Nonwoven entanglement system and method of manufacture

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 7-8 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 11lower body garment batch formed from the example process of

[0020] Figure 14 illustrates a first surface of an example composite nonwoven fabric having non-linear entangled seams that intersect each other according to aspects herein;

[0021] Figure 15 illustrates a cross-section of the example composite nonwoven fabric of Figure 14 taken at cut line 15-15;

[0022] Figure 16 illustrates an example upper body garment having zoned thermal features according to aspects herein, wherein the example upper body garment is formed using a composite nonwoven fabric of Figure 14

[0023] Figure 17 illustrates an example composite nonwoven fabric having intermittent non-linear entangled seams according to aspects herein;

[0024] Figure 18 illustrates an example single layer nonwoven fabric having non-linear entangled seams according to aspects herein; and

[0025] Figure 19 illustrates a cross-section of the example single layer nonwoven fabric of Figure 18 DETAILED DESCRIPTION

[0026] The subject innovation is described herein making specific reference to a presently preferred embodiment. However, one skilled in the art will understand that the subject innovation is not limited to the present embodiment, but is applied to any method and apparatus where similar results are desired. Moreover, although the terms "step" and / or "block" can be used herein to connote different elements of the methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

[0027] ​​Conventional insulated garments are often formed by positioning panels of fabric material (e.g., woven or knit fabric) adjacent to one another, optionally applying adhesive to the panels of fabric material at predetermined locations, heat pressing and / or stitching the fabric material together at the predetermined locations to form linear seams that separate panels, and filling the panels with insulating fill material, such as down or other types of insulating fill material. This method of construction can be expensive due to the number of different materials used to form the garment, and can also be time intensive. Additionally, the energy costs and carbon footprint associated with, for example, the yarn used in the textile fabric material, weaving or knitting the fabric material using the yarn, applying adhesive, heat pressing or stitching the seams, and filling the panels can be high, and the recyclability of the resulting garment can be limited due to the large number of different materials present. When the fabric material used to form the garment includes a repeating visual arrangement of elements (e.g., a visual arrangement of printed components, a visual arrangement of seams, etc.), there can be material waste to ensure that each garment in a batch of garments includes the visual arrangement of elements at a consistent location on the garment in order to present a uniform appearance for each garment in the batch of garments.

[0028] At a high level, aspects herein relate to composite nonwoven fabrics having non-linear entangled seams suitable for garments and methods and systems for producing the same. In example aspects, an entangling system can be used to form the composite nonwoven fabric. In example aspects, the entangling system can include one or more entangling stations that can be aligned in series along a conveyance system adapted to advance a stacked configuration of layers used to form the composite nonwoven fabric in a material flow direction along a surface of the conveyance system. In one example aspect, each entangling station includes an actuator adapted to move in a direction normal to the surface conveyance plane. Each entangling station also includes one or more entangling heads coupled to the actuator. In one aspect, the entangling head includes one or more entangling needles that, in example aspects, are arranged in a structured arrangement. In one example, movement of the actuator in the direction normal to the surface conveyance plane causes the entangling needles to engage the stacked configuration of layers. In another example, the actuator can remain stationary but the entangling head and / or the entangling needles are actuated or caused to move up and down in the direction normal to the conveyance plane such that the entangling needles engage the stacked configuration of layers. In another example aspect, the entangling head is adapted to eject one or more jets of pressurized fluid, such as water. In this example, the actuator can also remain stationary and the jets of fluid are ejected from the entangling head.

[0029] In example aspects, the carriage can also be directly or indirectly coupled to the entangling head, either directly or by way of the actuator, where the carriage is adapted to move in a direction that is not parallel to the material flow direction. Additionally or alternatively, the conveyance system can be adapted to move in a direction that is not parallel to the material flow direction. Thus, in example aspects, the entangling head and the conveyance system can be adapted to move relative to one another in a direction that is not parallel to the material flow direction.

[0030] In example aspects, the entangling head can be positioned at different locations on the respective entangling station so as to contact different portions of the stack configuration as the stack configuration is conveyed along the surface of the conveyance system. For example, a first entangling station can include a first entangling head positioned a first distance inward from a side edge of the surface of the conveyance system (i.e., perpendicular to the material flow direction), and a second entangling station positioned after the first entangling station can include a second entangling head positioned a second distance inward from the side edge of the conveyance system, where the second distance is different than the first distance.

[0031] In example aspects, the stack configuration of layers includes a first nonwoven layer, a second layer, and a filler material positioned between the first nonwoven layer and the second layer. The stack configuration is positioned on the surface of the conveyance system such that the first nonwoven layer faces upward or toward the actuator, the carriage, and the entangling head of the first entangling station, and the second layer faces the surface of the conveyance system. In one example aspect, when the entangling head includes an entangling needle, the actuator moves the entangling head and / or the entangling needle in a direction perpendicular to the surface conveyance plane when the composite nonwoven web is in a first stationary phase such that the entangling needle, and indirectly the entangling head, engages the stack configuration to form a first entanglement region. When the entangling needle engages the stack configuration, the needle drives fibers from the first nonwoven layer through the filler material and into the second layer. In another example aspect, when the entangling head sprays one or more jets of pressurized fluid, and the stack configuration is in a first stationary phase, the actuator actuates the entangling head to spray the one or more jets of fluid that contact the stack configuration to form a first entanglement region. Alternatively, the stack configuration can be continuously advanced while the entangling head continuously sprays one or more jets of fluid. In these aspects, when the jet of fluid contacts the stack configuration, the pressure of the jet drives fibers from the first nonwoven layer through the filler material and into the second layer.

[0032] When a tangle needle is used, the conveying system then advances the stack-up of the first nonwoven layer, the second layer, and the filler material in the material flow direction by a predetermined amount. In example aspects, the predetermined amount advanced can be less than or equal to the size of the tangle head in the material flow direction. Additionally, the tangle head and / or the conveying system can be moved in a direction that is not parallel to the material flow direction by a predetermined amount. In example aspects, the predetermined amount moved can be less than or equal to the size of the tangle head in the direction that is not parallel to the material flow direction. When the stack-up configuration is in the second stationary phase and when the tangle head comprises a tangle needle, the actuator moves the tangle head and / or the tangle needle in a direction that is perpendicular to the surface conveying plane such that the tangle needle engages with the stack-up configuration to form a second tangle region. When the tangle head is adapted to eject one or more jets of pressurized fluid, the actuator actuates the tangle head to eject the one or more jets of fluid to form the second tangle region. The second tangle region extends from the first tangle region to form a non-linear tangle seam.

[0033] As the stack-up configuration continues to advance through the first tangle station, additional tangle regions are formed that extend from the first tangle region and the second tangle region such that a distinct continuous tangle seam is formed in the material flow direction. By moving the tangle head and / or the conveying system in a direction that is not parallel to the material flow direction, the continuous tangle seam becomes non-linear in the material flow direction. In example aspects, the first tangle region and the second tangle region can partially overlap such that the overlapping region represents an area where the tangle needle and / or the jets of fluid engage with the stack-up configuration at least twice. In other example aspects, the first tangle region and the second tangle region can not overlap, but are positioned directly adjacent to one another to form a distinct continuous non-linear tangle seam. In other aspects, the first tangle region and the second tangle region can be spaced apart to form an intermittent non-linear tangle seam. Any and all aspects and any variations thereof are contemplated to be within the scope herein.

[0034] The stack-up configuration of the first nonwoven layer, the second layer, and the filler material can continue to advance through additional tangle stations where additional non-linear tangle seams are formed that can be separate and distinct from the non-linear tangle seam formed by the first tangle station. In other words, the additional non-linear tangle seams can be located at different positions along the direction that is not parallel to the material flow direction. Depending on the number of tangle stations in the tangle system, the resulting composite nonwoven fabric can have a short repeat of the visual arrangement of tangle seams, a long repeat of the visual arrangement of tangle seams, or no repeat of the visual arrangement of tangle seams.

[0035] The resulting composite nonwoven fabric can include a plurality of non-linear entangled seams extending in a material flow direction of the fabric. As described above, an entangled seam represents an area where fibers from the first nonwoven layer extend through the filler material and into the second layer. In example aspects, the fibers can extend through the second layer such that they extend outward from a second surface of the composite nonwoven fabric. The composite nonwoven fabric also includes a region where the first nonwoven layer, the second layer, and the filler material are substantially unentangled. The region where the first nonwoven layer, the second layer, and the filler material are substantially unentangled has a greater thickness than the entangled seams. When the composite nonwoven fabric is formed into a garment, the region where the first nonwoven layer, the second layer, and the filler material are substantially unentangled will correspond to a “baffle” present in traditional insulating garments and is configured to store and retain heat to provide warmth, while the entangled seams help to prevent the filler material from drifting or shifting during wear.

[0036] The systems, methods, fabrics, and garments described herein provide a number of advantages. For example, the composite nonwoven fabric is easy and fast to manufacture, requires a minimal amount of materials (e.g., no adhesive, no stitching) and equipment (e.g., no heat pressing), and does not require a post-processing step to deposit the filler material into the baffles as with traditional constructions. This, in turn, reduces the carbon footprint associated with the manufacturing process. Furthermore, the composite nonwoven fabric 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 by, for example, shredding, where the shredded material does not need to be subsequently sorted to remove different materials. Furthermore, because the non-linear seams are formed using, for example, recycled polyester fibers through an entangling process, the composite nonwoven fabric does not include adhesives and / or threads for stitching, which reduces the need to remove these portions of the fabric prior to recycling.

[0037] In example aspects, because the composite nonwoven fabric can be formed from materials of the same polymer class, and because the composite nonwoven fabric can not include different materials, such as threads, adhesives, etc., the resulting garment formed from the composite nonwoven fabric can be easily recycled by, for example, shredding. Furthermore, the shredded material from the garment can subsequently be formed into one or more of the first nonwoven layer, the second layer, and the filler material to create a sustainable life cycle for the garment. Consistent with this, scrap pieces generated during the process of manufacturing the garment from the composite nonwoven fabric can also be easily recycled by shredding, and the shredded material from the scrap can subsequently be formed into one or more of the first nonwoven layer, the second layer, and the filler material.

[0038] An additional advantage of using the entanglement system and manufacturing method described above is the ability to produce complex visual arrangements of entanglement seams. As used herein, the visual arrangement of entanglement seams is produced collectively by the different shapes associated with each of the entanglement seams, the spacing between the entanglement seams, the number of entanglement seams, the width of the entanglement seams, etc. To produce complex visual arrangements of entanglement seams, the entanglement heads can be positioned at different locations on the entanglement stations, the number and / or spacing of the entanglement heads at different entanglement stations can vary, the entanglement footprint produced by the entanglement heads can vary, and the movement of the entanglement heads and / or the transport system in different directions that are not parallel to the direction of material flow can vary. The complex visual arrangements of entanglement seams can include those arrangements in which the entanglement seams can cross over, intersect, or be closely positioned together. In addition to producing interesting aesthetics, the ability to produce areas in which the seams can cross over, intersect, or be closely positioned together allows for the creation of differential thicknesses of the composite nonwoven fabric. For example, areas in which the seams can cross over or intersect each other represent instances in which one or more entanglement heads from an entanglement station engaged the composite nonwoven fabric multiple times. As a result, these areas can have a reduced thickness compared to other entanglement seam areas, and compared to areas of the first nonwoven layer, the second layer, and the filler material that are substantially not entangled. When the composite nonwoven fabric is formed into a garment, these areas can be positioned proximate to body portions that require less thermal insulation (based on, for example, a heat map of the human body) because these areas generally have less loft and less thermal 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 a fabric with short repeats of the visual arrangement of entanglement seams, long repeats of the visual arrangement of entanglement seams, or no repeats of the visual arrangement of entanglement seams. This is accomplished by varying the number of entanglement stations arranged in series along the transport system. The ability to produce long repeats or no repeats using the entanglement system described herein addresses a potential shortcoming of traditional garment manufacturing. Traditional garment manufacturing using a fabric with short repeat visual arrangements of elements can generate material waste. This is because the pattern pieces used to form the garment are positioned in such a way as to produce garments with the same visual arrangement of elements at the same locations on the garment. This often results in a large amount of scrap material. The ability to produce the composite nonwoven fabric so that it has long repeats or no repeats of the visual arrangement of entanglement seams allows for the production of a batch of garments that have a common finished form, but have varying aesthetics due to the unique visual arrangement of entanglement seams, while having minimal material waste. When viewed as a batch or lot of garments, the consumer will perceive that the garments have a common origin and / or common manufacturer, but will be able to select garments from the batch that have a visual arrangement of entanglement seams that meets their preferences.

[0040] Another aspect related to the entanglement system and method of manufacture described herein is the ability to create non-linear entanglement seams on one or more individual nonwoven layers. The ability to create entanglement seams on individual layers also has advantages including ease of manufacture and rapid manufacture with minimal amounts of material (e.g., no adhesive, no stitching) and equipment (e.g., no heat pressing). This in turn reduces the carbon footprint associated with the manufacturing process. Further, 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 by, for example, shredding, where the shredded material does not need to be subsequently sorted to remove different materials. Further, because the non-linear seams are formed using, for example, recycled polyester fibers through the entanglement process, the nonwoven fabric does not include adhesives and / or threads for stitching, which reduces the need to remove these portions of the fabric prior to recycling.

[0041] The individual nonwoven layers can include a single layer of fibers (e.g., a lightly entangled web of fibers), multiple layers of fibers entangled with each other, a layer of fibers entangled with other materials such as an elastomeric layer, a fabric layer, etc. In example aspects, once the non-linear entanglement seams are created on the individual nonwoven layers, the nonwoven layers can be formed into, for example, a garment article. In other example aspects, different nonwoven layers having non-linear entanglement seams can be positioned adjacent to each other, with optional additional layers (nonwoven, knit, woven, film, etc.) therebetween, and the different layers can be secured together using entanglement, stitching, bonding, etc. Any and all aspects and any variations thereof are contemplated to be within the scope herein.

[0042] As used herein, the terms "garment" or "article of apparel" are intended to encompass articles worn by a wearer. As such, they can include upper body garments (e.g., shirts, T-shirts, pullovers, hooded shirts, jackets, coats, etc.) and lower body garments (e.g., pants, shorts, tights, leggings, jumpsuits, etc.). Garments can also include hats, gloves, sleeves (cuffs, calf sleeves), footwear articles (such as shoe uppers), etc. When referring to garments, the term "inner-facing surface" refers to a surface that is configured to face the surface of a wearer's body when the garment is worn as intended, and the term "outer-facing surface" refers to a surface that is configured to face away from the surface of a wearer's body and toward the external environment when the garment is worn as intended. The term "most inner-facing surface" refers to a surface that is closest to the surface of a wearer's body relative to other layers of the garment, and the term "most outer-facing surface" refers to a surface that is positioned furthest from the surface of a wearer's body relative to other layers of the garment. The term "pattern" or "pattern piece" used in relation to constructing garments refers to a pattern or pattern piece having an outer peripheral shape that corresponds to a structure on a finished garment (such as a sleeve, a front torso garment piece, a collar, etc.). The pattern or pattern piece is used when removing, extracting, or cutting a fabric portion having an outer peripheral shape that corresponds to the pattern or pattern piece, where the fabric portion is assembled to form a garment using, for example, a conventional cut-and-sew construction.

[0043] As used herein, the term "composite nonwoven fabric" encompasses any fabric that includes at least one nonwoven layer in combination with other layers, which can be substantially unattached to one another except for entanglement seams. Thus, it is contemplated herein that a composite nonwoven fabric is formed entirely of nonwoven layers. It is also contemplated herein that nonwoven layers can be combined with other constructions such as fibrous materials, films, woven layers, knit layers, braided layers, etc. It is contemplated herein that the term "composite nonwoven fabric" encompasses a stacked configuration of layers and one or more entanglement seams joining the stacked configuration of layers at seam areas.

[0044] The term "nonwoven layer" refers to a layer of fibers held together by mechanical and / or chemical interactions without being in the form of a knit, woven, braided construction, or other structured construction. In particular aspects, a nonwoven layer includes a collection of fibers that are mechanically or chemically manipulated to form a mat-like material. In other words, a nonwoven layer is made directly from fibers. The composite nonwoven fabrics described herein can include different layers formed into cohesive structures, where the different layers can have different or similar fiber or yarn compositions and / or different properties. In one example, the first nonwoven layer and optional second layer can include a spunbond layer. As used herein, a spunbond layer is formed by spinning continuous filaments of a molten polymeric material onto a moving belt and bonding the filaments together using, for example, a calendering process. Spunbond nonwovens generally have a soft hand and are strong and durable. They also generally have a smooth surface that is suitable for printing, including digital printing using digital print heads. In another example aspect, the first nonwoven layer and optional second layer can include a hydroentangled layer. As used herein, a hydroentangled layer includes a web of fibers that are entangled by means of, for example, hydroentanglement. Aspects herein contemplate that the filler material can include an entangled web of fibers that forms a sheet-like material. In example aspects, the fibers can be resin-bonded to form a cohesive structure. Other aspects herein contemplate that the filler material includes loose synthetic fibers / filaments, down, or a combination of any of the above materials.

[0045] The term "substantially unentangled" when referring to a composite nonwoven fabric refers to regions of the composite nonwoven fabric where the layers are not entangled with one another (such that the layers can move independently with respect to one another) or one or more of the layers are slightly entangled with one another. The term "entangled seam" when referring to a composite nonwoven fabric refers to regions of the composite nonwoven fabric where the layers of the composite nonwoven fabric have been mechanically entangled with one another by means of, for example, needlepunching or hydroentanglement. As such, the different layers of the composite nonwoven fabric in the seam region can include fibers that were originally 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 entangling process. When describing an entangled seam as "non-linear," aspects herein contemplate that the distance between the non-linear entangled seam and a linear edge of the composite nonwoven fabric can vary along the material flow direction of the nonwoven fabric. Aspects herein contemplate that the seam can include linear segments, curved segments, curvilinear segments, etc. that individually or in combination form a non-linear entangled seam. In example aspects, the distance between adjacent non-linear entangled seams can vary along the material flow direction of the composite nonwoven fabric.

[0046] The mechanical entanglement processes contemplated herein can include needle entanglement (commonly referred to as needling) using barbed or structured needles (e.g., forked needles) (referred to herein as entangling needles), or hydro-entanglement, which is referred to herein as hydro-needling. Needling generally uses entangling 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 (a z-direction orientation). With general reference to the needling process, the layers forming the composite nonwoven fabric can be stacked and the entangling needles associated with the entangling head are configured to pass through the stack in and out. Thus, when describing the entangling head engaging the nonwoven fabric, it is contemplated herein that the entangling needles associated with the entangling head are engaging the nonwoven fabric. A stripper plate can be used that strips the fibers from the needles after they have been moved in and out of the stack configuration. Each engagement of the entangling head with the stack configuration is referred to herein as a “pass.” Parameters associated with the entangling head can be adjusted to achieve desired properties (e.g., basis weight, thickness, etc.) of the resulting composite nonwoven fabric, as will be further explained below.

[0047] As the barbs move through the stack configuration from the first nonwoven layer, the barbs on the entangling needles “capture” fibers. Movement of the entangling 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 causes physical interaction with other fibers, thereby helping to “lock” the moved fibers in place through, for example, friction. It is also contemplated herein that the entangling needles can pass through the stack configuration from the second layer in a direction toward the first nonwoven layer. It is also contemplated herein that the entangling needles can pass through the stack configuration from the first nonwoven layer toward the second layer and from the second layer toward the first nonwoven layer. Hydro-entanglement works similarly to needling, except that instead of using entangling needles, the fibers are moved through the different layers by a pressurized fluid (e.g., water) jet. Parameters associated with the hydro-entanglement process, such as the pressure of the fluid jet, the number of fluid jets, the rate of delivery, etc., can be adjusted to achieve a desired degree of entanglement.

[0048] The term “entangling head” is used herein to describe a structure that includes one or more entangling needles in a defined arrangement and / or one or more orifices for ejecting a pressurized fluid jet in a defined arrangement. As the entangling needles and / or fluid jets engage the composite nonwoven fabric via the entangling head, they can form an entanglement footprint. As used herein, the term “entanglement footprint” is a structured arrangement of entanglement points resulting from the entangling head on the composite nonwoven fabric. For example, depending on the defined arrangement of the entangling needles and / or orifices in the entangling 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 a conveying system. The material flow direction can also be referred to as the machine direction. Thus, when describing a composite nonwoven fabric that includes a non-linear entanglement seam extending in the material flow direction, the non-linear entanglement seam extends in the direction of advancement of the composite nonwoven fabric along the conveying system of the entanglement system. As described herein, the entanglement head or fluid jet when hydroentanglement is used can be moved in a direction perpendicular to the plane of the conveying system. In other words, if the plane of the conveying system extends along the x, y plane, and the material flow direction extends in the positive x direction, the entanglement head or fluid jet can be moved in the positive or negative z direction. When describing a carriage or conveying system being moved in a direction that is not parallel to the material flow direction, it is contemplated herein that the carriage and / or conveying system is moved in the generally positive or negative y direction. This can also be referred to as the cross-machine direction.

[0050] The fibers contemplated herein for forming the nonwoven layer and other layers can be formed from a variety of different materials (e.g., cotton, nylon, etc.), including polyethylene terephthalate (PET), commonly referred to as polyester. The PET fibers can include virgin PET fibers (fibers that are not recycled) and recycled PET fibers. The recycled PET fibers include chipped PET fibers derived from chipped articles and re-extruded PET fibers (fibers re-extruded using recycled PET flake).

[0051] Various measurements are provided herein with respect to the composite nonwoven fabric. The thickness of the resulting composite nonwoven can be measured using a precision thickness gauge. For example, to measure thickness, the fabric can be placed on a flat anvil and the pressure foot is pressed onto the fabric from the upper surface under a standard fixed load. The dial indicator on the precision thickness gauge gives an indication of thickness in mm. The basis weight is measured using the ISO 3801 test standard and is in units of grams per square meter (gsm). The thermal resistance, which generally corresponds to the thermal insulation feature, is measured using the ISO 11092 test standard and is in units of RCT(M 2 All measurements provided herein are measured at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar), unless otherwise noted, with the nonwoven fabric in a resting (unstretched) state.

[0052] Figure 1A first surface 101 of the composite nonwoven fabric 100 is depicted, where the first surface 101 is formed from the first nonwoven layer 110. In example aspects, the first nonwoven layer 110 can comprise a spunbond or spunlace material, although other nonwoven constructions are also contemplated herein. Spunbond or spunlace materials generally have a soft hand and are durable, making them suitable for incorporation into an article of clothing. The first nonwoven layer 110 is formed from entangled fibers, as indicated by reference numeral 112. When the composite nonwoven fabric 100 is incorporated into an article of clothing, the first surface 101 can be positioned as an inward-facing surface or an innermost-facing surface of the article of clothing. Alternatively, the first surface 101 can be positioned as an outward-facing surface or an outermost-facing surface of the article of clothing.

[0053] The composite nonwoven fabric 100 also includes a second layer 114, which will be described in more detail with respect to Figure 2A and Figure 2B The filler material 116 can comprise a sheet of fibers with entangled fibers (which can optionally be resin-bonded to maintain a more cohesive structure), a lightly entangled web of fibers, a carded web, loose synthetic fibers, down, etc.

[0054] As Figure 1 shown, the composite nonwoven fabric 100 can include a plurality of non-linear entangled seams 118 extending in the material flow direction 105 of the composite nonwoven fabric 100. The entangled seams 118 represent areas where fibers from different layers are entangled with one another. In one example aspect, the entangled seams 118 represent areas where fibers from the first nonwoven layer 110 extend through the filler material 116 and into the second layer 114. Areas 122 of the composite nonwoven fabric 100 located between the entangled seams 118 represent areas where the first nonwoven layer 110, the second layer 114, and the filler material 116 are substantially unentangled, such that the different layers are not fixed or adhered to one another or are lightly fixed or adhered to one another at the areas 122. As shown, the areas 122 have a greater loft or a greater thickness than the entangled seams 118, and can help to store and retain heat when the composite nonwoven fabric 100 is incorporated into an article of clothing. In turn, the entangled seams 118 can help to prevent migration or drift of the filler material 116 when the article of clothing incorporating the composite nonwoven fabric 100 is worn.

[0055] With respect to 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, a first distance 124 between the entangled seam 118a and the first edge 120 can be less than a second distance 126 between the entangled seam 118a and the first edge 120. This also applies to Figure 1Another entangled seam 118 is shown. As depicted, the entangled seam 118 can include linear segments, curvilinear segments, and combinations thereof extending from one another. The depiction of the shape of the individual entangled seams 118, the number of entangled seams 118, the spacing between adjacent entangled seams 118, and the overall visual arrangement of the entangled seams 118 is illustrative, and it is contemplated herein that the entangled seams 118 can include other non-linear shapes, different numbers of entangled seams 118, different spacing, and different overall visual arrangements of the entangled seams 118.

[0056] Figure 2A A second, opposing surface 201 of the composite nonwoven fabric 100 is illustrated, wherein the second surface 201 is formed by the second layer 114. In this example, the second layer 114 is formed by a nonwoven material such as a spunbond or hydroentangled material. The entangled fibers forming the second layer 114 are indicated by reference numeral 212. Non-linear entangled seams 118 extend through the composite nonwoven fabric 100 such that they are present on the second surface 201 of the fabric 100. Figure 2A In one example aspect, the second layer 114 can include a woven layer as indicated by the example interlaced warp and weft yarns 210. In this example, the second layer 114 can be positioned to be the outer-facing surface or the outermost-facing surface of the garment when the composite nonwoven fabric 100 is incorporated into the garment. Woven materials generally have high abrasion resistance and are suitable for forming the outer-facing surface of a garment due to the tight woven construction, and thus can be used as an effective wind-resistant layer. In example aspects, the woven material can be treated with a durable water repellent to impart water-resistant properties to the composite nonwoven fabric 100. The non-linear entangled seams 118 are shown extending through the composite nonwoven fabric 100 such that they are present on the second surface 201 of the fabric 100.

[0057] Figure 2B A second example is illustrated in which the second layer 114 is formed by a nonwoven material such as a spunbond or hydroentangled material. The entangled fibers forming the second layer 114 are indicated by reference numeral 212. Non-linear entangled seams 118 extend through the composite nonwoven fabric 100 such that they are present on the second surface 201 of the fabric 100. Figure 2B

[0058] Figure 3 A cross-section of the composite nonwoven fabric 100 taken at cut line 3-3 is depicted. Figure 1 The first nonwoven layer 110, the second layer 114, and the filler material 116 are indicated, wherein the filler material 116 is positioned 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 filler material 116 are substantially unentangled such that the first nonwoven layer 110, the second layer 114, and the filler 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 filler material 116 and the second layer 114 at the entanglement seam 118 such that the entanglement seam 118 secures the different layers together at the seam region. In one example aspect, the fibers 112 can 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 shown. In this example, the fibers 112 can remain unmodified such that the second surface 201 presents a fuzzy surface at the entanglement seam 118. In another example, the fibers 112 can be removed, compressed, or melted. For example, a calendering process can be used to compress the fibers 112 such that they do not extend from the second surface 201. In another example, the filler material 116 can include low melt fibers, and any low melt fibers extending from the second surface 201 can be removed by the application of heat. Additionally, if desired, a skiving process can be used to remove the fibers 112. In another example aspect, the fibers 112 can extend into the second layer 114 but not through the second layer 114 such that the fibers 112 are generally not present on the second surface 201 of the composite nonwoven fabric 100.

[0060] The thickness 312 of the entanglement seam is less than the thickness 310 at the 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” refers to within ±10% of the indicated value. In example aspects, 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. As such, in example aspects, the thickness 312 of the entanglement seam 118 can be about 5% to about 30% of the thickness 310 of the region 122.

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

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

[0063] Overlapping region 412 represents an area where the entangling head engages the composite nonwoven fabric more than once. As such, the number and / or density of entangling points 414 within overlapping region 412 is greater than the number and / or density of entangling points 414 at the remainder of entangling region 410. In other words, the stitch density of overlapping region 412 is greater than the stitch density at the remainder of entangling region 410. As a result, overlapping region 412 can have a reduced thickness compared to the remainder of entangling region 410.

[0064] Figure 4B A second example manner in which the entangled seam 118 can be formed is illustrated. In this aspect, the entangling regions 410 extend from one another in a non-linear manner to form a distinct continuous entangled seam. However, the entangling regions 410 do not overlap one another as Figure 4A partially as illustrated. Rather, the entangling regions 410 can be positioned directly adjacent one another such that the entangling points 414 of a first entangling region 410 can share a common boundary with the entangling points 414 of an adjacent second entangling region 410. With respect to the non-linear entangled seam 118, the entangled seam 118 can include Figure 4A the configuration illustrated, Figure 4B the configuration illustrated, or Figure 4A and Figure 4B a combination of the configurations illustrated. It is also contemplated herein that the entangling regions 410 can be spaced apart from one another to form an interrupted non-linear entangled seam.

[0065] Figure 5 is a schematic depiction of a side view of an example entangling system 500. The depiction of the different components of the entangling system 500 is merely illustrative and does not represent the actual configuration or structure of the components. The entangling system 500 includes a conveyance system 512 having a surface 514 adapted to advance a stacked configuration of, for example, the first nonwoven layer 110, the second layer 114, and the filler material 116 in a material flow direction indicated by arrow 516. As with the 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 entangling station 518 also includes an actuator 528 coupled to the carriage 524. In one example aspect and as shown, the actuator 528 is adapted to move in a direction perpendicular to a plane of conveyance of the surface 514 of the conveyance system 512, as indicated by arrow 530. In other example aspects, the actuator can remain stationary and the actuator can actuate the entangling head and / or the entangling needles to move in a direction perpendicular to a plane of conveyance of the surface 514 of the conveyance system 512. In other example aspects and as described with respect to Figure 5 Figure 6B the actuator 528 can remain stationary and the actuator can actuate the entangling head to eject a fluid jet. The entangling head 532 is coupled to the actuator 528 and can be indirectly coupled to the carriage 524 through the actuator 528. In the example shown, the entangling head 532 can include one or more entangling needles 534 that extend toward the surface 514 of the conveyance system 512. Although only one entangling needle 534 is depicted, it is contemplated herein that the entangling head 532 can include multiple entangling needles, as further described with respect to Figure 5 Figure 9A and Figure 9B

[0069] Figure 6A A front view of the entangling station 518 is depicted, which depicts the chassis 526, the carriage 524, the actuator 528, the entangling head 532, and the entangling needles 534. Arrow 610 represents a first direction of movement of the carriage 524 and / or the conveyance system 512 in a direction that is not parallel to the material flow direction 516, and arrow 611 represents an opposite second direction of movement of the carriage 524 and / or the conveyance system 512 in a direction that is not parallel to the material flow direction 516. In example aspects, the first direction 610 and the second direction 611 are perpendicular to the material flow direction 516.

[0070] The front view of the entangling station 518 depicts three entangling heads 532a, 532b, and 532c that are generally evenly spaced apart, with each of the three entangling heads 532a, 532b, and 532c being adapted to form a respective non-linear entangling seam. This is merely illustrative, and it is contemplated herein that there can be more than three entangling heads 532a, 532b, and 532c or less than three entangling heads 532a, 532b, and 532c. Likewise, the spacing between the entangling heads 532a, 532b, and 532c can vary, such that the spacing between a first and a second of the entangling heads 532a, 532b, and 532c can be greater than the spacing between a second and a third of the entangling heads 532a, 532b, and 532c. As further described with respect to Figure 9A and Figure 9B ​​​As explained, the entangling heads 532a, 532b, and 532c can have different sizes, different structured arrangements of entangling needles and / or orifices, etc.

[0071] Figure 6B A front view of an alternative entangling station 612 is depicted, which can be part of an entangling system such as the entangling system 500, which is adapted to hydro-entangle the plies to form the composite structure, rather than needle-punching the plies to form the composite structure. As such, the entangling station 612 can represent a plurality of hydro-entangling stations as part of the entangling system 500.

[0072] The entangling station 612 further includes a chassis 614 to which a carriage 616 is slidably coupled, an actuator 618 coupled to the carriage 616, and an entangling head 620 coupled to the actuator 618. The carriage 616 and / or the conveyor system 512 are adapted to move in a first direction (as indicated by arrow 622) that is not parallel to the material flow direction 516 and in an opposite second direction 623 that is not parallel to the material flow direction 516. In example aspects, the directions 622 and 623 are perpendicular to the material flow direction 516. In example aspects, the actuator 618 can not move in the direction 530 that is perpendicular to the plane of the conveyor surface 514. Rather, in example aspects, the actuator 618 is adapted to actuate the entangling head 620 to emit one or more jets 624 of pressurized fluid that extend toward the surface 514 of the conveyor system 512. In relation to this aspect, it is contemplated herein that the conveyor system 512 can be advanced intermittently as described above, with the fluid jets 624 being emitted when the conveyor system 512 is in a stationary phase. Alternatively, the conveyor system 512 can be continuously advanced, and the fluid jets 624 can be continuously emitted from the entangling head 620. Similar to the entangling station 518, the number of entangling heads 620 can be different than shown, the spacing between the entangling heads 620 can be different than shown, and the entangling heads 620 can have different sizes, different structured arrangements of orifices, etc.

[0073] Figure 7A second entangling station 520 is depicted, where the second entangling station 520 includes the same components as the entangling station 518 (e.g., the chassis 526, the carriage 524, the actuator 528, and the entangling heads 532). Two entangling heads 532d and 532e are depicted for the second entangling station 520. In example aspects, the entangling heads 532d and 532e can be positioned such that they are not aligned with the entangling heads 532a, 532b, and 532c in the material flow direction 516. As a result, the entangling heads 532d and 532e are adapted to engage the composite nonwoven fabric at different locations in a direction that is not parallel to the material flow direction 516 as compared to the entangling heads 532a, 532b, and 532c. In other words, the entangling heads 532d and 532e are adapted to form a different and separate set of non-linear entangling seams than the non-linear entangling seams formed by the entangling heads 532a, 532b, and 532c. For example, the entangling head 532a can be offset from a first edge 660 of the surface 514 of the conveyance system 512 a first distance 613 in a direction perpendicular to the material flow direction 516, and the entangling head 532d can be offset from the first edge 660 of the surface 514 of the conveyance system 512 a second distance 615 in a direction perpendicular to the material flow direction 516, where the second distance 615 is greater than the first distance 613. As such, the spacing arrangement between the entangling heads 532d and 532e is different than the spacing arrangement between the entangling heads 532a, 532b, and 532c. As shown, the entangling station 520 includes a different number of entangling heads 532 than the number of entangling heads 532 at the entangling station 518. It is contemplated herein that the entangling station 520 can include fewer entangling heads than shown or more entangling heads than shown. The dimensions of the entangling heads 532e and 532d can be the same or different than the dimensions of the entangling heads 532a, 532b, and 532c. Additionally, the entangling footprint created by the entangling heads 532e and 532d can be the same or different than the entangling footprint created by the entangling heads 532a, 532b, and 532c.

[0074] Figure 8A third entangling station 522 is depicted, where the third entangling station 522 includes the same components as the entangling stations 518 and 522. Two entangling heads 532f and 532g are depicted for the third entangling station 522. In example aspects, the entangling heads 532f and 532g can be positioned such that they are not aligned with the entangling heads 532a, 532b, 532c, 532d, and 532e in the material flow direction 516. Accordingly, the entangling heads 532f and 532g are adapted to form another set of non-linear entangling seams that are different and separate from the non-linear entangling seams formed by the entangling heads 532a, 532b, 532c, 532d, and 532e. In other words, the distance of the entangling heads 532f and 532g from the first edge 660 of the surface 514 of the conveyance system 512 can be different from the distance of the entangling heads 532a, 532b, 532c, 532d, and 532e. The entangling station 522 can include a different number of entangling heads 532 than shown. The entangling heads 532f and 532g can also be spaced differently than shown. The dimensions of the entangling heads 532f and 532g can be the same or different from the dimensions of the entangling heads 532a, 532b, 532c, 532d, and 532e. Additionally, the entangling footprint created by the entangling heads 532f and 532g can be the same or different from the entangling footprint created by the entangling heads 532a, 532b, 532c, 532d, and 532e.

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

[0076] Figure 5 depicted and described above with respect to Figures 6A-8The further described illustrative entangling system 500 can produce a complex visual arrangement of non-linear entangling seams extending in the material flow direction 516. The components and movements of the entangling system 500 can be adjusted to produce non-linear entangling seams that are closely spaced together or further spaced apart. Additionally, the system 500 can produce non-linear entangling seams that cross or intersect each other one or more times along the material flow direction of a particular entangling seam. As with the entangling system 400, the entangling system 500 can produce a composite nonwoven fabric having a first direction 610 and a second direction 611 that are not parallel or perpendicular to the material flow direction 516 (i.e., along a cross-section of the resulting composite nonwoven fabric). Figures 14-16 As further described, this produces a differential thickness of the resulting composite nonwoven fabric in the first direction 610 and the second direction 611 that are not parallel or perpendicular to the material flow direction 516 (i.e., along a cross-section of the resulting composite nonwoven fabric).

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

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

[0079] In example aspects, the advancement distance of the transport system 512 in the material flow direction 516 during the movement phase of the entangling system 500 can be less than or equal to the dimensions 910 and 914 of the respective entangling heads 920 and 922. This ensures that the entangled regions produced by the entangling heads 920 and 922 are directly adjacent and / or overlapping with each other to form a distinct continuous non-linear entanglement seam. Further, the movement of the carriages 524 and / or the transport system 512 in the first and second directions 610 and 611 that are not parallel or perpendicular to the material flow direction 516 can be less than or equal to the dimensions 912 and 916 of the respective entangling heads 920 and 922. This further ensures that the entangled regions produced by the entangling heads 920 and 922 are directly adjacent and / or overlapping with each other to form a distinct continuous non-linear entanglement seam. The depiction of the shapes of the entangling heads 920 and 922 is illustrative, and it is contemplated herein that the entangling heads can have other shapes, such as oval, square, triangular, etc.

[0080] Figure 10A and Figure 10B schematically depict processes for manufacturing a composite nonwoven fabric having a non-linear entanglement seam, such as the composite nonwoven fabric 100. Figure 10A depicts a process using entangling needles and that can be performed at any of the entangling stations 518, 520, or 522. Figure 10B depicts a process using hydroentanglement and that can be performed, for example, at the entangling station 612. Regarding Figure 10A and Figure 10B Both provide a coordinate system indicating the x-direction, y-direction, and z-direction.

[0081] Referring to Figure 10AAt step 1010, the stack configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116 is positioned on the surface 514 of the conveyance 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 conveyance system 512 and the stack configuration are in a first stationary phase or position such that the conveyance 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 the direction 530 perpendicular to the conveyance plane of the surface 514 (i.e., the negative z-direction) such that the entangling head 532 is lowered, causing the entangling needles 534 and, indirectly, the entangling head 532 to engage the stack configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116. Alternatively, the actuator 528 can actuate the entangling head 532 and / or the entangling needles 534 such that the entangling needles 534 are moved downward to engage the stack 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 entangled region 1012, as shown at step 1014. The first entangled region 1012 can have an entangled footprint that corresponds to the shape of the structured arrangement of entangling needles 534 on the entangling head 532.

[0082] At step 1016, the entangling needles 534 disengage from the stack configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116, and the conveyance system 512 advances the stack configuration in the material flow direction 516 by a distance 1018. In example aspects, the distance 1018 can be equal to or less than the dimension of the entangling head 532 in the material flow direction 516. At step 1016, the carriage 524 is moved in the first direction 610 (i.e., the negative y-direction) that is not parallel to the material flow direction 516 by a first distance, where the first distance can be equal to or less than the dimension of the entangling head 532 in the first direction 610 that is not parallel to the material flow direction 516. The movement of the carriage 524 can occur simultaneously with the movement of the conveyance system 512 in the material flow direction 516, or it can occur after the movement of the conveyance system 512 in the material flow direction 516 (i.e., when the conveyance system 512 is in a second stationary phase). Alternatively or additionally, the conveyance system 512 can be moved in the first direction 610 that is not parallel to the material flow direction 516 by the first distance.

[0083] At step 1022, the transport system 512 and the stack configuration are in a second stationary phase or position such that the transport system 512 is not advancing in the material flow direction 516. The second stationary phase or position is advanced from the first stationary phase or position in the material flow direction 516. During the second stationary phase, the actuator 528 again moves in the direction 530 perpendicular to the transport plane of the surface 514 such that the entangling head 532 is lowered, resulting in the entangling needles 534 engaging the stack 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 transport system 512, the engagement of the entangling needles 534 with the stack configuration occurs at a location offset from the first entangling region 1012 in the first direction 610 that is not parallel to the material flow direction 516. The second engagement again drives fibers from the first nonwoven layer 110 through the filler material 116 and into (or through) the second layer 114, resulting in a second entangling region 1026, as shown in step 1024, to create a distinct continuous non-linear entanglement seam 1028 in the composite nonwoven fabric 100. The second entangling region 1026 can have an entangling footprint that corresponds to the shape of the structured arrangement of entangling needles 534 on the entangling head 532. As shown in 1024, the second entangling region 1026 partially overlaps the first entangling region 1012. This is illustrative, and it is contemplated herein that the second entangling region 1026 can not partially overlap the first entangling region 1012.

[0084] Figure 10A The depicted process can include a plurality of stationary phases or positions advanced from one another in the material flow direction during which the entangling needles 534 engage the stack configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116 to form entangling regions extending from one another. Likewise, Figure 10A The depicted process can include a plurality of moving phases during which the transport system 512 advances the stack configuration in the material flow direction 516 a distance that is less than or equal to the size of the entangling head 532 in the material flow direction 516 such that the resulting entangling regions partially overlap one another or directly extend from one another. Further, the carriage 524 and / or the transport system 512 can perform a plurality of movements in the first direction 610 and the opposite second direction 611 (i.e., the positive y-direction) that are not parallel to the material flow direction 516. The distance of the carriage 524 and / or the transport system 512 in the first direction 610 and the opposite second direction 611 can be less than or equal to the size of the entangling head 532 in the first direction 610 or the opposite second direction 611 such that the resulting entangling regions partially overlap one another or directly extend from one another.

[0085] Figure 10B The schematically depicted process is similar to Figure 10AThe process shown, but utilizing hydro-entanglement to create non-linear entanglement seams. At step 1050, the stack configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116 is positioned on the surface 514 of the conveyance 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 conveyance system 512 and the stack configuration are in a first stationary phase or position such that the conveyance system 512 is not advancing in the material flow direction 516. During the first stationary phase, the actuator 618 actuates the entanglement head 620 to eject one or more jets of pressurized fluid 1052 in a direction toward the surface 514 of the conveyance system 512 to form a first entanglement region 1054 as shown in step 1056. In example aspects, the actuator 618 can not move in a direction perpendicular to the plane of conveyance of the surface 514 during the first stationary phase, but it is contemplated herein that the actuator 618 can move in a direction perpendicular to the plane of conveyance of the surface 514 in order to position the fluid jets 1052 closer to the first nonwoven layer 110. In another example aspect, the conveyance system 512 can continuously advance in the material flow direction 516 while the actuator 618 continuously actuates the entanglement head 620 to eject one or more jets of pressurized fluid 1052. The fluid jets 1052 drive fibers from the first nonwoven layer 110 through the filler material 116 and into (or through) the second layer 114, thereby creating the first entanglement region 1054. The first entanglement region 1054 can have a shape that corresponds to the structured arrangement of the orifices on the entanglement head 620.

[0086] At step 1058, the conveyance system 512 advances the stack configuration in the material flow direction 516 by a distance 1060. In example aspects, the distance 1060 can be equal to or less than the size of the entanglement head 620 in the material flow direction 516. At step 1058, the carriage 616 and / or the conveyance system 512 moves by a first distance in a first direction 622 that is not parallel to the material flow direction 516, where the first distance can be equal to or less than the size of the entanglement head 620 in a direction that is not parallel to the material flow direction 516. The movement of the carriage 616 and / or the conveyance system 512 can occur simultaneously with the movement of the conveyance system 512 in the material flow direction 516, or it can occur after the movement of the conveyance system 512 in the material flow direction 516 (i.e., when the conveyance system 512 is in a second stationary phase or position that is advanced in the material flow direction from the first stationary phase or position).

[0087] At step 1064, the transport system 512 and the stack configuration are in a second stationary phase or position, and the actuator 618 again actuates the entangling head 620 to eject the fluid jet 1052 such that the fluid jet 1052 engages the stack 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 stack configuration occurs at a location offset from the first entangling 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 entangling region 1068, as shown in step 1066, to create a distinct continuous non-linear entangling seam 1070 in the composite nonwoven fabric 100 that extends in the material flow direction 516. As shown in step 1066, the second entangling region 1068 partially overlaps the first entangling region 1054. This is illustrative, and it is contemplated herein that the second entangling region 1068 can not partially overlap the first entangling region 1054.

[0088] Figure 10B The depicted process can include a plurality of stationary phases or positions during which the fluid jet 1052 engages the stack configuration of the first nonwoven layer 110, the second layer 114, and the filler material 116 to form entangling regions that extend from one another. Likewise, Figure 10B The depicted process can perform a plurality of movement phases during which the transport system 512 advances the fabric in the material flow direction 516 a distance that is less than or equal to the size of the entangling head 620 in the material flow direction 516 such that the resulting entangling regions partially overlap one another or directly extend from one another. Further, the carriage 616 and / or the transport system 512 can perform a plurality of movements in a first direction 622 that is not parallel to the material flow direction 516 and an opposite second direction 623. The distance that the carriage 616 and / or the transport system 512 moves in the first direction 610 and the opposite second direction 623 can be less than or equal to the size of the entangling head 620 in the first direction 610 or the opposite second direction 623 such that the resulting entangling regions partially overlap one another or directly extend from one another.

[0089] As previously described, the entanglement systems described herein, such as entanglement system 500, can produce a composite nonwoven fabric, such as composite nonwoven fabric 100, that includes a long repeat of the visual arrangement of non-linear entanglement seams or even a non-repeat of the visual arrangement of non-linear entanglement seams. The resulting composite nonwoven fabric can be used to produce a batch of garments that have a common finished form, but that have varying aesthetics due to the different visual arrangements of non-linear entanglement seams on the resulting garments. The batch of garments can share common features, such as a common finished form, color, etc., such that a consumer can easily identify the batch of garments as being from a common source (e.g., a common manufacturer). However, the consumer will be able to select a garment from the batch of garments that has the desired visual arrangement of entanglement seams. Moreover, because there is a long repeat or even a non-repeat of the visual arrangement of non-linear entanglement seams, there can be less material waste when forming the batch of garments because the pattern pieces do not have to be positioned in such a way as to ensure that each garment includes the same visual arrangement of entanglement seams at the same location on the garment.

[0090] Figure 11 A method of manufacturing a batch of garments having a common finished form, but having different visual arrangements of non-linear entanglement seams is schematically illustrated. At step 1110, a composite nonwoven fabric 100 is provided or obtained. In this example, the composite nonwoven fabric 100 includes a first non-linear entanglement seam 1112 and a second non-linear entanglement seam 1114, both of which extend in a material flow direction 516 of the composite nonwoven fabric 100. In example aspects, a distance between the first non-linear entanglement seam 1112 and the second non-linear 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 non-linear entanglement seam 1112 can be spaced apart from the second non-linear entanglement seam by a first distance 1111. At a second location 1115 on the composite nonwoven fabric 100, the first non-linear entanglement seam 1112 can be spaced apart from the second non-linear entanglement seam 1114 by a second distance 1117, where the second distance 1117 is greater than the first distance 1111.

[0091] At step 1110, a first instance of a pattern 1116 is removed, cut away, and / or cut out from the composite nonwoven fabric 100, where the pattern 1116 corresponds to a left sleeve of an upper body garment. In other words, at step 1110, a first portion 1120 is removed from the composite nonwoven fabric 100, where the first portion 1120 has a shape that corresponds to the pattern 1116. The pattern 1116 is merely illustrative, and it is contemplated herein that the pattern 1116 can correspond to any portion of an upper body garment, a lower body garment, a footwear upper, a headwear article, etc.

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

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

[0094] Figure 11 The depicted process can be repeated any number of times along the material flow direction 516 of the composite nonwoven fabric 100 to form a batch of garments having the first nonlinear entangled seam 1112 and the second nonlinear entangled seam 1114 located at different locations on the pattern 1116 and presenting different visible arrangements of the first nonlinear entangled seam 1112 and the second nonlinear entangled seam 1114. Although the depicted process is described as being repeated any number of times along the material flow direction 516 of the composite nonwoven fabric 100, it is contemplated that the depicted process can be repeated any number of times along the material flow direction 516 of the composite nonwoven fabric 100 and / or along the cross direction 518 of the composite nonwoven fabric 100.​​Figure 11 Only pattern 1116 is depicted as being applied to composite nonwoven fabric 100, but it is contemplated herein that additional pattern pieces can be applied to composite nonwoven fabric 100 such that the resulting garment can be formed from the additional pattern pieces applied to composite nonwoven fabric 100. In this regard, the visual arrangement of entangled seams at different areas of the garment can differ from one another to produce varying overall aesthetics. Similar to Figure 11 the process shown can be used to form, for example, a batch of lower body garments that have a common finished form but have different visual arrangements of non-linear entangled seams.

[0095] In example aspects, the process depicted by Figure 11 the scrap produced by the process depicted can be shredded and subsequently formed into, for example, one or more of first nonwoven layer 110, second layer 114, or filler material 116. This is possible because the materials forming composite nonwoven fabric 100 are in example aspects the same polymer class (e.g., recycled polyester). Moreover, because composite nonwoven fabric 100 is formed without the use of different materials such as threads, adhesives, etc., there is no need to remove portions of the scrap prior to shredding.

[0096] Figure 12 and Figure 13 further illustrate garments produced by the process depicted by Figure 11 . Figure 12 depicted is a front view of a batch of upper body garments in the form of sleeveless tops, including a first upper body garment 1210 and a second upper body garment 1212 that have a common finished form. Although shown as sleeveless tops, it is contemplated herein that the upper body garments can include other forms such as tank tops, pullovers, hoodies, jackets, etc. First upper body garment 1210 includes a neck opening 1214, a waist opening 1216, a first sleeve opening 1218, and a second sleeve opening 1220. Similarly, second upper body garment 1212 includes a neck opening 1222, a waist opening 1224, a first sleeve opening 1226, and a second sleeve opening 1228. Moreover, although the non-linear entangled seams are shown as extending in a horizontal orientation (in a direction extending, for example, from first sleeve opening 1218 / 1226 to second sleeve opening 1220 / 1228), it is contemplated herein that the non-linear entangled seams can extend in a vertical direction (in a direction extending, for example, from neck opening 1214 / 1222 to waist opening 1216 / 1224).

[0097] As depicted, at least the front panels 1230 of the first upper body garment 1210 and the front panels 1232 of the second upper body garment 1212 can be formed from the same pattern piece applied to the composite nonwoven fabric 100. The front panels 1230 of the first upper body garment 1210 include a first non-linear twist seam 1234 and a second non-linear twist seam 1236 at a first location 1238 on the first upper body garment 1210. In example aspects, the first location 1238 can correspond to a first distance 1237 measured at a front vertical centerline of the first upper body garment 1210 relative to a waist opening 1216 of the first upper body garment 1210 for each of the first non-linear twist seam 1234 and the second non-linear twist seam 1236. The first non-linear twist seam 1234 and the second non-linear twist seam 1236 exhibit a first visual arrangement of twist seams on the first upper body garment 1210.

[0098] The front panels 1232 of the second upper body garment 1212 also include the first non-linear twist seam 1234 and the second non-linear twist seam 1236 at a second location 1244 on the second upper body garment 1212, where the second location 1244 is different than the first location 1238. For example, the second location 1244 can correspond to a second distance 1245 measured at a front vertical centerline of the second upper body garment 1212 relative to a waist opening 1224 of the second upper body garment 1212 for each of the first non-linear twist seam 1234 and the second non-linear twist seam 1236, where the second distance 1245 for each of the first non-linear twist seam 1234 and the second non-linear twist seam 1236 is different than the first distance 1237. The first non-linear twist seam 1234 and the second non-linear twist seam 1236 exhibit a second visual arrangement of twist seams on the second upper body garment 1212.

[0099] Although not shown, additional upper body garments can be included in the batch, where the additional upper body garments have a common finished form with the first upper body garment 1210 and the second upper body garment 1212. The additional upper body garments in the batch can exhibit different visual arrangements of the first non-linear twist seam 1234 and the second non-linear twist seam 1236. In other words, the first non-linear twist seam 1234 and the second non-linear twist seam 1236 can be located at different locations on the additional garments relative to the pattern piece described above for forming the front panels of the additional upper body garments.

[0100] Figure 13A front view of a batch of lower body garments in the form of pants is illustrated, including a first lower body garment 1310 and a second lower body garment 1312 having a common finished form. Although shown as pants, it is contemplated herein that the lower body garments can include other forms, such as trousers, slacks, and the like. The first lower body garment 1310 includes a waist opening 1314, a first leg opening 1316a, and a second leg opening 1316b. Similarly, the second lower body garment 1312 includes a waist opening 1322, a first leg opening 1324a, and a second leg opening 1324b. Further, although the non-linear twist seams are shown as extending in a horizontal orientation, it is contemplated herein that the non-linear twist seams can extend in a vertical direction.

[0101] As depicted, at least a front panel 1330 of the first lower body garment 1310 and a front panel 1332 of the second lower body 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 body garment 1310 includes a first non-linear twist seam 1334 and a second non-linear twist seam 1336 at a first location 1338 on the first lower body garment 1310. In example aspects, the first location 1338 can correspond to a first distance 1337 measured at a front vertical centerline of the first lower body garment 1310 with respect to the waist opening 1314 of the first lower body garment 1310 for each of the first non-linear twist seam 1334 and the second non-linear twist seam 1336. The first non-linear twist seam 1334 and the second non-linear twist seam 1336 present a first visual arrangement of twist seams on the first lower body garment 1310.

[0102] The front panel 1332 of the second lower body garment 1312 also includes the first non-linear twist seam 1334 and the second non-linear twist seam 1336 at a second location 1344 on the second lower body garment 1312, where the second location 1344 is different than the first location 1338. For example, the second location 1344 can correspond to a second distance 1345 measured at a front vertical centerline of the second lower body garment 1312 with respect to the waist opening 1322 of the second lower body garment 1312 for each of the first non-linear twist seam 1334 and the second non-linear twist seam 1336, where the second distance 1345 for each of the first non-linear twist seam 1334 and the second non-linear twist seam 1336 is different than the first distance 1337. The first non-linear twist seam 1334 and the second non-linear twist seam 1336 present a second visual arrangement of twist seams on the second lower body garment 1312.

[0103] Although not shown, additional lower body garments can be included in the batch, where the additional lower body garments have a common finished form with the first lower body garment 1310 and the second lower body garment 1312. The additional lower body garments in the batch can exhibit different visual arrangements of the first non-linear entangled seam 1334 and the second non-linear entangled seam 1336. In other words, the first non-linear entangled seam 1334 and the second non-linear entangled seam 1336 can be located at different positions on the additional garments relative to the above-described pattern pieces used to form the front panels of the additional lower body garments.

[0104] Although the garments depicted in the garment batch of Figure 12 and Figure 13 include different visual arrangements of entangled seams, it is contemplated herein that the garments in a garment batch produced by the systems and methods described herein can include the same visual arrangement of entangled seams. For example, the entangling system 500 can be configured to generate a short repeat of the visual arrangement of entangled seams such that the composite nonwoven fabric can include multiple repeats of the visual arrangement of entangled seams along the material flow direction 516. In this regard, a pattern piece can be applied to the composite nonwoven fabric to form garments having the same visual arrangement of entangled seams.

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

[0106] This is shown in Figure 15 , Figure 15is a cross-section of the composite nonwoven fabric 1400 taken at the cut line 15-15. The region 1418 has a thickness 1514 measured from a first surface 1513 formed by the first nonwoven layer 110 to an opposing second surface 1516 formed by the second layer 114. The intersection 1412 has a thickness 1510 measured from the first surface 1513 to the opposing second surface 1516, and the nonlinear entangled seams 1410c and 1410d have a thickness 1512 measured from the first surface 1513 to the opposing second surface 1516. In example aspects, the thickness 1514 is greater than the thickness 1512, which is greater than the thickness 1510. The ability to create varying thicknesses of the composite nonwoven fabric 1400 in a direction that is not parallel to the material flow direction can be used to design high and low thermal insulation zones needed on an article incorporating the composite nonwoven fabric 1400. The thermal insulation zones can have increased thickness (e.g., greater loft) and can correspond to the regions 1418. The low thermal insulation zones can correspond to regions that include multiple intersections, such as the intersections 1412, 1414, and 1416.

[0107] Figure 16 A back view of an example upper body article 1600 having a torso portion 1610 is depicted, where the torso portion 1610 includes a neck opening 1612 and a waist opening 1614. The upper body article 1600 also includes an optional first sleeve 1616 and an optional second sleeve 1618. Although shown as a shirt with long sleeves, it is contemplated herein that the upper body article 1600 can be in the form of a vest, a pullover, a hooded shirt, a jacket, or the like.

[0108] The upper body garment includes a low insulation zone 1620 at a central back region of the torso portion 1610 and high insulation zones 1622 on either side of the low insulation zone 1620. The locations of the low insulation zone 1620 and the high insulation zones 1622 can be based on, for example, heat maps of the human body. For example, these maps can indicate that the central back torso of a person generates a large amount of heat and, as such, can require less insulation than other regions of the torso. The low insulation zone 1620 includes a plurality of non-linear entangled seams 1624a, 1624b, 1624c, and 1624d that extend 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 a plurality of intersections as they extend from the neck opening 1612 to the waist opening 1614 of the upper body garment 1600. This results in an overall increased stitch density and an overall decreased thickness in the low insulation zone 1620 as compared to other portions of the upper body garment 1600. In contrast, the high insulation zones 1622 include non-linear entangled seams 1626a, 1626b, 1626c, and 1626d. The non-linear entangled seams 1626a, 1626b, 1626c, and 1626d are generally spaced further apart as compared to the non-linear entangled seams 1624a, 1624b, 1624c, and 1624d, and the non-linear entangled seams 1626a, 1626b, 1626c, and 1626d do not intersect one another. As such, the high insulation zones 1622 have an overall decreased stitch density and an overall increased thickness as compared to the low insulation zone 1620. In other words, the high insulation zones 1622 can include a greater 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 as compared to the low insulation zone 1620. The greater thickness and loft of the regions 1628a, 1628b, 1628c, and 1628d help to trap and store heat.

[0109] Figure 16 The visual arrangement of the non-linear entangled seams is merely illustrative, and it is contemplated herein that other visual arrangements can be formed by the non-linear entangled seams. Further, although the entangled seams are shown as extending vertically (e.g., from the neck opening to the waist opening), the entangled seams can be oriented horizontally on the garment. Additionally, the upper body garment 1600 can include non-linear entangled seams at locations on the upper body garment that differ from the locations shown. Figure 16The depiction of the upper body garment 1600 is intended to convey the concept that parameters associated with the non-linear entangled seams can be adjusted to achieve desired properties, including thermal insulation properties. These parameters can include, for example, spacing between adjacent non-linear entangled seams (e.g., greater spacing results in regions 1628a, 1628b, 1628c, and 1628d occupying a greater overall surface area of the upper body garment 1600), number of intersections between non-linear entangled seams (e.g., more intersections result in increased stitch density and decreased thickness), width of individual non-linear entangled seams (e.g., greater width results in decreased thickness as compared to non-linear entangled seams having a smaller width), and the like.

[0110] Figure 17 An example composite nonwoven fabric 1700 formed from a first nonwoven layer 110, a second layer 114, and a filler material 116 is depicted. In example aspects, the composite nonwoven fabric 1700 includes non-linear entangled seams 1710a, 1710b, and 1710c. The non-linear entangled seam 1710a is similar to other non-linear entangled seams discussed herein with respect to, for example, the composite nonwoven fabric 100 and the composite nonwoven fabric 1400. The non-linear entangled seams 1710b and 1710c include intermittent non-linear entangled seams. For example, the non-linear entangled seam 1710b includes an interval segment 1712 in which no entangled seam is formed. The non-linear entangled seam 1710c includes multiple interval segments, such as interval segment 1714 and interval segment 1716. Further, the non-linear entangled seam 1710c includes an entangled seam portion 1718 in the form of a very short segment or even an entanglement node that is spaced apart from the remainder of the non-linear entangled seam 1710c by interval segment 1720 and interval segment 1722.

[0111] The interval segments 1712, 1714, 1716, 1720, and 1722 can be formed using the entangling system 500 and the methods described herein. For example, with respect to the interval segment 1712, it can be formed by not actuating the entangling heads 532 that form the non-linear entangled seam 1710b during one or more stationary phases such that the entangling needles 534 and / or orifices associated with the entangling heads 532 are not in contact with the composite nonwoven fabric 1700. The length of the interval segments 1712, 1714, 1716, 1720, and 1722 can be adjusted as desired by varying the number of stationary phases in which the entangling heads 532 are not 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, andFigure 19 A cross-section of a nonwoven fabric 1800 is depicted. The nonwoven fabric 1800 can include a single fibrous layer comprising entangled fibers; two or more fibrous layers having the same or different properties (e.g., fibers of different staple lengths, fibers of different deniers, fibers of different colors, different fiber types, different fiber coatings, etc.) that are joined together by an entangling process (e.g., needle punch or hydroentanglement) or other process such as bonding, adhesive, stitching, etc.; or one or more fibrous layers having the same or different properties that are joined to a film or a structured fabric (e.g., a knitted, woven, or braided fabric) by an entangling process or other process such as bonding, adhesive, stitching, etc.

[0116] The non-linear entangled seams 1810 and 1812 can be formed by the entangling processes described above, and the seams 1810 and 1812 can be used to create areas of reduced thickness and / or to create a visible arrangement of entangled seams. In example aspects, the nonwoven fabric 1800 can be combined with additional single layer materials. For example, the nonwoven fabric 1800 can be positioned adjacent to and joined to a structured fabric by entangling, stitching, bonding, adhesive, etc. One or more additional materials, such as a filler material, can be located between the nonwoven fabric 1800 and the structured fabric. In another example, the nonwoven fabric 1800 can be positioned adjacent to and secured to another single layer nonwoven fabric having entangled seams by entangling, stitching, bonding, adhesive, etc. One or more additional materials, such as a filler material, can be located between the nonwoven fabric 1800 and the additional single layer nonwoven fabric. Any and all aspects and any variations thereof are contemplated to be within the scope herein. The nonwoven fabric 1800 can be formed into different apparel articles as described herein, such as upper body garments, lower body garments, footwear articles (e.g., shoe uppers), etc. As described herein, the same type of apparel product can have different visible arrangements of entangled seams.

[0117] The following clauses represent example aspects of the concepts contemplated herein. Any one of the following clauses can be combined in a multiple-dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that expressly depend from a prior clause) can be combined while remaining within the aspects contemplated 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: engaging a entangling head with the composite nonwoven fabric to form a first entangled region on the composite nonwoven fabric when the composite nonwoven fabric is in a first position on an entangling machine; advancing the composite nonwoven fabric through the entangling machine in a material flow direction; moving one or more of the entangling head and the composite nonwoven fabric in a first direction that is not parallel to the material flow direction; and engaging the entangling head with the composite nonwoven fabric to form a second entangled region on the composite nonwoven fabric when the composite nonwoven fabric is in a second position advanced from the first position in the material flow direction, the second entangled region extending from the first entangled region to form a non-linear entangled seam.

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

[0120] Clause 3. The method of manufacturing a composite nonwoven fabric of any of clauses 1-2, wherein the first entangled region and the second entangled region partially overlap.

[0121] Clause 4. The method of manufacturing a composite nonwoven fabric of any of clauses 1-3, wherein a stitch density at an overlap region between the first entangled region and the second entangled region is greater than a stitch density at a remainder of the first entangled region and the second entangled region.

[0122] Clause 5. The method of manufacturing a composite nonwoven fabric of any of clauses 1-4, wherein the entangling head moves in a direction perpendicular to a surface plane of the composite nonwoven fabric when the composite nonwoven fabric is in the first position.

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

[0124] Clause 7. The method of manufacturing a composite nonwoven fabric according to Clause 6, wherein the third entanglement region partially overlaps 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. The method of manufacturing a composite nonwoven fabric according to any one of Clauses 6 to 8, wherein the second direction is opposite the first direction.

[0127] Clause 10. An article of clothing comprising: a first nonwoven layer having a material flow direction; a second layer; a filler material positioned between the first nonwoven layer and the second layer; at least one region of the article of clothing 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 one another to form the at least one nonlinear entanglement seam, wherein the one or more entanglement regions comprise fibers from the first nonwoven layer that extend through the filler material and into the second layer.

[0128] Clause 11. The article of clothing according to Clause 10, wherein the second layer is a nonwoven material.

[0129] Clause 12. The article of clothing according to any one of Clauses 10 to 11, wherein the one or more entanglement regions comprise discrete regions.

[0130] Clause 13. The article of clothing according to any one of Clauses 10 to 12, wherein the at least one region of the article of clothing in which the first nonwoven layer, the second layer, and the filler material are substantially unentangled has a thickness of about 7 mm to about 15 mm.

[0131] Clause 14. The article of clothing according to any one of Clauses 10 to 13, wherein a 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 article of clothing in which the first nonwoven layer, the second layer, and the filler material are substantially unentangled.

[0132] Clause 15. The article of clothing according to any one of Clauses 10 to 14, wherein the filler material is one or more of a synthetic fiber sheet, loose synthetic fibers, and down.

[0133] Clause 16. The article of clothing according to Clause 10 and Clauses 12 to 15, wherein the second layer is a woven material.

[0134] Clause 17. The garment of clauses 10-11 and 13-15, wherein the one or more entanglement region portions overlap one another.

[0135] Clause 18. The garment of clauses 10-17, further comprising a plurality of additional non-linear entanglement seams, wherein the plurality of additional non-linear 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 positioned 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 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 one another to form the at least one non-linear entanglement seam, wherein the one or more entanglement regions comprise fibers from the first nonwoven layer that extend through the filler material and into the second layer.

[0137] Clause 20. The composite nonwoven fabric of clause 19, wherein the second layer is a nonwoven material.

[0138] Clause 21. The composite nonwoven fabric of clauses 19-20, wherein the one or more entanglement regions comprise discrete entanglement regions.

[0139] Clause 22. The composite nonwoven fabric of clauses 19-21, wherein the 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 has a thickness of about 7 mm to about 15 mm.

[0140] Clause 23. The composite nonwoven fabric of any of clauses 19-22, wherein the at least one non-linear entanglement seam has a thickness that 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 filler material are substantially unentangled.

[0141] Clause 24. The composite nonwoven fabric of any of clauses 19-23, wherein the filler material is one or more of a sheet of synthetic fibers, loose synthetic fibers, and down.

[0142] Clause 25. The composite nonwoven fabric of any of clauses 19 and 21-24, wherein the second layer is a woven material.

[0143] Clause 26. The composite nonwoven fabric of any of clauses 19-20 and 22-25, wherein the one or more entanglement region portions overlap one another.

[0144] Clause 27. The composite nonwoven fabric of any of clauses 19-26, further comprising a plurality of additional non-linear entanglement seams, wherein the plurality of additional non-linear entanglement seams form a non-repeating visual arrangement of entanglement seams.

[0145] Clause 28. A system for entanglement, the system for forming at least one non-linear entanglement seam on a composite nonwoven fabric, the system comprising: a first entanglement station comprising: a conveyance 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 adapted to move the first entanglement head in a direction perpendicular to a conveyance plane of the conveyance system; and a first carriage coupled to the first entanglement head, the first carriage adapted to move in a first direction non-parallel to the material flow direction.

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

[0147] Clause 30. The system for entanglement of any of clauses 28-29, wherein the first carriage is further adapted to move in a second direction non-parallel to the material flow direction, the second direction opposite the first direction.

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

[0149] Clause 32. The system for entanglement of any of clauses 28-31, wherein the first entanglement head has a first dimension in the material flow direction.

[0150] Clause 33. The system for entanglement of any of clauses 28-32, wherein an advancement distance of the conveyance system is less than or equal to the first dimension of the first entanglement head.

[0151] Clause 34. The system for entanglement of any of clauses 28-33, wherein the first actuator is adapted to move in the direction perpendicular to the conveyance plane when the conveyance system is stationary.

[0152] Clause 35. The system for entanglement of any of clauses 28-34, wherein the first carriage is indirectly coupled to the first entanglement head by the first actuator.

[0153] Clause 36. The entanglement system of any of clauses 28-35, further comprising: a second entanglement station, the second entanglement station comprising: the conveying system having the 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 adapted to move the second entanglement head in a direction perpendicular to the conveyance plane of the conveying system; and a second carriage coupled to the second entanglement head, the second carriage adapted to move in the first direction that is not parallel to the material flow direction.

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

[0155] Clause 38. The entanglement system of any of clauses 36-37, wherein the second entanglement station is located at a position after the first entanglement station in the material flow direction.

[0156] Clause 39. The entanglement system of any of clauses 28-38, wherein the first entanglement head comprises a plurality of entanglement needles.

[0157] Clause 40. A method of manufacturing a batch of garments having a common finished form, the method comprising: obtaining a 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 composite nonwoven fabric comprising at least a first nonlinear entangled seam and a second nonlinear entangled seam, the first nonlinear entangled seam and the second nonlinear entangled seam each comprising an entangled region that extends from one another to form a distinct continuous nonlinear entangled seam, wherein the entangled region comprises fibers that extend from the first nonwoven layer through the filler material and into the second layer; removing a first instance of a pattern piece from the composite nonwoven fabric, the first instance of the pattern piece having the first nonlinear entangled seam and the second nonlinear entangled seam; forming a first garment using the first instance of the pattern piece, the first nonlinear entangled seam and the second nonlinear entangled seam being located at a first location 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 entangled seam and the second nonlinear entangled seam; and forming a second garment using the second instance of the pattern piece, the first nonlinear entangled seam and the second nonlinear entangled seam being located at a second location of the pattern piece, the second location being different than the first location.

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

[0159] Clause 42. The method of manufacturing a batch of garments according to any one of Clauses 40 to 41, wherein the entangled regions partially overlap one another.

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

[0161] Clause 44. The method of manufacturing a batch of garments according to any one of Clauses 41 to 43, wherein the batch of garments comprises an upper body garment.

[0162] Clause 45. The method of manufacturing a batch of garments according to any one of Clauses 41 to 43, wherein the batch of garments comprises a lower body garment.

[0163] Clause 46. A batch of garments having a common finished form, the batch of garments formed from a composite nonwoven fabric including a first nonwoven layer, a second layer, and a filler material located between the first nonwoven layer and the second layer, the composite nonwoven fabric including at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each including an entangled region extending from one another to form the respective first non-linear entangled seam and second non-linear entangled seam, wherein the entangled region includes fibers extending from the first nonwoven layer through the filler material and into the second layer, the batch of garments comprising: a first garment formed from a first instance of a pattern piece taken from the composite nonwoven fabric, the first non-linear entangled seam and the second non-linear entangled seam located at a first location on the first garment; and a second garment formed from a second instance of the pattern piece taken from the composite nonwoven fabric, the first non-linear entangled seam and the second non-linear entangled seam located at a second location on the second garment, the second location different from the first location with respect to the pattern piece.

[0164] Clause 47. The batch of garments according to Clause 46, wherein the first non-linear entangled seam and the second non-linear entangled seam each extend in a material flow direction.

[0165] Clause 48. The batch of garments according to any one of Clauses 46 to 47, wherein the entangled regions partially overlap one another.

[0166] Clause 49. The batch of garments according to any one of Clauses 46 to 48, further comprising a third garment formed from a third instance of the pattern piece taken from the composite nonwoven fabric, the first non-linear entangled seam and the second non-linear entangled seam located at a third location on the third garment, the third location different from one or more of the first location and the second location with respect to the pattern piece.

[0167] Clause 50. The batch of garments according to any one of Clauses 46 to 49, wherein the batch of garments comprises an upper body garment.

[0168] Clause 51. The batch of garments according to any one of Clauses 46 to 49, wherein the batch of garments comprises a lower body garment.

[0169] Clause 52. A method of manufacturing a batch of garments having a common finished form, the method comprising: obtaining a 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 composite nonwoven fabric comprising at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising an entangled region that extends from one another to form a distinct continuous non-linear entangled seam, wherein the entangled region comprises fibers that extend from the first nonwoven layer through the filler material and into the second layer; removing a first portion having a first pattern from the composite nonwoven fabric, the first portion having the first non-linear entangled seam and the second non-linear entangled seam; using the first portion to form a first garment, the first non-linear entangled seam and the second non-linear entangled seam being located at a first location on the first portion; removing a second portion having the first pattern from the composite nonwoven fabric, the second portion having the first non-linear entangled seam and the second non-linear entangled seam; and using the second portion to form a second garment, the first non-linear entangled seam and the second non-linear entangled seam being located at a second location on the second portion, the second location being different than the first location.

[0170] Clause 53. The method of manufacturing a batch of garments of clause 52, wherein the first non-linear entangled seam and the second non-linear entangled seam each extend in a material flow direction.

[0171] Clause 54. The method of manufacturing a batch of garments of clause 53, wherein a distance between the first non-linear entangled seam and the second non-linear entangled seam varies along the material flow direction, wherein the distance between the first non-linear entangled seam and the second non-linear entangled seam is measured in a direction that is not parallel to the material flow direction.

[0172] Clause 55. The method of manufacturing a batch of garments of any of clauses 52 to 54, wherein the first non-linear entangled seam and the second non-linear entangled seam comprise different visual arrangements of entangled seams.

[0173] Clause 56. The method of manufacturing a batch of garments of any of clauses 52 to 55, wherein the entangled regions partially overlap one another.

[0174] Clause 57. The method of manufacturing a batch of garments of any of clauses 52 to 56, wherein the batch of garments comprises an upper body garment.

[0175] Clause 58. The method of manufacturing a batch of garments of any of clauses 52-56, wherein the batch of garments comprises lower body garments.

[0176] Clause 59. A batch of garments having a common finished form, the batch of garments formed from a 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 composite nonwoven fabric comprising at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising an entangled region extending from one another to form the respective first non-linear entangled seam and the second non-linear entangled seam, wherein the entangled region comprises fibers extending from the first nonwoven layer through the filler material and into the second layer, the batch of garments comprising: a first garment formed from a first portion of the composite nonwoven fabric having a first pattern, the first non-linear entangled seam and the second non-linear entangled seam located at a first location on the first portion of the first garment; and a second garment formed from a second portion of the composite nonwoven fabric having the first pattern, the first non-linear entangled seam and the second non-linear entangled seam located at a second location on the second portion of the second garment, the second location different from the first location.

[0177] Clause 60. The batch of garments of clause 59, wherein the first non-linear entangled seam and the second non-linear entangled seam each extend in a material flow direction.

[0178] Clause 61. The batch of garments of clause 60, wherein a distance between the first non-linear entangled seam and the second non-linear entangled seam varies along the material flow direction, wherein the distance between the first non-linear entangled seam and the second non-linear entangled seam is measured in a direction non-parallel to the material flow direction.

[0179] Clause 62. The batch of garments of any of clauses 59-61, wherein the first non-linear entangled seam and the second non-linear entangled seam comprise different visual arrangements of entangled seams.

[0180] Clause 63. The batch of garments of any of clauses 59-62, wherein the entangled regions partially overlap one another.

[0181] Clause 64. The batch of garments of any of clauses 59-63, wherein the batch of garments comprises upper body garments.

[0182] Clause 65. The batch of garments of any one of clauses 59-63, wherein the batch of garments comprises lower body garments.

[0183] Clause 66. A entanglement system for forming at least one non-linear entanglement seam on a composite nonwoven fabric, the entanglement system comprising: a first entanglement station comprising: a conveyance 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 adapted to move in a first direction that is not parallel to the material flow direction.

[0184] Clause 67. The entanglement system of 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 of clause 66, wherein the first entanglement head comprises an entanglement needle, and wherein the first actuator is adapted to move one or more of the first entanglement head and the entanglement needle in a direction that is perpendicular to a conveyance plane of the surface.

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

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

[0188] Clause 71. The entanglement system of any one of clauses 66-70, wherein the first entanglement head has a first dimension in the material flow direction.

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

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

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

[0192] Clause 75. The entanglement system of clause 74, wherein the plurality of additional entanglement heads coupled to the first actuator are non-uniformly spaced apart from one another.

[0193] Clause 76. The entanglement system of any of clauses 66-75, further comprising: a second entanglement station comprising: the conveyance system having the 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 adapted to move in the first direction that is non-parallel to the material flow direction.

[0194] Clause 77. The entanglement system of clause 76, wherein the first entanglement head is positioned at a first distance inward from a first edge of the surface of the conveyance system and the second entanglement head is positioned at a second distance inward from the first edge of the surface of the conveyance system, the second distance being different than the first distance.

[0195] Clause 78. The entanglement system of any of clauses 76-77, wherein the second entanglement station is located at a position after the first entanglement station in the material flow direction.

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

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

[0198] Clause 81. The entanglement system of any of clauses 79-80, wherein a number of the plurality of additional entanglement heads coupled to the second actuator is different than a number of the plurality of additional entanglement heads coupled to the first actuator.

[0199] Clause 82. The entanglement system of any of clauses 76-81, wherein a size of the second entanglement head is different than a size of the first entanglement head.

[0200] Clause 83. The entanglement system of any of clauses 76-82, wherein an entanglement footprint produced by the second entanglement head is different than an entanglement pattern produced by the first entanglement head.

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

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

[0203] Clause 86. The method of manufacturing a nonwoven fabric of any of clauses 84-85, wherein the first entangled region partially overlaps the second entangled region.

[0204] Clause 87. The method of manufacturing a nonwoven fabric of clause 86, wherein a stitch density at an overlap region between the first entangled region and the second entangled region is greater than a stitch density at a remainder of the first entangled region and the second entangled region.

[0205] Clause 88. The method of manufacturing a nonwoven fabric of any of clauses 84-87, wherein the entangling head is moved in a direction perpendicular to a surface plane of the nonwoven fabric when the nonwoven fabric is in the first position.

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

[0207] Clause 90. The method of manufacturing a nonwoven fabric of clause 89, wherein the third entangled region partially overlaps the second entangled region.

[0208] Clause 91. An article of clothing comprising: a nonwoven fabric having a material flow direction; and at least one non-linear entangled seam extending along the material flow direction, the at least one non-linear entangled seam comprising one or more entangled regions extending from one another to form the at least one non-linear entangled seam, wherein at each of the one or more entangled regions, fibers forming the nonwoven fabric have a generally vertical orientation.

[0209] Clause 92. The article of clothing of Clause 91, wherein the one or more entangled regions comprise discrete regions.

[0210] Clause 93. The article of clothing of Clause 91, wherein the one or more entangled regions partially overlap one another.

[0211] Clause 94. The article of clothing of any of Clauses 91-93, further comprising a plurality of additional non-linear entangled seams, wherein the plurality of additional non-linear entangled seams form a non-repeating visual arrangement of entangled seams.

[0212] Clause 95. The article of clothing of any of Clauses 91-94, further comprising one or more additional layers secured to the nonwoven fabric by one or more of entanglement, stitching, bonding, and adhesive.

[0213] Clause 96. The article of clothing of Clause 95, wherein the one or more additional layers comprise one or more of a structured fabric, a nonwoven layer, a film, and a filler material.

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

[0215] Clause 98. The nonwoven fabric of Clause 97, wherein the one or more entangled regions comprise discrete entangled regions.

[0216] Clause 99. The nonwoven fabric of Clause 97, wherein the one or more entangled regions partially overlap one another.

[0217] Clause 100. The nonwoven fabric of any of Clauses 97-99, further comprising a plurality of additional non-linear entangled seams, wherein the plurality of additional non-linear entangled seams form a non-repeating visual arrangement of entangled seams.

[0218] Clause 101. A batch of garments having a common finished form, the batch of garments formed from a nonwoven fabric having at least a first non-linear entangled seam and a second non-linear entangled seam, the first and second non-linear entangled seams each comprising an entangled region extending from one another to form the respective first and second non-linear entangled seams, wherein the entangled region comprises fibers from the nonwoven layer, wherein the fibers have a generally vertical orientation, the batch of garments comprising: a first garment formed from a first instance of a pattern piece taken from the nonwoven fabric, the first and second non-linear entangled seams being located at a first location on the first garment; and a second garment formed from a second instance of the pattern piece taken from the nonwoven fabric, the first and second non-linear entangled seams being located at a second location on the second garment, the second location being different relative to the pattern piece than the first location.

[0219] Clause 102. The batch of garments according to Clause 101, wherein the first and second non-linear entangled seams each extend in a material flow direction.

[0220] Clause 103. The batch of garments according to any of Clauses 101-102, wherein the entangled regions partially overlap one another.

[0221] Clause 104. The batch of garments according to any of Clauses 101-103, further comprising a third garment formed from a third instance of the pattern piece taken from the nonwoven fabric, the first and second non-linear entangled seams being located at a third location on the third garment, the third location being different relative to the pattern piece than one or more of the first and second locations.

[0222] Clause 105. The batch of garments according to any of Clauses 101-104, wherein the batch of garments comprises an upper body garment.

[0223] Clause 106. The batch of garments according to any of Clauses 101-104, wherein the batch of garments comprises a lower body garment.

[0224] Clause 107. A method of manufacturing a batch of garments having a common finished form, the method comprising: obtaining a nonwoven fabric having at least a first non-linear entangled seam and a second non-linear entangled seam, the first and second non-linear entangled seams each comprising an entangled region extending from one another to form a distinct continuous non-linear entangled seam, wherein the entangled region comprises fibers having a generally vertical orientation; removing a first portion having a first pattern from the nonwoven fabric, the first portion having the first and second non-linear entangled seams; using the first portion to form a first garment, the first and second non-linear entangled seams being at a first location on the first portion; removing a second portion having the first pattern from the nonwoven fabric, the second portion having the first and second non-linear entangled seams; and using the second portion to form a second garment, the first and second non-linear entangled seams being at a second location on the second portion, the second location being different than the first location.

[0225] Clause 108. The method of manufacturing a batch of garments of Clause 107, wherein the first and second non-linear entangled seams each extend in a material flow direction.

[0226] Clause 109. The method of manufacturing a batch of garments of Clause 108, wherein a distance between the first and second non-linear entangled seams varies along the material flow direction, wherein the distance between the first and second non-linear entangled seams is measured in a direction that is not parallel to the material flow direction.

[0227] Clause 110. The method of manufacturing a batch of garments of any of Clauses 107-109, wherein the first and second non-linear entangled seams comprise different visual arrangements of entangled seams.

[0228] Clause 111. The method of manufacturing a batch of garments of any of Clauses 107-110, wherein the entangled regions partially overlap one another.

[0229] Clause 112. The method of manufacturing a batch of garments of any of Clauses 107-111, wherein the batch of garments comprises an upper body garment.

[0230] Clause 113. The method of manufacturing a batch of garments of any of Clauses 107-111, wherein the batch of garments comprises a lower body garment.

[0231] Clause 114. A batch of garments having a common finished form, the batch of garments formed from a nonwoven fabric having at least a first non-linear entangled seam and a second non-linear entangled seam, the first and second non-linear entangled seams each comprising an entangled region extending from one another to form the respective first and second non-linear entangled seams, wherein at each of the entangled regions, fibers forming the nonwoven fabric have a generally vertical orientation, the batch of garments comprising: a first garment formed from a first portion of the nonwoven fabric having a first style, the first and second non-linear entangled seams being located at a first location on the first portion of the first garment; and a second garment formed from a second portion of the nonwoven fabric having the first style, the first and second non-linear entangled seams being located at a second location on the second portion of the second garment, the second location being different than the first location.

[0232] Clause 115. The batch of garments of Clause 114, wherein the first and second non-linear entangled seams each extend in a material flow direction.

[0233] Clause 116. The batch of garments of Clause 115, wherein a distance between the first and second non-linear entangled seams varies along the material flow direction, wherein the distance between the first and second non-linear entangled seams is measured in a direction that is not parallel to the material flow direction.

[0234] Clause 117. The batch of garments of any of Clauses 114-116, wherein the first and second non-linear entangled seams comprise different visual arrangements of entangled seams.

[0235] Clause 118. The batch of garments of any of Clauses 114-117, wherein the entangled regions partially overlap one another.

[0236] Clause 119. The batch of garments of any of Clauses 114-118, wherein the batch of garments comprises an upper body garment.

[0237] Clause 120. The batch of garments of any of Clauses 114-118, wherein the batch of garments comprises a lower body garment.

[0238] Aspects of the disclosure have been described as being illustrative rather than limiting. Alternative aspects will become apparent to those skilled in the art without departing from the scope of the present disclosure. Alternative means of implementing the above described improvements will become apparent to those skilled in the art without departing from the scope of the present disclosure.

[0239] It is to be understood that certain features and subcombinations are useful and can be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all of the steps listed in each figure is required, nor is the particular order of the steps described necessary.

Claims

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 positioned between the first nonwoven layer and the second layer, the method comprising: while the composite nonwoven fabric is in a first position on a entanglement machine, engaging an entanglement head with the composite nonwoven fabric to form a first entanglement region on the composite nonwoven fabric; advancing the composite nonwoven fabric through the entanglement machine in a material flow direction; moving one or more of the entanglement head and the composite nonwoven fabric in a first direction that is not parallel to the material flow direction; and while the composite nonwoven fabric is in a second position advanced from the first position in the material flow direction, engaging the entanglement head with the composite nonwoven fabric to form a second entanglement region on the composite nonwoven fabric, the second entanglement region extending from the first entanglement region to form a non-linear entanglement seam.

2. The method of manufacturing a composite nonwoven fabric of claim 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.

3. The method of manufacturing a composite nonwoven fabric of claim 2, wherein the first entanglement region partially overlaps the second entanglement region.

4. The method of manufacturing a composite nonwoven fabric of claim 3, wherein a stitch density at an overlap region between the first entanglement region and the second entanglement region is greater than a stitch density at a remainder of the first entanglement region and the second entanglement region.

5. The method of manufacturing a composite nonwoven fabric of claim 1, wherein while the composite nonwoven fabric is in the first position, the entanglement head moves in a direction that is perpendicular to a surface plane of the composite nonwoven fabric.

6. The method of manufacturing a composite nonwoven fabric of claim 1, further comprising: after forming the second entanglement region, advancing the composite nonwoven fabric in the material flow direction; moving one or more of the entanglement head or the composite nonwoven fabric in a second direction that is not parallel to the material flow direction; and while 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 non-linear entanglement seam.

7. The method of manufacturing a composite nonwoven fabric of claim 6, wherein the third entanglement region partially overlaps the second entanglement region.

8. The method of manufacturing a composite nonwoven fabric of claim 6, wherein the third entanglement region is positioned adjacent to the second entanglement region.

9. The method of manufacturing a composite nonwoven fabric of claim 6, wherein the second direction is opposite the first direction. ​ ​ 10. An entanglement system for forming at least one non-linear entanglement seam on a composite nonwoven fabric, the entanglement system comprising: - a 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 adapted to move in a first direction that is not parallel to the material flow direction.

11. The entanglement system of claim 10, wherein the first actuator is adapted to actuate the first entanglement head to eject one or more fluid jets.

12. The entanglement system of claim 10, wherein the first entanglement head comprises an entanglement needle, and wherein the first actuator is adapted to move one or more of the first entanglement head and the entanglement needle in a direction that is perpendicular to a conveying plane of the surface.

13. The entanglement system of claim 10, wherein the first carriage is further adapted to move in a second direction that is not parallel to the material flow direction, the second direction being opposite to the first direction.

14. The entanglement system of claim 13, wherein the second direction is perpendicular to the material flow direction.

15. The entanglement system of claim 10, wherein the first entanglement head has a first dimension in the material flow direction.

16. The entanglement system of claim 15, wherein the conveying system is adapted to advance the composite nonwoven fabric in the material flow direction, and wherein an advancement distance of the conveying system is less than the first dimension of the first entanglement head.

17. The entanglement system of claim 10, wherein the first entanglement station further comprises a plurality of additional entanglement heads coupled to the first actuator.

18. The entanglement system of claim 10, further comprising: - a second entanglement station comprising: -- the conveying system having a surface adapted to advance the composite nonwoven fabric in a 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 adapted to move in the first direction that is not parallel to the material flow direction.

19. The entanglement system of claim 18, wherein the second entanglement station is located at a position behind the first entanglement station in the material flow direction.

20. The entanglement system of claim 18, wherein an entanglement footprint produced by the second entanglement head is different from an entanglement pattern produced by the first entanglement head.

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