Fabric having thermal and nap zones

Abstract

Aspects herein relate to a fabric and an article of clothing produced from the fabric, the fabric having one or more thermal insulation zones and one or more pile zones, wherein the pile zones seamlessly extend from the thermal insulation zones. The fabric includes a first woven layer, a second woven layer, and a nonwoven layer positioned between the first woven layer and the second woven layer. In the thermal insulation zones, the first woven layer, the second woven layer, and the nonwoven layer are unattached to one another. In the pile zones, fibers / filaments from the nonwoven layer are entangled with fibers, filaments, and yarns from each of the first woven layer and the second woven layer.

Description

TECHNICAL FIELD

[0001] Aspects herein relate to a fabric and an article of clothing formed from the fabric having a thermal zone and a pile zone formed from a combination of a woven layer and a nonwoven layer. BACKGROUND

[0002] Conventional articles of clothing including, for example, thermal zones and pile zones are often formed using a cut-and-sew construction where seams are used to attach fabric forming the thermal zone to fabric forming the pile zone. Seaming lines can introduce areas of structural weakness, can be aesthetically undesirable, and / or can cause chafing or discomfort to the wearer. SUMMARY

[0003] 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 scope of the aspects contemplated herein. The following clauses are examples and not limitations.

[0004] Clause 1. A fabric comprising: a thermal zone comprising a first woven layer, a second woven layer, and a nonwoven layer positioned between the first woven layer and the second woven layer, each of the first woven layer and the second woven layer being unattached to the nonwoven layer in the thermal zone; and a pile zone seamlessly extending from the thermal zone, the pile zone comprising the first woven layer, the second woven layer, and the nonwoven layer positioned between the first woven layer and the second woven layer, wherein fibers and / or filaments from the nonwoven layer are entangled with fibers, filaments, and / or yarns from each of the first woven layer and the second woven layer such that the first woven layer and the second woven layer are fixed to the nonwoven layer in the pile zone.

[0005] Clause 2. The fabric of Clause 1, wherein the nonwoven layer comprises two or more nonwoven sheets, and wherein fibers and / or filaments from each of the two or more nonwoven sheets are entangled with one another.

[0006] Clause 3. The fabric of Clause 2, wherein a first nonwoven sheet of the two or more nonwoven sheets comprises a first visual property, and wherein a second nonwoven sheet of the two or more nonwoven sheets comprises a second visual property different from the first visual property.

[0007] Clause 4. The fabric of Clause 3, wherein the first visual property comprises a first color, and wherein the second visual property comprises a second color.

[0008] Clause 5. The fabric of any of clauses 3-4, wherein the first visual property comprises a first pattern, and wherein the second visual property comprises a second pattern.

[0009] Clause 6. The fabric of any of clauses 1-5, wherein the nonwoven layer has a weight of from about 180 grams per square meter (gsm) to about 220 gsm.

[0010] Clause 7. A garment comprising: a thermal zone comprising a first woven layer, a second woven layer, and a nonwoven layer positioned between the first woven layer and the second woven layer, wherein the first woven layer, the second woven layer, and the nonwoven layer comprise separate and distinct layers in the thermal zone; and a pile zone seamlessly extending from the thermal zone, the pile zone comprising the first woven layer, the second woven layer, and the nonwoven layer, wherein fibers and / or filaments from the nonwoven layer are entangled with fibers, filaments, and / or yarns from each of the first woven layer and the second woven layer in the pile zone such that the first woven layer and the second woven layer are affixed to the nonwoven layer in the pile zone.

[0011] Clause 8. The garment of clause 7, wherein both the first woven layer and the second woven layer are unattached to the nonwoven layer in the thermal zone.

[0012] Clause 9. The garment of any of clauses 7-8, wherein the nonwoven layer has a visual property that is different from a visual property of one or more of the first woven layer and the second woven layer.

[0013] Clause 10. The garment of any of clauses 7-9, wherein the nonwoven layer comprises two or more nonwoven sheets, and wherein fibers and / or filaments from each of the two or more nonwoven sheets are entangled with one another.

[0014] Clause 11. The garment of clause 10, wherein a first nonwoven sheet of the two or more nonwoven sheets comprises a first visual property, and wherein a second nonwoven sheet of the two or more nonwoven sheets comprises a second visual property that is different from the first visual property.

[0015] Clause 12. The garment of any of clauses 7-11, wherein the nonwoven layer has a weight of from about 180 grams per square meter (gsm) to about 220 gsm.

[0016] Clause 13. The garment of any of clauses 7-12, wherein the thermal insulation zone is positioned on the garment in an area corresponding to a high heat loss area of a wearer when the garment is in a worn configuration.

[0017] Clause 14. A method of manufacturing a fabric, comprising: positioning a nonwoven layer between a first woven layer and a second woven layer to form a layered construction; and entangling fibers and / or filaments from the nonwoven layer with fibers, filaments, and / or yarns from each of the first woven layer and the second woven layer in a first area of the layered construction, wherein each of the first woven layer and the second woven layer remains unattached to the nonwoven layer in a second area of the layered construction.

[0018] Clause 15. The method of manufacturing a fabric of clause 14, wherein the nonwoven layer is formed by positioning two or more nonwoven sheets adjacent to one another and entangling fibers and / or filaments from each of the two or more nonwoven sheets with one another using an entangling process.

[0019] Clause 16. The method of manufacturing a fabric of clause 15, wherein the entangling process is performed in a direction from a first surface of the nonwoven layer toward a second surface of the nonwoven layer and in a direction from the second surface of the nonwoven layer toward the first surface of the nonwoven layer.

[0020] Clause 17. The method of manufacturing a fabric of any of clauses 14-16, wherein entangling the fibers and / or filaments from the nonwoven layer with the fibers, filaments, and / or yarns from each of the first woven layer and the second woven layer comprises: positioning the first woven layer adjacent to a first surface of the nonwoven layer; performing a first entangling process in a direction from the nonwoven layer toward the first woven layer; subsequently positioning the second woven layer adjacent to a second, opposite surface of the nonwoven layer; and performing a second entangling process in a direction from the first woven layer toward the second woven layer.

[0021] Clause 18. The method of manufacturing a fabric of any of clauses 14-17, wherein the nonwoven layer has a weight of from about 180 grams per square meter (gsm) to about 220 gsm.

[0022] Clause 19. The method of manufacturing a fabric of any of clauses 14-18, wherein the nonwoven layer has a visual property that is different from a visual property of one or more of the first woven layer and the second woven layer.

[0023] Clause 20. The method of manufacturing a fabric according to Clause 19, wherein the visual property of the nonwoven layer and the one or more of the first woven layer and the second woven layer comprises a color. BRIEF DESCRIPTION OF DRAWINGS

[0024] Examples of aspects herein are described in detail below with reference to the attached drawing figures, wherein:

[0025] Figure 1 FIG. illustrates a view of a first surface of an example fabric having thermal insulation zones and pile zones according to aspects herein;

[0026] Figure 2 FIG. illustrates a view of a second, opposite surface of the example fabric of Figure 1 and depicts thermal insulation zones and pile zones according to aspects herein;

[0027] Figure 3 FIG. illustrates a cross-sectional view of the example fabric of Figure 1 according to aspects herein;

[0028] Figure 4 FIG. illustrates a schematic of an example process for forming a nonwoven layer of the example fabric of Figure 1 according to aspects herein;

[0029] Figure 5 FIG. illustrates a schematic of an example process for forming the example fabric of Figure 1 according to aspects herein;

[0030] Figure 6 FIG. illustrates an example upper body garment incorporating the example fabric of Figure 1 according to aspects herein;

[0031] Figure 7 FIG. illustrates an example lower body garment incorporating the example fabric of Figure 1 according to aspects herein; and

[0032] Figure 8 FIG. illustrates a flowchart of an example method of manufacturing the fabric of Figure 1 according to aspects herein. DETAILED DESCRIPTION

[0033] The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter can also be embodied in other ways, including different steps or combinations of steps in a different order, to include in the disclosed subject matter other technologies that are currently known or that will become known in the future. Furthermore, although the terms "step" and / or "block" can be used herein to connote different elements of 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.

[0034] Conventional apparel articles having thermal-zoned and pile-zoned (i.e., fleece-zoned) regions are typically formed using a cut-and-sew construction where fabric used to form the thermal-zoned region is sewn to fabric used to form the pile-zoned region. The resulting seams can introduce areas of structural weakness, can create undesirable aesthetics, and / or can cause chafing or discomfort to the wearer. Likewise, fabric used to form conventional pile-zoned regions can lack features that make the fabric suitable for use in harsh weather conditions, such as rain, snow, and / or wind.

[0035] Aspects herein relate to a fabric, an article of clothing formed from the fabric, and a method of manufacturing the fabric, where the fabric has a thermal-zoned region and a pile-zoned region that seamlessly extend from one another. Also, due to the construction of the pile-zoned region, the pile-zoned region includes features that make it more resistant to harsh weather conditions than typical pile fabrics. In example aspects, the thermal-zoned region includes a first woven layer, a second woven layer, and a nonwoven layer positioned in a space between the first woven layer and the second woven layer. In the thermal-zoned region, the first woven layer, the second woven layer, and the nonwoven layer are unattached to one another such that the first woven layer, the second woven layer, and the nonwoven layer are separate and distinct layers. In addition to the space formed between the different layers that can be used to trap warm air, the nonwoven layer also includes a large amount of space between the fibers and filaments that form the nonwoven layer, which further contributes to the trapping of warm air and the thermal insulation of the wearer.

[0036] The pile zone includes a first woven layer, a second woven layer, and a nonwoven layer. In the pile zone, fibers / yarns from the nonwoven layer extend into and through the first woven layer and the second woven layer and are entangled with fibers, yarns, and / or threads from both the first woven layer and the second woven layer by, for example, an entangling process such as needling. As a result of the entanglement of the nonwoven fibers / yarns with the first woven layer and the second woven layer, the first woven layer and the second woven layer are secured or fixed to the nonwoven layer in the pile zone. As a result of the fibers / yarns from the nonwoven layer extending through the first woven layer and the second woven layer, the pile zone has a pile-like texture. Unlike a typical pile fabric in which tufts or loops extend entirely from a base fabric that can not exhibit weathering properties, the pile zone contemplated herein can have weathering properties as a result of the presence of the first woven layer and the second woven layer. For example, in aspects where the first woven layer and the second woven layer are tightly woven, the pile zone can exhibit wind resistance properties. In additional aspects where one or more of the first woven layer and the second woven layer are treated with a durable water repellent, the pile zone can be generally rain or precipitation resistant.

[0037] While the insulating zone and the pile zone are formed from the same materials, aspects herein contemplate having varying aesthetics between the insulating zone and the pile zone based on, for example, the entangling process. For example, the first woven layer and / or the second woven layer can have a first visual property. The nonwoven layer can have a second visual property that is different from the first visual property. In this aspect, the insulating zone can primarily exhibit or display the first visual property associated with the first woven layer and / or the second woven layer as the nonwoven layer is positioned between the first woven layer and the second woven layer and can not be visible. As a result of the entanglement of the fibers and yarns of the nonwoven layer with the fibers, yarns, and threads of the first woven layer and / or the second woven layer, the pile zone can exhibit or display a different visual property that is intermediate the first visual property and the second visual property. For example, the color of the first woven layer and / or the second woven layer can be white and the color of the nonwoven layer can be gray. As a result of the mixing of the white threads forming the first woven layer and / or the second woven layer with the gray fibers / yarns forming the nonwoven layer, the insulating zone can primarily exhibit or display white and the pile zone can have a heather gray and white appearance.

[0038] As used herein, the term "garment" encompasses any number of products intended to be worn by a wearer, including upper body garments (e.g., shirts, jackets, hooded shirts, vests, pullovers), lower body garments (e.g., pants, shorts, leggings), footwear articles (such as shoes or socks), headwear articles (e.g., hats), gloves, sleeves (e.g., sleeves, leg sleeves), and the like. Positional terms used when describing garments, such as front, back, inner-facing surface, outer-facing surface, and the like, are relative to a wearer standing upright as the garment is intended to be worn. As such, when a garment is in the form of an upper body garment, the front of the upper body garment is configured to cover, for example, a front upper torso region and a front arm region (when the garment has sleeves), and the back of the upper body garment is configured to cover a back upper torso region and a back arm region (when the garment has sleeves). When a garment is in the form of a lower body garment, the front of the lower body garment is configured to cover, for example, a front lower torso region and a front leg region of the wearer, and the back of the lower body garment is configured to cover a back lower torso region and a back leg region. Similarly, the inner-facing surface of a garment is configured to face inward (e.g., toward the body surface of the wearer), and the outer-facing surface of a garment is configured to face the external environment or away from the inner-facing surface of the garment. In some aspects, it is contemplated herein that the inner-facing surface of a garment can include the most inward-facing surface of the garment. In some aspects, the outer-facing surface of a garment can include the most outward-facing surface of the garment.

[0039] As used herein, the term "yarn" can refer to a collection of fibers or filaments twisted or laid together so as to form a continuous strand. The term "yarn" can also encompass individual filaments that form a continuous strand. In example aspects, the first and second woven layers described herein can be formed from yarns and fibers or filaments that form the yarns. The nonwoven layers described herein can be formed from fibers and / or filaments.

[0040] The term "woven layer" refers to a fabric having a plurality of warp yarns and a plurality of weft yarns interwoven with the plurality of warp yarns, wherein the plurality of weft yarns extend generally orthogonally to the plurality of warp yarns. As used herein, the term "nonwoven layer" refers to fibers or filaments 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, nonwoven fabrics include a collection of fibers or filaments that are mechanically manipulated to form a mat-like material. In other words, nonwoven fabrics are made directly from fibers or filaments. As used herein, the term "pile" or "pile zone" refers to a fabric having a raised surface formed from the upstanding loops or strands of fibers / filaments, including composite fabrics.

[0041] The term "seamlessly extend" refers to two areas or zones extending from one another without a seam. With respect to the present disclosure, the thermal insulation zone and the pile zone seamlessly extend from one another such that one or more warp and / or weft yarns in the thermal insulation zone extend continuously and uninterrupted into the pile zone.

[0042] As used herein, the term "visual property" broadly refers to the visual impression produced by a fabric. This can be due to differences in the different characteristics of the yarns / fibers / filaments used to form the fabric, including texture, denier, luster, color, and the like. With respect to the term "pattern," the term generally refers to a repeating decorative design. With respect to the term "color," the term generally relates to the color of the fabric that can be provided by dyes and / or colorants. Further, when describing, for example, a fabric, the term "color" refers to the observable color of the yarns / fibers / filaments that form the fabric. This aspect contemplates that the color can be any color that can be provided to the yarns / fibers / filaments using dyes, pigments, and / or colorants known in the art. As such, the yarns / fibers / filaments can be configured to have a color including, but not limited to, red, orange, yellow, green, blue, indigo, violet, white, black, and shades thereof.

[0043] Aspects related to color further contemplate determining whether one color is different from another color. In these aspects, the color can include a digital color value, which can be determined by using an instrument that objectively measures and / or calculates the color value of an object's color by standardizing and / or quantifying factors that can affect color perception. Such instruments include, but are not limited to, a spectroradiometer, a spectrophotometer, and the like. Thus, aspects herein contemplate that the "color" of a fabric provided by a yarn / fiber / filament can include a digital color value measured and / or calculated using a spectroradiometer and / or a spectrophotometer. Further, the digital color value can be associated with a color space or color model, which is a particular organization of colors that provides a color representation for digital color values, and thus, each digital color value corresponds to a single color represented in the color space or color model.

[0044] In these aspects, one color can be determined to be different from another color if the digital color value of each color is different. Such a determination can be made by measuring and / or calculating a digital color value of a first fabric having a first color with a spectroradiometer or a spectrophotometer, measuring and / or calculating a digital color value of a second fabric having a second color with the same instrument (i.e., if a spectrophotometer is used to measure the digital color value of the first color, a spectrophotometer is used to measure the digital color value of the second color), and comparing the digital color value of the first color to the digital color value of the second color. In another example, the determination can be made by measuring and / or calculating a digital color value of a first region of a fabric with a spectroradiometer or a spectrophotometer, measuring and / or calculating a digital color value of a second region of the fabric having a second color with the same instrument, and comparing the digital color value of the first color to the digital color value of the second color. If the digital color values are not equal, the first color is different from the second color, and vice versa.

[0045] Further, it is contemplated that the visual distinction between the two colors can be related to a percentage difference between the digital color values of the first color and the second color, and that as the percentage difference between the color values increases, the visual distinction will be greater. Further, the visual distinction can be based on a comparison between color representations of the color values in a color space or model. For example, when the first color has a digital color value corresponding to a represented color that is black or dark blue, and the second color has a digital color value corresponding to a represented color that is red or yellow, the visual distinction between the first color and the second color is greater than the visual distinction between the first color represented as red and the second color represented as yellow.

[0046] Unless otherwise stated, all measurements provided herein are made at standard temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar).

[0047] Figure 1 and Figure 2 depict a view of a first surface 101 and a second, opposite surface 201, respectively, of an example fabric 100. The fabric 100 includes a thermal zone 110 and a pile zone 112. With respect to Figure 1 The first surface 101 of the thermal zone 110 is formed by a first woven layer 114. In example aspects, the first woven layer 114 can include nylon yarns, polyester yarns, a combination of nylon and polyester yarns, etc. The first woven layer 114 of the thermal zone 110 can form an outermost-facing surface of an article of clothing when the fabric 100 is incorporated into the article of clothing. In example aspects, the first woven layer 114 can be tightly woven such that the first woven layer 114 is substantially wind- and / or rain-penetrable. Having a tightly woven first woven layer 114 also helps to maintain hot air in the space between the first woven layer 114 and the second woven layer. In further example aspects, the first woven layer 114 can be treated with a durable water repellent finish to enhance the water- or water-resistant properties of the first woven layer 114. The first woven layer 114 can have visual properties, such as a color or a pattern.

[0048] As discussed below, the first surface 101 of the pile zone 112 is formed by the first woven layer 114 and the fibers / filaments 116 of a nonwoven layer positioned between the first woven layer 114 and the second woven layer. The fibers / filaments 116 of the nonwoven layer in the pile zone 112 extend through the first surface 101 such that the fibers / filaments 116 of the nonwoven layer extend outward from the surface plane of the first woven layer 114 (i.e., extend in the positive z-direction). This configuration imparts a pile-like texture to the pile zone 112. Due to the presence of the first woven layer 114, the pile zone 112 can also exhibit wind-and rain-resistant properties while providing a pleasing hand feel and pile-like aesthetic.

[0049] With respect to Figure 2The second surface 201 of the thermal zone 110 is formed by a second woven layer 214. In example aspects, the second woven layer 214 can include nylon yarns, polyester yarns, a combination of nylon and polyester yarns, or the like. The second woven layer 214 of the thermal zone 110 can form an innermost facing surface of the article of clothing when the fabric 100 is incorporated into the article of clothing. Similar to the first woven layer 114, the second woven layer 214 can be tightly woven such that the hot air trapped in the space between the first woven layer 114 and the second woven layer 214 generally remains in the space to help keep the wearer warm or thermally insulated. The second woven layer 214 can also have visual properties, such as a color or pattern. The visual properties of the second woven layer 214 can be the same or different than the visual properties of the first woven layer 114.

[0050] The second surface 201 of the thermal zone 110 is formed by a second woven layer 214. In example aspects, the second woven layer 214 can include nylon yarns, polyester yarns, a combination of nylon and polyester yarns, or the like. The second woven layer 214 of the thermal zone 110 can form an innermost facing surface of the article of clothing when the fabric 100 is incorporated into the article of clothing. Similar to the first woven layer 114, the second woven layer 214 can be tightly woven such that the hot air trapped in the space between the first woven layer 114 and the second woven layer 214 generally remains in the space to help keep the wearer warm or thermally insulated. The second woven layer 214 can also have visual properties, such as a color or pattern. The visual properties of the second woven layer 214 can be the same or different than the visual properties of the first woven layer 114.

[0051] Figure 3 A cross-section of the fabric 100 taken through the thermal zone 110 and the pile zone 112 is depicted. As shown, the thermal zone 110 includes a first woven layer 114 and a second woven layer 214. The first woven layer 114 includes a first surface 113 and a second surface 115 opposite the first surface 113. In example aspects, the first surface 113 of the first woven layer 114 forms the first surface 101 of the thermal zone 110 of the fabric 100. The second woven layer 214 also includes a first surface 213 and a second surface 215 opposite the first surface 213. In example aspects, the first surface 213 of the second woven layer 214 forms the second surface 201 of the thermal zone 110 of the fabric 100.

[0052] The nonwoven layer 310, having a first surface 312 and a second surface 314 opposite the first surface 312, is positioned in the space formed between the first woven layer 114 and the second woven layer 214. More specifically, the first surface 312 of the nonwoven layer 310 is positioned adjacent the second surface 115 of the first woven layer 114, and the second surface 314 of the nonwoven layer 310 is positioned adjacent the second surface 215 of the second woven layer 214. As explained in greater detail below, the nonwoven layer 310 can include two or more nonwoven sheets that are entangled together. In example aspects, the fibers / yarns 116 of the nonwoven layer 310 can be formed from polyester fibers / yarns, including recycled polyester fibers / yarns, although other materials including natural materials are also contemplated herein. In example aspects, the nonwoven layer 310 has a weight from about 150 grams per square meter (gsm) to about 250 gsm, from about 170 gsm to about 230 gsm, from about 190 gsm to about 210 gsm, or about 200 gsm. As used herein, the term“about” means within ±10% of the indicated value. The weight of the nonwoven layer 310 can be measured using, for example, the ISO 3801 test standard.

[0053] In the thermal insulation zone 110, the first woven layer 114, the nonwoven layer 310, and the second woven layer 214 are separate and distinct from one another such that a space or potential space is maintained between the second surface 115 of the first woven layer 114 and the first surface 312 of the nonwoven layer 310 and between the second surface 215 of the second woven layer 214 and the second surface 314 of the nonwoven layer 310. In other words, in the thermal insulation zone 110, the first woven layer 114, the nonwoven layer 310, and the second woven layer 214 are not attached to one another or are not attached to one another. In the thermal insulation zone 110, the space between the first woven layer 114, the second woven layer 214, and the nonwoven layer 310 traps hot air to help insulate a wearer of an article of clothing incorporating the fabric 100. Additionally, the spaces between the fibers / yarns 116 forming the nonwoven layer 310 also help trap hot air to further increase the insulating characteristics of the thermal insulation zone 110.

[0054] As Figure 3As shown, the pile section 112 of fabric 100 extends seamlessly from the insulation section 110. In other words, one or more warp or weft yarns in the insulation section 110 extend continuously and uninterruptedly into the pile section 112. The pile section 112 is created by an entanglement process, whereby the fibers / filaments 116 of the nonwoven layer 310 are entangled with the fibers, filaments, and / or yarns of the first woven layer 114 and the second woven layer 214. In an example, the integrity of the first woven layer 114 and the second woven layer 214 remains substantially intact in the pile section 112. For example, the warp and weft yarns forming the first woven layer 114 and the second woven layer 214 remain substantially interwoven in the pile section 112.

[0055] like Figure 3 As shown, the fibers / filaments 116 of the nonwoven layer 310 extend into the first woven layer 114. In some examples, the fibers / filaments 116 of the nonwoven layer 310 extend through the first woven layer 114 (i.e., through the first surface 113 of the first woven layer 114) such that in the pile section 112, the fibers / filaments 116 of the nonwoven layer 310 extend outward from the first surface 101 of the fabric 100. Similarly, the fibers / filaments 116 of the nonwoven layer 310 extend into the second woven layer 214. In some examples, the fibers / filaments 116 of the nonwoven layer 310 extend through the second woven layer 214 (i.e., through the first surface 213 of the second woven layer 214) such that in the pile section 112, the fibers / filaments 116 of the nonwoven layer 310 extend outward from the second surface 201 of the fabric 100. Due to the entanglement of the fibers / filaments 116 of the nonwoven layer 310 with the first woven layer 114 and the second woven layer 214 in the pile section 112, the first woven layer 114 and the second woven layer 214 are fixed or secured to the nonwoven layer 310 in the pile section 112. The extension of the fibers / filaments 116 of the nonwoven layer 310 through the first woven layer 114 and the second woven layer 214 in the pile section 112 creates a pile or velvety texture on the first surface 101 and the second surface 201 of the fabric 100. This provides a good hand feel and a pleasing aesthetic. Furthermore, because the first woven layer 114 and the second woven layer 214 are present in the pile section 112, the pile section 112 also exhibits wind and / or rain resistance or windproof and / or rainproof properties due to the tightly woven nature of the first woven layer 114 and / or the second woven layer 214.

[0056] Figure 4A schematic diagram illustrating an example process 400 of forming the nonwoven layer 310 is shown. At step 410, two or more nonwoven sheets are provided. The two or more nonwoven sheets can each be formed from a fibrous web that has undergone a carding and lapping process that generally aligns the fibers in one or more common directions extending along the x, y plane and achieves a desired basis weight. The fibrous web can also undergo a light needle punching process or a mechanical entangling process that entangles the fibers of the web to a degree such that the fibrous web forms a cohesive structure that can be manipulated (e.g., wound onto a roll, unwound from a roll, stacked, etc.). The nonwoven sheets can also undergo one or more additional processing steps such as printing (digital printing, sublimation printing, inkjet printing, etc.). In an example aspect, four nonwoven sheets 412, 414, 416, and 418 are provided. Each of the four nonwoven sheets 412, 414, 416, and 418 can have a basis weight from about 35 gsm to about 65 gsm, from about 40 gsm to about 60 gsm, from about 45 gsm to about 55 gsm, or about 50 gsm to achieve a desired basis weight of the nonwoven layer 310 from about 150 gsm to about 250 gsm. The nonwoven sheets 412, 414, 416, and 418 can have visual properties 420, 422, 424, and 426, respectively, as indicated by the different shading patterns. The visual properties 420, 422, 424, and 426 can be imparted by a printing process (digital printing, sublimation printing, inkjet printing, etc.). Additionally or alternatively, the visual properties 420, 422, 424, and 426 can be imparted by using fiber / yarns that are spun-dyed to form the nonwoven sheets 412, 414, 416, and 418. Although the visual properties 420, 422, 424, and 426 are shown as being different, it is contemplated herein that two or more of the visual properties can be the same. The visual properties 420, 422, 424, and 426 can include color, pattern, a combination of color and pattern, etc.

[0057] At step 428, the nonwoven sheets 412, 414, 416, and 418 are positioned or layered on top of one another to form a layered construction. Depending on the desired visual properties of the nonwoven layer 310, the nonwoven sheets 412, 414, 416, and 418 can be arranged in a particular order, although random arrangement is also contemplated. At step 430, a first entangling process 432 is performed from a first side or surface of the layered construction to a second side or surface of the layered construction. Additionally, a second entangling process 434 is performed from the second side or surface of the layered construction to the first side or surface of the layered construction. The first entangling process 432 and the second entangling process 434 can include mechanical processes, such as needle punching or hydro-entanglement, although other entangling processes are also contemplated herein. The first entangling process 432 and the second entangling process 434 cause the fibers / filaments from each of the nonwoven sheets 412, 414, 416, and 418 to become entangled, thereby affixing the nonwoven sheets 412, 414, 416, and 418 together to form a cohesive single layer structure. In example aspects, to achieve the desired integrity or cohesiveness of the nonwoven layer 310, the first entangling process 432 and the second entangling process 434 can be performed multiple times, such as two times up to seven times, respectively. In one example aspect, the first entangling process 432 and the second entangling process 434 can each be performed five times to achieve the desired cohesiveness while still having the desired loft of the nonwoven layer 310.

[0058] Step 436 depicts the nonwoven layer 310 formed from the entanglement of the fibers / filaments of the nonwoven sheets 412, 414, 416, and 418. The nonwoven layer 310 is shown as a continuous sheet without holes or apertures. It is contemplated herein that the nonwoven layer 310 can include holes or apertures. The holes or apertures can be formed during the entangling process, or they can be formed in a post-processing step using, for example, die cutting, laser cutting, water jet cutting, or the like.

[0059] Because the fibers / filaments from each of the nonwoven sheets 412, 414, 416, and 418 are entangled with one another, the visual properties of the nonwoven layer 310 represent a composite or mixture of the respective visual properties 420, 422, 424, and 426 as indicated by the shaded pattern in step 436. In example aspects, the amount of entanglement between the different nonwoven sheets 412, 414, 416, and 418 affects the visual properties of the resulting nonwoven layer 310. Using the illustrative example, the visual properties 420 and 424 can include blue, and the visual properties 422 and 426 can include yellow. When a greater number of the first entangling process 432 and the second entangling process 434 are performed, the visual properties of the nonwoven layer 310 can include a generally green color due to the greater degree of entanglement of the blue and yellow fibers and filaments. When a smaller number of the first entangling process 432 and the second entangling process 434 are performed, the visual properties of the nonwoven layer 310 can include a mottled color of blue regions intermixed with yellow regions.

[0060] In one example aspect, one of the nonwoven sheets, such as nonwoven sheet 412 or nonwoven sheet 418, or an additional nonwoven sheet not shown, can be added after the first entangling process 432 and the second entangling process 434 have been performed one or more times. By introducing the nonwoven sheet later in the entangling process, visual characteristics present on the introduced nonwoven sheet can be more pronounced or less intermingled in the resulting nonwoven layer 310. In an illustrative example, nonwoven sheet 412 can be introduced after the first entangling process 432 and the second entangling process 434 have been performed, for example, three times. Visual characteristics 420 in this example can include a pattern such as diagonal stripes. The first entangling process 432 and the second entangling process 434 can be performed, for example, two or more times to produce the nonwoven layer 310. Because nonwoven sheet 412 is subjected to less entangling than the remaining nonwoven sheets 414, 416, and 418, visual characteristics 420 are more pronounced in the resulting nonwoven layer 310 than visual characteristics 422, 424, and 426.

[0061] Figure 5 A schematic diagram of an example process 500 for forming the fabric 100 is depicted. At step 510, the first woven layer 114 and the nonwoven layer 310 are provided. The first woven layer 114 includes visual characteristics 512, and the nonwoven layer 310 includes visual characteristics 514 as indicated by the hatched pattern. In example aspects, the visual characteristics 512 can be the same as or different from the visual characteristics 514. The visual characteristics 512 and 514 can include color, pattern, a combination of color and pattern, and the like.

[0062] At step 516, the second surface 115 of the first woven layer 114 is positioned adjacent to the first surface 312 of the nonwoven layer 310 to form a layered construction. At step 518, a first entangling process 520, such as needling, is performed on the first region of the layered construction to at least partially form the pile zone 112. The first entangling process 520 is performed in a direction from the nonwoven layer 310 toward the first woven layer 114 to entangle the fibers / filaments 116 from the nonwoven layer 310 with the fibers / filaments / yarns of the first woven layer 114. In example aspects, the first entangling process 520 can be performed once, although it is contemplated herein that the first entangling process 520 can also be performed more than once. As there are more fibers / filaments available in the nonwoven layer 310, performing the first entangling process 520 in a direction from the nonwoven layer 310 toward the first woven layer 114 effectively secures or affixes the layers 114 and 310 together in the pile zone 112. Conversely, it has been found that performing an entangling process in a direction from the first woven layer 114 toward the nonwoven layer 310 does not secure these layers together as there are fewer fibers / filaments available in the first woven layer 114. For example, when needling is used as the entangling process, the needling creates holes in the first woven layer 114 but generally does not entangle the fibers / filaments / yarns from the first woven layer 114 with the fibers / filaments 116 of the nonwoven layer 310. It has also been found that needling better secures the first woven layer 114 to the nonwoven layer 310 than other mechanical entangling processes, such as hydroentanglement. This can be because hydroentanglement does not generate enough force to push the fibers / filaments 116 of the nonwoven layer 310 into and through the first woven layer 114.

[0063] At step 522, the first woven layer 114 is depicted as being entangled with the nonwoven layer 310 in the pile zone 112. As further shown, because the fibers / filaments 116 from the nonwoven layer 310 include the visual characteristic 514 (e.g., a color), the visual characteristic 514 is visible on the first surface 113 of the first woven layer 114 in the pile zone 112 due to the entanglement of the fibers / filaments 116 of the nonwoven layer 310 with the fibers / filaments / yarns of the first woven layer 114. At step 522, a second woven layer 214 is provided. In example aspects, the second woven layer 214 includes a visual characteristic 524. The visual characteristic 524 can be the same as or different from the visual characteristic 512 and / or the visual characteristic 514. Similar to the visual characteristics above, the visual characteristic 524 can include a color, a pattern, a combination of a color and a pattern, etc.

[0064] At step 526, the first surface 213 of the second woven layer 214 is positioned adjacent to the second surface 314 of the nonwoven layer 310 to form a layered construction. At step 528, a second entangling process 530, such as needling, is performed on an area of the layered construction corresponding to the pile zone 112. The second entangling process 530 is performed in a direction from the first woven layer 114 toward the second woven layer 214 to entangle the fibers / filaments 116 of the nonwoven layer 310, including the fibers / filaments 116 present within and on the first surface 113 of the first woven layer 114, with the fibers / filaments / yarns of the second woven layer 214. In example aspects, the second entangling process 530 can be performed once, although it is contemplated herein that the second entangling process 530 can also be performed more than once. Similar to the first entangling process 520, it has been found that needling can better secure the second woven layer 214 to the nonwoven layer 310 than other mechanical entangling processes, such as hydro-entanglement, possibly due to the large amount of force that can be generated by the needling process.

[0065] Step 532 depicts the first surface 101 and the second surface 201 of the fabric 100. With respect to the first surface 101, and as described above, the thermal zone 110 generally includes the visual characteristic 512 of the first woven layer 114, and the pile zone 112 generally includes a mix of the visual characteristic 512 of the first woven layer 114 and the visual characteristic 514 of the nonwoven layer 310. With respect to the second surface 201 of the fabric 100, the thermal zone 110 generally includes the visual characteristic 524 of the second woven layer 214, and the pile zone 112 generally includes a mix of the visual characteristic 514 of the nonwoven layer 310 and the visual characteristic 524 of the second woven layer 214. The depiction of the process 500 is illustrative only, and it is contemplated herein that the visual characteristics can differ from those shown. For example, in some aspects, the first woven layer 114 and / or the second woven layer 214 can be translucent or partially translucent, such that the visual characteristic 514 of the nonwoven layer 310 is partially visible through the first woven layer 114 and / or the second woven layer 214 in the thermal zone 110 of the fabric 100. Likewise, the location, size, and shape of the thermal zone 110 and the pile zone 112 can differ from those shown.

[0066] The described process 500 utilizes two woven layers, such as the first woven layer 114 and the second woven layer 214, and one nonwoven layer, such as the nonwoven layer 310, to produce a fabric that includes both a thermal zone and a pile zone in a seamless construction. The process 500 produces a varying aesthetic between the thermal zone and the pile zone on a particular surface of the fabric, as well as a varying aesthetic on both the first surface and the second surface of the fabric.

[0067] The fabric 100 can be incorporated into a variety of different garments. For example, Figure 6An upper body garment 600 formed from the fabric 100 is depicted. The upper body garment 600 is shown in the form of a vest having a torso portion 610, a neck opening 612, a waist opening 614, a first arm portion opening 616, and a second arm portion opening 618. Although shown as a vest, it is contemplated herein that the upper body garment 600 can be in the form of a jacket with sleeves, a pullover, a shirt, a hoodie, or the like.

[0068] The upper body garment 600 includes thermal zones 620 corresponding to the thermal zones 110 of the fabric 100 and pile zones 622 corresponding to the pile zones 112 of the fabric 100. The locations of the thermal zones 620 and the pile zones 622 can be based on, for example, a heat map of a human body. For example, the thermal zones 620 can be located on the upper body garment 600 in areas corresponding to high heat loss by a wearer, such as the upper front torso and the upper back torso, and the pile zones 622 can be located on the upper body garment 600 in areas of lower heat loss, such as the lower front torso and the lower back torso. The size, shape, and number of the thermal zones 620 and the pile zones 622 on the upper body garment 600 are illustrative only. In example aspects, the upper body garment 600 can include a plurality of thermal zones and a plurality of pile zones. Any and all aspects and any variations thereof are contemplated within the aspects herein.

[0069] Figure 7 A lower body garment 700 formed from the fabric 100 is depicted. The lower body garment 700 is in the form of pants having a torso portion 710 with a waist opening 712, a first leg portion 714 with a first leg opening 716, and a second leg portion 718 with a second leg opening 720. Although shown as pants, it is contemplated herein that the lower body garment 700 can be in the form of shorts, leggings, capris, jumpsuits, or the like.

[0070] The lower body garment 700 includes thermal zones 722 located on the torso portion 710 and on lower portions of the first leg portion 714 and the second leg portion 718. Pile zones 724 are located on upper and middle portions of the first leg portion 714 and the second leg portion 718. The locations of the thermal zones 722 and the pile zones 724 can be based on a heat map of a human body. The size, shape, and number of the thermal zones 722 and the pile zones 724 are illustrative.

[0071] Although not shown, it is contemplated that the fabric 100 can be used to form additional articles, such as hats, gloves, limb sleeves, socks, shoe uppers, and the like.

[0072] Figure 8is a flowchart of an example method 800 of manufacturing a fabric, such as fabric 100. At step 810, a nonwoven layer, such as nonwoven layer 310, is positioned between a first woven layer, such as first woven layer 114, and a second woven layer, such as second woven layer 214, to form a layered construction. At step 812, fibers and filaments from the nonwoven layer are entangled with fibers, filaments, and / or yarns from each of the first woven layer and the second woven layer in a first region of the layered construction to form a pile zone. It is contemplated herein that in a second region of the layered construction corresponding to a thermal barrier zone, the entangling process is not performed such that the first woven layer, the second woven layer, and the nonwoven layer comprise separate and distinct layers.

[0073] Aspects herein also contemplate forming the nonwoven layer by entangling fibers and filaments from two or more nonwoven sheets together, as described with respect to process 400.

[0074] As Figure 5 illustrated, step 812 can include positioning the first woven layer adjacent to a first surface of the nonwoven layer and performing a first entangling process in a direction from the nonwoven layer toward the first woven layer. After completing the first entangling process, the second woven layer is positioned adjacent to a second, opposite surface of the nonwoven layer. A second entangling process is then performed in a direction from the first woven layer toward the second woven layer to complete formation of the pile zone.

[0075] As described with respect to processes 400 and 500, the visual properties of the nonwoven sheet used to form the nonwoven layer can be selected to achieve desired visual properties of the nonwoven layer. Further, the visual properties of the first woven layer and the second woven layer can be selected to achieve desired visual properties of the thermal barrier zone and the pile zone on a first surface of the fabric and desired visual properties of the thermal barrier zone and the pile zone on a second, opposite surface of the fabric. The visual properties of the fabric can also be adjusted based on the degree of entanglement of the nonwoven sheet used to form the nonwoven layer and the degree of entanglement of the nonwoven layer with each of the first woven layer and the second woven layer.

[0076] Aspects of the disclosure have been described with the intention of being illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art without departing from the scope of the disclosure. Alternative means of implementing the aforementioned improvements will become apparent to those skilled in the art without departing from the scope of the disclosure.

[0077] It should be appreciated that certain features and subcombinations are of utility 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 of the figures is required, nor is there any particular order required for the steps described.

Claims

1. A fabric comprising: a thermal zone, the thermal zone comprising a first woven layer, a second woven layer, and a nonwoven layer positioned between the first woven layer and the second woven layer, each of the first woven layer and the second woven layer being unattached to the nonwoven layer in the thermal zone; and a pile zone seamlessly extending from the thermal zone, the pile zone comprising the first woven layer, the second woven layer, and the nonwoven layer positioned between the first woven layer and the second woven layer, wherein fibers and / or filaments from the nonwoven layer extend into and through the first woven layer and the second woven layer and entangle with one or more of fibers, filaments, and yarns from each of the first woven layer and the second woven layer, such that the first woven layer and the second woven layer are affixed to the nonwoven layer in the pile zone, and wherein the fibers and / or filaments of the nonwoven layer extend outwardly from a surface plane of the first woven layer and the second woven layer, respectively, in the pile zone to impart a pile texture to the pile zone.

2. The fabric of claim 1, wherein the nonwoven layer comprises two or more nonwoven sheets, and wherein fibers and / or filaments from each of the two or more nonwoven sheets entangle with one another.

3. The fabric of claim 2, wherein a first nonwoven sheet of the two or more nonwoven sheets comprises a first visual characteristic, and wherein a second nonwoven sheet of the two or more nonwoven sheets comprises a second visual characteristic different from the first visual characteristic.

4. The fabric of claim 3, wherein the first visual characteristic comprises a first color, and wherein the second visual characteristic comprises a second color.

5. The fabric of any one of claims 3-4, wherein the first visual characteristic comprises a first pattern, and wherein the second visual characteristic comprises a second pattern.

6. The fabric of any one of claims 1-4, wherein the nonwoven layer has a weight from about 180 grams per square meter (gsm) to about 220 gsm.

7. An article of clothing comprising: a thermal zone, the thermal zone comprising a first woven layer, a second woven layer, and a nonwoven layer positioned between the first woven layer and the second woven layer, wherein the first woven layer, the second woven layer, and the nonwoven layer comprise separate and distinct layers in the thermal zone; and a pile zone seamlessly extending from the thermal zone, the pile zone comprising the first woven layer, the second woven layer, and the nonwoven layer positioned between the first woven layer and the second woven layer, wherein fibers and / or filaments from the nonwoven layer extend into and through the first woven layer and the second woven layer and entangle with one or more of fibers, filaments, and yarns from each of the first woven layer and the second woven layer, such that the first woven layer and the second woven layer are affixed to the nonwoven layer in the pile zone, and wherein the fibers and / or filaments of the nonwoven layer extend outwardly from a surface plane of the first woven layer and the second woven layer, respectively, in the pile zone to impart a pile texture to the pile zone. ​ a pile zone seamlessly extending from the thermal zone, the pile zone including the first woven layer, the second woven layer, and the nonwoven layer, wherein fibers and / or filaments from the nonwoven layer in the pile zone extend into and through the first woven layer and the second woven layer and entangle with one or more of fibers, filaments, and yarns from each of the first woven layer and the second woven layer, such that the first woven layer and the second woven layer are affixed to the nonwoven layer in the pile zone, and wherein the fibers and / or filaments of the nonwoven layer in the pile zone extend outwardly from surface planes of the first woven layer and the second woven layer, respectively, to impart a pile texture to the pile zone.

8. The garment of claim 7, wherein neither the first woven layer nor the second woven layer is affixed to the nonwoven layer in the thermal zone.

9. The garment of any one of claims 7 to 8, wherein the nonwoven layer has a visual property that is different from a visual property of one or more of the first woven layer and the second woven layer.

10. The garment of any one of claims 7 to 8, wherein the nonwoven layer includes two or more nonwoven sheets, and wherein fibers and / or filaments from each of the two or more nonwoven sheets are entangled with one another.

11. The garment of claim 10, wherein a first nonwoven sheet of the two or more nonwoven sheets includes a first visual property, and wherein a second nonwoven sheet of the two or more nonwoven sheets includes a second visual property that is different from the first visual property.

12. The garment of any one of claims 7, 8, and 11, wherein the nonwoven layer has a weight of from about 180 grams per square meter (gsm) to about 220 gsm.

13. The garment of any one of claims 7, 8, and 11, wherein the thermal zone is positioned on the garment in an area corresponding to a high heat loss area of a wearer when the garment is in a worn configuration.

14. A method of manufacturing a garment, comprising: positioning a nonwoven layer between a first woven layer and a second woven layer to form a layered construction; and extending fibers and / or filaments from the nonwoven layer into and through the first woven layer and the second woven layer in a first area of the layered construction and entangling the fibers and / or filaments from the nonwoven layer with one or more of fibers, filaments, and yarns from each of the first woven layer and the second woven layer, wherein each of the first woven layer and the second woven layer remains unaffixed to the nonwoven layer in a second area of the layered construction, and wherein the fibers and / or filaments of the nonwoven layer extend outwardly from surface planes of the first woven layer and the second woven layer, respectively, in the first area of the layered construction to impart a pile texture to the first area of the layered construction.

15. The method of manufacturing an article of clothing of claim 14, wherein the nonwoven layer is formed by positioning two or more nonwoven sheets adjacent to one another and entangling fibers and / or filaments from each of the two or more nonwoven sheets with one another using an entangling process.

16. The method of manufacturing an article of clothing of claim 15, wherein the entangling process is performed in a direction from a first surface of the nonwoven layer toward a second surface of the nonwoven layer and in a direction from the second surface of the nonwoven layer toward the first surface of the nonwoven layer.

17. The method of manufacturing a garment according to any of claims 14-16, wherein entangling the fibers and / or filaments from the nonwoven layer with one or more of the fibers, filaments, and yarns from each of the first woven layer and the second woven layer comprises: positioning the first woven layer adjacent to a first surface of the nonwoven layer; performing a first entangling process in a direction from the nonwoven layer toward the first woven layer; subsequently positioning the second woven layer adjacent to a second, opposite surface of the nonwoven layer; and performing a second entangling process in a direction from the first woven layer toward the second woven layer.

18. The method of manufacturing an article of clothing of any of claims 14-16, wherein the nonwoven layer has a weight of from about 180 grams per square meter (gsm) to about 220 gsm.

19. The method of manufacturing an article of clothing of any of claims 14-16, wherein the nonwoven layer has a visual property that is different from a visual property of one or more of the first woven layer and the second woven layer.

20. The method of manufacturing an article of clothing of claim 19, wherein the visual property of the nonwoven layer and the one or more of the first woven layer and the second woven layer includes color.

Images