 85 degrees Celsius to about 100 degrees Celsius, or from about 90 degrees Celsius to about 95 degrees Celsius. When the adhesive 724 cools and cures, a bond is formed between the first non-woven fabric layer 110 and the waterproof breathable membrane 112. The adhesive 724 then undergoes a moisture curing step to further strengthen the bond between the first non-woven fabric layer 110 and the waterproof breathable membrane 112, which further reduces the likelihood of delamination. The result of the bonding step 720 can be the final composite fabric 120, or if the second non-woven fabric layer 114 is utilized, the result is the partially composite fabric 728 as shown in step 726.

[0079] As described above, the bonding step 720 is performed after the step 710 to avoid the higher temperature (e.g., about 160 degrees Celsius) associated with the application of the colorant 712 from affecting the structural integrity of the waterproof breathable membrane 112, which can have a melting temperature of about 155 degrees Celsius. For example, if the application of the colorant 712 occurs after the bonding step 720, the waterproof breathable membrane 112 can be partially melted, which may affect one or more of the waterproof and breathable characteristics of the membrane 112.

[0080] Step 730 depicts a padding system 732 adapted to apply a durable water repellent to the first side 210 of the first non-woven fabric layer 110. The components depicted in association with the padding system 732 are illustrative and are intended to convey the general concepts associated with the padding system 732. Padding can include a printing padding process or a bath padding process. The system 732 can include additional components or fewer components, and these components can have configurations different from the configurations shown. Other application methods known in the art are envisioned herein, including additional types of padding systems, spraying systems, and the like. In an exemplary aspect, the padding step 730 occurs after the bonding step 720. This can be done to prevent the durable water repellent deposits from negatively affecting the moisture curing step associated with the first adhesive film 724. After the padding step 730, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, or at least about 100% of the surface area of the first side 210 of the first non-woven fabric layer 110 is envisioned to include durable water repellent deposits in various aspects herein. In various aspects herein, the durable water repellent deposits can be primarily located on the first side 210 of the first non-woven fabric layer 110. In some aspects, the durable water repellent can at least partially penetrate the first non-woven fabric layer 110 such that the durable water repellent deposits can be at least partially located in the volume between the first side 210 and the second side 212 of the first non-woven fabric layer 110.

[0081] In an optional step 734, a portion of the composite fabric 728 is bonded to the second non-woven fabric layer 114. In an exemplary aspect, the bonding can be achieved by using a second adhesive film 736 positioned between the second side 412 of the second non-woven fabric layer 114 and the waterproof breathable membrane 112. In an exemplary aspect, the second adhesive film 736 includes a PUR-reactive adhesive film, but other types of adhesive films are envisioned herein. Various aspects herein also envision the use of non-film adhesives. For example, a liquid adhesive can be applied to one or more of the second non-woven fabric layer 114 and the waterproof breathable membrane 112 prior to the second bonding step. With respect to the second adhesive film 736 in the form of a PUR-reactive adhesive, one or more of heat and pressure 738 are applied to the portion of the composite fabric 728 and / or the second non-woven fabric layer 114 to bond the second non-woven fabric layer 114 to the waterproof breathable membrane 112. The result of step 734 is the composite fabric 120 as shown in step 740, where the composite fabric 120 includes a first side 510 and an opposite second side 512.

[0082] As indicated above, the various steps and operations depicted in FIG. 7 may include additional or different operations and may be performed in a different order. For example, in at least one instance, the first non-woven fabric 110 may be subjected to a coloring process via CO2 printing (e.g., impregnating the fabric with supercritical CO2 dyes). After the CO2 printing, an anti-pilling coating (e.g., a chemical binder) may be applied to the colored first non-woven fabric 110 via a process such as gravure printing. Additionally, after the gravure printing, the first non-woven fabric 110 may receive a DRW treatment via a process such as padding (e.g., print padding, solution bath padding, etc.). After the first non-woven fabric 110 has been treated in these different aspects, the first non-woven fabric 110 may then be laminated to the waterproof breathable membrane 112 via a PUR adhesive layer and optionally laminated to a second fabric layer (e.g., a spunlace layer, a spunbonded scrim, etc.) to form a composite fabric layer 120.

[0083] In step 742, the composite fabric 120 is formed into a wearable article or a garment article 744. Although shown as an upper body garment article, aspects herein contemplate that the composite fabric 120 may be formed into other types of garment articles, such as lower body garment articles, the upper portion of a shoe, gloves, hats, etc. When the composite fabric 120 is formed into the garment article 744, the first side 510 of the composite fabric 120 forms the outermost facing surface of the garment article 744. As described above, the first side 510 of the composite fabric 120 includes the first side 210 of the first non-woven fabric layer 110, and the first side 210 includes the printed component 514, the plurality of chemical bonding sites 516, and the durable water repellent deposit. Thus, the visible side of the garment article 744 includes the printed component 514 that enhances the aesthetic appeal of the garment article 744. Additionally, the chemical bonding sites 516 on the first side 510 help improve the anti-pilling property of the first side 510. The durable water repellent on the first side 510 renders the garment article 744 suitable for inclement weather, including rain, sleet, or snow. The opposite second side 512 of the composite fabric 120 includes the second non-woven fabric layer 114. Since the second non-woven fabric layer 114 generally does not include any deposits (e.g., chemical binders, colorants, or durable water repellents), the soft handfeel and drapability of the second non-woven fabric layer 114 are maintained, making it suitable for contact with the wearer's skin surface.

[0084] FIG. 8 depicts a schematic diagram of a second exemplary process for forming the first composite fabric 120. In step 810, a sublimation printing system 812 applies a printed component 514 to a first side 210 of the first nonwoven fabric layer 110. The components depicted in association with the sublimation printing system 812 are illustrative and are intended to convey the general concepts associated with the sublimation printing system 812. System 812 may include additional components or fewer components, and these components may have configurations different from the configurations shown. Other application methods known in the art are contemplated herein, including additional types of sublimation printing systems, CO2 printing, etc.

[0085] System 812 may include sublimation paper 814, and patterns and / or colors are deposited onto the sublimation paper 814 via, for example, a sublimation printing press (not shown). The first nonwoven fabric layer 110 may be positioned such that the first side 210 is adjacent to and / or in contact with the sublimation paper 814. In one exemplary aspect, a roller 816 may advance the first nonwoven fabric layer 110 in the machine direction while a heat source 818 applies heat to transfer the patterns and / or colors on the sublimation paper 814 to the first side 210 of the first nonwoven fabric layer 110 to form the printed component 514. In an exemplary aspect, the temperature associated with the heat source 818 may be from about 130 degrees Celsius to about 220 degrees Celsius, from about 135 degrees Celsius to about 210 degrees Celsius, or from about 140 degrees Celsius to about 200 degrees Celsius. The printed component 514 imparted by sublimation printing may have a desired color intensity that is different from or stronger than the printed component 514 imparted by the process depicted in FIG. 7.

[0086] In step 820, the first non-woven fabric layer 110 is bonded to the waterproof breathable membrane 112. In an exemplary aspect, the bonding can be achieved by using a first adhesive film 822 positioned between the second side 212 of the first non-woven fabric layer 110 and the waterproof breathable membrane 112. In an exemplary aspect, the first adhesive film 724 includes a PUR-reactive adhesive film, but other types of adhesive films are contemplated herein. Aspects herein also contemplate the use of non-film adhesives. For example, a liquid adhesive can be applied to one or more of the first non-woven fabric layer 110 and the waterproof breathable membrane 112 prior to the bonding step 820. Regarding the first adhesive film 822 in the form of a PUR-reactive adhesive, one or more of heat and pressure 824 are applied to the first non-woven fabric layer 110 and / or the waterproof breathable membrane 112 to activate the first adhesive film 822 such that the first adhesive film 822 melts. The application temperature discussed with respect to the bonding step 720 in FIG. 7 is applicable to the bonding step 820, and the further discussion regarding the first adhesive film 724 is also applicable to the first adhesive film 822, including how the first adhesive film 822 bonds the first non-woven fabric layer 110 to the waterproof breathable membrane 112. The result of the bonding step 820 can be the final composite fabric 120, or if the second non-woven fabric layer 114 is utilized, the result is the partial composite fabric 828 as shown in step 826.

[0087] The bonding step 820 is performed after the sublimation printing step 810 to avoid the higher temperature associated with the sublimation printing system 812 from affecting the structural integrity of the waterproof breathable membrane 112, which can have a melting temperature of about 155 degrees Celsius. For example, if the sublimation printing step 810 occurs after the bonding step 820, the waterproof breathable membrane 112 can be partially melted, which may affect one or more of the waterproof and breathable characteristics of the membrane 112.

[0088] In step 830, a chemical linking agent 834 (instead of a colorant) is deposited onto the first side 210 of the first non-woven fabric layer 110 using, for example, a screen gravure printing system 832. The screen gravure printing system 832 can be the same as the screen gravure printing system 705 of FIG. 7, and the discussion of the screen gravure printing system 705 and the chemical linking agent 714 also applies to the screen gravure printing system 832 and the chemical linking agent 834. In an example aspect, the application temperature of the chemical linking agent 834 can be from about 105 degrees Celsius to about 145 degrees Celsius, from about 110 degrees Celsius to about 140 degrees Celsius, or from about 120 degrees Celsius to about 130 degrees Celsius. For a different description, the application temperature of the chemical linking agent 834 is generally lower than the melting temperature of the waterproof breathable membrane 112. Similar to the chemical linking agent 714, the chemical linking agent 834 is applied to the first side 210 of the first non-woven fabric layer 110 in a discontinuous pattern to create a plurality of discrete chemical bonding sites 516.

[0089] In step 836, a padding system 838 applies a durable water repellent to the first side 210 of the first non-woven fabric layer 110. The components depicted in association with the padding system 838 are illustrative and are intended to convey the general concepts associated with the padding system 838. The system 838 can include additional components or fewer components, and these components can have configurations different from the configurations shown. Other application methods known in the art are contemplated herein, including additional types of padding systems, spraying systems, and the like. In an example aspect, the padding step 836 occurs after the bonding step 820. As described above, this is done to prevent the durable water repellent deposit from negatively affecting the moisture curing step associated with the first adhesive film 822. In another example aspect, the padding step 836 occurs after applying the chemical linking agent 834 during step 830. In an example aspect, this can be done to prevent the durable water repellent from inhibiting the adhesion of the chemical linking agent 834 to the first non-woven fabric layer 110. For example, if the chemical linking agent 834 is water-based and the durable water repellent is solvent-based, the durable water repellent can prevent the chemical linking agent from adhering to the surface of the first non-woven fabric layer 110. In other example aspects, when both the chemical linking agent 834 and the durable water repellent are water-based, the two deposits can be compatible with each other such that the application order can include applying the chemical linking agent 834 first and then the durable water repellent, or applying the durable water repellent first and then the chemical linking agent 834.

[0090] After the padding step 836, in various aspects herein, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90% or at least about 100% of the surface area of the first side 210 of the first nonwoven fabric layer 110 comprises a durable water repellent deposit. In various aspects herein, it is contemplated that the durable water repellent deposit may be primarily located on the first side 210 of the first nonwoven fabric layer 110. In some aspects, the durable water repellent may at least partially penetrate the first nonwoven fabric layer 110 such that the durable water repellent deposit may be at least partially located in the volume between the first side 210 and the second side 212 of the first nonwoven fabric layer 110.

[0091] In an optional step 840, a portion of the composite fabric 828 is bonded to the second nonwoven fabric layer 114. In an exemplary aspect, the bonding may be achieved by using a second adhesive film 842 positioned between the second side 412 of the second nonwoven fabric layer 114 and the waterproof breathable membrane 112. In an exemplary aspect, the second adhesive film 842 comprises a PUR reactive adhesive film, but other types of adhesive films are contemplated herein. In various aspects herein, non-film adhesives are also contemplated. For example, a liquid adhesive may be applied to one or more of the second nonwoven fabric layer 114 and the waterproof breathable membrane 112 prior to the second bonding step 840. With respect to the second adhesive film 842 in the form of a PUR reactive adhesive, one or more of heat and pressure 844 are applied to the portion of the composite fabric 828 and / or the second nonwoven fabric layer 114 to bond the second nonwoven fabric layer 114 to the waterproof breathable membrane 112. The result of step 840 is a composite fabric 120 as shown in step 846, wherein the composite fabric 120 comprises a first side 510 and an opposite second side 512.

[0092] In step 848, the composite fabric 120 is formed into a wearable article or a garment article 850. Although shown as an upper body garment article, in various aspects herein, it is contemplated that the composite fabric 120 may be formed into other types of garment articles, such as lower body garment articles, the upper portion of a shoe, gloves, hats, etc. When the composite fabric 120 is formed into a garment article 850, the first side 510 of the composite fabric 120 forms the outermost facing surface of the garment article 850. The characteristics associated with the garment article 744 of FIG. 7 are also applicable to the garment article 850 and these characteristics are not repeated herein.

[0093] FIG. 9 depicts a schematic diagram of a third exemplary process for forming the first composite fabric 120. The process depicted in FIG. 9 is similar to the process depicted in FIG. 8, except that a sublimation printing is used to impart the printed component 514 to the first side 210 and the second side 212 of the first non-woven fabric layer 110. In step 910, the sublimation printing system 912 applies the printed component 514 to the first side 210 of the first non-woven fabric layer 110. Similar to FIG. 8, the components depicted in association with the sublimation printing system 912 are illustrative and are intended to convey the general concepts associated with the sublimation printing system 912. The system 912 may include additional components or fewer components, and these components may have configurations different from the configurations shown. Other application methods known in the art are contemplated herein, including additional types of sublimation printing systems.

[0094] The system 912 may include sublimation paper 914, and patterns and / or colors are deposited on the sublimation paper 914, for example, by a sublimation printing press (not shown). The first non-woven fabric layer 110 may be positioned such that the first side 210 is adjacent to and / or in contact with the sublimation paper 914. In one exemplary aspect, the roller 916 may advance the first non-woven fabric layer 110 in the machine direction, while the heat source 918 applies heat to transfer the patterns and / or colors on the sublimation paper 914 to the first side 210 of the first non-woven fabric layer 110 to form the printed component 514. In an exemplary aspect, the temperature associated with the heat source 918 may be from about 130 degrees Celsius to about 220 degrees Celsius, from about 135 degrees Celsius to about 210 degrees Celsius, or from about 140 degrees Celsius to about 200 degrees Celsius.

[0095] In step 920, the first non-woven fabric layer 110 may be positioned such that the second side 212 is adjacent to and / or in contact with the sublimation paper 914. In various aspects herein, it is contemplated that the same patterns and / or colors are applied to the sublimation paper 914 in the first printing step 910 and the second printing step 920. In other aspects herein, it is contemplated that different patterns and / or colors from the first printing step 910 are applied to the sublimation paper 914 in the second printing step 920. In one exemplary aspect, the roller 916 may advance the first non-woven fabric layer 110 in the machine direction, while the heat source 918 applies heat to transfer the patterns and / or colors on the sublimation paper 914 to the second side 212 of the first non-woven fabric layer 110 to form the printed component 514 on the second side 212.

[0096] When the same pattern and / or color is applied to the sublimation paper 914 in the first printing step 910 and the second printing step 920, the intensity of the pattern and / or color on the first non-woven fabric layer 110 can be increased compared to single-sided printing in the process shown in FIG. 8. When different patterns and / or colors are applied to the sublimation paper 914 in the first printing step 910 and the second printing step 920, a desired color effect representing a certain combination of two different patterns and / or colors can be achieved. For example, due to the inherent space between the fibers and / or filaments in the first non-woven fabric layer 110, the color or pattern present on the second side 212 of the first non-woven fabric layer 110 can be at least partially visible on the first side 210 of the first non-woven fabric layer 110. Thus, for example, a variegated type effect can be achieved by imparting, for example, light green to the first side 210 of the first non-woven fabric layer 110 and gray or black to the second side 212 of the first non-woven fabric layer 110.

[0097] In step 922, the second side 212 of the first non-woven fabric layer 110 is bonded to the waterproof breathable membrane 112. In an exemplary aspect, the bonding can be achieved by using a first adhesive film 924 positioned between the second side 212 of the first non-woven fabric layer 110 and the waterproof breathable membrane 112. In an exemplary aspect, the first adhesive film 924 includes a PUR reactive adhesive film, but other types of adhesive films are contemplated herein. Other aspects herein also contemplate the use of non-film adhesives. For example, a liquid adhesive can be applied to one or more of the first non-woven fabric layer 110 and the waterproof breathable membrane 112 prior to the bonding step 922. With respect to the first adhesive film 924 in the form of a PUR reactive adhesive, one or more of heat and pressure 926 are applied to the first non-woven fabric layer 110 and / or the waterproof breathable membrane 112 to activate the first adhesive film 924 such that the first adhesive film 924 melts. The application temperature discussed with respect to the bonding step 720 in FIG. 7 is applicable to the bonding step 922, and the further discussion with respect to the first adhesive film 724 is also applicable to the first adhesive film 924, including how the first adhesive film 924 bonds the first non-woven fabric layer 110 to the waterproof breathable membrane 112. The result of step 922 can be the final composite fabric 120, or if a second non-woven fabric layer 114 is utilized, the result is the partially composite fabric 930 as shown in step 928.

[0098] Similar to FIG. 8, the bonding step 922 is performed after the sublimation printing steps 910 and 920 to avoid the higher temperatures associated with the sublimation printing system 912 from affecting the structural integrity of the waterproof breathable membrane 112, which may have a melting temperature of about 155 degrees Celsius. For example, if the sublimation printing steps 910 and 920 occur after the bonding step 922, the waterproof breathable membrane 112 may be partially melted, which may affect one or more of the waterproof and breathable characteristics of the membrane 112.

[0099] In step 932, a chemical binder 936 is deposited onto the first side 210 of the first nonwoven fabric layer 110 using, for example, a screen gravure printing system 934. The screen gravure printing system 934 may be the same as the screen gravure printing system 705 of FIG. 7, and the discussion of the screen gravure printing system 705 and the chemical binder 714 also applies to the screen gravure printing system 934 and the chemical binder 936. In exemplary aspects, the application temperature of the chemical binder 936 may be from about 105 degrees Celsius to about 145 degrees Celsius, from about 110 degrees Celsius to about 140 degrees Celsius, or from about 120 degrees Celsius to about 130 degrees Celsius. Generally, the application temperature of the chemical binder 936 is typically lower than the melting temperature of the waterproof breathable membrane 112. Similar to the chemical binder 714, the chemical binder 936 is applied to the first side 210 of the first nonwoven fabric layer 110 in a discontinuous pattern to create a plurality of discrete chemical bonding sites 516.

[0100] In step 938, a padding system 940 applies a durable water repellent to the first side 210 of the first nonwoven fabric layer 110. The components depicted in association with the padding system 940 are illustrative and are intended to convey the general concepts associated with the padding system 940. The system 940 may include additional components or fewer components, and these components may have configurations different from the configurations shown. Other application methods known in the art are contemplated herein, including additional types of padding systems, spraying systems, and the like. In exemplary aspects, the padding step 938 occurs after the bonding step 922. As described above, this is done to prevent the durable water repellent deposits from negatively affecting the moisture curing step associated with the first adhesive film 924. In additional exemplary aspects, the padding step 938 may occur before or after the application of the chemical binder 936 as described above.

[0101] After the padding step 938, in various aspects herein, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90% or at least about 100% of the surface area of the first side 210 of the first non-woven fabric layer 110 includes a durable water repellent deposit. In various aspects herein, it is contemplated that the durable water repellent deposit may be primarily located on the first side 210 of the first non-woven fabric layer 110. In some aspects, the durable water repellent may at least partially penetrate the first non-woven fabric layer 110 such that the durable water repellent deposit may be at least partially located in the volume between the first side 210 and the second side 212 of the first non-woven fabric layer 110.

[0102] In an optional step 942, a portion of the composite fabric 930 is bonded to the second non-woven fabric layer 114. In an exemplary aspect, the bonding may be achieved by using a second adhesive film 946 positioned between the second side 412 of the second non-woven fabric layer 114 and the waterproof breathable membrane 112. In an exemplary aspect, the second adhesive film 946 includes a PUR reactive adhesive film, but other types of adhesive films are contemplated herein. In various aspects herein, non-film adhesives are also contemplated. For example, a liquid adhesive may be applied to one or more of the second non-woven fabric layer 114 and the waterproof breathable membrane 112 prior to the second bonding step. With respect to the second adhesive film 946 in the form of a PUR reactive adhesive, one or more of heat and pressure 948 are applied to the portion of the composite fabric 930 and / or the second non-woven fabric layer 114 to bond the second non-woven fabric layer 114 to the waterproof breathable membrane 112. The result of step 942 is a composite fabric 120 as shown in step 950, wherein the composite fabric 120 includes a first side 510 and an opposite second side 512.

[0103] In step 952, the composite fabric 120 is formed into a wearable article or a garment article 954. Although shown as an upper body garment article, in various aspects herein, it is contemplated that the composite fabric 120 may be formed into other types of garment articles, such as lower body garment articles, the upper part of shoes, gloves, hats, etc. When the composite fabric 120 is formed into a garment article 954, the first side 510 of the composite fabric 120 forms the outermost facing surface of the garment article 954. The characteristics associated with the garment article 744 of FIG. 7 are also applicable to the garment article 954, and these characteristics are not repeated herein.

[0104] The processes depicted in FIGS. 7-9 are illustrative examples, and other processes for forming the first composite fabric 120 are envisioned herein. For example, in one exemplary aspect, the first non-woven fabric layer 110 can be bonded to the waterproof breathable membrane 112 as an initial step. After bonding, a durable water repellent can be deposited on the first non-woven fabric layer 110 using a padding system. After the durable water repellent deposit, the second non-woven fabric layer 114 can be bonded to the waterproof breathable membrane, and then a colorant and a chemical linking agent can be applied to the first side 210 of the first non-woven fabric layer 110 using a screen gravure printing system similar to the screen gravure printing system discussed with respect to 710 of FIG. 7. As described above, in some aspects, the high temperatures associated with applying the colorant using a screen gravure printing system may affect the properties of the waterproof breathable membrane 112, but lower application temperatures may be suitable for the process.

[0105] Aspects herein also envision an exemplary second composite fabric that exhibits waterproof and breathable properties and includes a non-woven fabric layer, making the resulting garment product suitable for inclement weather conditions. With respect to FIG. 10, the second composite fabric can include a waterproof breathable membrane 1010 having a first side 1012 and an opposite second side 1014. When formed as the second composite fabric, the first side 1012 of the waterproof breathable membrane 1010 forms the first side of the composite fabric. The waterproof breathable membrane 1010 can have the same properties as the waterproof breathable membrane 112. In one exemplary aspect, the waterproof breathable membrane 1010 can include an rPU material having micro-perforations 1016, but aspects herein envision that the waterproof breathable membrane 1010 can include other materials discussed herein. In one exemplary aspect, the waterproof breathable membrane 1010 can have a basis weight of from about 20 gsm to about 40 gsm, from about 25 gsm to about 35 gsm, or about 30 gsm. In exemplary aspects, the waterproof breathable membrane 1010 can include a desired color or pattern imparted to the waterproof breathable membrane 1010 during manufacture (i.e., the color or pattern is not added in a post-formation step).

[0106] FIG. 11 depicts a nonwoven fabric layer 1110 having a first side 1112 and an opposite second side 1114. When formed as a second composite fabric, the first side 1112 of the nonwoven fabric layer 1110 forms the opposite second side of the composite fabric. The nonwoven fabric layer 1110 includes entangled fibers and / or filaments, such as those indicated by reference numeral 1116. In one example, the nonwoven fabric layer 1110 may include a spunlace fabric. In another example, the nonwoven fabric layer 1110 may include a needle-punched web formed from virgin fibers, recycled pelletized polymer fibers, chopped product fibers, and any combination thereof. When in the form of a needle-punched web, the nonwoven fabric layer 1110 may have a basis weight ranging from about 50 gsm to about 100 gsm, from about 60 gsm to about 90 gsm, or from about 70 gsm to about 80 gsm.

[0107] FIG. 12 depicts the first side 1215 of a composite fabric 1210 formed by bonding a waterproof breathable membrane 1010 to the nonwoven fabric layer 1110. The first side 1215 of the composite fabric 1210 is formed by the first side 1012 of the waterproof breathable membrane 1010. In exemplary aspects, since the waterproof breathable membrane 1010 includes a film, there is generally no concern about pilling, and chemical binders are generally not required. When formed as a garment product, the first side 1215 of the composite fabric 1210 forms the outermost-facing surface, and in some aspects, forms the outermost-facing surface of the resulting garment product. In exemplary aspects, and as discussed with respect to FIG. 14, the composite fabric 1210 may include a durable water repellent deposit on the first side 1215, but this is optional in some aspects. Due to the waterproof properties of the waterproof breathable membrane 1010, the first side 1215 of the composite fabric 1210 is suitable for adverse weather conditions, such as rain, sleet, or snow.

[0108] FIG. 13 depicts the opposite second side 1315 of the composite fabric 1210. The second side 1315 is formed by the first side 1112 of the nonwoven fabric layer 1110. When formed as a garment product, the second side 1315 forms the innermost-facing surface, and in some aspects, forms the innermost-facing surface of the garment product. Because nonwoven fabrics (especially needle-punched webs) generally have a soft handfeel, when the garment product formed from the composite fabric 1210 is worn, the second side 1315 formed by the nonwoven fabric layer 1110 contributes to the comfort of the wearer.

[0109] FIG. 14 is a schematic diagram of an example process for forming an example second composite fabric 1210. In step 1410, the second side 1014 of the waterproof breathable membrane 1010 is bonded to the non-woven fabric layer 1110. In an example aspect, the bonding can be achieved by using an adhesive film 1412 positioned between the second side 1014 of the waterproof breathable membrane 1010 and the second side 1114 of the non-woven fabric layer 1110. In an example aspect, the adhesive film 1412 includes a PUR reactive adhesive film, but other types of adhesive films are contemplated herein. Other aspects herein also contemplate the use of non-film adhesives. For example, a liquid adhesive can be applied to one or more of the waterproof breathable membrane 1010 and / or the non-woven fabric layer 1110 prior to the bonding step 1410. With respect to the adhesive film 1412 in the form of a PUR reactive adhesive, one or more of heat and pressure 1414 are applied to the waterproof breathable membrane 1010 and / or the non-woven fabric layer 1110 to activate the adhesive film 1412 and bond the two layers together. In an example aspect, the applied temperature can be from about 80 degrees Celsius to about 105 degrees Celsius, from about 85 degrees Celsius to about 100 degrees Celsius, or from about 90 degrees Celsius to about 95 degrees Celsius. The result of the bonding step 1410 is a composite fabric 1210 having a first side 1215 and an opposite second side 1315 as shown in step 1416.

[0110] Step 1418 depicts an optional padding step, where a padding system 1420 or other similar application system deposits a durable water repellent onto the first side 1215 of the composite fabric 1210. In some aspects, this step can be implemented when an additional level of water protection is desired.

[0111] Step 1422 describes a wearable article or a garment 1424 formed from the composite fabric 1210. As depicted, the first side 1215 of the composite fabric 1210 forms the outermost facing surface of the garment 1424. The waterproof properties of the waterproof breathable membrane and the optional water repellent properties make the first side 1215 suitable for exposure to rain, sleet, snow, etc. The second side 1315 of the composite fabric 1210 (not shown) formed by the non-woven fabric layer 1110 faces the wearer, and the soft feel of the non-woven fabric layer 1110 contributes to the comfort of the wearer.

[0112] Compared to the first composite fabric 120, the second composite fabric 1210 and the method of forming a composite fabric as depicted in FIG. 14 may include fewer processing steps (e.g., no colorants and no chemical linking agents), which can reduce the overall carbon footprint associated with the second composite fabric 1210. Additionally, compared to the first composite fabric 120, the second composite fabric 1210 may have a lower basis weight because it includes fewer layers, making the second composite fabric 1210 suitable for lighter-weight outerwear.

[0113] FIGS. 15A and 15B depict a front view and a rear view, respectively, of an exemplary upper body garment article 1500 formed from one or more of the first composite fabric 120 and / or the second composite fabric 1210. The garment article 1500 is shown in the form of a jacket / coat, but other configurations are also contemplated herein, including, for example, sweaters, hoodies, jackets / coats with hoods, vests, etc. The garment article 1500 includes a front torso portion 1510 and a rear torso portion 1512 that together define a neck opening 1514 and a waist opening 1516. In an exemplary aspect, the front torso portion 1510 may include a reversible closure mechanism 1511. The garment article 1500 also includes a first sleeve 1518 and a second sleeve 1520.

[0114] In various aspects herein, it is contemplated that the entire garment article 1500 or one or more portions thereof may be formed from the first composite fabric 120 and / or the second composite fabric 1210. With respect to the first composite fabric 120, in various aspects herein, it is contemplated that the first side 510 forms the outward-facing surface 1522 of the garment article 1500, and the second side 512 forms the inward-facing surface (not shown in FIGS. 15A - 15B) of the garment article 1500. When the second composite fabric 1210 forms the garment article 1500, in various aspects herein, it is contemplated that the first side 1215 forms the outward-facing surface 1522 of the garment article 1500, and the second side 1315 forms the inward-facing surface of the garment article 1500.

[0115] When one or more portions of the garment product 1500 are formed by one or more of the first composite fabric 120 and / or the second composite fabric 1210, aspects herein contemplate that the first composite fabric 120 and / or the second composite fabric 1210 may be positioned on portions of the garment product 1500 that experience a greater amount of precipitation contact compared to other portions of the garment product 1500. The location of these portions may be based on a rainwater distribution map of the human body. For example, the first composite fabric 120 and / or the second composite fabric 1210 may be positioned on the shoulder region of the garment product 1500, the upper back region of the garment product, the hood of the garment product 1500 (when in use), etc. The remaining portions of the garment product 1500 may be formed by additional non-woven materials or other structured fabrics (e.g., knitted or woven fabrics).

[0116] Aspects herein also contemplate forming a first portion of the garment product 1500 from the first composite fabric 120 and other portions of the garment product 1500 from the second composite fabric 1210. For example, since the first side 1215 of the second composite fabric 1210 includes the waterproof breathable membrane 1010, it is generally less prone to pilling. Thus, the second composite fabric 1210 may be used in portions of the garment product 1500 that are subject to a large amount of friction and / or abrasion, such as the area around the neck opening 1514, the area around the waist opening 1516, the elbow areas on the first sleeve 1518 and the second sleeve 1520, etc. The remaining portions of the garment product 1500 may be formed from the first composite fabric 120, other non-woven fabrics, and / or other structured fabrics. These are illustrative examples, and aspects herein contemplate that the garment product 1500 may be formed from only the first composite fabric 120, only the second composite fabric 1210, any combination of the first composite fabric 120 and the second composite fabric 1210, and / or any combination of the first composite fabric 120 and / or the second composite fabric 1210 with other non-woven fabrics and / or structured fabrics.

[0117] Figures 16A and 16B respectively depict a front view and a rear view of an exemplary lower body garment product 1600 formed by one or more of the first composite fabric 120 and / or the second composite fabric 1210. The garment product 1600 is shown in the form of pants, but aspects herein contemplate other forms, including leggings, shorts, capris, full body tights, etc. The garment product 1600 includes a front torso portion 1610 and a rear torso portion 1612 that together define a waist opening 1614. The garment product 1600 also includes a first leg 1616 that terminates at a first leg opening 1618 and a second leg 1620 that terminates at a second leg opening 1622.

[0118] Aspects herein contemplate that the entirety or one or more portions of the garment product 1600 may be formed from the first composite fabric 120 and / or the second composite fabric 1210. With respect to the first composite fabric 120, aspects herein contemplate that the first side 510 forms the outward-facing surface 1624 of the garment product 1600, and the second side 512 forms the inward-facing surface (not shown in FIGS. 16A-16B) of the garment product 1600. When the second composite fabric 1210 forms the garment product 1600, aspects herein contemplate that the first side 1215 forms the outward-facing surface 1624 of the garment product 1600, and the second side 1315 forms the inward-facing surface of the garment product 1600.

[0119] When one or more portions of the garment product 1600 are formed from one or more of the first composite fabric 120 and / or the second composite fabric 1210, aspects herein contemplate that the first composite fabric 120 and / or the second composite fabric 1210 may be positioned on portions of the garment product 1600 that experience a greater amount of precipitation contact compared to other portions of the garment product 1600. The location of these portions may be based on a rainwater distribution map of the human body. For example, the first composite fabric 120 and / or the second composite fabric 1210 may be positioned on the rear torso portion 1612 of the garment product 1600, and / or around the first leg opening 1618 and the second leg opening 1622. The remaining portions of the garment product 1600 may be formed from additional non-woven materials or other structured fabrics (e.g., knitted or woven fabrics).

[0120] Aspects herein also contemplate forming a first portion of the garment product 1600 from the first composite fabric 120 and other portions of the garment product 1600 from the second composite fabric 1210. For example, since the first side 1215 of the second composite fabric 1210 includes a waterproof breathable membrane 1010, it is generally less prone to pilling. Thus, the second composite fabric 1210 may be used in portions of the garment product 1600 that are subject to a large amount of friction and / or abrasion, such as the rear torso portion 1612 when sitting, the knee regions of the first leg 1616 and the second leg 1620, etc. The remaining portions of the garment product 1600 may be formed from the first composite fabric 120, other non-woven fabrics, and / or other structured fabrics. These are illustrative examples, and aspects herein contemplate that the garment product 1600 may be formed from only the first composite fabric 120, only the second composite fabric 1210, any combination of the first composite fabric 120 and the second composite fabric 1210, and / or any combination of the first composite fabric 120 and / or the second composite fabric 1210 with other non-woven fabrics and / or structured fabrics.

[0121] Figures 15A, 15B, 16A, and 16B depict upper body garments and lower body garments. In at least some examples, the first composite fabric 120, the second composite fabric 1210, any other composite fabric described herein, and any combination thereof may include at least a portion of a footwear product (e.g., an upper of a footwear product).

[0122] The following clauses represent example aspects of the concepts contemplated herein. Any one of the following clauses may be combined in multiple dependent manners to be dependent on one or more other clauses. Additionally, any combination of dependent clauses (clauses that explicitly depend on a previous clause) may be combined while remaining within the scope of the aspects contemplated herein. The following clauses are examples and are not restrictive.

[0123] Clause 1. A composite fabric having a first side and an opposite second side, the composite fabric comprising: a first nonwoven fabric layer having a first side and an opposite second side, the first side of the first nonwoven fabric layer comprising the first side of the composite fabric, the first nonwoven fabric layer including a durable water repellent deposit; a waterproof breathable membrane; and a first adhesive layer positioned between the waterproof breathable membrane and the second side of the first nonwoven fabric layer, the first adhesive layer bonding the waterproof breathable membrane to the first nonwoven fabric layer.

[0124] Clause 2. The composite fabric according to Clause 1, wherein the first nonwoven fabric layer includes a printed component.

[0125] Clause 3. The composite fabric according to Clause 2, wherein the printed component includes at least one of a colorant and a sublimation dye.

[0126] Clause 4. The composite fabric according to any one of Clauses 1 to 3, wherein the first nonwoven fabric layer includes a plurality of chemical bonding sites.

[0127] Clause 5. The composite fabric according to Clause 4, wherein one or more of the fibers and filaments of the first nonwoven fabric layer are adhered together at the plurality of chemical bonding sites.

[0128] Clause 6. The composite fabric according to any one of Clauses 1 to 5, wherein the first nonwoven fabric layer includes a spunlace fabric.

[0129] Clause 7. The composite fabric according to any one of Clauses 1 to 5, wherein the first non-woven fabric layer comprises one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0130] Clause 8. The composite fabric according to any one of Clauses 1 to 5, wherein the first non-woven fabric layer comprises one or more of fibers derived from a chopped product fiber source, recycled polymer fibers, and virgin fibers.

[0131] Clause 9. The composite fabric according to any one of Clauses 1 to 5, wherein the first non-woven fabric layer comprises from about 10% to about 100% of fibers derived from a chopped product fiber source and having varying lengths.

[0132] Clause 10. The composite fabric according to Clause 1, wherein the waterproof breathable membrane comprises a polymer.

[0133] Clause 11. The composite fabric according to Clause 10, wherein the polymer comprises an olefin.

[0134] Clause 12. The composite fabric according to Clause 11, wherein the olefin comprises a polyolefin.

[0135] Clause 13. The composite fabric according to Clause 12, wherein the polyolefin comprises polyethylene or polypropylene.

[0136] Clause 14. The composite fabric according to Clause 10, wherein the polymer comprises polyurethane.

[0137] Clause 15. The composite fabric according to Clause 10, wherein the polymer comprises a thermoplastic polymer.

[0138] Clause 16. The composite fabric according to Clause 15, wherein the thermoplastic polymer comprises a thermoplastic elastomer.

[0139] Clause 17. The composite fabric according to Clause 10, wherein the polymer comprises a recycled polymer.

[0140] Clause 18. The composite fabric according to Clause 10, wherein the polymer comprises one or more of recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0141] Clause 19. The composite fabric according to any one of Clauses 1 to 18, wherein the first adhesive layer comprises a polyurethane-reactive adhesive.

[0142] Clause 20. The composite fabric according to any one of Clauses 1 to 19, further comprising: a second non-woven fabric layer having a first side and an opposite second side, the first side of the second non-woven fabric layer comprising the second side of the composite fabric; and a second adhesive layer positioned between the waterproof breathable membrane and the second side of the second non-woven fabric layer, the second adhesive layer bonding the waterproof breathable membrane to the second non-woven fabric layer.

[0143] Clause 21. The composite fabric according to Clause 20, wherein the second non-woven fabric layer comprises a spunlace fabric.

[0144] Clause 22. The composite fabric according to Clause 20, wherein the second non-woven fabric layer comprises one or more of entangled staple fibers having a uniform length and entangled fibers having different lengths.

[0145] Clause 23. The composite fabric according to any one of Clauses 20 to 22, wherein the second adhesive layer comprises a polyurethane-reactive adhesive.

[0146] Clause 24. A wearable article having an outward-facing surface and an opposite inward-facing surface, the wearable article comprising: a first non-woven fabric layer having a first side and an opposite second side, the first side of the first non-woven fabric layer comprising the outward-facing surface of the wearable article, the first non-woven fabric layer comprising a durable water repellent deposit; a waterproof breathable membrane; and a first adhesive layer positioned between the waterproof breathable membrane and the second side of the first non-woven fabric layer, the first adhesive layer bonding the waterproof breathable membrane to the first non-woven fabric layer.

[0147] Clause 25. The wearable article according to Clause 24, wherein the first non-woven fabric layer comprises a printed component.

[0148] Clause 26. The wearable article according to Clause 25, wherein the printed component comprises at least one of a colorant and a sublimation dye.

[0149] Clause 27. The wearable article according to any one of Clauses 24 to 26, wherein the first non-woven fabric layer includes a plurality of chemical bonding sites.

[0150] Clause 28. The wearable article according to Clause 27, wherein one or more of the fibers and filaments of the first non-woven fabric layer are adhered together at the plurality of chemical bonding sites.

[0151] Clause 29. The wearable article according to any one of Clauses 24 to 28, wherein the first non-woven fabric layer includes a spunlace fabric.

[0152] Clause 30. The wearable article according to any one of Clauses 24 to 28, wherein the first non-woven fabric layer includes one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0153] Clause 31. The wearable article according to any one of Clauses 24 to 30, wherein the waterproof breathable membrane includes one selected from the following: recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0154] Clause 32. The wearable article according to any one of Clauses 24 to 31, wherein the first adhesive layer includes a polyurethane reactive adhesive.

[0155] Clause 33. The wearable article according to any one of Clauses 24 to 32, further comprising: a second non-woven fabric layer having a first side and an opposite second side, the first side of the second non-woven fabric layer including the inward-facing surface of the wearable article; and a second adhesive layer positioned between the waterproof breathable membrane and the second side of the second non-woven fabric layer, the second adhesive layer bonding the waterproof breathable membrane to the second non-woven fabric layer.

[0156] Clause 34. The wearable article according to Clause 33, wherein the second non-woven fabric layer includes a spunlace fabric.

[0157] Clause 35. The wearable article according to Clause 33, wherein the second non-woven fabric layer includes one or more of entangled staple fibers having a uniform length and entangled fibers having varying lengths.

[0158] Clause 36. The wearable article according to any one of Clauses 33 to 35, wherein the second adhesive layer comprises a polyurethane reactive adhesive.

[0159] Clause 37. A method of forming a composite fabric having a first side and an opposite second side, the method comprising: positioning a first adhesive film between a first non-woven fabric layer and a waterproof breathable membrane, the first non-woven fabric layer comprising a first side and an opposite second side, wherein the first adhesive film is positioned adjacent to the second side of the first non-woven fabric layer; applying one or more of heat and pressure to the first adhesive film to bond the first non-woven fabric layer to the waterproof breathable membrane, wherein after bonding, the first side of the first non-woven fabric layer comprises the first side of the composite fabric; and depositing a durable water repellent onto the first non-woven fabric layer.

[0160] Clause 38. The method of forming a composite fabric according to Clause 37, wherein after bonding the first non-woven fabric layer to the waterproof breathable membrane, a durable water repellent is deposited onto the first non-woven fabric layer.

[0161] Clause 39. The method of forming a composite fabric according to any one of Clauses 37 to 38, further comprising applying a printed component to the first non-woven fabric layer.

[0162] Clause 40. The method of forming a composite fabric according to Clause 39, wherein the printed component is applied to the first non-woven fabric layer before bonding the first non-woven fabric layer to the waterproof breathable membrane.

[0163] Clause 41. The method of forming a composite fabric according to any one of Clauses 39 to 40, wherein the printed component comprises a colorant.

[0164] Clause 42. The method of forming a composite fabric according to Clause 41, wherein the colorant comprises a chemical linker, and wherein applying the colorant to the first non-woven fabric layer creates a plurality of chemical bonding sites.

[0165] Clause 43. The method of forming a composite fabric according to Clause 42, wherein one or more of the fibers and filaments of the first non-woven fabric layer adhere together at the plurality of chemical bonding sites.

[0166] Clause 44. A method of forming a composite fabric according to any one of Clauses 37 to 40, wherein the printing member comprises a sublimation dye.

[0167] Clause 45. The method of forming a composite fabric according to Clause 44, further comprising applying a chemical linking agent to the first non-woven fabric layer to create a plurality of chemical bonding sites.

[0168] Clause 46. The method of forming a composite fabric according to Clause 45, wherein the chemical linking agent is applied to the first non-woven fabric layer before depositing the durable water repellent onto the first non-woven fabric layer.

[0169] Clause 47. The method of forming a composite fabric according to any one of Clauses 45 to 46, wherein the chemical linking agent is applied to the first non-woven fabric layer after bonding the first non-woven fabric layer to the waterproof breathable membrane.

[0170] Clause 48. The method of forming a composite fabric according to any one of Clauses 45 to 47, wherein one or more fibers and filaments of the first non-woven fabric layer are adhered together at the plurality of chemical bonding sites.

[0171] Clause 49. The method of forming a composite fabric according to any one of Clauses 37 to 48, wherein the first non-woven fabric layer is a spunlace fabric.

[0172] Clause 50. The method of forming a composite fabric according to any one of Clauses 37 to 48, wherein the first non-woven fabric layer comprises one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0173] Clause 51. The method of forming a composite fabric according to any one of Clauses 37 to 50, wherein the waterproof breathable membrane comprises one selected from the following: recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0174] Clause 52. The method of forming a composite fabric according to any one of Clauses 37 to 51, wherein the first adhesive film comprises a polyurethane reactive adhesive.

[0175] Clause 53. The method of forming a composite fabric according to any one of Clauses 37 to 52 further includes: positioning a second adhesive film between the second non-woven fabric layer and the waterproof and breathable film, the second non-woven fabric layer including a first side and an opposite second side, wherein the second adhesive film is positioned adjacent to the second side of the second non-woven fabric layer; and applying one or more of heat and pressure to the second adhesive film to bond the second non-woven fabric layer to the waterproof and breathable film, wherein after bonding, the first side of the second non-woven fabric layer includes the second side of the composite fabric.

[0176] Clause 54. The method according to Clause 53, wherein after depositing the durable water repellent onto the first non-woven fabric layer, the second non-woven fabric layer is bonded to the waterproof and breathable film.

[0177] Clause 55. The method of forming a composite fabric according to any one of Clauses 53 to 54, wherein the second non-woven fabric layer includes a spunlace fabric.

[0178] Clause 56. The method of forming a composite fabric according to any one of Clauses 53 to 54, wherein the second non-woven fabric layer includes one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0179] Clause 57. The method of forming a composite fabric according to any one of Clauses 53 to 56, wherein the second adhesive film includes a polyurethane reactive adhesive.

[0180] Clause 58. The method of forming a composite fabric according to any one of Clauses 53 to 57 further includes forming the composite fabric into a garment, wherein the first side of the composite fabric forms the outward-facing surface of the garment, and wherein the second side of the composite fabric forms the inward-facing surface of the garment.

[0181] Clause 59. A composite fabric having a first side and an opposite second side, the composite fabric including: a first non-woven fabric layer having a first side and an opposite second side, the first side of the first non-woven fabric layer including the first side of the composite fabric, the first non-woven fabric layer including a durable water repellent deposit; and a waterproof and breathable film bonded to the second side of the first non-woven fabric layer.

[0182] Clause 60. The composite fabric according to Clause 59 further includes a first adhesive layer positioned between the second side of the first non-woven fabric layer and the waterproof breathable membrane, and the first adhesive layer bonds the first non-woven fabric layer to the waterproof breathable membrane.

[0183] Clause 61. The composite fabric according to any one of Clauses 59 to 60, wherein the first non-woven fabric layer includes a printed component.

[0184] Clause 62. The composite fabric according to Clause 61, wherein the printed component includes at least one of a colorant and a sublimation dye.

[0185] Clause 63. The composite fabric according to any one of Clauses 59 to 62, wherein the first non-woven fabric layer includes a plurality of chemical bonding sites.

[0186] Clause 64. The composite fabric according to Clause 63, wherein one or more of the fibers and filaments of the first non-woven fabric layer are adhered together at the plurality of chemical bonding sites.

[0187] Clause 65. The composite fabric according to any one of Clauses 59 to 64, wherein the first non-woven fabric layer includes a spunlace fabric.

[0188] Clause 66. The composite fabric according to any one of Clauses 59 to 64, wherein the first non-woven fabric layer includes one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0189] Clause 67. The composite fabric according to any one of Clauses 59 to 66, wherein the waterproof breathable membrane includes one selected from the following: recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0190] Clause 68. The composite fabric according to any one of Clauses 59 to 67 further includes a second non-woven fabric layer having a first side and an opposite second side, the first side of the second non-woven fabric layer includes the second side of the composite fabric, and the second side of the second non-woven fabric layer is bonded to the waterproof breathable membrane.

[0191] Clause 69. The composite fabric according to Clause 68 further includes a second adhesive layer positioned between the second side of the second non-woven fabric layer and the waterproof breathable membrane, and the second adhesive layer bonds the second non-woven fabric layer to the waterproof breathable membrane.

[0192] Clause 70. The composite fabric according to any one of Clauses 68 to 69, wherein the second non-woven fabric layer includes a spunlace fabric.

[0193] Clause 71. The composite fabric according to any one of Clauses 68 to 69, wherein the second non-woven fabric layer includes one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0194] Clause 72. A clothing article having an outward-facing surface and an opposite inward-facing surface, the clothing article including: a first non-woven fabric layer having a first side and an opposite second side, the first side of the first non-woven fabric layer including the outward-facing surface of the clothing article, the first non-woven fabric layer including a durable water repellent deposit; and a waterproof breathable membrane bonded to the second side of the first non-woven fabric layer.

[0195] Clause 73. The clothing article according to Clause 72 further includes a first adhesive layer positioned between the second side of the first non-woven fabric layer and the waterproof breathable membrane, and the first adhesive layer bonds the first non-woven fabric layer to the waterproof breathable membrane.

[0196] Clause 74. The clothing article according to any one of Clauses 72 to 73, wherein the first non-woven fabric layer includes a printed component.

[0197] Clause 75. The clothing article according to Clause 74, wherein the printed component includes at least one of a colorant and a sublimation dye.

[0198] Clause 76. The clothing article according to any one of Clauses 72 to 75, wherein the first non-woven fabric layer includes a plurality of chemical bonding sites.

[0199] Clause 77. The clothing article according to Clause 77, wherein one or more of the fibers and filaments of the first non-woven fabric layer are adhered together at the plurality of chemical bonding sites.

[0200] Clause 78. The garment product according to any one of Clauses 72 to 77, wherein the first non-woven fabric layer comprises a spunlace fabric.

[0201] Clause 79. The garment product according to any one of Clauses 72 to 77, wherein the first non-woven fabric layer comprises one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0202] Clause 80. The garment product according to any one of Clauses 72 to 79, wherein the waterproof breathable membrane comprises one selected from the following: recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0203] Clause 81. The garment product according to any one of Clauses 72 to 80, further comprising: a second non-woven fabric layer having a first side and an opposite second side, the first side of the second non-woven fabric layer comprising the inward-facing surface of the garment product, and the second side of the second non-woven fabric layer being bonded to the waterproof breathable membrane.

[0204] Clause 82. The garment product according to Clause 81, further comprising a second adhesive layer positioned between the second side of the second non-woven fabric layer and the waterproof breathable membrane, the second adhesive layer bonding the second non-woven fabric layer to the waterproof breathable membrane.

[0205] Clause 83. The garment product according to any one of Clauses 81 to 82, wherein the second non-woven fabric layer comprises a spunlace fabric.

[0206] Clause 84. The garment product according to any one of Clauses 81 to 82, wherein the second non-woven fabric layer comprises one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0207] Clause 85. A method of forming a composite fabric having a first side and an opposite second side, the method comprising: bonding a waterproof breathable membrane to a first non-woven fabric layer, the first non-woven fabric layer having a first side and an opposite second side, the first side forming the first side of the composite fabric, and the second side being bonded to the waterproof breathable membrane; and depositing a durable water repellent onto the first non-woven fabric layer.

[0208] Clause 86. The method for forming a composite fabric according to Clause 85, wherein after bonding the waterproof and breathable film to the first non-woven fabric layer, a durable water repellent is deposited on the first non-woven fabric layer.

[0209] Clause 87. The method for forming a composite fabric according to any one of Clauses 85 to 86 further includes applying a printed component to the first non-woven fabric layer.

[0210] Clause 88. The method for forming a composite fabric according to Clause 87, wherein the printed component is applied to the first non-woven fabric layer before bonding the waterproof and breathable film to the first non-woven fabric layer.

[0211] Clause 89. The method for forming a composite fabric according to any one of Clauses 87 to 88, wherein the printed component includes a colorant.

[0212] Clause 90. The method for forming a composite fabric according to Clause 89, wherein the colorant includes a chemical linker, and wherein applying the colorant to the first non-woven fabric layer creates multiple chemical bonding sites.

[0213] Clause 91. The method for forming a composite fabric according to Clause 90, wherein one or more of the fibers and filaments in the first non-woven fabric layer adhere together at the multiple chemical bonding sites.

[0214] Clause 92. The method for forming a composite fabric according to any one of Clauses 87 to 88, wherein the printed component includes a sublimation dye.

[0215] Clause 93. The method for forming a composite fabric according to Clause 92 further includes applying a chemical linker to the first non-woven fabric layer to create multiple chemical bonding sites.

[0216] Clause 94. The method for forming a composite fabric according to Clause 93, wherein the chemical linker is applied to the first non-woven fabric layer before depositing the durable water repellent on the first non-woven fabric layer.

[0217] Clause 95. A method for forming a composite fabric according to any one of Clauses 93 to 94, wherein after bonding the waterproof and breathable membrane to the first non-woven fabric layer, the chemical binder is applied to the first non-woven fabric layer.

[0218] Clause 96. A method for forming a composite fabric according to any one of Clauses 93 to 95, wherein one or more fibers and filaments of the first non-woven fabric layer are adhered together at the plurality of chemical bonding sites.

[0219] Clause 97. A method for forming a composite fabric according to any one of Clauses 85 to 96, wherein the first non-woven fabric layer is a spunlace fabric.

[0220] Clause 98. A method for forming a composite fabric according to any one of Clauses 85 to 96, wherein the first non-woven fabric layer includes one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0221] Clause 99. A method for forming a composite fabric according to any one of Clauses 85 to 98, wherein the waterproof and breathable membrane includes one selected from the following: recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0222] Clause 100. A method for forming a composite fabric according to any one of Clauses 85 to 99, further comprising bonding the waterproof and breathable membrane to a second non-woven fabric layer, the second non-woven fabric layer including a first side and an opposite second side, the first side of the second non-woven fabric layer forming the second side of the composite fabric, and the second side of the second non-woven fabric layer being bonded to the waterproof and breathable membrane.

[0223] Clause 101. A method for forming a composite fabric according to Clause 100, wherein the second non-woven fabric layer includes a spunlace fabric.

[0224] Clause 102. A method for forming a composite fabric according to Clause 100, wherein the second non-woven fabric layer includes one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0225] Clause 103. The method of forming a composite fabric according to any one of Clauses 100 to 102 further includes forming the composite fabric into a clothing article, wherein the first side of the composite fabric forms the outward-facing surface of the clothing article, and wherein the second side of the composite fabric forms the inward-facing surface of the clothing article.

[0226] Clause 104. A composite fabric having a first side and an opposite second side, the composite fabric comprising: a waterproof and breathable membrane having a first side and an opposite second side, the first side including the first side of the composite fabric, the waterproof and breathable membrane including a durable water repellent deposit; and a non-woven fabric layer bonded to the second side of the waterproof and breathable membrane, the non-woven fabric layer including the second side of the composite fabric.

[0227] Clause 105. The composite fabric according to Clause 104 further includes an adhesive layer positioned between the waterproof and breathable membrane and the non-woven fabric layer, the adhesive layer bonding the waterproof and breathable membrane to the non-woven fabric layer.

[0228] Clause 106. The composite fabric according to any one of Clauses 104 to 105, wherein the non-woven fabric layer includes a spunlace fabric.

[0229] Clause 107. The composite fabric according to any one of Clauses 104 to 105, wherein the non-woven fabric layer includes one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0230] Clause 108. The composite fabric according to any one of Clauses 104 to 107, wherein the waterproof and breathable membrane includes one selected from the following: recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0231] Clause 109. A clothing article formed from the composite fabric according to Clause 104, wherein the first side of the composite fabric includes the outward-facing surface of the clothing article, and wherein the second side of the composite fabric includes the inward-facing surface of the clothing article.

[0232] Clause 110. A method of forming a composite fabric having a first side and an opposite second side, the method comprising: bonding a waterproof breathable membrane to a non-woven fabric layer, the waterproof breathable membrane comprising the first side of the composite fabric, the non-woven fabric layer comprising the second side of the composite fabric; and depositing a durable water repellent on the waterproof breathable membrane.

[0233] Clause 111. The method of forming a composite fabric according to Clause 110, wherein the waterproof breathable membrane is bonded to the non-woven fabric layer using an adhesive film.

[0234] Clause 112. The method of forming a composite fabric according to any one of Clauses 110 to 111, wherein the non-woven fabric layer comprises a spunlace fabric.

[0235] Clause 113. The method of forming a composite fabric according to any one of Clauses 110 to 112, wherein the non-woven fabric layer comprises one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0236] Clause 114. The method of forming a composite fabric according to any one of Clauses 110 to 113, wherein the waterproof breathable membrane comprises one selected from the following: recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0237] Clause 115. The method of forming a composite fabric according to any one of Clauses 110 to 114, further comprising forming the composite fabric into a garment article, wherein the first side of the composite fabric forms the outward-facing surface of the garment article, and wherein the second side of the composite fabric forms the inward-facing surface of the garment article.

[0238] Clause 116. A composite fabric comprising a first side and an opposite second side, the composite fabric comprising: a first non-woven fabric layer having a first side and an opposite second side, the first side of the first non-woven fabric layer comprising the first side of the composite fabric, the first non-woven fabric layer comprising a printed component; a waterproof breathable membrane; and a first adhesive layer positioned between the waterproof breathable membrane and the second side of the first non-woven fabric layer, the first adhesive layer bonding the waterproof breathable membrane to the first non-woven fabric layer.

[0239] Clause 117. The composite fabric according to Clause 116, wherein the printing component comprises at least one of a colorant and a sublimation dye.

[0240] Clause 118. The composite fabric according to any one of Clauses 116 to 117, wherein the first non-woven fabric layer comprises a durable water repellent deposit.

[0241] Clause 119. The composite fabric according to any one of Clauses 116 to 118, wherein the first non-woven fabric layer comprises a plurality of chemical bonding sites.

[0242] Clause 120. The composite fabric according to Clause 119, wherein one or more of the fibers and filaments of the first non-woven fabric layer are adhered together at the plurality of chemical bonding sites.

[0243] Clause 121. The composite fabric according to any one of Clauses 116 to 120, wherein the first non-woven fabric layer comprises a spunlace fabric.

[0244] Clause 122. The composite fabric according to any one of Clauses 116 to 120, wherein the first non-woven fabric layer comprises one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0245] Clause 123. The composite fabric according to any one of Clauses 116 to 122, wherein the waterproof breathable membrane comprises one selected from the following: recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0246] Clause 124. The composite fabric according to any one of Clauses 116 to 123, wherein the first adhesive layer comprises a polyurethane reactive adhesive.

[0247] Clause 125. The composite fabric according to any one of Clauses 116 to 124, further comprising: a second non-woven fabric layer having a first side and an opposite second side, the first side of the second non-woven fabric layer comprising the second side of the composite fabric; and a second adhesive layer positioned between the waterproof breathable membrane and the second side of the second non-woven fabric layer, the second adhesive layer bonding the waterproof breathable membrane to the second non-woven fabric layer.

[0248] Clause 126. The composite fabric according to Clause 125, wherein the second non-woven fabric layer comprises a spunlace fabric.

[0249] Clause 127. The composite fabric according to Clause 125, wherein the second non-woven fabric layer comprises one or more of entangled staple fibers having a substantially uniform length and entangled fibers having different lengths.

[0250] Clause 128. The composite fabric according to any one of Clauses 125 to 127, wherein the second adhesive layer comprises a polyurethane reactive adhesive.

[0251] Clause 129. A clothing article formed from the composite fabric according to Clause 125, wherein the first side of the composite fabric comprises the outward-facing surface of the clothing article, and wherein the second side of the composite fabric comprises the inward-facing surface of the clothing article.

[0252] Clause 130. A composite non-woven fabric having a first side and an opposite second side, the composite non-woven fabric comprising: a waterproof and breathable membrane positioned between and bonded to a first non-woven fabric layer and a second non-woven fabric layer, the composite non-woven fabric having: a basis weight ranging from about 100 grams per square meter (gsm) to about 180 gsm; a water vapor transport resistance (RET) ranging from about 12 RET to about 22 RET; and a water resistance to penetration ranging from about 9000 mm to about 1200 mm.

[0253] Clause 131. The composite non-woven fabric according to Clause 130, wherein the composite non-woven fabric comprises a water repellency ranging from about 3 to about 4.5.

[0254] Clause 132. The composite non-woven fabric according to any one of Clauses 130 to 131, wherein the composite non-woven fabric has a pilling resistance ranging from about 3 to about 3.5.

[0255] Clause 133. The composite non-woven fabric according to any one of Clauses 130 to 132, wherein the first non-woven fabric layer comprises the first side of the composite non-woven fabric, and wherein the second non-woven fabric layer comprises the second side of the composite non-woven fabric.

[0256] Article 134. A clothing product formed from the composite fabric according to Article 130, wherein the first side of the composite fabric includes the outward-facing surface of the clothing product, and wherein the second side of the composite fabric includes the inward-facing surface of the clothing product.

[0257] Article 135. A composite fabric having a first side and an opposite second side, the composite fabric comprising: a first non-woven fabric layer having a first side and an opposite second side, the first side of the first non-woven fabric layer including the first side of the composite fabric; a second non-woven fabric layer having a first side and an opposite second side, the first side of the second non-woven fabric layer including the second side of the composite fabric; and a waterproof breathable membrane bonded between the first non-woven fabric layer and the second non-woven fabric layer.

[0258] Article 136. The composite fabric according to Article 135, wherein the first non-woven fabric layer includes a durable water repellent deposit.

[0259] Article 137. The composite fabric according to any one of Articles 135 to 136, wherein the first non-woven fabric layer includes a printed component.

[0260] Article 138. The composite fabric according to Article 137, wherein the printed component includes at least one of a colorant and a sublimation dye.

[0261] Article 139. The composite fabric according to any one of Articles 135 to 138, further comprising a first adhesive layer positioned between the first non-woven fabric layer and the waterproof breathable membrane and a second adhesive layer positioned between the second non-woven fabric layer and the waterproof breathable membrane.

[0262] Article 140. The composite fabric according to any one of Articles 135 to 139, wherein the first non-woven fabric layer includes a plurality of chemical bonding sites.

[0263] Article 141. The composite fabric according to Article 140, wherein one or more of the fibers and filaments of the first non-woven fabric layer are adhered together at the plurality of chemical bonding sites.

[0264] Article 142. The composite fabric according to any one of Articles 135 to 141, wherein the waterproof breathable membrane includes a polymer.

[0265] Clause 143. The composite fabric according to Clause 142, wherein the polymer comprises an olefin.

[0266] Clause 144. The composite fabric according to Clause 143, wherein the olefin comprises a polyolefin.

[0267] Clause 145. The composite fabric according to Clause 144, wherein the polyolefin comprises polyethylene or polypropylene.

[0268] Clause 146. The composite fabric according to Clause 142, wherein the polymer comprises polyurethane.

[0269] Clause 147. The composite fabric according to Clause 142, wherein the polymer comprises a thermoplastic polymer.

[0270] Clause 148. The composite fabric according to Clause 147, wherein the thermoplastic polymer comprises a thermoplastic elastomer.

[0271] Clause 149. The composite fabric according to Clause 142, wherein the polymer comprises a recycled polymer.

[0272] Clause 150. The composite fabric according to Clause 142, wherein the polymer comprises one or more of recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

[0273] Clause 151. The composite fabric according to any one of Clauses 135 to 150, wherein the first non-woven fabric layer comprises a first spunlace non-woven fabric, and the second non-woven fabric layer comprises a second spunlace non-woven fabric.

[0274] Clause 152. The composite fabric according to any one of Clauses 135 to 150, wherein the first non-woven fabric layer comprises a spunlace non-woven fabric, and the second non-woven fabric layer comprises entangled fibers.

[0275] Clause 153. The composite fabric according to any one of Clauses 135 to 150, wherein the first non-woven fabric layer comprises a first web of entangled fibers, and the second non-woven fabric layer comprises a second web of entangled fibers.

[0276] Clause 154. A wearable article comprising the composite fabric according to Clause 135.

[0277] Clause 155. The wearable article according to Clause 154, wherein the wearable article comprises upper body clothing, lower body clothing, footwear, headgear, gloves or sleeves.

[0278] Clause 156. The wearable article according to Clause 154, wherein the wearable article comprises an upper for a footwear.

[0279] Clause 157. A composite fabric having a first side and an opposite second side, the composite fabric comprising: a first nonwoven fabric layer having a first side and an opposite second side, the first side of the first nonwoven fabric layer comprising the first side of the composite fabric, the first nonwoven fabric layer comprising a durable water repellent finish and one or more of a plurality of chemical bonding sites; wherein the first nonwoven fabric layer comprises one or more entangled fiber webs.

[0280] Clause 158. The composite fabric according to Clause 157, wherein at least one of the one or more entangled fiber webs comprises recycled polymer fibers and shredded product fibers.

[0281] Clause 159. The composite fabric according to any one of Clauses 157 to 158, further comprising: a waterproof breathable membrane comprising a thermoplastic polymer.

[0282] Clause 160. The composite fabric according to any one of Clauses 157 to 159, wherein the amount of the surface area of the first nonwoven fabric layer occupied by the plurality of chemical bonding sites is from about 40% to about 60%.

[0283] Clause 161. A composite fabric having a first side and an opposite second side, the composite fabric comprising: a first nonwoven fabric layer having a first side and an opposite second side, the first side of the first nonwoven fabric layer comprising the first side of the composite fabric, the first nonwoven fabric layer comprising a durable water repellent deposit; and a waterproof breathable membrane; wherein the first nonwoven fabric layer is bonded to the waterproof breathable membrane, and wherein the first nonwoven fabric layer comprises one or more of shredded product fibers and recycled polymer fibers.

[0284] Clause 162. A composite fabric including a first side and an opposite second side, the composite fabric comprising: a first non-woven fabric layer having a first side and an opposite second side, the first side of the first non-woven fabric layer including the first side of the composite fabric, the first non-woven fabric layer including supercritical CO2 impregnated dyes; a waterproof and breathable membrane; and a first adhesive layer positioned between the waterproof and breathable membrane and the second side of the first non-woven fabric layer, the first adhesive layer bonding the waterproof and breathable membrane to the first non-woven fabric layer.

[0285] Clause 163. The composite fabric according to Clause 162, wherein the first non-woven fabric layer includes a chemical linker.

[0286] Clause 164. The composite fabric according to Clause 162 or Clause 163, wherein the first non-woven fabric layer includes a DWR finish.

[0287] Clause 165. The composite fabric according to any one of Clauses 162 to 164, wherein the first non-woven fabric layer includes a spunlace fabric.

[0288] Clause 166. The composite fabric according to any one of Clauses 162 to 165, further comprising a second non-woven fabric layer bonded to the waterproof and breathable membrane via a second adhesive layer.

[0289] Clause 167. The composite fabric according to Clause 166, wherein the second non-woven fabric includes a spunlace fabric.

[0290] Clause 168. The composite fabric according to Clause 166, wherein the second non-woven fabric includes a spunbonded scrim.

[0291] Clause 169. The composite fabric according to any one of Clauses 162 to 165, wherein the opposite second side of the composite fabric includes a printed component.

[0292] Clause 170. The composite fabric according to any one of Clauses 162 to 169, wherein the first side of the composite fabric includes the outward-facing surface of a garment product.

[0293] Aspects of the present disclosure have been described with an illustrative rather than a restrictive intent. Alternative aspects will become apparent to those skilled in the art without departing from its scope. Those skilled in the art may develop alternative means of implementing the improvements described above without departing from the scope of the present disclosure.

[0294] It should be understood that certain features and subcombinations are useful and may be used without reference to other features and subcombinations, and are contemplated to be within the scope of the claims. Not all steps listed in each figure need to be performed in the specific order described.

[0295] 100: First non-woven fabric layer 110, waterproof breathable membrane 112, and optional second non-woven fabric layer 114 in a stacked configuration prior to bonding 110: First non-woven fabric layer 112: Waterproof breathable membrane 114: Second non-woven fabric layer 118: Arrow 120: First composite fabric 122: Arrow 124: Garment product 126: Arrow 205: Fibers and / or filaments 210: First side 212: Second side 405: Fibers and / or filaments 410: First side 412: Opposite second side 510: First surface 512: Second surface 514: Printing component 516: Multiple chemical bonding sites 705: Screen gravure printing system 710: Step 712: Colorant 714: Chemical linking agent 715: Opening 716: Screen roller 718: First direction 720: Bonding step 722: Heat and pressure 724: First adhesive film 726: Step 728: Partial composite fabric 730: Padding step 732: Padding system 734: Step 736: Second adhesive film 738: Heat and pressure 740: Step 742: Step 744: Wearable product or clothing product 810: Step 812: System 814: Sublimation paper 816: Roller 818: Heat source 820: Bonding step 822: First adhesive film 824: Heat and pressure 826: Step 828: Partially composite fabric 830: Step 832: Screen gravure printing system 834: Chemical linking agent 836: Padding step 838: Padding system 840: Second bonding step 842: Second adhesive film 844: Heat and pressure 846: Step 848: Step 850: Wearable product or clothing product 910: First printing step 912: Sublimation printing system 914: Sublimation paper 916: Roller 918: Heat source 920: Second printing step 922: Bonding step 924: First adhesive film 926: Heat and pressure 928: Step 930: Partially composite fabric 932: Step 934: Screen gravure printing system 936: Chemical linking agent 938: Padding step 940: Padding system 942: Step 946: Second adhesive film 948: 950: Step 952: Step 954: Garment product 1010: Waterproof breathable film 1012: First side 1014: Opposite second side 1016: Micro-perforations 1110: Non-woven fabric layer 1112: First side 1114: Opposite second side 1116: Entangled fibers and / or filaments 1210: Second composite fabric 1215: First side 1315: Opposite second side 1410: Step 1412: Adhesive film 1414: Heat and pressure 1416: Step 1418: Step 1420: Padding system 1422: Step 1424: Wearable product or garment product 1500: Garment product 1510: Front torso part 1511: Reversible closure mechanism 1512: Rear torso part 1514: Together define a neck opening 1516: Waist opening 1518: First sleeve 1520: Second sleeve 1522: Outward-facing surface 1600: Garment product 1610: Front torso part 1612: Rear torso part when sitting 1614: Together define a waist opening 1616: First leg 1618: First leg opening 1620: Second leg 1622: Second leg opening 1624: Outward-facing surface

Claims

1. A composite fabric having a first side and an opposing second side, the composite fabric comprising: A first nonwoven fabric layer having a first side and an opposing second side, the first side of the first nonwoven fabric layer comprising a first face of the composite fabric, the first nonwoven fabric layer comprising a durable water-repellent deposit; and a waterproof and breathable membrane bonded to the second side of the first nonwoven fabric layer, wherein the first face comprises an outward-facing surface of the garment article, and wherein the opposing second side of the composite fabric comprises a printed component configured to perform an anti-adhesion function or a breathability balance.

2. The composite fabric according to claim 1 further includes a first adhesive layer positioned between the second side of the first nonwoven fabric layer and the waterproof and breathable membrane, the first adhesive layer bonding the first nonwoven fabric layer to the waterproof and breathable membrane.

3. The composite fabric according to claim 1 or claim 2, wherein the first nonwoven fabric layer includes printed components.

4. The composite fabric according to claim 3, wherein the printed component comprises supercritical CO2 impregnated dye.

5. The composite fabric according to claim 1 or 2, wherein the first nonwoven fabric layer includes a plurality of chemical bonding sites on the outward-facing surface, wherein each of the plurality of chemical bonding sites includes discrete chemical bonding sites comprising a chemical binder that bonds the fibers of the first nonwoven fabric layer together such that the ends of the fibers are not prone to migration and pilling.

6. The composite fabric according to claim 1 or 2, wherein the first nonwoven fabric layer comprises a spunlace fabric.

7. The composite fabric according to claim 1 or 2, wherein the waterproof and breathable membrane comprises a film, the film comprising recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

8. The composite fabric according to claim 1 or 2, further comprising a second nonwoven fabric layer having a first side and an opposing second side, the first side of the second nonwoven fabric layer comprising the second surface of the composite fabric, the second side of the second nonwoven fabric layer being bonded to the waterproof and breathable membrane via a second adhesive layer.

9. The composite fabric according to claim 8, wherein the second nonwoven fabric layer comprises a spunlace fabric.

10. The composite fabric according to claim 8, wherein the second nonwoven fabric layer comprises a spunbond sparse fabric having a basis weight in the range of about 8 gsm to about 16 gsm.

11. The composite fabric according to claim 6, wherein the spunlace fabric comprises a basis weight in the range of about 40 gsm.

12. The composite fabric according to claim 6, wherein the fibers and filaments of the spunlace fabric are cross-overlapping.

13. The composite fabric according to claim 1 or 2, wherein the printed components are connected to the waterproof and breathable membrane.

14. A composite fabric having a first side and an opposing second side, the composite fabric comprising: A first nonwoven fabric layer having a first side and an opposing second side, the first side of the first nonwoven fabric layer comprising the first surface of the composite fabric, the first nonwoven fabric layer comprising a durable water-repellent deposit; and a waterproof and breathable membrane bonded to the second side of the first nonwoven fabric layer, wherein the first surface comprises the outward-facing surface of the garment article, and wherein the first nonwoven fabric layer comprises a spunlace fabric.

15. The composite fabric according to claim 14 further includes a first adhesive layer positioned between the second side of the first nonwoven fabric layer and the waterproof and breathable membrane, the first adhesive layer bonding the first nonwoven fabric layer to the waterproof and breathable membrane.

16. The composite fabric according to claim 14 or 15, wherein the first nonwoven fabric layer includes printed components.

17. The composite fabric according to claim 16, wherein the printed component comprises supercritical CO2 impregnated dye.

18. The composite fabric according to claim 14 or 15, wherein the first nonwoven fabric layer includes a plurality of chemical bonding sites on the outward-facing surface, wherein each of the plurality of chemical bonding sites includes discrete chemical bonding sites comprising a chemical binder that bonds the fibers of the first nonwoven fabric layer together such that the ends of the fibers are not prone to migration and pilling.

19. The composite fabric according to claim 14 or 15, wherein the waterproof and breathable membrane comprises a film, the film comprising recycled polyurethane, thermoplastic polyurethane, recycled thermoplastic polyether ester elastomer, or recycled polytetrafluoroethylene.

20. The composite fabric according to claim 14 or 15 further includes a second nonwoven fabric layer having a first side and an opposing second side, the first side of the second nonwoven fabric layer comprising the second surface of the composite fabric, and the second side of the second nonwoven fabric layer being bonded to the waterproof and breathable membrane via a second adhesive layer.

21. The composite fabric according to claim 20, wherein the second nonwoven fabric layer comprises a spunlace fabric.

22. The composite fabric according to claim 20, wherein the second nonwoven fabric layer comprises a spunbond sparse fabric having a basis weight in the range of about 8 gsm to about 16 gsm.

23. The composite fabric according to claim 14 or 15, wherein the opposing second side of the composite fabric includes printed elements.

24. The composite fabric according to claim 14 or 15, wherein the spunlace fabric comprises a basis weight in the range of about 40 gsm.

25. The composite fabric according to claim 14 or 15, wherein the fibers and filaments of the spunlace fabric are cross-overlapping.

26. The composite fabric according to claim 16, wherein the printed components are connected to the waterproof and breathable membrane.

27. A method for manufacturing a composite fabric having a first side and an opposing second side, the method comprising: A first adhesive film is positioned between a first nonwoven fabric layer and a waterproof and breathable membrane, the first nonwoven fabric layer including a first side and an opposing second side, wherein the first adhesive film is positioned adjacent to the second side of the first nonwoven fabric layer; one or more of heat and pressure are applied to the first adhesive film to bond the first nonwoven fabric layer to the waterproof and breathable membrane, wherein after bonding, the first side of the first nonwoven fabric layer includes the first surface of the composite fabric. A durable water-repellent agent is applied to the first nonwoven fabric layer; The composite fabric is used to construct garment articles by oriented the first side of the composite fabric to be the outward-facing surface of the garment article and the second side of the composite fabric to be the inward-facing surface of the garment article; wherein the opposing second sides of the composite fabric include printed elements configured to perform anti-adhesion or breathability balance, or wherein the first nonwoven fabric layer is a spunlace fabric.

28. The method of manufacturing a composite fabric according to claim 27, wherein the durable water-repellent agent is applied to the first nonwoven fabric layer before the first nonwoven fabric layer is bonded to the waterproof and breathable membrane.

29. The method of manufacturing a composite fabric according to claim 27 or claim 28 further includes impregnating the first nonwoven fabric layer with a dye via a CO2 medium prior to bonding.

30. The method of manufacturing a composite fabric according to claim 27 or claim 28, further comprising applying a chemical binder to the first side of the first nonwoven fabric layer.

31. The method of manufacturing a composite fabric according to claim 30, wherein the chemical binder is applied to the first nonwoven fabric layer after impregnating the first nonwoven fabric layer with a dye via a CO2 medium.

32. The method for manufacturing a composite fabric according to claim 27 or claim 28, further comprising: Positioning a second adhesive film between a second nonwoven fabric layer and the waterproof and breathable membrane, the second nonwoven fabric layer including a first side and an opposing second side, wherein the second adhesive film is positioned adjacent to the second side of the second nonwoven fabric layer; and applying one or more of heat and pressure to the second adhesive film to bond the second nonwoven fabric layer to the waterproof and breathable membrane, wherein after bonding, the first side of the second nonwoven fabric layer includes the second surface of the composite fabric.

33. The method of manufacturing a composite fabric according to claim 32, wherein the second nonwoven fabric layer comprises a spunlace fabric.

34. The method of manufacturing a composite fabric according to claim 32, wherein the second nonwoven fabric layer comprises spunbond loose fabric.

35. The method of manufacturing a composite fabric according to claim 27 or claim 28, wherein the printed component is connected to the waterproof and breathable membrane.

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