Nonwoven fabric garment batch and method of making same

Abstract

Aspects herein relate to composite nonwoven fabrics including non-linear entangled seams and methods and systems for producing the same. The composite nonwoven fabric includes at least a first nonwoven layer, a second layer, and a filler material positioned between the first nonwoven layer and the second layer. When the composite nonwoven fabric is formed into a garment, the areas between the non-linear entangled seams can help store and retain heat to provide thermal insulation, and the non-linear entangled seams can help prevent migration or drift of the filler material.

Description

Technical Field

[0001] This article relates to various aspects of nonwoven textiles with non-linear entangled seams suitable for clothing, as well as their production methods and systems. Background Technology

[0002] Traditional insulating clothing is typically formed by positioning pieces of fabric material (e.g., woven or knitted fabric) adjacent to each other, optionally applying an adhesive to the fabric pieces at predetermined locations, heat-pressing and / or sewing the fabric pieces together at predetermined locations to form linear seams separating the partitions, and filling the partitions with down or other types of insulating filling material. This construction method can be expensive and time-intensive due to the number of different materials used to form the clothing. Furthermore, the energy costs and carbon footprint associated with, for example, the yarn used in the woven fabric material, the weaving or knitting of the fabric material using the yarn, the application of adhesives, the heat-pressing or sewing of the seams, and the filling of the partitions can be high, and the recyclability of the resulting clothing can be limited due to the large number of different materials involved. When the fabric material used to form garments includes a repeating visual arrangement of certain types of elements (e.g., a visual arrangement of printed parts, a visual arrangement of seams, etc.), there may be material waste. To ensure that each garment in a batch of garments includes a visual arrangement of elements in a consistent position on the garment, so as to present a uniform appearance for each garment in that batch of garments. Attached Figure Description

[0003] Examples of various aspects of this article are described in detail below with reference to the accompanying drawings, in which:

[0004] Figure 1 The illustration shows the first surface of an example composite nonwoven fabric with a nonlinear entangled seam according to various aspects of this paper;

[0005] Figure 2A The diagram illustrates the various aspects based on this article. Figure 1 A first example of a composite nonwoven fabric is relative to a second surface, wherein the second surface is formed by a woven fabric;

[0006] Figure 2B The diagram illustrates the various aspects based on this article. Figure 1 A second example of a composite nonwoven fabric is relative to a second surface, wherein the second surface is formed of a nonwoven fabric;

[0007] Figure 3 The diagram illustrates the various aspects based on this article. Figure 1 The cross-section of the composite nonwoven fabric taken at the cutting line 3-3;

[0008] Figure 4A The illustration shows an enlarged view of a portion of a nonlinear tangled joint, as illustrated in the first example of various aspects of this paper.

[0009] Figure 4B The illustration shows an enlarged view of a portion of the nonlinear tangled seam according to various aspects of this paper;

[0010] Figure 5 The diagram illustrates the various aspects used in production according to this article. Figure 1 A side view of an example entanglement system of composite nonwoven fabrics;

[0011] Figure 6A The diagram illustrates the actions taken based on various aspects of this article. Figure 5 A front view of the first example entanglement station, which is part of an entanglement system;

[0012] Figure 6B The diagram illustrates the actions taken based on various aspects of this article. Figure 5 An alternative example of an entanglement station, representing a part of an entanglement system;

[0013] Figures 7 to 8 The diagram illustrates the actions taken based on various aspects of this article. Figure 5 An additional example front view of an entanglement station, representing a part of an entanglement system;

[0014] Figure 9A and Figure 9B The diagram illustrates the various aspects used in this article. Figure 5 An example of an entangled head in an entangled system;

[0015] Figure 10A The diagram illustrates the use of various aspects of this article. Figure 6A A schematic diagram illustrating an example process of forming a nonlinear entangled joint at the entanglement station;

[0016] Figure 10B The diagram illustrates the use of various aspects of this article. Figure 6B A schematic diagram illustrating an example process of forming a nonlinear entangled joint at the entanglement station;

[0017] Figure 11 The illustration shows an example process for manufacturing a batch of clothing with a common finished product form, according to various aspects of this article, wherein the batch of clothing includes different visible arrangements of non-linear tangled seams;

[0018] Figure 12 The diagram illustrates the use of various aspects of this article. Figure 11 The example process forms a batch of upper body clothing;

[0019] Figure 13 The diagram illustrates the use of various aspects of this article. Figure 11The example process forms a batch of lower body clothing;

[0020] Figure 14 The illustration shows the first surface of an example composite nonwoven fabric with intersecting nonlinear entangled seams according to various aspects of this paper.

[0021] Figure 15 The diagram illustrates the various aspects based on this article. Figure 14 The cross-section taken at 15-15 of the cutting line;

[0022] Figure 16 The illustration shows an example upper garment with zoned insulation features according to various aspects of this article, wherein the example upper garment uses... Figure 14 The formation of composite nonwoven fabrics;

[0023] Figure 17 The illustration shows an example composite nonwoven fabric with discontinuous nonlinear entanglement seams according to various aspects of this paper;

[0024] Figure 18 The illustration shows an example single-layer nonwoven fabric with a nonlinear entangled seam according to various aspects of this paper; and

[0025] Figure 19 The diagram illustrates the various aspects based on this article. Figure 18 Example cross-section of a single-layer nonwoven fabric. Detailed Implementation

[0026] The subject matter of this invention has been specifically described herein to satisfy legal requirements. However, this description itself is not intended to limit the scope of this disclosure. Rather, the inventors have envisioned that the claimed or disclosed subject matter may also be embodied in other ways in combination with other current or future techniques to include different steps or combinations of steps similar to those described herein. Furthermore, although the terms “step” and / or “box” may be used herein to refer to different elements of the method employed, these terms should not be construed as implying any particular order among or between the various steps disclosed herein, unless and only as expressly stated.

[0027] Traditional insulated clothing is typically formed by positioning pieces of fabric material (e.g., woven or knitted fabric) adjacent to each other, optionally applying an adhesive to the pieces of fabric material at predetermined locations, heat-pressing and / or sewing the fabric material together at predetermined locations to form linear seams separating the partitions, and filling the partitions with down or other types of insulating filling material. This construction method can be expensive and time-intensive due to the number of different materials used to form the clothing. Furthermore, the energy costs and carbon footprint associated with, for example, the yarn used in the woven fabric material, the woven or knitted fabric material, the application of adhesives, the heat-pressing or sewing of the seams, and the filling of the partitions can be high, and the recyclability of the resulting clothing can be limited due to the large number of different materials involved. Material waste may occur when the fabric material used to form the clothing includes a repetitive visual arrangement of some type of element (e.g., a visual arrangement of printed parts, a visual arrangement of seams, etc.) to ensure that each garment in a batch includes a visual arrangement of elements at consistent locations on the garment to present a uniform appearance for each garment in that batch.

[0028] At a high level, aspects of this document relate to composite nonwoven fabrics with nonlinear entanglement seams suitable for garments, and methods and systems for their production. In one example aspect, an entanglement system can be used to form composite nonwoven fabrics. In another example aspect, the entanglement system may include one or more entanglement stations that can be aligned in series along a conveyor system adapted to advance a stacked configuration of layers for forming the composite nonwoven fabric along the surface of the conveyor system in the material flow direction. In one example aspect, each entanglement station includes an actuator adapted to move in a direction perpendicular to the surface conveyor plane. Each entanglement station also includes one or more entanglement heads coupled to the actuator. In one aspect, the entanglement head includes one or more entanglement needles, which, in an example aspect, are arranged in a structured arrangement. In one example, movement of the actuator in a direction perpendicular to the surface conveyor plane causes the entanglement needles to engage the stacked configuration of the layers. In another example, the actuator may remain stationary but actuate or cause the entanglement head and / or entanglement needles to move up and down in a direction perpendicular to the conveyor plane, causing the entanglement needles to engage the stacked configuration of the layers. In another example, the tangled head is adapted to eject one or more jets of pressurized fluid (such as water). In this example, the actuator can also remain stationary while the fluid jet is ejected from the tangled head.

[0029] In an example embodiment, the carriage may also be directly or indirectly coupled to the entanglement head via an actuator, wherein the carriage is adapted to move in a direction not parallel to the material flow direction. Additionally or alternatively, the conveying system may be adapted to move in a direction not parallel to the material flow direction. Therefore, in an example embodiment, the entanglement head and the conveying system may be adapted to move relative to each other in a direction not parallel to the material flow direction.

[0030] In terms of examples, the tangling head can be located at different positions on the respective tangling station to contact different portions of the stack configuration as it is conveyed along the surface of the conveying system. For example, a first tangling station may include a first tangling head positioned at a first distance inward from the side edge of the surface of the conveying system (i.e., perpendicular to the material flow direction), and a second tangling station positioned after the first tangling station may include a second tangling head positioned at a second distance inward from the side edge of the conveying system, wherein the second distance is different from the first distance.

[0031] In one example, the stacked configuration of the layers includes a first nonwoven layer, a second layer, and a filler material located between the first nonwoven layer and the second layer. The stacked configuration is located on the surface of the conveying system such that the first nonwoven layer faces upward or toward the actuator, carriage, and entanglement head of the first entanglement station, and the second layer faces the surface of the conveying system. In one example, when the entanglement head includes entanglement needles, when the composite nonwoven fabric is in a first rest phase, the actuator moves the entanglement head and / or entanglement needles in a direction perpendicular to the surface conveying plane, such that the entanglement needles and indirectly the entanglement head engage with the stacked configuration to form a first entanglement region. When the entanglement needles engage with the stacked configuration, the needles drive fibers from the first nonwoven layer through the filler material and into the second layer. In another example, when the entanglement head ejects one or more pressurized fluid jets and the stacked configuration is in a first rest phase, the actuator actuates the entanglement head to eject one or more fluid jets that contact the stacked configuration to form the first entanglement region. Alternatively, the stacked configuration can be continuously advanced as the entanglement head continuously ejects one or more fluid jets. In these respects, when the fluid jets contact the stacked configuration, the pressure of the jets drives the fibers from the first nonwoven layer through the filler material and into the second layer.

[0032] When using entanglement needles, the conveying system then advances the stacked configuration of the first nonwoven layer, the second layer, and the filler material by a predetermined amount in the material flow direction. In an example, the predetermined amount advanced may be less than or equal to the dimension of the entanglement head in the material flow direction. Additionally, the entanglement head and / or the conveying system may move by a predetermined amount in a direction not parallel to the material flow direction. In an example, the predetermined amount moved may be less than or equal to the dimension of the entanglement head in a direction not parallel to the material flow direction. When the stacked configuration is in a second stationary phase and when the entanglement head includes entanglement needles, the actuator moves the entanglement head and / or the entanglement needles in a direction perpendicular to the surface conveying plane, causing the entanglement needles to engage with the stacked configuration to form a second entanglement region. When the entanglement head is adapted to eject one or more pressurized fluid jets, the actuator actuates the entanglement head to eject one or more fluid jets to form the second entanglement region. The second entanglement region extends from the first entanglement region to form a nonlinear entanglement seam.

[0033] As the stack configuration continues to advance through the first entanglement station, additional entanglement regions extending from the first and second entanglement regions are formed, resulting in a distinct continuous entanglement seam in the material flow direction. The continuous entanglement seam becomes non-linear in the material flow direction by moving the entanglement head and / or the conveying system in a direction not parallel to the material flow direction. In one example, the first and second entanglement regions may partially overlap, such that the overlapping area represents the region where the entanglement needle and / or fluid jet engages with the stack configuration at least twice. In other examples, the first and second entanglement regions may not overlap, but rather be positioned directly adjacent to each other to form a distinct continuous non-linear entanglement seam. In still other examples, the first and second entanglement regions may be spaced apart to form a discontinuous non-linear entanglement seam. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0034] The stacked configuration of the first nonwoven layer, the second layer, and the filler material can be further advanced through additional entanglement stations, where additional nonlinear entanglement seams are formed. These additional nonlinear entanglement seams can be separate from and different from the nonlinear entanglement seams formed by the first entanglement station. In other words, the additional nonlinear entanglement seams can be located at different positions along directions not parallel to the material flow direction. Depending on the number of entanglement stations in the entanglement system, the resulting composite nonwoven fabric can have short repetitions of the visible arrangement of entanglement seams, long repetitions of the visible arrangement of entanglement seams, or repetitions of the visible arrangement of entanglement seams without entanglement seams.

[0035] The resulting composite nonwoven fabric may include multiple nonlinear entanglement seams extending in the material flow direction of the fabric. As described above, an entanglement seam represents a region where fibers from the first nonwoven layer extend through the filling material and into the second layer. In an example, the fibers may extend through the second layer such that they extend outward from the second surface of the composite nonwoven fabric. The composite nonwoven fabric also includes regions where the first nonwoven layer, the second layer, and the filling material are substantially unentangled. The regions where the first nonwoven layer, the second layer, and the filling material are substantially unentangled have a greater thickness than the entanglement seams. When the composite nonwoven fabric is formed into clothing, the regions where the first nonwoven layer, the second layer, and the filling material are substantially unentangled correspond to the “partitions” present in conventional insulating clothing and are configured to store and retain heat to provide warmth, while the entanglement seams help prevent the filling material from drifting or shifting during wear.

[0036] The systems, methods, fabrics, and garments described herein offer numerous advantages. For example, composite nonwoven fabrics are easy and quick to manufacture, requiring minimal materials (e.g., no adhesives, no seams) and equipment (e.g., no hot pressing), and eliminating the need for post-processing steps such as depositing filler material into separators, as is common in conventional constructions. This, in turn, reduces the carbon footprint associated with the manufacturing process. Furthermore, composite nonwoven fabrics can be formed from the same or similar materials (i.e., materials of the same polymer class). In one example aspect, each of the first nonwoven layer, the second layer, and the filler material can be formed from recycled polyester fibers. This allows the entire fabric to be easily recycled, for example, by shredding, where the shredded material does not require subsequent sorting to remove different materials. Moreover, because the nonlinear seams are formed using, for example, recycled polyester fibers through an entanglement process, composite nonwoven fabrics do not include adhesives and / or threads for sewing, reducing the need to remove these portions of the fabric prior to recycling.

[0037] In terms of examples, because composite nonwoven fabrics can be formed from materials of the same polymer class, and because composite nonwoven fabrics may not include different materials such as yarns, adhesives, etc., garments made from composite nonwoven fabrics can be easily recycled, for example, by shredding. Furthermore, the shredded material from the garment can then be formed into one or more of a first nonwoven layer, a second layer, and a filling material to create a sustainable lifecycle for the garment. Similarly, scrap pieces generated during the manufacture of garments from composite nonwoven fabrics can also be easily recycled by shredding, and the shredded material from the scrap can then be formed into one or more of a first nonwoven layer, a second layer, and a filling material.

[0038] An additional advantage of using the aforementioned entanglement system and manufacturing method is the ability to produce complex visual arrangements of entangled seams. As used herein, the visual arrangement of entangled seams is generated by the different shapes associated with each of the entangled seams, the spacing between the entangled seams, the number of entangled seams, the width of the entangled seams, etc. To produce a complex visual arrangement of entangled seams, the entanglement heads can be positioned at different locations on the entanglement station, the number and / or spacing of the entanglement heads at different entanglement stations can vary, the entanglement footprint generated by the entanglement heads can vary, and the movement of the entanglement heads and / or the conveying system in different directions not parallel to the material flow direction can vary. Complex visual arrangements of entangled seams can include those arrangements in which the entangled seams can intersect, intersect, or be closely positioned together. In addition to producing interesting aesthetics, the ability to create areas where seams can intersect, intersect, or be closely positioned together also allows for the generation of differential thicknesses in composite nonwoven fabrics. For example, areas where seams may intersect or overlap represent instances where one or more knots from the knotting station are joined multiple times to the composite nonwoven fabric. Therefore, these areas can have a reduced thickness compared to other knotted seam areas, and compared to areas where the first nonwoven layer, second layer, and filling material are substantially un-knotted. When the composite nonwoven fabric is formed into garments, these areas can be positioned adjacent to body parts requiring less insulation (based on, for example, a thermal map of the human body) because these areas typically have less bulk and less insulating properties compared to other areas of the composite nonwoven fabric.

[0039] Another advantage of using the entanglement system and manufacturing method described herein is the ability to produce fabrics with short repeats of visible entanglement seams, long repeats of visible entanglement seams, or repeats of visible entanglement seams without seams. This is achieved by varying the number of entanglement stations arranged in a series along the conveyor system. The ability to produce long repeats or no repeats using the entanglement system described herein addresses a potential drawback of conventional garment manufacturing. Conventional garment manufacturing using fabrics with short repeats of visible entanglement seams can generate material waste. This is because the pattern pieces used to form the garments are positioned in such a way that they produce garments with the same visible entanglement seams at the same locations on the garment. This typically results in a large amount of waste. The ability to produce composite nonwoven fabrics with long repeats or no repeats of visible entanglement seams allows for the production of garment batches that share a common finished form but possess varied aesthetics due to the unique visible arrangement of the entanglement seams, while with minimal material waste. When considered as a clothing group or batch, consumers will assume that the clothing has a common source and / or a common manufacturer, but will be able to select from the group clothing with a visible arrangement of tangled seams that suits their preferences.

[0040] Another aspect related to the entanglement system and manufacturing method described herein is the ability to generate nonlinear entangled seams on one or more individual nonwoven layers. The ability to generate entangled seams on a single layer also offers the advantages of ease and speed of manufacture with minimal material (e.g., no adhesives, no grouting) and equipment (e.g., no hot pressing). This, in turn, reduces the carbon footprint associated with the manufacturing process. Furthermore, the nonwoven fabric can be formed from the same or similar materials (i.e., materials of the same polymer class). This allows the entire fabric to be easily recycled, for example, by shredding, where the shredded material does not require subsequent sorting to remove different materials. Moreover, because the nonlinear seams are formed using, for example, recycled polyester fibers through the entanglement process, the nonwoven fabric does not include adhesives and / or yarns for sewing, which reduces the need to remove these portions of the fabric prior to recycling.

[0041] A single nonwoven layer may comprise a single fiber layer (e.g., a slightly entangled fiber web), multiple fiber layers entangled with each other, or fiber layers entangled with other materials such as elastomer layers, fabric layers, etc. In one example, once a nonlinear entanglement seam is created on a single nonwoven layer, the nonwoven layer can be formed, for example, into a garment article. In other examples, different nonwoven layers having nonlinear entanglement seams can be positioned adjacent to each other, with optional additional layers (nonwoven, knitted, woven, membrane, etc.) located therebetween, and the different layers can be secured together using entanglement, sewing, bonding, etc. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0042] As used herein, the terms "clothing" or "clothing articles" are intended to encompass articles worn by a wearer. Accordingly, they may include upper garments (e.g., shirts, T-shirts, pullovers, hoodies, jackets, coats, etc.) and lower garments (e.g., trousers, shorts, leggings, capri pants, bodysuits, etc.). Clothing may also include hats, gloves, sleeves (arm sleeves, calf sleeves), footwear articles (such as shoe uppers), etc. When referring to clothing, the term "inward-facing surface" means the surface that is configured to face the wearer's body surface when the clothing is intended to be worn, and the term "outward-facing surface" means the surface that is configured to face away from the wearer's body surface and towards the external environment when the clothing is intended to be worn. The term "innermost-facing surface" means the surface that is closest to the wearer's body surface relative to the other layers of the clothing, and the term "outermost-facing surface" means the surface that is furthest from the wearer's body surface relative to the other layers of the clothing. The term "pattern" or "pattern piece" used in relation to the construction of garments refers to a pattern or pattern piece having an outer perimeter shape that corresponds to a structure on a finished garment (such as sleeves, front panels, collars, etc.). Patterns or pattern pieces are used when fabric portions having an outer perimeter shape corresponding to a pattern or pattern piece are removed, extracted, or cut, where fabric portions are assembled to form garments using, for example, a conventional cut-and-sew construction.

[0043] As used herein, the term "composite nonwoven fabric" encompasses any fabric comprising at least one nonwoven layer combined with other layers that are substantially non-adhesive to each other, except for entangled seams. Therefore, this document envisions composite nonwoven fabrics formed entirely of nonwoven layers. This document also envisions nonwoven layers being combined with other constructions such as fibrous materials, membranes, woven layers, knitted layers, braided layers, etc. This document envisions the term "composite nonwoven fabric" encompassing the stacked configuration of layers and one or more entangled seams connecting the stacked configuration of the layers at seam areas.

[0044] The term "nonwoven layer" refers to a layer in which fibers are held together by mechanical and / or chemical interactions without being knitted, woven, braided, or otherwise structured. In a particular aspect, a nonwoven layer comprises an assembly of fibers manipulated mechanically or chemically to form a mat-like material. In other words, a nonwoven layer is made directly from fibers. The composite nonwoven fabrics described herein may include different layers formed as cohesive structures, wherein the different layers may have different or similar fiber or yarn compositions and / or different properties. In one example, a first nonwoven layer and an optional second layer may include a spunbond layer. As used herein, a spunbond layer is formed by spinning continuous filaments of molten polymer material onto a moving belt and bonding the filaments together using, for example, a calendering process. Spunbond nonwovens typically have a soft hand feel and are strong and durable. They also typically have a smooth surface suitable for printing, including digital printing using digital printheads. In another example aspect, a first nonwoven layer and an optional second layer may include a spunlace layer. As used herein, a spunlace layer comprises a web of fibers entangled by, for example, hydroentanglement. Various aspects of this document envision filling materials that may include entangled fiber webs forming sheet-like materials. As an example, the fibers may be bonded with resin to form a cohesive structure. Other aspects of this document envision filling materials that include loose synthetic fibers / filaments, down, or any combination of the foregoing.

[0045] When referring to composite nonwoven fabrics, the term "substantially unentangled" means a region of the composite nonwoven fabric where the layers are not entangled with each other (so that the layers can move independently relative to each other) or where one or more layers are slightly entangled with each other. When referring to composite nonwoven fabrics, the term "entangled seam" means a region of the composite nonwoven fabric where the layers have been mechanically entangled with each other by means such as needle punching or hydraulic entanglement. Accordingly, the different layers of the composite nonwoven fabric in the seam region may include fibers initially present in a particular layer as well as fibers present in other layers, including additional nonwoven layers or filler material that has been moved into the layers by the entanglement process. When describing an entangled seam as "non-linear," this document envisions that the distance between the non-linear entangled seam and the linear edge of the composite nonwoven fabric can vary along the material flow direction of the nonwoven fabric. Various aspects of this document envision seams as including, individually or in combination, linear segments, curved segments, curve segments, etc., forming non-linear entangled seams. In an example, the distance between adjacent nonlinear entangled seams can vary along the material flow direction of the composite nonwoven fabric.

[0046] The mechanical entanglement process envisioned herein may include needle entanglement (generally referred to as needle punching) using barbed or structured needles (e.g., forked needles) (referred to herein as entanglement needles), or fluid entanglement, referred to herein as hydraulic entanglement. Needling typically uses entanglement needles to reposition a proportion of fibers from a generally horizontal orientation (an orientation extending along the x, y plane) to a generally vertical orientation (z-direction orientation). Generally referring to the needle punching process, the layers forming the composite nonwoven fabric can be stacked, and the entanglement needles associated with the entanglement head move in and out of the stacked configuration. Therefore, when describing the engagement of the entanglement head with the nonwoven fabric, this document envisions the engagement of the entanglement needles associated with the entanglement head with the nonwoven fabric. A stripper plate can be used to strip the fibers from the needles after the needles have moved in and out of the stacked configuration. Each engagement of the entanglement head with the stacked configuration is referred to herein as a “pass.” Parameters associated with the entanglement head can be adjusted to achieve desired properties of the resulting composite nonwoven fabric (e.g., basis weight, thickness, etc.), which will be explained further below.

[0047] As the barbs move from the first nonwoven layer through the stacked configuration, the barbs on the entanglement needles "capture" the fibers. The movement of the entanglement needles effectively moves or pushes the fibers captured by the barbs from a position near or at the surface of the first nonwoven layer to a position near or at the surface of the second layer, and further induces physical interactions with other fibers, thereby helping to "lock" the moving fibers into place by, for example, friction. This paper also envisions that the entanglement needles can move from the second layer toward the first nonwoven layer through the stacked configuration. Furthermore, this paper envisions that the entanglement needles can move from the first nonwoven layer toward the second layer and from the second layer toward the first nonwoven layer through the stacked configuration. The operation of hydraulic entanglement is similar to needle punching, except that instead of using entanglement needles, fibers are moved through different layers by jets of pressurized fluid (e.g., water). Parameters associated with the hydraulic entanglement process, such as the pressure of the fluid jet, the number of fluid jets, the delivery rate, etc., can be adjusted to achieve the desired degree of entanglement.

[0048] The term "entanglement head" is used herein to describe a structure comprising one or more entanglement needles in a defined arrangement and / or one or more orifices in a defined arrangement for ejecting a pressurized fluid jet. When the entanglement needles and / or the fluid jet are engaged with a composite nonwoven fabric via the entanglement head, they can form an entanglement footprint. As used herein, the term "entanglement footprint" is a structured arrangement of entanglement points generated by the entanglement head on the composite nonwoven fabric. For example, depending on the defined arrangement of the orifices in the entanglement needles and / or the entanglement head, the entanglement footprint can have a circular shape, a square shape, a rectangular shape, a triangular shape, etc.

[0049] As used herein, the term "material flow direction" refers to the direction in which material is advanced along the conveying system. The material flow direction can also be referred to as the machine direction. Therefore, when describing a composite nonwoven fabric including a nonlinear entanglement seam extending in the material flow direction, the nonlinear entanglement seam extends along the conveying system of the entanglement system in the direction of advancement of the composite nonwoven fabric. As described herein, the entanglement head, or the fluid jet when using hydraulic entanglement, can move in a direction perpendicular to the conveying plane of the conveying system. In other words, if the conveying plane extends along the x, y plane, and the material flow direction extends in the positive x direction, the entanglement head or fluid jet can move in the positive or negative z direction. When describing the carriage or conveying system moving in a direction not parallel to the material flow direction, this document assumes that the carriage and / or conveying system moves in a generally positive or negative y direction. This can also be referred to as the cross-machine direction.

[0050] The fibers envisioned in this paper for forming nonwoven layers and other layers can be formed from a variety of different materials (e.g., cotton, nylon, etc.), including polyethylene terephthalate (PET), commonly known as polyester. PET fibers can include virgin PET fibers (unrecycled fibers) and recycled PET fibers. Recycled PET fibers include shredded PET fibers derived from shredded articles and re-extruded PET fibers (fibers re-extruded using recycled PET scraps).

[0051] This article provides various measurements for composite nonwoven fabrics. The thickness of the resulting composite nonwoven fabric can be measured using a precision thickness gauge. For example, to measure thickness, the fabric can be placed on a flat anvil, and a pressure foot can be pressed onto the fabric from the top surface under a standard fixed load. The dial indicator on the precision thickness gauge provides a thickness indication in mm. Basis weight is measured using the ISO 3801 test standard, and the unit is grams per square meter (gsm). Thermal resistance, which typically corresponds to the insulation characteristics, is measured using the ISO 11092 test standard, and the unit is RCT (m²). 2 *K / W). Unless otherwise stated, all measurements provided herein are taken at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar), with the nonwoven fabric in a static (unstretched) state.

[0052] Figure 1A first surface 101 of a composite nonwoven fabric 100 is depicted, wherein the first surface 101 is formed of a first nonwoven layer 110. In an exemplary embodiment, the first nonwoven layer 110 may comprise a spunbond or spunlace material, but other nonwoven constructions are also contemplated herein. Spunbond or spunlace materials generally have a soft hand feel and are durable, making them suitable for integration into garments. The first nonwoven layer 110 is formed of entangled fibers as indicated by reference numeral 112. When the composite nonwoven fabric 100 is integrated into garments, the first surface 101 may be positioned as the inward-facing surface or the innermost surface of the garment. Alternatively, the first surface 101 may be positioned as the outward-facing surface or the outermost surface of the garment.

[0053] The composite nonwoven fabric 100 also includes a second layer 114, which will be about Figure 2A and Figure 2B A more detailed description follows. The filling material 116 is located between the first nonwoven layer 110 and the second layer 114. The filling material 116 may include a fiber sheet with entangled fibers (which may optionally be bonded with resin to maintain a more cohesive structure), a slightly entangled fiber web, a carded web, loose synthetic fibers, down, etc.

[0054] like Figure 1 As shown, the composite nonwoven fabric 100 may include a plurality of nonlinear entanglement seams 118 extending in the material flow direction 105 of the composite nonwoven fabric 100. An entanglement seam 118 represents a region where fibers from different layers are entangled with each other. In one example aspect, an entanglement seam 118 represents a region where fibers from the first nonwoven layer 110 extend through the filling material 116 and into the second layer 114. Regions 122 of the composite nonwoven fabric 100 located between the entanglement seams 118 represent regions where the first nonwoven layer 110, the second layer 114, and the filling material 116 are substantially unentangled, such that the different layers are not fixed or adhered to each other at regions 122, or are only slightly fixed or adhered. As shown, regions 122 have greater bulk or greater thickness than the entanglement seams 118 and can help store and retain heat when the composite nonwoven fabric 100 is incorporated into clothing. Conversely, when wearing garments incorporating composite nonwoven fabric 100, the tangled seams 118 can help prevent the filling material 116 from shifting or drifting.

[0055] Regarding at least the entangled seam 118a, the distance between the entangled seam 118a and the linear first edge 120 of the composite nonwoven fabric 100 varies along the material flow direction 105 of the composite nonwoven fabric 100. For example, the first distance 124 between the entangled seam 118a and the first edge 120 can be smaller than the second distance 126 between the entangled seam 118a and the first edge 120. This also applies to... Figure 1Another tangled joint 118 is shown. As depicted, tangled joints 118 may include linear segments extending from each other, curved segments, and combinations thereof. The depiction of the shape of each tangled joint 118, the number of tangled joints 118, the spacing between adjacent tangled joints 118, and the overall visual arrangement of the tangled joints 118 is illustrative, and it is envisioned herein that tangled joints 118 may include other nonlinear shapes, different numbers of tangled joints 118, different spacing, and different overall visual arrangements of the tangled joints 118.

[0056] Figure 2A The illustration shows the opposing second surface 201 of a composite nonwoven fabric 100, wherein the second surface 201 is formed by a second layer 114. In such a way... Figure 2A In one example aspect shown, the second layer 114 may comprise a woven layer as indicated by the example interlaced warp and weft yarns 210. In this example, when the composite nonwoven fabric 100 is incorporated into clothing, the second layer 114 may be positioned as either the outward-facing surface or the outermost surface of the clothing. Woven materials typically possess high abrasion resistance, and their tight weave makes them suitable for forming the outward-facing surface of clothing, thus serving as an effective windproof layer. In one example aspect, the woven material may be treated with a durable waterproofing agent to impart waterproof properties to the composite nonwoven fabric 100. Nonlinear entanglement seams 118 are shown extending through the composite nonwoven fabric 100, such that they exist on the second surface 201 of the fabric 100.

[0057] Figure 2B The illustration shows a second example, in which the second layer 114 is formed of a nonwoven material such as spunbond or hydroentangled material. The entangled fibers forming the second layer 114 are indicated by reference numeral 212. Nonlinear entangled seams 118 extend through the composite nonwoven fabric 100, such that they exist... Figure 2B On the second surface 201 of the middle fabric 100.

[0058] Figure 3 Depicting in Figure 1 The cross-section of the composite nonwoven fabric 100 taken at the cutting line 3-3 is shown. It indicates the first nonwoven layer 110, the second layer 114, and the filling material 116, wherein the filling material 116 is located between the first nonwoven layer 110 and the second layer 114. At region 122, each of the first nonwoven layer 110, the second layer 114, and the filling material 116 is substantially untangled, such that the first nonwoven layer 110, the second layer 114, and the filling material 116 generally remain as separate and distinct layers having a combined thickness 310 measured from the first surface 101 to the second surface 201.

[0059] Fibers 112 from the first nonwoven layer 110 are shown extending through the filling material 116 and the second layer 114 at a tangled seam 118, such that the tangled seam 118 holds the different layers together at the seam area. In one example aspect, the fibers 112 may extend through the second layer 114 such that they extend away from the second surface 201 of the composite nonwoven fabric 100, as... Figure 3 As shown. In this example, fiber 112 may remain unmodified, such that the second surface 201 has a fuzzy surface at the tangled seam 118. In another example, fiber 112 may be removed, compressed, or melted. For example, a calendering process may be used to compress fiber 112 so that it does not extend from the second surface 201. In another example, filler material 116 may include low-melting-point fibers, and any low-melting-point fibers extending from the second surface 201 may be removed by applying heat. Additionally, if desired, a scraping process may be used to remove fiber 112. In another example aspect, fiber 112 may extend into the second layer 114 but not through it, such that fiber 112 is generally not present on the second surface 201 of the composite nonwoven fabric 100.

[0060] The thickness 312 of the entangled joint is less than the thickness 310 at region 122. In one example aspect, the thickness 310 can be about 7 mm to about 15 mm, about 8 mm to about 13 mm, about 9 mm to about 11 mm, or about 10 mm. As used herein, the term "about" means within ±10% of the indicated value. In one example aspect, the thickness 312 can be about 5 mm to about 0.2 mm, about 4 mm to about 1 mm, about 3 mm to about 1.5 mm, or about 2 mm. Accordingly, in one example aspect, the thickness 312 of the entangled joint 118 can be about 5% to about 30% of the thickness 310 of region 122.

[0061] Figure 4A The illustration shows an enlarged view of one of the entanglement seams 118 of the composite nonwoven fabric 100 as viewed from the first surface 101. A similar view of the entanglement seam 118 would be taken from the second surface 201. Figure 4A A first example manner in which an entanglement seam 118 can be formed is illustrated. In this example, the entanglement seam 118 can be formed by discrete entanglement regions 410 that partially overlap each other at an overlapping region 412. Each of the discrete entanglement regions 410 has an entanglement footprint. For example, the entanglement footprints of the entanglement regions 410 are depicted as having a circular form, but this is illustrative and depends on the structured arrangement of the entanglement needles and / or orifices in the entanglement head used to form the entanglement regions 410. As shown, the entanglement regions 410 extend from each other in a non-linear manner to form a distinctly continuous non-linear entanglement seam.

[0062] Each point within the entanglement region 410 is designated as an entanglement point 414, at which an entanglement needle or fluid jet engages with the composite nonwoven fabric 100 to entangle the fibers. The number of entanglement points 414 per square centimeter may be referred to herein as the stitch density. The stitch density depends on, for example, the number of entanglement needles associated with the entanglement head, the number of fluid jets ejected from the entanglement head, the structured arrangement of the entanglement needles and / or ejection orifices, etc. A higher stitch density can result in a reduction in thickness at the entanglement seam 118 compared to a lower stitch density, as a higher stitch density generally implies a greater degree of fiber entanglement.

[0063] The overlapping region 412 represents the area where the knotted head is joined to the composite nonwoven fabric more than once. Accordingly, the number and / or density of knotted points 414 within the overlapping region 412 is greater than the number and / or density of knotted points 414 in the remaining portion of the entanglement region 410. In other words, the stitch density of the overlapping region 412 is greater than the stitch density in the remaining portion of the entanglement region 410. As a result, the overlapping region 412 can have a reduced thickness compared to the remaining portion of the entanglement region 410.

[0064] Figure 4B A second example of how tangled seams 118 can be formed is illustrated. In this respect, tangled regions 410 extend from one another in a non-linear manner to form a distinctly continuous tangled seam. However, tangled regions 410 are not as... Figure 4A Such parts do not overlap. Instead, the entangled regions 410 can be positioned directly adjacent to each other, such that the entanglement point 414 of the first entangled region 410 can share a common boundary with the entanglement point 414 of the adjacent second entangled region 410. Regarding the nonlinear entanglement joint 118, the entanglement joint 118 may include Figure 4A The configuration shown Figure 4B The configuration shown or Figure 4A and Figure 4B The combination of configurations shown is also proposed. This paper also envisions that the entangled regions 410 can be spaced apart to form discontinuous nonlinear entangled seams.

[0065] Figure 5 This is a schematic depiction of a side view of an example entanglement system 500. The depiction of the different components of the entanglement system 500 is illustrative only and does not represent an actual configuration or structure of the components. The entanglement system 500 includes a conveying system 512 having a surface 514 adapted to advance a stacked configuration, such as a first nonwoven layer 110, a second layer 114, and a filler material 116, in the material flow direction indicated by arrow 516. (See also: Regarding...) Figure 18 and Figure 19Further described, in another aspect, the conveying system 512 can advance a single nonwoven layer, such as the first nonwoven layer 110, in the material flow direction 516. The conveying system 512 can include conveying systems known in the art, such as rollers, belts, etc. In an example aspect, the advancement of the conveying system 512 can include a stationary phase or a moving phase in position and material flow direction 516. The durations of the stationary and moving phases can be adjusted to achieve one or more desired features in the resulting composite nonwoven fabric. For example, the duration of the stationary phase can be adjusted to achieve more or less entanglement in the resulting entangled seam. In other words, a longer stationary phase can allow more passage of entangled needles in the entangled area, a greater needle density in the entangled area, and a greater degree of entanglement in the entangled area. The advance distance during the moving phase can also be adjusted to achieve desired features in the resulting composite nonwoven fabric. For example, increasing the advance distance during the moving phase can result in entangled areas not overlapping or even spaced apart from each other, while decreasing the advance distance during the moving phase can increase the amount of overlap between adjacent entangled areas. The conveying speed during the moving phase can be adjusted to increase and / or decrease production time.

[0066] The entanglement system 500 also includes numerous entanglement stations, such as entanglement stations 518, 520, and 522. Although only three entanglement stations are depicted, this paper envisions that the number of entanglement stations could be greater than... Figure 5 More or fewer are shown. Entanglement stations 518, 520, and 522 are aligned in series along the material flow direction 516 of the conveying system 512. In an example, including a larger number of entanglement stations in the entanglement system 500 produces a composite nonwoven fabric with a long repeat or no repeat of a visible arrangement of nonlinear entanglement seams. Including a smaller number of entanglement stations in the entanglement system 500 produces a composite nonwoven fabric with a short repeat of a visible arrangement of nonlinear entanglement seams. Therefore, the number of entanglement stations as part of the entanglement system 500 can be customized to achieve the desired repeat length of the visible arrangement of nonlinear entanglement seams.

[0067] The components associated with the different entanglement stations 518, 520, and 522 can be substantially similar, and accordingly, the components associated with entanglement station 518 will be described herein, and it should be understood that the description of the components also applies to entanglement stations 520 and 522. Entanglement station 518 includes a carriage 524 slidably coupled to, for example, a base frame 526. The carriage 524 is adapted to move in a direction not parallel to the material flow direction 516. Alternatively, the carriage 524 may be omitted when the conveying system 512 is adapted to move in a direction not parallel to the material flow direction 516. In an example aspect, the carriage 524 and / or the conveying system 512 are adapted to move in a direction perpendicular to the material flow direction 516 toward a first side edge and an opposite second side edge (i.e., in the positive y-direction and the negative y-direction).

[0068] The entanglement station 518 also includes an actuator 528 coupled to the carriage 524. In one example aspect and as... Figure 5 As shown, actuator 528 is adapted to move in a direction perpendicular to the transport plane of surface 514 of transport system 512, as indicated by arrow 530. In other examples, the actuator may remain stationary, and the actuator may actuate the tangled head and / or tangled needle to move in a direction perpendicular to the transport plane of surface 514 of transport system 512. In other examples and as per [reference to...] Figure 6B The actuator 528 can remain stationary, and can actuate the tangled head to eject a fluid jet. The tangled head 532 is coupled to the actuator 528 and can be indirectly coupled to the carriage 524 via the actuator 528. Figure 5 In the example shown, the tangled head 532 may include one or more tangled needles 534 extending toward the surface 514 of the conveying system 512. Although only one tangled needle 534 is depicted, it is envisioned herein that the tangled head 532 may include multiple tangled needles, as per [reference to...]. Figure 9A and Figure 9B As further described.

[0069] Figure 6A A front view of the entanglement station 518 is depicted, showing the base 526, carriage 524, actuator 528, entanglement head 532, and entanglement needle 534. Arrow 610 indicates a first direction of movement of the carriage 524 and / or the conveying system 512 in a direction not parallel to the material flow direction 516, and arrow 611 indicates a opposite second direction of movement of the carriage 524 and / or the conveying system 512 in a direction not parallel to the material flow direction 516. In an example, the first direction 610 and the second direction 611 are perpendicular to the material flow direction 516.

[0070] The front view of entanglement station 518 depicts three entangled heads 532a, 532b, and 532c that are approximately evenly spaced, each of which is adapted to form a corresponding nonlinear entanglement joint. This is merely illustrative, and it is envisioned herein that there may be more or fewer than three entangled heads 532a, 532b, and 532c. Similarly, the spacing between entangled heads 532a, 532b, and 532c can vary, such that the spacing between the first and second entangled heads 532a, 532b, and 532c can be greater than the spacing between the second and third entangled heads 532a, 532b, and 532c. (See also: Regarding...) Figure 9A and Figure 9BAs explained, the tangled heads 532a, 532b and 532c can have different sizes, different structured arrangements of tangling needles and / or orifices, etc.

[0071] Figure 6B A front view of an alternative entanglement station 612 is depicted, which may be part of an entanglement system such as entanglement system 500, adapted to hydraulically entangle the layers to form a composite structure, rather than needle-punching the layers to form a composite structure. Accordingly, entanglement station 612 may represent multiple hydraulic entanglement stations as part of entanglement system 500.

[0072] The entanglement station 612 also includes a base 614 to which a carriage 616 is slidably coupled, an actuator 618 coupled to the carriage 616, and an entanglement head 620 coupled to the actuator 618. The carriage 616 and / or the conveying system 512 are adapted to move in a first direction (as indicated by arrow 622) not parallel to the material flow direction 516 and in a second opposite direction 623 not parallel to the material flow direction 516. In an example aspect, directions 622 and 623 are perpendicular to the material flow direction 516. In an example aspect, the actuator 618 may not move in a direction 530 perpendicular to the conveying plane of surface 514. Instead, in an example aspect, the actuator 618 is adapted to actuate the entanglement head 620 to eject one or more pressurized fluid jets 624 extending toward the surface 514 of the conveying system 512. Regarding this aspect, this paper envisions that the conveying system 512 can be advanced intermittently as described above, wherein the fluid jet 624 is ejected when the conveying system 512 is in a stationary phase. Alternatively, the conveying system 512 can be advanced continuously, and the fluid jet 624 can be continuously ejected from the entanglement head 620. Similar to the entanglement station 518, the number of entanglement heads 620 may differ from that shown, the spacing between the entanglement heads 620 may differ from that shown, and the entanglement heads 620 may have different sizes, different orifice arrangements, etc.

[0073] Figure 7A second entanglement station 520 is depicted, which includes the same components as entanglement station 518 (e.g., base 526, carriage 524, actuator 528, and entanglement head 532). Two entanglement heads 532d and 532e for the second entanglement station 520 are depicted. In an example, entanglement heads 532d and 532e may be positioned such that they are not aligned with entanglement heads 532a, 532b, and 532c in the material flow direction 516. As a result, entanglement heads 532d and 532e are adapted to engage with the composite nonwoven fabric at different locations in a direction not parallel to the material flow direction 516, compared to entanglement heads 532a, 532b, and 532c. In other words, entanglement heads 532d and 532e are adapted to form a set of nonlinear entanglement joints that are different from and separate from the nonlinear entanglement joints formed by entanglement heads 532a, 532b, and 532c. For example, entanglement head 532a may deviate from the first edge 660 of the surface 514 of the conveying system 512 by a first distance 613 in a direction perpendicular to the material flow direction 516, and entanglement head 532d may deviate from the first edge 660 of the surface 514 of the conveying system 512 by a second distance 615 in a direction perpendicular to the material flow direction 516, wherein the second distance 615 is greater than the first distance 613. Accordingly, the spacing arrangement between entanglement heads 532d and 532e is different from the spacing arrangement between entanglement heads 532a, 532b, and 532c. As shown, the number of entanglement heads 532 included in entanglement station 520 is different from the number of entanglement heads 532 at entanglement station 518. This document envisions that entanglement station 520 may include fewer or more entanglements than shown. The dimensions of entanglements 532e and 532d may be the same as or different from those of entanglements 532a, 532b, and 532c. Additionally, the entanglement footprints produced by entanglements 532e and 532d may be the same as or different from those produced by entanglements 532a, 532b, and 532c.

[0074] Figure 8A third entanglement station 522 is depicted, comprising the same components as entanglement stations 518 and 522. Two entanglement heads 532f and 532g for the third entanglement station 522 are depicted. In an example, entanglement heads 532f and 532g can be positioned such that they are not aligned with entanglement heads 532a, 532b, 532c, 532d, and 532e in the material flow direction 516. Therefore, entanglement heads 532f and 532g are adapted to form another set of nonlinear entanglement joints that are different from and separate from the nonlinear entanglement joints formed by entanglement heads 532a, 532b, 532c, 532d, and 532e. In other words, the distances by which the tangled heads 532f and 532g deviate from the first edge 660 of the surface 514 of the conveying system 512 can be different from the deviation distances of the tangled heads 532a, 532b, 532c, 532d, and 532e. The tangling station 522 may include a different number of tangled heads 532 than shown. The tangled heads 532f and 532g may also be spaced apart differently than shown. The dimensions of the tangled heads 532f and 532g may be the same as or different from the dimensions of the tangled heads 532a, 532b, 532c, 532d, and 532e. Furthermore, the tangling footprints produced by the tangled heads 532f and 532g may be the same as or different from the tangling footprints produced by the tangled heads 532a, 532b, 532c, 532d, and 532e.

[0075] Although the entanglement system 500 is depicted as comprising a series of entanglement stations positioned along the material flow direction 516 of the conveying system 512, it is also contemplated herein that the entanglement system 500 may include a single entanglement station, such as entanglement station 518. In this respect, the stacked configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116 can be passed through entanglement station 518 multiple times to form the resulting composite nonwoven fabric 100. In this respect, the positioning of the entanglement heads 532a, 532b, and 532c can be adjusted between each pass, such that different regions of the stacked configuration are engaged by the entanglement heads 532a, 532b, and 532c during each pass. Similarly, different entanglement heads can be added, and existing entanglement heads can be removed, etc. The movement of the carriage 524 can also be adjusted during each pass, such that the entanglement heads 532a, 532b, and 532c engage with different portions of the stacked configuration.

[0076] Figure 5 As shown and about Figures 6A to 8The illustrative entanglement system 500, further described, can produce a complex visual arrangement of nonlinear entangled seams extending in the material flow direction 516. The components and movements of the entanglement system 500 can be adjusted to produce nonlinear entangled seams that are closely spaced together or further spaced apart. Additionally, the system 500 can produce nonlinear entangled seams that intersect or cross each other once or multiple times along the material flow direction of a particular entangled seam. (See also: Regarding...) Figures 14 to 16 As further described, this produces a difference in thickness of the resulting composite nonwoven fabric in a first direction 610 and a second direction 611 that are not parallel to or perpendicular to the material flow direction 516 (i.e., along the cross-section of the resulting composite nonwoven fabric).

[0077] Figure 9A and Figure 9B Bottom views of two example entanglement heads 920 and 922 are depicted. Entanglement heads 920 and 922 can be any of the entanglement heads described with respect to entanglement system 500 or entanglement station 612. Regarding entanglement head 920, it includes a structured arrangement of entanglement needles 924, or alternatively, an orifice 924 adapted to eject a fluid jet. Entanglement head 920 has an example circular shape, such that the entanglement needles 924 or the orifice 924 is adapted to form a circular entanglement footprint on the composite nonwoven fabric. Entanglement head 920 has a dimension 910 in the material flow direction and a dimension 912 in a first direction 610 and a second direction 611 that are not parallel to or perpendicular to the material flow direction 516. Because entanglement head 920 has a circular shape, dimensions 910 and 912 are equivalent to and equal to the diameter of entanglement head 920.

[0078] The entanglement head 922 also includes a structured arrangement of entanglement needles 926, or alternatively, an orifice 926 adapted to eject a water jet. The entanglement head 922 has an exemplary rectangular shape, such that the entanglement needles 926 or the orifice 926 is adapted to form a rectangular entanglement footprint on the composite nonwoven fabric. The entanglement head 922 has a dimension 914 in the material flow direction 516 and dimensions 916 in a first direction 610 and a second direction 611 that are not parallel to or perpendicular to the material flow direction 516.

[0079] In an example, during the moving phase of the entanglement system 500, the advance distance of the conveyor system 512 in the material flow direction 516 can be less than or equal to the dimensions 910 and 914 of the corresponding entanglement heads 920 and 922. This ensures that the entanglement regions generated by the entanglement heads 920 and 922 are directly adjacent to each other and / or overlap to form a distinct continuous nonlinear entanglement seam. Furthermore, the movement of the carriage 524 and / or the conveyor system 512 in a first direction 610 and a second direction 611 that are not parallel to or perpendicular to the material flow direction 516 can be less than or equal to the dimensions 912 and 916 of the corresponding entanglement heads 920 and 922. This further ensures that the entanglement regions generated by the entanglement heads 920 and 922 are directly adjacent to each other and / or overlap to form a distinct continuous nonlinear entanglement seam. The depiction of the shapes of the entanglement heads 920 and 922 is illustrative, and it is envisioned herein that the entanglement heads can have other shapes, such as elliptical, square, triangular, etc.

[0080] Figure 10A and Figure 10B The processes for manufacturing composite nonwoven fabrics (such as composite nonwoven fabric 100) with nonlinear entangled seams are schematically depicted respectively. Figure 10A The process is described using a tangling needle and can be performed at any of the tangling stations 518, 520 or 522. Figure 10B The process using hydraulic entanglement and which can be performed, for example, at entanglement station 612 is described. About Figure 10A and Figure 10B Both provide a coordinate system indicating the x, y, and z directions.

[0081] Reference Figure 10AIn step 1010, the stacked configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116 is positioned on the surface 514 of the transport system 512, such that the second layer 114 is positioned against the surface 514, and the first nonwoven layer 110 is spaced apart from the surface 514 by the filler material 116. The transport system 512 and the stacked configuration are in a first stationary phase or position such that the transport system 512 is not advancing in the material flow direction 516 (i.e., the positive x-direction). During the first stationary phase, the actuator 528 moves in a direction 530 (i.e., the negative z-direction) perpendicular to the transport plane of the surface 514, causing the tangling head 532 to lower, resulting in the tangling needle 534 and the indirect tangling head 532 engaging with the stacked configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116. Alternatively, actuator 528 may actuate entanglement head 532 and / or entanglement needle 534 such that entanglement needle 534 moves downward to engage with a stacked configuration. This engagement drives fibers from the first nonwoven layer through the filler material 116 and into (or through) the second layer 114, thereby creating a first entanglement region 1012, as shown in step 1014. The first entanglement region 1012 may have an entanglement footprint corresponding to the shape of the structured arrangement of the entanglement needles 534 on the entanglement head 532.

[0082] At step 1016, the tangling needle 534 disengages from the stacked configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116, and the conveying system 512 advances the stacked configuration a distance 1018 in the material flow direction 516. In an example, the distance 1018 may be equal to or less than the dimension of the tangling head 532 in the material flow direction 516. At step 1016, the carriage 524 moves a first distance in a first direction 610 (i.e., the negative y-direction) not parallel to the material flow direction 516, wherein the first distance may be equal to or less than the dimension of the tangling head 532 in the first direction 610 not parallel to the material flow direction 516. The movement of the carriage 524 may occur simultaneously with the movement of the conveying system 512 in the material flow direction 516, or it may occur after the movement of the conveying system 512 in the material flow direction 516 (i.e., when the conveying system 512 is in the second stationary phase). Alternatively or additionally, the conveying system 512 may move a first distance in a first direction 610 that is not parallel to the material flow direction 516.

[0083] At step 1022, the conveying system 512 and the stacked configuration are in a second stationary phase or position, such that the conveying system 512 is no longer advancing in the material flow direction 516. The second stationary phase or position advances from the first stationary phase or position in the material flow direction 516. During the second stationary phase, the actuator 528 again moves in a direction 530 perpendicular to the conveying plane of surface 514, causing the tangling head 532 to lower, resulting in the tangling needle 534 engaging with the stacked configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116. Due to the movement of the carriage 524 and / or the conveying system 512, the engagement of the tangling needle 534 with the stacked configuration occurs at a position offset from the first tangled region 1012 in a first direction 610 that is not parallel to the material flow direction 516. The second bonding again drives the fibers from the first nonwoven layer 110 through the filler material 116 and into (or through) the second layer 114, thereby creating a second entanglement region 1026, as shown in step 1024, to create a distinct continuous nonlinear entanglement seam 1028 in the composite nonwoven fabric 100. The second entanglement region 1026 may have an entanglement footprint corresponding to the shape of a structured arrangement of entanglement needles 534 on the entanglement head 532. As shown in 1024, the second entanglement region 1026 partially overlaps with the first entanglement region 1012. This is illustrative, and it is envisioned herein that the second entanglement region 1026 may not partially overlap with the first entanglement region 1012.

[0084] Figure 10A The depicted process may include multiple stationary phases or positions advancing from each other in the material flow direction, during which entanglement needles 534 engage with a stacked configuration of a first nonwoven layer 110, a second layer 114, and filler material 116 to form entangled regions extending from each other. Similarly, Figure 10A The depicted process may include multiple movement phases during which the conveying system 512 advances the stacked configuration by a distance less than or equal to the dimension of the entangled head 532 in the material flow direction 516, such that the resulting entangled regions partially overlap each other or extend directly from each other. Furthermore, the carriage 524 and / or the conveying system 512 may perform multiple movements in a first direction 610 and an opposite second direction 611 (i.e., the positive y-direction) that are not parallel to the material flow direction 516. The movement distance of the carriage 524 and / or the conveying system 512 in the first direction 610 and the opposite second direction 611 may be less than or equal to the dimension of the entangled head 532 in the first direction 610 or the opposite second direction 611, such that the resulting entangled regions partially overlap each other or extend directly from each other.

[0085] Figure 10B The process of depicting schematically is similar to Figure 10AThe process is illustrated, but hydraulic entanglement is used to create a nonlinear entangled seam. At step 1050, a stacked configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116 is positioned on the surface 514 of the conveying system 512, such that the second layer 114 is positioned against the surface 514, and the first nonwoven layer 110 is spaced apart from the surface 514 by the filler material 116. In one example aspect, the conveying system 512 and the stacked configuration are in a first stationary phase or position such that the conveying system 512 is not advancing in the material flow direction 516. During the first stationary phase, actuator 618 actuates the entanglement head 620 to eject one or more pressurized fluid jets 1052 in a direction toward the surface 514 of the conveying system 512 to form a first entangled region 1054, as shown in step 1056. In one example, the actuator 618 may not move in a direction perpendicular to the transport plane of surface 514 during the first stationary phase; however, it is envisioned herein that the actuator 618 may move in a direction perpendicular to the transport plane of surface 514 to position the fluid jet 1052 closer to the first nonwoven layer 110. In another example, the transport system 512 may advance continuously in the material flow direction 516 while the actuator 618 continuously actuates the entanglement head 620 to eject one or more pressurized fluid jets 1052. The fluid jet 1052 drives fibers from the first nonwoven layer 110 through the filler material 116 and into (or through) the second layer 114, thereby creating a first entanglement region 1054. The first entanglement region 1054 may have an entanglement footprint with a shape corresponding to a structured arrangement of orifices on the entanglement head 620.

[0086] At step 1058, the conveying system 512 advances the stack configuration a distance 1060 in the material flow direction 516. In an example, the distance 1060 may be equal to or less than the dimension of the tangled head 620 in the material flow direction 516. At step 1058, the carriage 616 and / or the conveying system 512 moves a first distance in a first direction 622 not parallel to the material flow direction 516, wherein the first distance may be equal to or less than the dimension of the tangled head 620 in the direction not parallel to the material flow direction 516. The movement of the carriage 616 and / or the conveying system 512 may occur simultaneously with the movement of the conveying system 512 in the material flow direction 516, or it may occur after the movement of the conveying system 512 in the material flow direction 516 (i.e., when the conveying system 512 is in a second resting phase or position advanced in the material flow direction from a first resting phase or position).

[0087] At step 1064, with the conveying system 512 and the stacked configuration in a second stationary phase or position, actuator 618 again actuates the entanglement head 620 to eject a fluid jet 1052, such that the fluid jet 1052 engages with the stacked configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116. Due to the movement of the carriage 616, the engagement of the fluid jet 1052 with the stacked configuration occurs at a position offset from the first entanglement region 1054 in a direction 622 that is not parallel to the material flow direction 516. The second engagement again drives the fibers from the first nonwoven layer 110 through the filler material 116 and into (or through) the second layer 114, thereby creating a second entanglement region 1068, as shown in step 1066, to create a distinct continuous nonlinear entanglement seam 1070 extending in the material flow direction 516 in the composite nonwoven fabric 100. As shown in step 1066, the second entanglement region 1068 partially overlaps with the first entanglement region 1054. This is illustrative, and the paper envisions that the second entanglement region 1068 may not partially overlap with the first entanglement region 1054.

[0088] Figure 10B The depicted process may include multiple stationary phases or locations during which the fluid jet 1052 engages with a stacked configuration of a first nonwoven layer 110, a second layer 114, and a filler material 116 to form entangled regions extending from each other. Similarly, Figure 10B The described process can execute multiple movement phases, during which the conveyor system 512 advances the fabric in the material flow direction 516 by a distance less than or equal to the dimension of the entanglement head 620 in the material flow direction 516, such that the resulting entangled areas partially overlap each other or extend directly from each other. Furthermore, the carriage 616 and / or the conveyor system 512 can perform multiple movements in a first direction 622 and an opposite second direction 623 that are not parallel to the material flow direction 516. The movement distance of the carriage 616 and / or the conveyor system 512 in the first direction 610 and the opposite second direction 623 can be less than or equal to the dimension of the entanglement head 620 in the first direction 610 or the opposite second direction 623, such that the resulting entangled areas partially overlap each other or extend directly from each other.

[0089] As previously described, the entanglement system described herein (such as entanglement system 500) can produce composite nonwoven fabrics (such as composite nonwoven fabric 100) that include long repetitions of the visible arrangement of nonlinear entanglement seams or even non-repetitions of the visible arrangement of nonlinear entanglement seams. The resulting composite nonwoven fabric can be used to produce garment batches with a common finished form, but with varying aesthetics due to the different visible arrangements of the nonlinear entanglement seams on the resulting garments. Garment batches can share common characteristics, such as a common finished form, color, etc., making it easy for consumers to identify garment batches from a common source (e.g., a common manufacturer). However, consumers will be able to select garments from the garment batches with the desired visible arrangement of entanglement seams. Furthermore, because of the long repetitions or even non-repetitions of the visible arrangement of nonlinear entanglement seams, there can be less material waste when forming garment batches, as the pattern pieces do not need to be positioned in such a way that each garment includes the same visible arrangement of entanglement seams at the same location on the garment.

[0090] Figure 11 A method for manufacturing a batch of garments is schematically illustrated, the batch having a common finished form but with different visible arrangements of nonlinear entanglement seams. At step 1110, a composite nonwoven fabric 100 is provided or obtained. In this example, the composite nonwoven fabric 100 includes a first nonlinear entanglement seam 1112 and a second nonlinear entanglement seam 1114, both extending in the material flow direction 516 of the composite nonwoven fabric 100. In an example embodiment, the distance between the first nonlinear entanglement seam 1112 and the second nonlinear entanglement seam 1114 varies along the material flow direction 516. For example, at a first location 1113 on the composite nonwoven fabric 100, the first nonlinear entanglement seam 1112 may be spaced a first distance 1111 from the second nonlinear entanglement seam. At a second position 1115 on the composite nonwoven fabric 100, the first nonlinear entanglement seam 1112 may be spaced apart from the second nonlinear entanglement seam 1114 by a second distance 1117, wherein the second distance 1117 is greater than the first distance 1111.

[0091] At step 1110, a first instance of pattern 1116 is removed, cut off, and / or excised from the composite nonwoven fabric 100, wherein pattern 1116 corresponds to the left sleeve of an upper garment. In other words, at step 1110, a first portion 1120 is removed from the composite nonwoven fabric 100, wherein the first portion 1120 has a shape corresponding to pattern 1116. Pattern 1116 is merely illustrative, and it is contemplated herein that pattern 1116 may correspond to any part of an upper garment, lower garment, shoe upper, headwear, etc.

[0092] Step 1118 illustrates a first portion 1120 having pattern 1116 (after it has been removed from the composite nonwoven fabric 100). As shown, the first portion 1120 includes a first nonlinear entanglement seam 1112 and a second nonlinear entanglement seam 1114, wherein the first nonlinear entanglement seam 1112 and the second nonlinear entanglement seam 1114 are located at a first position on the first portion 1120 and / or pattern 1116, generally indicated by reference numeral 1119. At step 1122, the first portion 1120 is incorporated into the first garment 1124. Figure 11 As shown, the first nonlinear entanglement seam 1112 and the second nonlinear entanglement seam 1114 present a first visible arrangement of nonlinear entanglement seams on the first garment 1124, as generally indicated by reference numeral 1126.

[0093] At step 1128, a second instance of pattern 1116 is removed, cut off, and / or excised from the composite nonwoven fabric 100. The second instance of pattern 1116 includes a first nonlinear entanglement seam 1112 and a second nonlinear entanglement seam 1114. In other words, at step 1128, a second portion 1132, having a shape corresponding to pattern 1116, is removed from the composite nonwoven fabric 100. Step 1130 illustrates the second portion 1132 having pattern 1116 (after it has been removed from the composite nonwoven fabric 100). As shown, the second portion 1132 includes the first nonlinear entanglement seam 1112 and the second nonlinear entanglement seam 1114, located at a second position on the second portion 1132 and / or pattern 1116, as generally indicated by reference numeral 1131. In step 1134, the second part 1132 is incorporated into the second garment 1138, wherein the second garment 1138 has the same finished form as the first garment 1124. Figure 11 As shown, the first nonlinear entanglement seam 1112 and the second nonlinear entanglement seam 1114 present a second visible arrangement of nonlinear entanglement seams on the second garment 1138, as generally indicated by reference numeral 1136, wherein the second visible arrangement 1136 of the nonlinear entanglement seams is different from the first visible arrangement 1126 of the nonlinear entanglement seams.

[0094] Figure 11 The described process can be repeated any number of times along the material flow direction 516 of the composite nonwoven fabric 100 to form a garment batch with a first nonlinear entanglement seam 1112 and a second nonlinear entanglement seam 1114 located at different positions on the pattern 1116 and presenting different visual arrangements of the first nonlinear entanglement seam 1112 and the second nonlinear entanglement seam 1114. Although Figure 11 Only pattern 1116 is depicted being applied to composite nonwoven fabric 100, but this paper envisions that additional pattern pieces could be applied to composite nonwoven fabric 100, allowing garments to be formed from these additional pattern pieces. In this respect, the visible arrangement of the entangled seams in different areas of the garment can differ from one another to create a varied overall aesthetic. Similar to... Figure 11 The process shown can be used to form, for example, a batch of lower garments that have a common finished form but different visible arrangements of non-linear entangled seams.

[0095] In terms of examples, by Figure 11 The waste generated by the depicted process can be shredded and subsequently formed into one or more of, for example, a first nonwoven layer 110, a second layer 114, or a filler material 116. This is possible because the materials forming the composite nonwoven fabric 100 are, in example, of the same polymer class (e.g., recycled polyester). Furthermore, because the composite nonwoven fabric 100 is formed without using different materials such as yarn, adhesives, etc., it is not necessary to remove the waste portion before shredding.

[0096] Figure 12 and Figure 13 Further illustrations show the composition of Figure 11 The clothing produced by the process shown. Figure 12 The illustration shows a front view of a batch of upper garments in the form of sleeveless tops, including a first upper garment 1210 and a second upper garment 1212 having a common finished form. Although shown as sleeveless tops, it is envisioned that the upper garments may include other forms, such as vests, pullovers, hoodies, jackets, etc. The first upper garment 1210 includes a neck opening 1214, a waist opening 1216, a first sleeve opening 1218, and a second sleeve opening 1220. Similarly, the second upper garment 1212 includes a neck opening 1222, a waist opening 1224, a first sleeve opening 1226, and a second sleeve opening 1228. Furthermore, although the nonlinear tangled seam is shown to extend in a horizontal orientation (in a direction, for example, from the first sleeve opening 1218 / 1226 to the second sleeve opening 1220 / 1228), it is envisioned herein that the nonlinear tangled seam may extend in a vertical direction (in a direction, for example, from the neck opening 1214 / 1222 to the waist opening 1216 / 1224).

[0097] As depicted, at least the front panel 1230 of the first garment 1210 and the front panel 1232 of the second garment 1212 can be formed from the same pattern piece applied to the composite nonwoven fabric 100. The front panel 1230 of the first garment 1210 includes a first nonlinear entanglement seam 1234 and a second nonlinear entanglement seam 1236 located at a first position 1238 on the first garment 1210. In an example, the first position 1238 may correspond to a first distance 1237 measured at the front vertical center line of the first garment 1210 relative to the waist opening 1216 of the first garment 1210, for each of the first nonlinear entanglement seam 1234 and the second nonlinear entanglement seam 1236. The first nonlinear entanglement seam 1234 and the second nonlinear entanglement seam 1236 present a first visible arrangement of entanglement seams on the first garment 1210.

[0098] The front panel 1232 of the second upper garment 1212 also includes a first nonlinear entanglement seam 1234 and a second nonlinear entanglement seam 1236 located at a second position 1244 on the second upper garment 1212, wherein the second position 1244 is different from the first position 1238. For example, the second position 1244 may correspond to a second distance 1245 measured at the front vertical center line of the second upper garment 1212 relative to the waist opening 1224 of the second upper garment 1212, for each of the first nonlinear entanglement seam 1234 and the second nonlinear entanglement seam 1236, wherein the second distance 1245 for each of the first nonlinear entanglement seam 1234 and the second nonlinear entanglement seam 1236 is different from the first distance 1237. The first nonlinear entanglement seam 1234 and the second nonlinear entanglement seam 1236 present a second visible arrangement of entanglement seams on the second upper garment 1212.

[0099] Although not shown, the batch may include additional upper garments, which share a common finished form with the first upper garment 1210 and the second upper garment 1212. The additional upper garments in the batch may exhibit different visual arrangements of the first nonlinear entanglement seam 1234 and the second nonlinear entanglement seam 1236. In other words, the first nonlinear entanglement seam 1234 and the second nonlinear entanglement seam 1236 may be located at different positions on the additional garment relative to the aforementioned pattern piece used to form the front panel of the additional upper garment.

[0100] Figure 13The illustration shows a front view of a batch of lower garments in the form of shorts, comprising a first lower garment 1310 and a second lower garment 1312 having a common finished form. Although shown as shorts, it is envisioned herein that the lower garments may include other forms, such as trousers, capri pants, etc. The first lower garment 1310 includes a waist opening 1314, a first leg opening 1316a, and a second leg opening 1316b. Similarly, the second lower garment 1312 includes a waist opening 1322, a first leg opening 1324a, and a second leg opening 1324b. Furthermore, although the nonlinear tangled seam is shown as extending in a horizontal direction, it is envisioned herein that the nonlinear tangled seam may extend in a vertical direction.

[0101] As depicted, at least the front panel 1330 of the first lower garment 1310 and the front panel 1332 of the second lower garment 1312 can be formed from the same pattern piece applied to the composite nonwoven fabric 100. The front panel 1330 of the first lower garment 1310 includes a first nonlinear entanglement seam 1334 and a second nonlinear entanglement seam 1336 located at a first position 1338 on the first lower garment 1310. In an example, the first position 1338 may correspond to a first distance 1337 measured at the front vertical center line of the first lower garment 1310 relative to the waist opening 1314 of the first lower garment 1310, for each of the first nonlinear entanglement seam 1334 and the second nonlinear entanglement seam 1336. The first nonlinear entanglement seam 1334 and the second nonlinear entanglement seam 1336 present a first visible arrangement of entanglement seams on the first lower garment 1310.

[0102] The front panel 1332 of the second lower garment 1312 also includes a first nonlinear entanglement seam 1334 and a second nonlinear entanglement seam 1336 located at a second position 1344 on the second lower garment 1312, wherein the second position 1344 is different from the first position 1338. For example, the second position 1344 may correspond to a second distance 1345 measured at the front vertical center line of the second lower garment 1312 relative to the waist opening 1322 of the second lower garment 1312 for each of the first nonlinear entanglement seam 1334 and the second nonlinear entanglement seam 1336, wherein the second distance 1345 for each of the first nonlinear entanglement seam 1334 and the second nonlinear entanglement seam 1336 is different from the first distance 1337. The first nonlinear entanglement seam 1334 and the second nonlinear entanglement seam 1336 present a second visible arrangement of entanglement seams on the second lower garment 1312.

[0103] Although not shown, the batch may include additional lower garments, which share a common finished form with the first lower garment 1310 and the second lower garment 1312. The additional lower garments in the batch may exhibit different visual arrangements of the first nonlinear entanglement seam 1334 and the second nonlinear entanglement seam 1336. In other words, the first nonlinear entanglement seam 1334 and the second nonlinear entanglement seam 1336 may be located at different positions on the additional garment relative to the aforementioned pattern piece used to form the front panel of the additional lower garment.

[0104] Despite Figure 12 and Figure 13 The garments depicted in the garment batches described herein include different visible arrangements of entangled seams, but this document envisions that garments in garment batches produced by the systems and methods described herein may include the same visible arrangement of entangled seams. For example, the entanglement system 500 may be configured to generate short repetitions of the visible arrangement of entangled seams, such that the composite nonwoven fabric may include multiple repetitions of the visible arrangement of entangled seams along the material flow direction 516. In this respect, pattern pieces may be applied to the composite nonwoven fabric to form garments with the same visible arrangement of entangled seams.

[0105] Figure 14 A second example composite nonwoven fabric 1400 is depicted, formed, for example, a first nonwoven layer 110, a second layer 114, and a filler material 116. The composite nonwoven fabric 1400 can be formed according to the methods and systems described herein, including an entanglement system 500. The composite nonwoven fabric 1400 includes nonlinear entanglement seams 1410a, 1410b, 1410c, and 1410d extending in a material flow direction 516. As shown, nonlinear entanglement seams 1410a and 1410b intersect or cross each other at intersection 1412, and nonlinear entanglement seams 1410c and 1410d intersect or cross each other at intersections 1414 and 1416. Intersections 1412, 1414, and 1416 represent areas where the entangled head engages with the composite nonwoven fabric 1400 at least twice. Accordingly, the stitch density at intersections 1412, 1414, and 1416 is greater than that of the remainder of nonlinear entanglement seams 1410a, 1410b, 1410c, and 1410d. This greater stitch density at intersections 1412, 1414, and 1416 results in a further reduction in thickness compared to the remainder of nonlinear entanglement seams 1410a, 1410b, 1410c, and 1410d, and compared to the region 1418 extending between nonlinear entanglement seams 1410a, 1410b, 1410c, and 1410d.

[0106] This is Figure 15 As shown in the figure, Figure 15This is a cross-section of the composite nonwoven fabric 1400 taken at cut lines 15-15. Region 1418 has a thickness 1514 measured from a first surface 1513 formed by the first nonwoven layer 110 to a relative second surface 1516 formed by the second layer 114. Intersection 1412 has a thickness 1510 measured from the first surface 1513 to the relative second surface 1516, and nonlinear entanglement seams 1410c and 1410d have a thickness 1512 measured from the first surface 1513 to the relative second surface 1516. In this example, thickness 1514 is greater than thickness 1512, and thickness 1512 is greater than thickness 1510. The ability to produce varying thicknesses of the composite nonwoven fabric 1400 in a direction not parallel to the material flow direction can be used to design high-insulation and low-insulation zones required on garments incorporating the composite nonwoven fabric 1400. Insulation zones can have increased thickness (e.g., greater bulk) and can correspond to zone 1418. Low insulation zones can correspond to zones that include multiple intersections (such as intersections 1412, 1414, and 1416).

[0107] Figure 16 A rear view of an example upper garment 1600 with a torso portion 1610 is depicted, wherein the torso portion 1610 includes a neck opening 1612 and a waist opening 1614. The upper garment 1600 also includes optional first sleeves 1616 and optional second sleeves 1618. Although shown as a top with long sleeves, it is envisioned herein that the upper garment 1600 may be in the form of a vest, pullover, hoodie, jacket, etc.

[0108] The upper garment includes a low-insulation section 1620 located in the central back region of the torso portion 1610 and a high-insulation section 1622 located on either side of the low-insulation section 1620. The locations of the low-insulation section 1620 and the high-insulation section 1622 can be based on, for example, a thermal map of the human body. For example, these maps may indicate that the central back torso generates a large amount of heat and, accordingly, may require less insulation than other areas of the torso. The low-insulation section 1620 includes a plurality of non-linear entangled seams 1624a, 1624b, 1624c, and 1624d extending in the material flow direction 516. As depicted, the non-linear entangled seams 1624a, 1624b, 1624c, and 1624d are generally closely spaced together and include multiple intersections as they extend from the neck opening 1612 of the upper garment 1600 to the waist opening 1614. This results in an overall increase in stitch density and an overall decrease in thickness in the low-insulation zone 1620 compared to other parts of the upper garment 1600. Conversely, the high-insulation zone 1622 includes non-linear entangled seams 1626a, 1626b, 1626c, and 1626d. Compared to non-linear entangled seams 1624a, 1626b, 1624c, and 1624d, the non-linear entangled seams 1626a, 1626b, 1626c, and 1626d are generally more widely spaced, and they do not intersect each other. Consequently, the high-insulation zone 1622 has an overall decrease in stitch density and an overall increase in thickness compared to the low-insulation zone 1620. In other words, compared to the low-insulation zone 1620, the high-insulation zone 1622 may include a larger surface area occupied by regions 1628a, 1628b, 1628c, and 1628d, in which the first nonwoven layer 110, the second layer 114, and the filler material 116 are substantially unentangled. The greater thickness and bulkiness of regions 1628a, 1628b, 1628c, and 1628d help to trap and store heat.

[0109] Figure 16 The visible arrangement of the nonlinear entangled seams is illustrative only, and other visible arrangements are envisioned herein to be formed by nonlinear entangled seams. Furthermore, although the entangled seams are shown as extending vertically (e.g., from the neck opening to the waist opening), the entangled seams may be horizontally oriented on the garment. Additionally, the upper garment 1600 may include nonlinear entangled seams at locations on the upper garment different from those shown. Figure 16The depiction of the upper garment 1600 is intended to convey the concept that parameters associated with the nonlinear entanglement seams can be adjusted to achieve desired properties, including thermal insulation properties. These parameters may include, for example, the spacing between adjacent nonlinear entanglement seams (e.g., a larger spacing results in regions 1628a, 1628b, 1628c, and 1628d occupying a larger overall surface area of ​​the upper garment 1600), the number of intersections between nonlinear entanglement seams (e.g., more intersections result in increased stitch density and reduced thickness), the width of each nonlinear entanglement seam (e.g., a larger width results in reduced thickness compared to a nonlinear entanglement seam with a smaller width), and so on.

[0110] Figure 17 An example composite nonwoven fabric 1700 is depicted, formed from a first nonwoven layer 110, a second layer 114, and a filling material 116. In an example aspect, the composite nonwoven fabric 1700 includes nonlinear entanglement seams 1710a, 1710b, and 1710c. Nonlinear entanglement seam 1710a is similar to other nonlinear entanglement seams discussed herein with respect to, for example, composite nonwoven fabric 100 and composite nonwoven fabric 1400. Nonlinear entanglement seams 1710b and 1710c include discontinuous nonlinear entanglement seams. For example, nonlinear entanglement seam 1710b includes a spacer segment 1712 in which no entanglement seam is formed. Nonlinear entanglement seam 1710c includes multiple spacer segments, such as spacer segment 1714 and spacer segment 1716. Furthermore, the nonlinear entanglement joint 1710c includes an entanglement joint portion 1718, which takes the form of a very short segment or even an entanglement point, which is spaced apart from the rest of the nonlinear entanglement joint 1710c by interval segments 1720 and 1722.

[0111] The interval segments 1712, 1714, 1716, 1720, and 1722 can be formed using the entanglement system 500 and the methods described herein. For example, with respect to interval segment 1712, it can be formed by non-actuating the entanglement head 532 that forms the nonlinear entanglement seam 1710b during one or more stationary phases, such that the entanglement needles 534 and / or orifices associated with the entanglement head 532 do not contact the composite nonwoven fabric 1700. The lengths of interval segments 1712, 1714, 1716, 1720, and 1722 can be adjusted as needed by varying the number of stationary phases in which the entanglement head 532 is non-actuated.

[0112] In an example, when the tangled head 532 is subsequently actuated, and as shown with respect to the nonlinear tangled joint 1710b, the carriage 524 and / or the conveying system 512 can be positioned in the material flow direction 516 to align with the previous tangled region 1711 formed before the formation of the discontinuous segment 1712, such that the next tangled region 1713 is aligned with the previous tangled region 1711 in the material flow direction 516. Alternatively, and as shown with respect to the interval segment 1714 of the nonlinear tangled joint 1710, when the tangled head 532 is actuated after the formation of the interval segment 1714, the carriage 524 and / or the conveying system 512 can be positioned in the first direction 610 to offset from the previous tangled region 1715 formed before the formation of the interval segment 1714, such that the next tangled region 1717 is offset in the first direction 610 from the previous tangled region 1715. This document also envisions that the carriage 524 and / or the transport system 512 could be positioned offset in the second direction 611, such that the subsequent entanglement area is offset in the second direction 611 from the previous entanglement area, as shown with respect to the discontinuity segment 1716.

[0113] Regarding the tangled joint portion 1718, in an example, the tangled joint portion 1718 can be formed by actuating the tangled head 532 at least once after generating the interval segment 1720 and before generating the interval segment 1722. The length of the tangled joint portion 1718 can be adjusted based on the number of times the tangled head 532 is actuated after generating the interval segment 1720 and before generating the interval segment 1722. For example, actuating the tangled head 532 once or twice can generate a tangled point, while actuating the tangled head 532 three to ten times can generate a short tangled segment.

[0114] This paper envisions any combination of continuous nonlinear entanglement seams and discontinuous nonlinear entanglement seams. As an example, when it is necessary to increase the bulk and thickness of the composite nonwoven fabric 1700, spaced segments can be created. For instance, when the composite nonwoven fabric 1700 is incorporated into clothing, discontinuous nonlinear entanglement seams can be located in areas of the clothing requiring higher insulation. Furthermore, the length of the spaced segments can be adjusted according to the insulation requirements (e.g., longer spaced segments equal greater bulk and more insulation, and shorter spaced segments equal less bulk and less insulation).

[0115] This paper envisions the use of entangled seams on monolayer materials comprising nonwoven fibers, rather than on discrete layers or stacked configurations of materials bonded or secured together at seam areas using an entanglement process. The term "monolayer" is intended to express a cohesive structure, as opposed to individual layers not bonded together prior to the formation of the entangled seams described herein. For example, Figure 18 Example nonwoven fabric 1800 with entangled seams 1810 and 1812 is depicted, and Figure 19 A cross-section of nonwoven fabric 1800 is depicted. Nonwoven fabric 1800 may include a single fiber layer containing entangled fibers; two or more fiber layers having the same or different properties (e.g., fibers of different short fiber lengths, fibers of different deniers, fibers of different colors, different fiber types, different fiber coatings, etc.), which are joined together by an entanglement process (e.g., needle punching or hydroentangling) or other processes (such as bonding, adhesives, sewing, etc.); or one or more fiber layers having the same or different properties, which are joined together with a membrane or structured fabric (e.g., knitted, woven, or braided fabric) by an entanglement process or other processes (such as bonding, adhesives, sewing, etc.).

[0116] Nonlinear entanglement seams 1810 and 1812 can be formed by the entanglement process described above, and seams 1810 and 1812 can be used to create areas of reduced thickness and / or to create a visible arrangement of entanglement seams. In an example, nonwoven fabric 1800 can be combined with an additional monolayer material. For example, nonwoven fabric 1800 can be positioned adjacent to a structured fabric and attached to the structured fabric by entanglement, sewing, bonding, adhesives, etc. One or more additional materials, such as filler material, can be located between nonwoven fabric 1800 and the structured fabric. In another example, nonwoven fabric 1800 can be positioned adjacent to another monolayer nonwoven fabric having entanglement seams and fixed thereto by entanglement, sewing, bonding, adhesives, etc. One or more additional materials, such as filler material, can be located between nonwoven fabric 1800 and the additional monolayer nonwoven fabric. Any and all aspects and any variations thereof are contemplated within the scope of this document. Nonwoven fabric 1800 can be formed into various garment articles as described herein, such as upper garments, lower garments, footwear (e.g., shoe uppers), etc. As described herein, garment products of the same type can have different visible arrangements of entangled seams.

[0117] The following clauses represent exemplary aspects of the concepts envisioned herein. Any of the following clauses may be combined in a multi-dependent manner to depend on one or more other clauses. Furthermore, any combination of dependent clauses (clauses that explicitly depend on preceding clauses) may be combined while remaining within the scope of the aspects envisioned herein. The following clauses are examples and not limitations.

[0118] Clause 1. A method of manufacturing a composite nonwoven fabric, the composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material located between the first nonwoven layer and the second layer, the method comprising: when the composite nonwoven fabric is in a first position on a tangling machine, engaging a tangling head with the composite nonwoven fabric to form a first tangled region on the composite nonwoven fabric; advancing the composite nonwoven fabric through the tangling machine in a material flow direction; moving one or more of the tangling head and the composite nonwoven fabric in a first direction not parallel to the material flow direction; and when the composite nonwoven fabric is in a second position advanced from the first position in the material flow direction, engaging the tangling head with the composite nonwoven fabric to form a second tangled region on the composite nonwoven fabric, the second tangled region extending from the first tangled region to form a nonlinear tangled seam.

[0119] Clause 2. The method of manufacturing a composite nonwoven fabric according to Clause 1, wherein at each of the first entanglement region and the second entanglement region, fibers from the first nonwoven layer extend through the filler material and into the second layer.

[0120] Clause 3. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 1 to 2, wherein the first entanglement region partially overlaps with the second entanglement region.

[0121] Clause 4. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 1 to 3, wherein the stitch density at the overlapping region between the first entanglement region and the second entanglement region is greater than the stitch density at the remaining portions of the first entanglement region and the second entanglement region.

[0122] Clause 5. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 1 to 4, wherein when the composite nonwoven fabric is in the first position, the tangled head moves in a direction perpendicular to the surface plane of the composite nonwoven fabric.

[0123] Clause 6. The method of manufacturing a composite nonwoven fabric according to any one of Clauses 1 to 5 further comprises: advancing the composite nonwoven fabric in the material flow direction after forming the second entanglement region; moving one or more of the entanglement head or the composite nonwoven fabric in a second direction not parallel to the material flow direction; and when the composite nonwoven fabric is in a third position advanced from the second position in the material flow direction, engaging the entanglement head with the composite nonwoven fabric to form a third entanglement region on the composite nonwoven fabric, the third entanglement region extending from the second entanglement region to form the nonlinear entanglement seam.

[0124] Clause 7. The method of manufacturing a composite nonwoven fabric according to Clause 6, wherein the third entanglement region partially overlaps with the second entanglement region.

[0125] Clause 8. The method of manufacturing a composite nonwoven fabric according to Clause 6, wherein the third entanglement region is positioned adjacent to the second entanglement region.

[0126] Clause 9. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 6 to 8, wherein the second direction is opposite to the first direction.

[0127] Clause 10. A garment comprising: a first nonwoven layer having a material flow direction; a second layer; a filling material located between the first nonwoven layer and the second layer; at least one region of the garment in which the first nonwoven layer, the second layer, and the filling material are substantially unentangled; and at least one non-linear entanglement seam extending along the material flow direction, the at least one non-linear entanglement seam comprising one or more entanglement regions extending from each other to form the at least one non-linear entanglement seam, wherein the one or more entanglement regions comprise fibers from the first nonwoven layer extending through the filling material and into the second layer.

[0128] Clause 11. The garment as described in Clause 10, wherein the second layer is a nonwoven material.

[0129] Clause 12. Garment according to any one of Clauses 10 to 11, wherein the one or more tangled areas include discrete areas.

[0130] Clause 13. The garment according to any one of Clauses 10 to 12, wherein the thickness of the at least one region of the first nonwoven layer, the second layer and the filling material being substantially untangled is from about 7 mm to about 15 mm.

[0131] Clause 14. The garment according to any one of Clauses 10 to 13, wherein the thickness of the at least one non-linear tangled seam is about 5% to about 30% of the thickness of the at least one region of the garment in which the first nonwoven layer, the second layer and the filling material are substantially untangled.

[0132] Clause 15. Garment according to any one of Clauses 10 to 14, wherein the filling material is one or more of synthetic fiber sheets, loose synthetic fibers and down.

[0133] Clause 16. Garments as described in Clauses 10 and 12 through 15, wherein the second layer is a woven material.

[0134] Clause 17. The garments described in Clauses 10 to 11 and Clauses 13 to 15, wherein one or more tangled areas partially overlap each other.

[0135] Clause 18. The garments described in Clauses 10 to 17 further include a plurality of additional nonlinear entanglement seams, wherein the plurality of additional nonlinear entanglement seams form a non-repeating visual arrangement of entanglement seams.

[0136] Clause 19. A composite nonwoven fabric comprising: a first nonwoven layer having a material flow direction; a second layer; a filler material located between the first nonwoven layer and the second layer; at least one region of the composite nonwoven fabric in which the first nonwoven layer, the second layer, and the filler material are substantially unentangled; and at least one nonlinear entanglement seam extending along the material flow direction, the at least one nonlinear entanglement seam comprising one or more entanglement regions extending from each other to form the at least one nonlinear entanglement seam, wherein the one or more entanglement regions comprise fibers from the first nonwoven layer extending through the filler material and into the second layer.

[0137] Clause 20. The composite nonwoven fabric as described in Clause 19, wherein the second layer is a nonwoven material.

[0138] Clause 21. The composite nonwoven fabric according to Clauses 19 to 20, wherein the one or more entanglement regions include discrete entanglement regions.

[0139] Clause 22. The composite nonwoven fabric according to Clauses 19 to 21, wherein the thickness of the at least one region of the first nonwoven layer, the second layer and the filling material being substantially unentangled is from about 7 mm to about 15 mm.

[0140] Clause 23. The composite nonwoven fabric according to any one of Clauses 19 to 22, wherein the thickness of the at least one nonlinear entanglement seam is about 5% to about 30% of the thickness of the at least one region of the composite nonwoven fabric in which the first nonwoven layer, the second layer and the filling material are substantially unentangled.

[0141] Clause 24. A composite nonwoven fabric according to any one of Clauses 19 to 23, wherein the filling material is one or more of synthetic fiber sheets, loose synthetic fibers, and down.

[0142] Clause 25. A composite nonwoven fabric according to any one of Clauses 19 and 21 to 24, wherein the second layer is a woven material.

[0143] Clause 26. A composite nonwoven fabric according to any one of Clauses 19 to 20 and Clauses 22 to 25, wherein one or more entangled regions partially overlap each other.

[0144] Clause 27. The composite nonwoven fabric according to any one of Clauses 19 to 26 further includes a plurality of additional nonlinear entanglement seams, wherein the plurality of additional nonlinear entanglement seams form a non-repeating visual arrangement of entanglement seams.

[0145] Clause 28. An entanglement system for forming at least one nonlinear entanglement seam on a composite nonwoven fabric, the entanglement system comprising: a first entanglement station, the first entanglement station comprising: a conveying system having a surface adapted to intermittently advance the composite nonwoven fabric in a material flow direction; a first actuator; a first entanglement head coupled to the first actuator, the first actuator being adapted to move the first entanglement head in a direction perpendicular to a conveying plane of the conveying system; and a first carriage coupled to the first entanglement head, the first carriage being adapted to move in a first direction not parallel to the material flow direction.

[0146] Clause 29. The entanglement system according to Clause 28, wherein the first direction is perpendicular to the material flow direction.

[0147] Clause 30. The entanglement system according to any one of Clauses 28 to 29, wherein the first carriage is further adapted to move in a second direction not parallel to the material flow direction, the second direction being opposite to the first direction.

[0148] Clause 31. The entanglement system according to Clause 30, wherein the second direction is perpendicular to the material flow direction.

[0149] Clause 32. The entanglement system according to any one of Clauses 28 to 31, wherein the first entanglement head has a first dimension in the material flow direction.

[0150] Clause 33. The entanglement system according to any one of Clauses 28 to 32, wherein the advancing distance of the conveying system is less than or equal to the first dimension of the first entangled head.

[0151] Clause 34. An entanglement system according to any one of Clauses 28 to 33, wherein when the transport system is stationary, the first actuator is adapted to move in the direction perpendicular to the transport plane.

[0152] Clause 35. The entanglement system according to any one of Clauses 28 to 34, wherein the first carriage is indirectly coupled to the first entanglement head via the first actuator.

[0153] Clause 36. The entanglement system according to any one of Clauses 28 to 35 further comprises: a second entanglement station, the second entanglement station comprising: the conveying system having a surface adapted to intermittently advance the composite nonwoven fabric in the material flow direction; a second actuator; a second entanglement head coupled to the second actuator, the second actuator being adapted to move the second entanglement head in a direction perpendicular to the conveying plane of the conveying system; and a second carriage coupled to the second entanglement head, the second carriage being adapted to move in the first direction not parallel to the material flow direction.

[0154] Clause 37. The entanglement system according to Clause 36, wherein the first entanglement head is located at a first distance inward from a first edge of the surface of the conveying system, and the second entanglement head is located at a second distance inward from the first edge of the surface of the conveying system, the second distance being different from the first distance.

[0155] Clause 38. The entanglement system according to any one of Clauses 36 to 37, wherein the second entanglement station is located after the first entanglement station in the material flow direction.

[0156] Clause 39. The entanglement system according to any one of Clauses 28 to 38, wherein the first entanglement head comprises a plurality of entanglement needles.

[0157] Clause 40. A method of manufacturing a garment batch having a common finished product form, the method comprising: obtaining a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filling material located between the first nonwoven layer and the second layer, the composite nonwoven fabric comprising at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, the first nonlinear entanglement seam and the second nonlinear entanglement seam each comprising an entanglement region extending from each other to form a distinct continuous nonlinear entanglement seam, wherein the entanglement region comprises fibers extending from the first nonwoven layer through the filling material and into the second layer; removing from the composite nonwoven fabric... A first instance of a pattern piece, the first instance of the pattern piece having a first nonlinear entanglement seam and a second nonlinear entanglement seam; forming a first garment using the first instance of the pattern piece, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a first position of the pattern piece; removing a second instance of the pattern piece from the composite nonwoven fabric, the second instance of the pattern piece having the first nonlinear entanglement seam and the second nonlinear entanglement seam; and forming a second garment using the second instance of the pattern piece, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a second position of the pattern piece, the second position being different from the first position.

[0158] Clause 41. The method of manufacturing a batch of garments according to Clause 40, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

[0159] Clause 42. A method for manufacturing a batch of garments according to any one of Clauses 40 to 41, wherein the tangled areas partially overlap each other.

[0160] Clause 43. The method of manufacturing a batch of garments according to any one of Clauses 40 to 42 further comprises: removing a third instance of the pattern piece from the composite nonwoven fabric, the third instance of the pattern piece having a first nonlinear entanglement seam and a second nonlinear entanglement seam; and forming a third garment using the third instance of the pattern piece, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a third position of the pattern piece, the third position being different from one or more of the first position and the second position.

[0161] Clause 44. A method for manufacturing a batch of clothing according to any one of Clauses 41 to 43, wherein the batch of clothing includes upper garments.

[0162] Clause 45. A method for manufacturing a batch of clothing according to any one of Clauses 41 to 43, wherein the batch of clothing includes lower garments.

[0163] Clause 46. A garment batch having a common finished form, the garment batch being formed of a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filling material located between the first nonwoven layer and the second layer, the composite nonwoven fabric comprising at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, each of the first nonlinear entanglement seam and the second nonlinear entanglement seam comprising an entanglement region extending from each other to form a corresponding first nonlinear entanglement seam and second nonlinear entanglement seam, wherein the entanglement region comprises extending from the first nonlinear entanglement seam and the second nonlinear entanglement seam. The nonwoven layer extends through the filling material and into the fibers of the second layer. The garment batch includes: a first garment formed from a first instance of a pattern piece taken from the composite nonwoven fabric, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a first position on the first garment; and a second garment formed from a second instance of the pattern piece taken from the composite nonwoven fabric, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a second position on the second garment, the second position being different from the first position relative to the pattern piece.

[0164] Clause 47. The garment batch as described in Clause 46, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

[0165] Clause 48. A garment batch according to any one of Clauses 46 to 47, wherein the tangled areas partially overlap each other.

[0166] Clause 49. The garment batch according to any one of Clauses 46 to 48 further includes a third garment formed from a third instance of the pattern piece taken from the composite nonwoven fabric, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a third position on the third garment, the third position being different from one or more of the first and second positions relative to the pattern piece.

[0167] Clause 50. A clothing batch according to any one of Clauses 46 to 49, wherein the clothing batch includes upper garments.

[0168] Clause 51. A clothing batch according to any one of Clauses 46 to 49, wherein the clothing batch includes lower garments.

[0169] Clause 52. A method of manufacturing a garment batch having a common finished product form, the method comprising: obtaining a composite nonwoven fabric, the composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filling material located between the first nonwoven layer and the second layer, the composite nonwoven fabric comprising at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, the first nonlinear entanglement seam and the second nonlinear entanglement seam each comprising an entanglement region extending from each other to form a distinct continuous nonlinear entanglement seam, wherein the entanglement region comprises fibers extending from the first nonwoven layer through the filling material and into the second layer; from the composite nonwoven fabric The woven fabric is used to remove a first portion having a first pattern, the first portion having a first nonlinear entanglement seam and a second nonlinear entanglement seam; a first garment is formed using the first portion, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a first position on the first portion; a second portion having the first pattern is removed from the composite nonwoven fabric, the second portion having the first nonlinear entanglement seam and the second nonlinear entanglement seam; and a second garment is formed using the second portion, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a second position on the second portion, the second position being different from the first position.

[0170] Clause 53. The method of manufacturing a batch of garments according to Clause 52, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

[0171] Clause 54. The method of manufacturing a batch of garments according to Clause 53, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam varies along the material flow direction, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam is measured in a direction not parallel to the material flow direction.

[0172] Clause 55. A method for manufacturing a batch of garments according to any one of Clauses 52 to 54, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam include different visible arrangements of the entanglement seams.

[0173] Clause 56. A method for manufacturing a batch of garments according to any one of Clauses 52 to 55, wherein the tangled areas partially overlap each other.

[0174] Clause 57. A method for manufacturing a batch of clothing according to any one of Clauses 52 to 56, wherein the batch of clothing includes upper garments.

[0175] Clause 58. A method for manufacturing a batch of clothing according to any one of Clauses 52 to 56, wherein the batch of clothing includes lower garments.

[0176] Clause 59. A garment batch having a common finished form, the garment batch being formed of a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filling material located between the first nonwoven layer and the second layer, the composite nonwoven fabric comprising at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, each of the first nonlinear entanglement seam and the second nonlinear entanglement seam comprising an entanglement region extending from each other to form a corresponding first nonlinear entanglement seam and second nonlinear entanglement seam, wherein the entanglement region comprises extending from the first nonwoven layer... The garment batch comprises: a first garment formed of a first portion of the composite nonwoven fabric having a first pattern, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a first position on the first portion of the first garment; and a second garment formed of a second portion of the composite nonwoven fabric having the first pattern, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a second position on the second portion of the second garment, the second position being different from the first position.

[0177] Clause 60. The garment batch as described in Clause 59, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

[0178] Clause 61. The garment batch as described in Clause 60, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam varies along the material flow direction, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam is measured in a direction not parallel to the material flow direction.

[0179] Clause 62. A garment batch according to any one of Clauses 59 to 61, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam include different visible arrangements of the entanglement seams.

[0180] Clause 63. A garment batch according to any one of Clauses 59 to 62, wherein the tangled areas partially overlap each other.

[0181] Clause 64. A clothing batch according to any one of Clauses 59 to 63, wherein the clothing batch includes upper garments.

[0182] Clause 65. A clothing batch according to any one of Clauses 59 to 63, wherein the clothing batch includes lower garments.

[0183] Clause 66. An entanglement system for forming at least one nonlinear entanglement seam on a composite nonwoven fabric, the entanglement system comprising: a first entanglement station, the first entanglement station comprising: a conveying system having a surface adapted to advance the composite nonwoven fabric in a material flow direction; a first actuator adapted to actuate a first entanglement head coupled to the first actuator; and a first carriage coupled to the first entanglement head, the first carriage being adapted to move in a first direction not parallel to the material flow direction.

[0184] Clause 67. The entanglement system according to Clause 66, wherein the first actuator is adapted to actuate the first entanglement head to eject one or more fluid jets.

[0185] Clause 68. The entanglement system according to Clause 66, wherein the first entanglement head includes entanglement needles, and wherein the first actuator is adapted to move one or more of the first entanglement head and the entanglement needles in a direction perpendicular to a transfer plane of the surface.

[0186] Clause 69. The entanglement system according to any one of Clauses 66 to 68, wherein the first carriage is further adapted to move in a second direction not parallel to the material flow direction, the second direction being opposite to the first direction.

[0187] Clause 70. The entanglement system according to Clause 69, wherein the second direction is perpendicular to the material flow direction.

[0188] Clause 71. An entanglement system according to any one of Clauses 66 to 70, wherein the first entanglement head has a first dimension in the material flow direction.

[0189] Clause 72. The entanglement system according to Clause 71, wherein the conveying system is adapted to advance the composite nonwoven fabric in the material flow direction, and wherein the advancing distance of the conveying system is less than the first dimension of the first entanglement head.

[0190] Clause 73. The entanglement system according to any one of Clauses 66 to 72, wherein the first carriage is indirectly coupled to the first entanglement head via the first actuator.

[0191] Clause 74. The entanglement system according to any one of Clauses 66 to 73, wherein the first entanglement station further comprises a plurality of additional entanglement heads coupled to the first actuator.

[0192] Clause 75. The entanglement system according to Clause 74, wherein the plurality of additional entangled heads coupled to the first actuator are non-uniformly spaced from each other.

[0193] Clause 76. The entanglement system according to any one of Clauses 66 to 75 further comprises: a second entanglement station, the second entanglement station comprising: the conveying system having a surface adapted to advance the composite nonwoven fabric in the material flow direction; a second actuator adapted to actuate a second entanglement head coupled to the second actuator; and a second carriage coupled to the second entanglement head, the second carriage being adapted to move in the first direction not parallel to the material flow direction.

[0194] Clause 77. The entanglement system according to Clause 76, wherein the first entanglement head is located at a first distance inward from a first edge of the surface of the conveying system, and the second entanglement head is located at a second distance inward from the first edge of the surface of the conveying system, the second distance being different from the first distance.

[0195] Clause 78. The entanglement system according to any one of Clauses 76 to 77, wherein the second entanglement station is located after the first entanglement station in the material flow direction.

[0196] Clause 79. The entanglement system according to any one of Clauses 76 to 78, wherein the second entanglement station further comprises a plurality of additional entanglement heads coupled to the second actuator.

[0197] Clause 80. The entanglement system according to Clause 79, wherein the spacing arrangement between the plurality of additional entangled heads coupled to the second actuator is different from the spacing arrangement between the plurality of additional entangled heads coupled to the first actuator.

[0198] Clause 81. An entanglement system according to any one of Clauses 79 to 80, wherein the number of the plurality of additional entangled heads coupled to the second actuator is different from the number of the plurality of additional entangled heads coupled to the first actuator.

[0199] Clause 82. The entanglement system according to any one of Clauses 76 to 81, wherein the size of the second entanglement head is different from the size of the first entanglement head.

[0200] Clause 83. An entanglement system according to any one of Clauses 76 to 82, wherein the entanglement footprint generated by the second entanglement head is different from the entanglement pattern generated by the first entanglement head.

[0201] Clause 84. A method of manufacturing a nonwoven fabric, comprising: when the nonwoven fabric is in a first position on a tangling machine, engaging a tangling head with the nonwoven fabric to form a first tangled region on the nonwoven fabric; advancing the nonwoven fabric through the tangling machine in a material flow direction; moving one or more of the tangling head and the nonwoven fabric in a first direction not parallel to the material flow direction; and when the nonwoven fabric is in a second position advanced from the first position in the material flow direction, engaging the tangling head with the nonwoven fabric to form a second tangled region on the nonwoven fabric, the second tangled region extending from the first tangled region to form a nonlinear tangled seam.

[0202] Clause 85. The method of manufacturing a nonwoven fabric according to Clause 84, wherein at each of the first entanglement region and the second entanglement region, the fibers forming the nonwoven fabric are moved from a generally horizontal orientation to a generally vertical orientation.

[0203] Clause 86. A method of manufacturing a nonwoven fabric according to any one of Clauses 84 to 85, wherein the first entanglement region partially overlaps with the second entanglement region.

[0204] Clause 87. The method of manufacturing a nonwoven fabric according to Clause 86, wherein the stitch density at the overlapping region between the first entanglement region and the second entanglement region is greater than the stitch density at the remaining portions of the first entanglement region and the second entanglement region.

[0205] Clause 88. A method of manufacturing a nonwoven fabric according to any one of Clauses 84 to 87, wherein when the nonwoven fabric is in the first position, the tangled head moves in a direction perpendicular to the surface plane of the nonwoven fabric.

[0206] Clause 89. A method of manufacturing a nonwoven fabric according to any one of Clauses 84 to 88, further comprising: advancing the nonwoven fabric in the material flow direction after forming the second entanglement region; moving one or more of the entanglement head and the nonwoven fabric in a second direction not parallel to the material flow direction, the second direction being opposite to the first direction; and when the nonwoven fabric is in a third position advanced from the second position in the material flow direction, engaging the entanglement head with the nonwoven fabric to form a third entanglement region on the nonwoven fabric, the third entanglement region extending from the second entanglement region to form the nonlinear entanglement seam.

[0207] Clause 90. The method of manufacturing a nonwoven fabric according to Clause 89, wherein the third entanglement region partially overlaps with the second entanglement region.

[0208] Clause 91. A garment comprising: a nonwoven fabric having a material flow direction; and at least one nonlinear entanglement seam extending along the material flow direction, the at least one nonlinear entanglement seam comprising one or more entanglement regions extending from each other to form the at least one nonlinear entanglement seam, wherein at each of the one or more entanglement regions, fibers forming the nonwoven fabric have a generally vertical orientation.

[0209] Clause 92. The garment as described in Clause 91, wherein the one or more tangled areas include discrete areas.

[0210] Clause 93. The garment as described in Clause 91, wherein one or more tangled areas partially overlap each other.

[0211] Clause 94. The garment according to any one of Clauses 91 to 93 further includes a plurality of additional nonlinear entanglement seams, wherein the plurality of additional nonlinear entanglement seams form a non-repeating visual arrangement of entanglement seams.

[0212] Clause 95. Garments according to any one of Clauses 91 to 94 further include one or more additional layers attached to the nonwoven fabric by one or more of entanglement, sewing, bonding, and adhesives.

[0213] Clause 96. The garment as described in Clause 95, wherein the one or more additional layers comprise one or more of structured fabrics, nonwoven layers, membranes, and filling materials.

[0214] Clause 97. A nonwoven fabric having a material flow direction, the nonwoven fabric comprising: at least one nonlinear entanglement seam extending along the material flow direction, the at least one nonlinear entanglement seam comprising one or more entanglement regions extending from each other to form the at least one nonlinear entanglement seam, wherein at each of the one or more entanglement regions, the fibers forming the nonwoven fabric have a generally vertical orientation.

[0215] Clause 98. The nonwoven fabric as described in Clause 97, wherein the one or more entanglement regions include discrete entanglement regions.

[0216] Clause 99. The nonwoven fabric as described in Clause 97, wherein one or more entangled regions partially overlap each other.

[0217] Clause 100. The nonwoven fabric according to any one of Clauses 97 to 99 further includes a plurality of additional nonlinear entanglement seams, wherein the plurality of additional nonlinear entanglement seams form a non-repeating visual arrangement of entanglement seams.

[0218] Clause 101. A garment batch having a common finished form, the garment batch being formed of a nonwoven fabric having at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, the first nonlinear entanglement seam and the second nonlinear entanglement seam each including an entanglement region extending from each other to form a corresponding first nonlinear entanglement seam and second nonlinear entanglement seam, wherein the entanglement region includes fibers from the nonwoven layer, wherein the fibers have a generally vertical orientation, the garment batch comprising: a first garment formed from a first instance of a pattern piece taken from the nonwoven fabric, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a first position on the first garment; and a second garment formed from a second instance of the pattern piece taken from the nonwoven fabric, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a second position on the second garment, the second position being different from the first position relative to the pattern piece.

[0219] Clause 102. The garment batch as described in Clause 101, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

[0220] Clause 103. A garment batch according to any one of Clauses 101 to 102, wherein the tangled areas partially overlap each other.

[0221] Clause 104. The garment batch according to any one of Clauses 101 to 103 further includes a third garment formed from a third instance of the pattern piece taken from the nonwoven fabric, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a third position on the third garment, the third position being different from one or more of the first position and the second position relative to the pattern piece.

[0222] Clause 105. A clothing batch according to any one of Clauses 101 to 104, wherein the clothing batch includes upper garments.

[0223] Clause 106. A clothing batch according to any one of Clauses 101 to 104, wherein the clothing batch includes lower garments.

[0224] Clause 107. A method of manufacturing a batch of garments having a common finished product form, the method comprising: obtaining a nonwoven fabric having at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, the first nonlinear entanglement seam and the second nonlinear entanglement seam each including an entanglement region extending from each other to form a distinct, continuous nonlinear entanglement seam, wherein the entanglement region includes fibers having a generally vertical orientation; removing from the nonwoven fabric a first portion having a first pattern, the first portion having the first nonlinear entanglement seam and the second nonlinear entanglement seam; using the first portion to form a first garment, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a first position on the first portion; removing from the nonwoven fabric a second portion having the first pattern, the second portion having the first nonlinear entanglement seam and the second nonlinear entanglement seam; and using the second portion to form a second garment, the first nonlinear entanglement seam and the second nonlinear entanglement seam being located at a second position on the second portion, the second position being different from the first position.

[0225] Clause 108. The method of manufacturing a batch of garments according to Clause 107, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

[0226] Clause 109. The method of manufacturing a batch of garments according to Clause 108, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam varies along the material flow direction, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam is measured in a direction not parallel to the material flow direction.

[0227] Clause 110. A method for manufacturing a batch of garments according to any one of Clauses 107 to 109, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam include different visible arrangements of the entanglement seams.

[0228] Clause 111. A method of manufacturing a batch of garments according to any one of Clauses 107 to 110, wherein the tangled areas partially overlap each other.

[0229] Clause 112. A method for manufacturing a batch of clothing according to any one of Clauses 107 to 111, wherein the batch of clothing includes upper garments.

[0230] Clause 113. A method for manufacturing a batch of clothing according to any one of Clauses 107 to 111, wherein the batch of clothing includes lower garments.

[0231] Clause 114. A garment batch having a common finished form, the garment batch being formed of a nonwoven fabric having at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, each of the first and second nonlinear entanglement seams including an entanglement region extending from each other to form a corresponding first and second nonlinear entanglement seam, wherein at each of the entanglement regions, fibers forming the nonwoven fabric have a generally vertical orientation, the garment batch comprising: a first garment formed of a first portion of the nonwoven fabric having a first pattern, the first and second nonlinear entanglement seams being located at a first position on the first portion of the first garment; and a second garment formed of a second portion of the nonwoven fabric having the first pattern, the first and second nonlinear entanglement seams being located at a second position on the second portion of the second garment, the second position being different from the first position.

[0232] Clause 115. The garment batch as described in Clause 114, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

[0233] Clause 116. The garment batch as described in Clause 115, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam varies along the material flow direction, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam is measured in a direction not parallel to the material flow direction.

[0234] Clause 117. A garment batch according to any one of Clauses 114 to 116, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam include different visible arrangements of the entanglement seams.

[0235] Clause 118. A garment pack according to any one of Clauses 114 to 117, wherein the tangled areas partially overlap each other.

[0236] Clause 119. A clothing batch according to any one of Clauses 114 to 118, wherein the clothing batch includes upper garments.

[0237] Clause 120. A clothing batch according to any one of Clauses 114 to 118, wherein the clothing batch includes lower garments.

[0238] The aspects of this disclosure have been described in an illustrative rather than restrictive manner. Alternative aspects will become apparent to those skilled in the art without departing from its scope. Those skilled in the art can develop alternative means to implement the above-described improvements without departing from the scope of this disclosure.

[0239] It should be understood that certain features and sub-combinations are useful and can be used without reference to other features and sub-combinations, and are contemplated within the scope of the claims. Not all steps listed in the various figures need to be performed in the specific order described.

Claims

1. A method for manufacturing a batch of clothing, the batch of clothing having a common finished product form, the method comprising: A composite nonwoven fabric is obtained, the composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filling material located between the first nonwoven layer and the second layer, the composite nonwoven fabric comprising at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, the first nonlinear entanglement seam and the second nonlinear entanglement seam each comprising an entanglement region, the entanglement regions extending from each other to form a distinct continuous nonlinear entanglement seam, wherein the entanglement region comprises fibers extending from the first nonwoven layer through the filling material and into the second layer; Remove a first instance of the pattern piece from the composite nonwoven fabric, the first instance of the pattern piece having a first nonlinear entanglement seam and a second nonlinear entanglement seam; The first instance of the pattern piece is used to form a first garment, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a first position on the pattern piece; The second instance of the pattern piece is removed from the composite nonwoven fabric, the second instance of the pattern piece having the first nonlinear entanglement seam and the second nonlinear entanglement seam; as well as A second garment is formed using the second instance of the pattern piece, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a second position on the pattern piece, which is different from the first position.

2. The method for manufacturing a batch of garments according to claim 1, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

3. The method for manufacturing a batch of garments according to claim 1, wherein the entangled regions partially overlap each other.

4. The method for manufacturing a batch of clothing according to claim 1, further comprising: The third instance of the pattern piece is removed from the composite nonwoven fabric, the third instance of the pattern piece having the first nonlinear entanglement seam and the second nonlinear entanglement seam; as well as A third garment is formed using the third instance of the pattern piece, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a third position on the pattern piece, the third position being different from one or more of the first and second positions.

5. The method for manufacturing a batch of clothing according to claim 1, wherein the batch of clothing includes upper garments.

6. The method for manufacturing a batch of clothing according to claim 1, wherein the batch of clothing includes lower garments.

7. A garment batch having a common finished form, the garment batch being formed of a composite nonwoven fabric, the composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filling material located between the first nonwoven layer and the second layer, the composite nonwoven fabric comprising at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, the first nonlinear entanglement seam and the second nonlinear entanglement seam each comprising an entanglement region extending from each other to form a corresponding first nonlinear entanglement seam and second nonlinear entanglement seam, wherein the entanglement region comprises fibers extending from the first nonwoven layer through the filling material and into the second layer, the garment batch comprising: The first garment is formed from a first instance of a pattern piece taken from the composite nonwoven fabric, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a first position on the first garment. The second garment is formed from a second instance of the pattern piece taken from the composite nonwoven fabric, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a second position on the second garment, the second position being different from the first position relative to the pattern piece; as well as The third garment is formed from a third instance of the pattern piece taken from the composite nonwoven fabric, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a third position on the third garment, the third position being different from one or more of the first and second positions relative to the pattern piece.

8. The garment batch according to claim 7, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

9. The garment batch according to claim 7, wherein the tangled areas partially overlap each other.

10. The clothing batch according to claim 7, wherein the clothing batch includes upper body clothing.

11. The clothing batch according to claim 7, wherein the clothing batch includes lower garments.

12. A garment batch having a common finished form, the garment batch being formed of a composite nonwoven fabric, the composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filling material located between the first nonwoven layer and the second layer, the composite nonwoven fabric comprising at least a first nonlinear entanglement seam and a second nonlinear entanglement seam, the first nonlinear entanglement seam and the second nonlinear entanglement seam each comprising an entanglement region extending from each other to form a corresponding first nonlinear entanglement seam and second nonlinear entanglement seam, wherein the entanglement region comprises fibers extending from the first nonwoven layer through the filling material and into the second layer, the garment batch comprising: A first garment, the first garment being formed from a first portion of the composite nonwoven fabric having a first pattern, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a first position on the first garment; as well as The second garment is formed from a second portion of the composite nonwoven fabric having the first pattern, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam are located at a second position on the second garment, which is different from the first position.

13. The garment batch according to claim 12, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam each extend in the material flow direction.

14. The garment batch according to claim 13, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam varies along the material flow direction, wherein the distance between the first nonlinear entanglement seam and the second nonlinear entanglement seam is measured in a direction not parallel to the material flow direction.

15. The garment batch according to claim 12, wherein the first nonlinear entanglement seam and the second nonlinear entanglement seam include different visible arrangements of the entanglement seams.

16. The garment batch according to claim 12, wherein the tangled areas partially overlap each other.

17. The clothing batch according to claim 12, wherein the clothing batch includes upper body clothing.

18. The clothing batch according to claim 12, wherein the clothing batch includes lower garments.

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