Embossed and pleated finish of composite nonwoven fabric and method for producing the same

Abstract

The present application relates to embossed and pleated finish sections of composite nonwoven fabrics and methods of producing the same. Aspects herein relate to a composite nonwoven fabric having at least a first entangled fibrous web, a second entangled fibrous web, and an elastomeric layer positioned between the first entangled fibrous web and the second entangled fibrous web. The composite nonwoven fabric includes different features including one or more embossed portions and one or more pleated configurations.

Description

Technical Field

[0001] This article covers various aspects of debossed and pleated finishes for composite nonwoven fabrics applicable to clothing and other products, and their production methods. Background Technology

[0002] Traditional nonwoven fabrics possess characteristics that generally make them unsuitable for use in apparel. Due to these characteristics and their end uses in industries such as cleaning and personal hygiene, traditional nonwoven fabrics may be incompatible with finishing processes and techniques typically used for knitted and / or woven fabrics. Consequently, traditional nonwoven fabrics often lack the aesthetic and / or functional characteristics desired in apparel. 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 an example lifecycle of a printed composite nonwoven fabric based on various aspects of this article;

[0005] Figure 2 The diagram illustrates the various aspects used in this article. Figure 1 Example of a composite nonwoven fabric's first fiber web;

[0006] Figure 3 The diagram illustrates the various aspects used in this article. Figure 1 Example of a printed layer in a composite nonwoven fabric;

[0007] Figure 4 The diagram illustrates the various aspects used in this article. Figure 1 Example of a second fiber web in a composite nonwoven fabric;

[0008] Figure 5 The diagram illustrates the various aspects used in this article. Figure 1 An example of an optional third fiber web for composite nonwoven fabrics;

[0009] Figure 6 The diagram illustrates the various aspects used in this article. Figure 1 An example of an elastomer layer in a composite nonwoven fabric;

[0010] Figure 7 The illustration shows the various aspects used in the production process according to this article. Figure 1 Example of printed composite nonwoven fabric and further used in Figure 1 Example manufacturing process for making garments using printed composite nonwoven fabrics;

[0011] Figure 8 The diagram illustrates the use of various aspects of this article. Figure 7 An example printed layer produced by a manufacturing process, the example printed layer comprising an inner fiber web and printed components;

[0012] Figure 9 The diagram illustrates the various aspects based on this article. Figure 8 A cross-sectional view taken at the cutting line 9-9;

[0013] Figure 10 The diagram illustrates the various aspects based on this article. Figure 8 A cross-sectional view of an alternative printed component in an example printed layer;

[0014] Figure 11 The diagram illustrates the usefulness of various aspects according to this article. Figure 7 The manufacturing process produced Figure 8 Example of a printed composite nonwoven fabric with a printed layer;

[0015] Figure 12 The diagram illustrates the various aspects based on this article. Figure 11 A cross-sectional view taken at the cutting line 12-12;

[0016] Figure 13 The diagram illustrates the various aspects based on this article. Figure 12 Enlarged views cropped from 13 locations in the area;

[0017] Figure 14 The diagram illustrates the various aspects based on this article. Figure 12 Enlarged views cropped from 14 locations in the region;

[0018] Figure 15 The diagram illustrates the use of various aspects of this article. Figure 7 An example printed layer produced by a manufacturing process, the example printed layer comprising a spunlace layer and printed components;

[0019] Figure 16 The diagram illustrates the various aspects based on this article. Figure 15 A cross-sectional view taken at the cutting line 16-16;

[0020] Figure 17 The diagram illustrates the various aspects based on this article. Figure 15 A cross-sectional view of an alternative printed component in an example printed layer;

[0021] Figure 18 The diagram illustrates the usefulness of various aspects according to this article. Figure 7 The manufacturing process produced Figure 15 Example of a printed composite nonwoven fabric with a printed layer;

[0022] Figure 19 The diagram illustrates the various aspects based on this article. Figure 18A cross-sectional view taken at the cutting line 19-19;

[0023] Figure 20 The diagram illustrates the various aspects based on this article. Figure 19 Enlarged views cropped from 20 locations in the area;

[0024] Figure 21 The diagram illustrates the various aspects based on this article. Figure 19 A magnified view cropped from area 21;

[0025] Figure 22 The illustrations show examples of upper body clothing products based on various aspects of this article;

[0026] Figure 23 The illustrations show examples of lower body clothing products based on various aspects of this article;

[0027] Figure 24 The diagram illustrates the various aspects based on this article. Figure 22 A cross-sectional view taken at the cutting line 24-24;

[0028] Figure 25 The diagram illustrates the various aspects based on this article. Figure 23 A cross-sectional view taken at the cutting line 25-25;

[0029] Figure 26 The illustration shows an exploded view of an example composite nonwoven fabric used for finishing processes and techniques according to various aspects of this article.

[0030] Figure 27A The illustration shows the first outer facing side of an example composite nonwoven fabric with a recessed portion according to various aspects of this article;

[0031] Figure 27B The diagram illustrates the various aspects based on this article. Figure 27A Example of a composite nonwoven fabric with a second outer surface side;

[0032] Figure 28 The diagram illustrates the various aspects based on this article. Figure 27A Example cross-sectional view of a composite nonwoven fabric;

[0033] Figure 29 The diagram illustrates the various aspects used to form according to this article. Figure 27A Example of a embossed portion of a composite nonwoven fabric and further used for... Figure 27A Example manufacturing process for making garments using composite nonwoven fabrics;

[0034] Figure 30A The illustration shows the outward-facing surface of an example upper garment garment according to various aspects of this article;

[0035] Figure 30B The diagram illustrates the various aspects based on this article. Figure 30A Example of an inward-facing surface of an upper garment;

[0036] Figure 31A The illustration shows the outward-facing surface of a lower garment garment as shown in the examples from various aspects of this article;

[0037] Figure 31B The diagram illustrates the various aspects based on this article. Figure 31A Example of an inward-facing surface of a lower garment;

[0038] Figure 32A The illustration shows the first outer surface side of the pleated construction based on various aspects of this article;

[0039] Figure 32B The diagram illustrates the various aspects based on this article. Figure 32A Example of a pleated construction on the second outer surface side;

[0040] Figure 33 The diagram illustrates the various aspects based on this article. Figure 32A An exploded view of an example pleated construction;

[0041] Figure 34 The diagram illustrates the various aspects used to form according to this article. Figure 32A The pleated construction and further used for Figure 32A An example of a manufacturing process for creating garments using pleats;

[0042] Figure 35 The illustrations show examples of upper body clothing products based on various aspects of this article;

[0043] Figure 36 The illustrations show examples of lower garments based on various aspects of this article; and

[0044] Figure 37 The diagram illustrates the various aspects based on this article. Figure 35 Example cross-sectional view of an upper garment. Detailed Implementation

[0045] The subject matter of this invention has been specifically described herein to satisfy legal requirements. However, this description itself is not intended to limit the scope of this disclosure. Rather, the inventors have envisioned that the claimed or disclosed subject matter may also be embodied in other ways in combination with other current or future techniques to include different steps or combinations of steps similar to those described herein. Furthermore, although the terms “step” and / or “box” may be used herein to refer to different elements of the method employed, these terms should not be construed as implying any particular order among or between the various steps disclosed herein, unless and only if the order of individual steps is explicitly stated.

[0046] Traditional nonwoven fabrics often possess characteristics unsuitable for apparel. These characteristics may include a lack of stretch and resilience, high weight, poor drape, a rough hand feel, symmetrical faces or surfaces, and a lack of insulation properties in some cases where increased insulation is desired. Due to these characteristics and their end-uses in industries such as cleaning and personal hygiene, traditional nonwoven fabrics may be difficult to print on and may lack aesthetic appeal. Furthermore, when printing on nonwoven fabrics, the print aesthetic is applied to the outermost surface, resulting in poor quality and diminishing over time due to factors such as wear and tear. Such print aesthetics are undesirable for nonwoven fabrics intended for apparel.

[0047] This document relates in various aspects to printed composite nonwoven fabrics suitable for clothing and other articles, and methods of manufacturing thereof. At a high level, a printed composite nonwoven fabric includes one or more entangled webs of fibers and a printed layer (e.g., an inner layer including a printed component). In an exemplary embodiment, the printed composite nonwoven fabric includes a first entangled web of fibers and an inner layer. The first entangled web of fibers has a first side and an opposing second side. The first side of the first entangled web of fibers at least partially forms a first facing side of the printed composite nonwoven fabric. The inner layer has a first side positioned adjacent to the second side of the first entangled web of fibers. The first side of the inner layer includes a printed component having a first portion that is more incorporated into the first entangled web of fibers than a second portion of the printed component.

[0048] In other examples, the printed composite nonwoven fabric may include one or more additional layers (e.g., a second entangled fiber web, a third entangled fiber web, and / or an elastomer layer) laminated together and / or entangled with a first entangled web and / or an inner layer. In one such aspect, the printed composite nonwoven fabric includes a second entangled fiber web having a first side and an opposing second side, the second side at least partially forming a second facing side of the printed composite nonwoven fabric. Accordingly, an inner layer is located between the first entangled fiber web and the second entangled fiber web, such that the first side of the inner layer is adjacent to the second side of the first entangled fiber web, and the second side of the inner layer is adjacent to the first side of the second entangled fiber web.

[0049] Additionally, and according to various aspects thereof, the printed composite nonwoven fabric can be asymmetrically finished (e.g., a printed asymmetrical-faced composite nonwoven textile) due to the characteristics of the first and second entangled fiber webs, as well as the characteristics of the inner layers and / or any additional layers. In another example aspect, these characteristics can be configured to make the printed composite nonwoven fabric suitable for garment articles. When the printed composite nonwoven fabric is incorporated into a garment article, the first facing side forms the outward-facing surface of the garment article, and the second facing side forms the inward-facing surface of the article. Accordingly, when the printed asymmetrically-faced composite nonwoven fabric is incorporated into a garment article, the first entangled web may have characteristics that make it suitable for exposure to the external environment. For example, the fibers forming the first entangled web may have a denier approximately twice that of the fibers used to form the second entangled web, so that the first entangled web can better withstand abrasion without fiber breakage, and thus enhance the durability of the printed part.

[0050] When a composite nonwoven fabric with a printed asymmetrical finish is formed into a garment, the characteristics of the second entangled fiber web make it suitable for forming the skin-facing surface. For example, the fibers forming the second entangled web may have a denier of approximately half that of the fibers used to form the first entangled web, because the second finished side may be less exposed to abrasion forces. Furthermore, a lower denier can produce a softer hand feel, making it comfortable for skin or near-skin contact. Additionally, the second entangled web may include silicone-coated fibers, which also contribute to the soft hand feel and improve the fabric's drape (i.e., make the fabric less stiff).

[0051] Other asymmetrical features of the printed composite nonwoven fabrics envisioned in this paper include printed components and / or different color characteristics associated with the first and second facing sides. In one aspect, the printed components are more visible on the first facing side than on the second facing side. In another aspect, the printed components may be visible on the first facing side but not on the second facing side. Other aspects envision the color characteristics as taking the form of a more pronounced color mixing effect on the first facing side than on the second facing side. The printed components and different color characteristics can impart a desired aesthetic to garments formed from nonwoven fabrics and can also provide the wearer with a visual marker as to which side of the garment faces outward and which side faces inward. Different color characteristics may also make the garment suitable for reversible wear (i.e., "inside out"). For example, different color characteristics can be imparted to the sides by selecting specific colors for the fibers forming different layers of the fabric and / or by selecting entanglement parameters such that colored fibers selectively move more towards the first side than the second side (or vice versa).

[0052] One or more additional layers of the printed composite nonwoven fabric may also include an elastomeric layer located between a first entangled fiber web and a second entangled fiber web. The elastomeric layer imparts tensile and recovery properties to the printed composite nonwoven fabric, making it suitable for apparel products such as tops and bottoms. The elastomeric layer itself may lack sufficient tensile strength to withstand normal wear and tear. Therefore, the elastomeric layer is integrated into the printed composite nonwoven fabric by using an entanglement process to extend fibers from different webs through the elastomeric layer to create a cohesive structure.

[0053] In some examples, one or more additional layers of the printed composite nonwoven fabric include additional entangled webs (e.g., a third entangled fiber web) laminated together with the elastomer layer. The weight of the pre-entangled webs can be selected to achieve a lightweight composite nonwoven fabric with minimal thickness after entanglement. Furthermore, the selection of the number of entangled webs, fiber denier, fiber type, fiber length, etc., results in a printed composite nonwoven fabric that provides enhanced insulation by trapping air between the fibers forming the fabric. Additionally, the characteristics and / or the number of different webs used to form the printed composite nonwoven fabric can be adjusted to achieve different desired final characteristics of the printed nonwoven fabric, including different desired final characteristics of each side of the printed composite nonwoven fabric. The result is a lightweight, printed, asymmetrically finished composite nonwoven fabric with stretch and recovery properties, good drape, interesting visual appeal, good abrasion resistance, and a soft hand feel, making composite nonwoven fabrics ideal for forming apparel articles suitable for sportswear.

[0054] The composite nonwoven fabrics envisioned in this paper can be finished in various ways. For example, the fabric can be printed with one or more patterns, graphics, logos, etc., using selected printing techniques. In one example, the print can be applied to one or more fiber webs before entanglement, allowing the printed elements to be integrated into the nonwoven fabric during entanglement. Furthermore, when the nonwoven fabric is formed into a garment, different techniques can be used to sew the fabric edges together. For example, the fabric edges can overlap, and an entanglement process can be used to entangle the fibers from the fabric edges together, thereby forming a seam.

[0055] This paper also envisions that printed composite nonwoven fabrics are recyclable, and in some respects, the fabrics can be fully recyclable. Therefore, in various aspects, the fibers selected for forming the entangled web can include recycled materials, including recycled polyethylene terephthalate (PET) fibers, commonly referred to as polyester fibers. Additionally, the materials selected for forming the elastomer layer can also be fully recyclable. The use of recycled fibers and materials reduces the carbon footprint of printed composite nonwoven fabrics.

[0056] Printed composite nonwoven fabrics are formed by positioning a printed layer (e.g., an inner layer including printed components) between a first fiber web and one or more additional layers to form a composite structure. Prior to forming the composite structure, the printed layer can be formed by creating printed components on the inner layer using a printing technique. Furthermore, characteristics such as the number of webs, fiber denier, weight of each web, fiber length, fiber color, and fiber coating are selected for the first fiber web, the inner layer, and the one or more additional layers, based on the desired final characteristics of the printed composite nonwoven fabric. After forming the printed layer and then combining it with the first fiber web and one or more additional layers to form the composite structure, a mechanical entanglement process is performed. In one example aspect, the mechanical entanglement process is needle punching. Based on the desired final characteristics of the asymmetric finish printed composite nonwoven fabric, different parameters associated with the needle punching process are selected, such as needle selection, stitch density, penetration depth, penetration direction, number of needle passes, etc. For example, parameters can be selected to produce nonwoven fabrics with desired thickness, desired tensile and recovery degree, desired weight, desired drape, or stiffness, etc.

[0057] Additional aspects of this document relate to methods for manufacturing printed composite nonwoven fabrics, and generally, such methods include one or more steps related to forming a printed layer, combining the printed layer with a first fiber web and / or an additional layer to form a composite structure, and subjecting the composite structure to a needle entanglement process. In an example aspect, the method of manufacturing a printed composite nonwoven fabric includes the step of positioning a first side of the printed layer adjacent to a second side of the first fiber web to form the composite structure. The printed layer includes printed elements, which may be at least partially formed by a colorant pre-applied to an inner layer. The manufacturing method also includes the step of subjecting the composite structure to a needle entanglement process, wherein at least a portion of the printed elements is subsequently bonded to the first fiber web.

[0058] In some examples, a method for manufacturing a printed asymmetrical composite nonwoven fabric includes the steps of forming printed elements on an inner layer using a printing technique to form a printed layer, and a subsequent step of positioning a first side of the printed layer adjacent to a second side of a first fiber web to form a composite structure. The method includes another step of subjecting the composite structure to a variable entanglement process, wherein at least a portion of the subsequently printed elements and the first side of the first fiber web at least partially form a first finished side of the asymmetrically finished composite nonwoven fabric.

[0059] In another example, printing techniques (e.g., applying colorants via digital printing, applying sublimation dyes via sublimation printing, etc.) can be used to form printed parts on an inner layer. Such aspects envision that the printed parts can be formed on the inner layer prior to entanglement (i.e., prior to entanglement of fibers comprising one or more entangled fiber webs in a printed composite nonwoven fabric). These aspects envision that the inner layer may comprise fiber webs (e.g., fiber webs prior to entanglement), and also envision that the inner layer may be a spunlace layer and / or may comprise spunlace fibers.

[0060] As used herein, the term "clothing article" is intended to encompass articles worn by a wearer. Accordingly, these may include upper garments (e.g., shirts, t-shirts, pullovers, hoodies, jackets, coats, etc.) and lower garments (e.g., trousers, shorts, leggings, capri pants, bodysuits, etc.). Clothing articles may also include hats, gloves, sleeves (arm sleeves, calf sleeves), footwear (such as shoe uppers), etc. The term "inward-facing surface" in relation to clothing articles refers to a surface configured to face the wearer's body surface, and the term "outward-facing surface" refers to a surface configured to face away from the wearer's body surface and towards the external environment. The term "innermost surface" refers to the surface closest to the wearer's body surface relative to other layers of the clothing article, and the term "outermost surface" refers to the surface positioned furthest from the wearer's body surface relative to other layers of the clothing article.

[0061] As used herein, the term "nonwoven fabric" refers to fibers held together by mechanical and / or chemical interactions without being knitted, woven, braided, or otherwise structured. In a specific aspect, nonwoven fabrics comprise an assembly of fibers mechanically manipulated to form a cushion-like material. In other words, nonwoven fabrics are made directly from fibers. Nonwoven fabrics can include different fiber webs formed as cohesive structures, wherein different fiber webs may have different or similar fiber compositions and / or different properties. The term "fiber web" refers to a fiber web prior to undergoing a mechanical entanglement process with one or more other fiber webs. Fiber webs include fibers that have undergone carding and overlapping processes, typically aligning fibers in one or more common directions extending along the xy plane and achieving a desired basis weight. Fiber webs may also undergo light needle punching or mechanical entanglement processes, which entangle the fibers of the web to a degree that allows the fiber web to form a manipulable cohesive structure (e.g., wound onto a roller, unwound from a roller, stacked, etc.). The fiber web may also undergo one or more additional processing steps, such as printing before entanglement with other fiber webs to form a composite nonwoven fabric. The term "entangled fiber web," when referring to a composite nonwoven fabric, refers to a fiber web that has undergone mechanical entanglement with one or more other fiber webs. Accordingly, the entangled fiber web may include fibers initially present in the forming layer, as well as fibers present in other fiber webs that have been moved into the entangled fiber web through the entanglement process. As used herein, the term "inner layer" refers to a nonwoven fabric layer located between at least two other layers of the nonwoven fabric. As used herein, the term "printed layer" refers to a composite nonwoven fabric layer comprising printed elements.

[0062] In one example, the printed layer is arranged such that it is located inside the outermost fiber web (e.g., the first fiber web) or layer of the printed composite nonwoven fabric. This aspect envisions that the printed layer, and consequently the printed components, are less exposed to or not exposed to the external environment. Therefore, the printed layer and printed components are less susceptible to wear and tear. In another example, the arrangement of the printed layer as an inner layer can also help secure the printed layer in its proper position within the printed composite nonwoven fabric. Furthermore, the characteristics of the printed layer can result in less entanglement than other fiber webs and / or layers of the printed composite nonwoven fabric. Accordingly, positioning the printed layer between two fiber webs and / or layers, making it an inner layer of the printed composite nonwoven fabric, can provide more entanglement for the printed layer than when it is positioned as an outer or outermost layer of the printed composite nonwoven fabric.

[0063] The mechanical entanglement processes envisioned herein may include needle entanglement (commonly referred to as needle punching) using barbed or structured needles (e.g., forked needles), or fluid entanglement. In the aspects envisioned herein, needle punching can be used due to the small denier of the fibers used and the ability to fine-tune different parameters associated with the needle punching process. Needling typically uses barbed or spiked needles to reposition a proportion of fibers from a generally horizontal orientation (an orientation extending along the xy-plane) to a generally vertical orientation (z-direction orientation). Referring typically to the needle punching process, carded, overlapped, and pre-needled webs can be stacked together with other carded, overlapped, and pre-needled webs, passing between a bed plate and a stripper plate located on opposite sides of a stacked web configuration. Barbed needles, fixed to the needle board, move in and out of the stacked web configuration, and the stripper plate peels the fibers from the needles after the needles have entered and exited the stacked web configuration. The distance between the stripper plate and the base plate can be adjusted to control web compression during needle punching. As the stacked web configuration moves along the conveyor system in the machine direction, needle plates repeatedly engage and disengage with the stacked web configuration, thus needle punching the length of the stacked web configuration. This document envisions the use of multiple needle plates located sequentially at different points along the conveyor system, wherein different needle plates can engage the stacked web configuration from different faces (e.g., top and bottom) as the stacked web configuration moves in the machine direction. Each engagement of the needle plate with the stacked web configuration is referred to herein as a “pass.” Parameters associated with a particular needle plate can be adjusted to achieve desired properties of the resulting needle-punched nonwoven fabric (e.g., basis weight, thickness, etc.). Different parameters may include stitch density (SD) and penetration depth (PD), where stitch density is the depth per centimeter used during the entanglement process. 2 Number of stitches (n / cm) 2 Penetration depth is the distance the needle travels through the stacked web configuration before being pulled out of it. Parameters related to the needle punching process, such as the spacing between the base plate and the peeling plate, and the feed speed of the stacked web configuration, can also typically be adjusted.

[0064] This document envisions the use of barbed needles (needles with barbs arranged along the length of the needle), although other needle types are also envisioned. As the barbs move from a first face of a stacked web configuration to an opposing second face, the barbs on the needle "capture" fibers. The movement of the needle through the stacked web configuration effectively moves or pushes the fibers captured by the barbs from a position near or at the first finish side to a position near or at the second finish side, and further induces physical interaction with other fibers, thereby helping to "lock" the moved fibers into place by, for example, friction. This document also envisions that these needles can pass through the stacked web configuration from the second finish side toward the first finish side. In an example aspect, the number of barbs on the needle interacting with the fibers can be based on the needle's penetration depth. For example, when the penetration depth is a first amount, all barbs can interact with the fibers, and as the penetration depth decreases, fewer barbs can interact with the fibers. In another example aspect, the size of the barbs can be adjusted based on the denier of the fibers used in the web. For example, the barb size can be selected to engage with low denier (e.g., fine) fibers rather than high denier fibers, so as to cause selective movement of the low denier fibers rather than the high denier fibers. In another example, the barb size can be selected to engage with both low denier and high denier fibers, so as to cause both fibers to move through the web.

[0065] After entanglement, the nonwoven fabric may include a first facing side and an opposing second facing side, both of which face outwards relative to the interior of the nonwoven fabric and include the outermost part of the nonwoven fabric. Thus, when the nonwoven fabric is observed, both the first and second facing sides are fully visible. Both the first and second facing sides may extend along generally parallel and offset xy-planes.

[0066] As used herein, the term "elastomer layer" refers to a layer having tensile and recovery properties (i.e., elastic resilience) along at least one directional axis, including layers having tensile and recovery properties along a single directional axis and layers having tensile and recovery properties along multiple directional axes. Examples of directional axes include the length direction, width direction, x-direction, y-direction, and any direction deviating at an angle from the length direction, width direction, x-direction, and y-direction. Elastomer layers can be formed from thermoplastic elastomers, such as thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), combinations of TPU and TPEE, etc. Elastomer layers can include spunbond layers, films, webs, etc. In example, an elastomeric layer can include spunbond TPEE or meltblown TPU. Nonwoven elastomer materials (such as spunbond TPEE or meltblown TPU) allow for lower basis weights than elastomer films. Similarly, webs are generally more breathable and permeable due to their fibrous nature relative to films, and they are generally more flexible (i.e., less stiff) than films. These factors (low basis weight, breathability and permeability, flexibility) make them ideal for use in the example composite nonwoven fabrics described herein, especially in garments where these are desired characteristics.

[0067] When referring to fibers, the term denier, or denier per fiber, is a unit of measurement for the linear mass density of a fiber, and more specifically, it is the mass in grams per 9,000 meters of fiber. In one example aspect, the denier of a fiber can be measured using ASTM D1577-07. The diameter of a fiber can be calculated based on its denier and density. The fibers envisioned herein can be formed from a variety of different materials (e.g., cotton, nylon, etc.), including polyethylene terephthalate (PET), commonly known as polyester. PET fibers can include virgin PET fibers (unrecycled fibers) and recycled PET fibers. Recycled PET fibers include shredded PET fibers derived from shredded products and re-extruded PET fibers (fibers re-extruded using recycled PET scraps). In another aspect, the fibers envisioned herein can be configured to provide hydrophobic properties to printed composite nonwoven fabrics.

[0068] As used herein, the term "silicone-coated fiber" can refer to a fiber having a continuous silicone coating such that the silicone coating completely covers the fiber along its length. In one example, the fiber can form a core and the silicone can form a sheath surrounding the core. In other examples, the term "silicone-coated fiber" can refer to a fiber having an intermittent silicone coating in at least some regions along the fiber length. For example, the fiber can be sprayed with a silicone coating. In this respect, if a particular fiber web comprises 100% by weight of silicone-coated fiber, it is contemplated that the fibers forming the web can have regions that do not contain a silicone coating. It is contemplated that silicone-coated fibers are incorporated into fiber webs forming composite nonwoven fabrics. In other words, after forming a composite nonwoven fabric using, for example, silicone spray finishing, the silicone coating on the fiber is not applied to the fiber.

[0069] As used herein, the term "color" or "color property" in relation to nonwoven fabrics generally refers to the observable color of the fibers forming the fabric. Such an aspect envisions that the color can be any color that can be provided to the fiber using dyes, pigments, and / or colorants known in the art. Accordingly, fibers can be configured to have a color, including but not limited to red, orange, yellow, green, blue, indigo, purple, white, black, and their shades. In one example aspect, the fiber color can be imparted during fiber formation (often referred to as pre-spinning dyeing). In pre-spinning dyeing, the color is added to the fiber as it is extruded, such that the color is integrated into the fiber, rather than being added to the fiber in a post-forming step (e.g., by a post-weaving dyeing step).

[0070] The aspects related to color also envision determining whether one color is different from another, and whether one color is substantially the same as another. In these aspects, color can include digital color values, which can be determined using instruments that objectively measure and / or calculate the color value of an object's color by standardizing and / or quantifying factors that may affect color perception. Such instruments include, but are not limited to, colorimeters, spectroradiometers, and spectrophotometers. Therefore, the aspects herein envision that the "color" of a fabric provided by fibers can include digital color values ​​measured and / or calculated using colorimeters, spectroradiometers, and / or spectrophotometers. Furthermore, digital color values ​​can be associated with a color space or color model, which is a specific organization of colors that provides a color representation for the digital color values, and thus, each digital color value corresponds to a single color represented in the color space or color model.

[0071] Such determination can be made by measuring and / or calculating, for example, the digital color value of a first fabric having a first color using a colorimeter, spectroradiometer, or spectrophotometer; measuring and / or calculating the digital color value of a second fabric having a second color using the same instrument (i.e., if a spectrophotometer is used to measure the digital color value of the first color, then a spectrophotometer is used to measure the digital color value of the second color); and comparing the digital color value of the first color with the digital color value of the second color. In another example, this determination can be made by measuring and / or calculating the digital color value of a first region of the fabric using a colorimeter, spectroradiometer, or spectrophotometer; measuring and / or calculating the digital color value of a second region of the fabric having a second color using the same instrument; and comparing the digital color value of the first color with the digital color value of the second color. If the digital color values ​​are not equal, then the first color or first color characteristic is different from the second color or second color characteristic, and vice versa.

[0072] Furthermore, it is envisioned that the visual difference between two colors could be related to the percentage difference between the numerical color values ​​of the first and second colors, with the visual difference increasing as the percentage difference between the color values ​​increases. Additionally, the visual difference could be based on a comparison between color representations of color values ​​in a color space or model. For example, when the first color has a numerical color value corresponding to the represented color being black or dark blue, and the second color has a numerical color value corresponding to the represented color being red or yellow, the visual difference between the first color (represented as red) and the second color (represented as yellow) is greater than the visual difference between the first color (represented as red) and the second color (represented as yellow).

[0073] The term "transparency" relates to the transmission of light, and "transparency" refers to the physical property of an object when light strikes its surface, where some of the light passes through or is transmitted through the object and some is diffused, reflected, and / or absorbed. Therefore, when describing the fiber web and / or one or more additional layers of a printed composite nonwoven fabric, the term "transparency" refers to a fiber web or layer through which light partially passes. Furthermore, when a fiber web or layer is referred to herein as "at least partially" translucent, it should be understood that "at least partially" means a portion, area, zone, or location of the fiber web or layer where the fiber web or layer is translucent, and does not indicate its transmittance. For example, a fiber web or layer of a printed composite nonwoven fabric that is at least partially translucent means that light partially passes through some portions, areas, zones, or locations of the layer. In another case, a fiber web or layer that is at least partially translucent means that light partially passes through one or more portions of the fiber web or layer, and that light may or may not partially pass through other different portions of the fiber web or layer.

[0074] As used herein, the term "printing technology" generally refers to the process of applying a colored substance to a substrate (e.g., the inner layer of a printed nonwoven composite fabric) and includes any printing process, technique, or method known to those skilled in the art. Typically, the colored substance can be a colorant, a sublimated dye, or both, and colorants and sublimated dyes can be configured to have colors including, but not limited to, red, orange, yellow, green, blue, indigo, purple, white, black, and hues thereof. Accordingly, in an example aspect, the printing technology contemplated herein includes direct printing technology in which one or more colorants are transferred to a substrate, and examples of direct printing technology include screen printing, rotary printing, digital printing, etc. As used herein, the term "colorant" generally refers to any ink, pigment, dye, or other substance that colors something, and can include a broad range of inks, pigments, or dyes compatible with at least one direct printing technology discussed herein. In an example aspect, the colorant can include commercially available inks known to those skilled in the art or proprietary inks used with digital printing technology. Such inks can be water-based or oil-based, and can include, but are not limited to, pyrolysis inks, discharge inks, glitter or glossy inks, glossy inks, metallic inks, mirror silver inks, plastisol inks, polyvinyl chloride (PVC) inks, non-PVC inks, phthalate inks, non-phthalate inks, acrylic inks, suede-like inks, oil-based acrylic inks, polyurethane inks, high-density inks, solvent inks, UV inks, and combinations thereof. Nevertheless, it is also envisioned that inks can include specialty inks, which may possess one or more properties not typically found in commercially available inks. Such properties can include visual properties that give specialty inks a metallic, pearlescent, color-shifted, or reflective appearance. Furthermore, any of these inks can include additives that can affect certain properties or components of the ink or provide additional properties or components to the ink. For example, additives can make the ink more compatible with certain inks and materials, and therefore, additives can be used to promote compatibility between the ink and the surface of a nonwoven fabric layer.

[0075] In other examples, the printing techniques envisioned herein include sublimation printing. As used herein, the term "sublimation printing process" refers to a printing technique that uses heat and pressure to apply dyes to a substrate. Typically, a sublimation printing process may apply one or more sublimation dyes that have an affinity for a substrate (e.g., the inner layer of a nonwoven fabric) and are applied thereto via sublimation printing. Sublimation dyes may include colorants derived from plant or synthetic sources, which may be finely ground and included with a dispersant, and the sublimation dyes may be injected into the substrate at the molecular level, impregnating the material with color. As understood by those skilled in the art, sublimation printing utilizes the science of sublimation, in which heat is applied to a solid, converting it into a gas through an endothermic reaction without passing through a liquid phase.

[0076] Sublimation printing can include solid thermosensitive dyes dissolved in a liquid that, when subjected to heat and pressure, transforms into a gas, binds to a compatible substrate, and then reverts to a solid. Thus, the sublimation dye is injected into the substrate at the molecular level. Furthermore, the sublimation printing processes envisioned herein can utilize various components and techniques to apply sublimation dyes to a substrate (e.g., an inner layer of a nonwoven fabric), and different sublimation printing processes can include similar and / or different aspects. For example, one process can apply sublimation dyes directly to the substrate, while another process can use transfer sheets. Additionally, some sublimation printing techniques can include a sublimation printing machine and / or can also use heat or energy to induce the adsorption of sublimation dyes onto the substrate. In a non-limiting example, one or more sublimation dyes can be transferred to an inner layer using a hot press, subjecting the inner layer and the one or more sublimation dyes applied thereto to a temperature of approximately 195°C for approximately 1 second. Thus, one or more sublimation dyes are transferred to the inner layer and adsorbed by at least a portion of the inner layer. In other respects, one or more sublimated dyes can be transferred to the inner layer using a hot press, such that the inner layer and one or more sublimated dyes applied thereon are subjected to temperatures of about 225°C to about 165°C, about 220°C to about 170°C, about 215°C to about 175°C, about 210°C to about 180°C, about 205°C to about 185°C, about 200°C to about 190°C, or about 195°C for about 30 seconds, about 25 seconds, about 20 seconds, about 15 seconds, about 10 seconds, or about 5 seconds. As used herein, the term “about” means within approximately ±10% of the indicated value.

[0077] As used herein, the term "printed part" refers to an image, graphic, design, or visual mark formed on a layer by one or more colorants or sublimated dyes applied to the layer via printing techniques according to various aspects thereof. Furthermore, printed parts may also include shapes, including shapes associated with branding, such as logos, images, geometric shapes, organic shapes, patterns, letters, numbers, etc. Additionally, printed parts may be formed at least in part by one or more colors provided by one or more colorants or sublimated dyes, which can be configured to have any color, including but not limited to red, orange, yellow, green, blue, indigo, purple, and their hues.

[0078] Another aspect of this document relates to embossing and pleating finishing sections of composite nonwoven fabrics suitable for clothing and other articles, and methods for producing such sections. At a high level, the composite nonwoven fabric may include a first region comprising a first entangled fiber web, a second entangled fiber web, and an elastomer layer located between the first and second entangled fiber webs. The composite nonwoven fabric may also include a second region comprising an embossed portion and a second entangled fiber web, the embossed portion comprising a plurality of fibers from the first entangled fiber web integrated within the elastomer layer.

[0079] Continuing at a higher level, the pleated structure may include a composite nonwoven fabric comprising a first entangled fiber web, a second entangled fiber web, and an elastomer layer located between the first and second entangled fiber webs. The pleated structure may also include an elastically resilient structured textile positioned adjacent to the outermost surface of the second entangled fiber web, and may further include multiple pleats formed by the composite nonwoven fabric and the elastically resilient structured textile.

[0080] This document provides various measurements of the entangled front fabric and the resulting composite nonwoven fabric. The thickness of the resulting composite nonwoven fabric can be measured using a precision thickness gauge. For example, to measure thickness, the fabric can be positioned on a flat anvil, and a pressure foot can be pressed onto the fabric from the top surface under a standard fixed load. The dial indicator on the precision thickness gauge provides a thickness indication in mm. Basis weight is measured using the ISO 3801 test standard and is expressed in grams per square meter (gsm). Fabric stiffness, which typically corresponds to drape, is measured using the ASTM D4032 (2008) test standard and is expressed in kilogram-forces (Kgf). Fabric growth and resilience are measured using the ASTM 2594 test standard and expressed as a percentage. As used herein, the term “tension” refers to a fabric property measured by an increase of a specified distance under a specified tension and is typically expressed as a percentage of the original reference distance (i.e., resting length or width). As used herein, the term "growth" refers to the increase in distance of a specified reference (i.e., resting length or width) over a period of time after the tension is released following extension to a specified tension, and is usually expressed as a percentage of the original reference distance. As used herein, "resilience" refers to the ability of a fabric to recover to its original reference distance (i.e., its resting length or width), and is also expressed as a percentage of the original reference distance. Thermal resistance, which typically corresponds to insulation characteristics, is measured using the ISO 11092 test standard, and the unit is RCT (m²). 2 *K / W).

[0081] Unless otherwise stated, all measurements provided herein were taken at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar) with the nonwoven fabric in a resting (unstretched) state.

[0082] Figure 1 This is a schematic diagram of an example lifecycle of the composite nonwoven fabric contemplated herein. Reference numeral 100 indicates a first fiber web 110, an inner layer 120 having printed components 130 (e.g., a printed layer), and one or more additional layers 140 (e.g., a second fiber web, a third fiber web, and / or an elastomer layer) prior to entanglement. It is contemplated herein that, in some example aspects, any one of the one or more additional layers 140 may be optional. In example aspects, the fibers used to form the first fiber web 110, the inner layer 120, and the one or more additional layers 140 may include recycled fibers, and specifically recycled PET fibers. Additionally, when the one or more additional layers 140 include an elastomer layer, the example aspects of this document contemplate that the elastomer layer may be formed from recyclable material. Arrow 102 schematically represents the entanglement step, wherein the fibers in the first fiber web 110, the inner layer 120, and / or the one or more additional layers 140 are entangled with each other such that one or more of the fibers extend into another layer to form a cohesive printed composite nonwoven fabric 150. Arrow 104 schematically indicates a processing step in which printed composite nonwoven fabric 150 is formed into garment article 160 including printed components 130. Although garment article 160 is shown as upper garment, it is envisioned herein that garment article 160 may take other forms, such as lower garment, shoe uppers, hats, gloves, sleeves, etc. At the end of the life of garment article 160, it is envisioned that the wearer may return garment article 160 to, for example, a manufacturer / retailer, where garment article 160 may be fully recycled, as indicated by arrow 106, to form shredded fibers and / or re-extruded fibers, which are used to form fiber webs, such as a first fiber web 110, an inner layer 120, and / or one or more additional layers 140, thereby creating a self-sustaining cycle. This self-sustaining cycle reduces the carbon impact typically associated with the production of printed garment articles (including knitted, woven, and nonwoven garment articles).

[0083] Figure 2A first fiber web 110 is depicted prior to entanglement with other webs and / or lamination with other layers. In an example, properties associated with the first fiber web 110 can be selected to achieve the desired final properties of the printed composite nonwoven fabric 150. As discussed above, when entangled with other webs and / or lamination with other layers, the first fiber web 110 is envisioned to form the first facing side of the printed composite nonwoven fabric 150. When the printed composite nonwoven fabric 150 is formed into a garment article, the first facing side is envisioned to form the outward-facing surface of the garment article, and in some respects, the outermost surface. Accordingly, desired properties associated with the first fiber web 110 include, for example, durability and abrasion resistance, as well as humility. In an example, the basis weight of the first fiber web 110 is from about 20 gsm to about 150 gsm, 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. After the first fiber web 110 is combined with other webs and / or layers, a resulting nonwoven fabric with a basis weight within the desired range is provided for the first fiber web 110 at this range.

[0084] The first fiber web 110 is formed of fibers, such as fiber 210 (schematically depicted), which can be oriented generally in a common direction due to a carding and cross-lapping process. In one example aspect, fiber 210 may include PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also contemplated herein. In one example aspect, fiber 210 may include 100% by weight recycled fibers, such as 100% by weight recycled PET fibers. However, in other aspects, fiber 210 may include 100% by weight virgin fibers, or other combinations of virgin and recycled fibers, as needed. The short fiber length of fiber 210 can range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. This use of fiber length provides optimal entanglement. For example, when below 40 mm, the fibers may not have sufficient length for entanglement, and when above 60 mm, the fibers may not actually be entangled when the needles are withdrawn from the nonwoven fabric during entanglement. In one example, fiber 210 may include a uniform length, such as when the fiber is formed from virgin extruded or re-extruded PET and cut to a defined length. In other aspects, fiber 210 may include variations in short fiber length, such as when fiber 210 is derived from a shredded fiber source. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0085] Fiber 210 may include deniers greater than or equal to about 1.2D, or about 1.2D to about 3.5D, about 1.2D to about 1.7D, about 1.3D to about 1.6D, or about 1.5D. Utilizing deniers within this range makes fiber 210 less prone to breakage, which in turn enhances the durability and abrasion resistance of the first facing side of the printed composite nonwoven fabric 150. Furthermore, selecting a denier within this range while still achieving the basis weight of the first fiber web 110 provides good, uniform coverage of the first facing side, which helps enhance the durability characteristics of the first facing side. Selecting a denier greater than, for example, 3.5D while still maintaining the basis weight of the first fiber web 110 can provide less coverage of the first facing side, which may be desirable in some cases, such as when it is desired to expose or at least partially expose the printed parts.

[0086] In one example, the fiber 210 used to form the first fiber web 110 may include a first color characteristic. During, for example, an extrusion process that forms the fiber 210, the first color characteristic may be imparted to the fiber 210 such that the fiber 210 is dope-dyed. In one example, the color characteristic may be white, although other colors are also contemplated herein. Using dope-dyed fibers to form the printed composite nonwoven fabric 150 eliminates the post-forming dyeing step, which further contributes to reducing the carbon footprint of the printed composite nonwoven fabric 150. In another example, the fiber 210 may be configured such that the first fiber web 110 is at least partially translucent. That is, the first fiber web 110, before or after entanglement, makes the printed portion 130 of the inner layer 120 of the printed composite nonwoven fabric 150 at least partially visible through the first fiber web 110 on the first finished side.

[0087] Figure 3 An inner layer 120 is depicted having a printed part 130 prior to entanglement and / or lamination with other webs and / or layers. In an example aspect, the characteristics associated with the inner layer 120 can be selected to achieve the desired final characteristics of the printed part 130 and / or the printed composite nonwoven fabric 150. Typically, the inner layer 120 can be configured such that it is compatible with at least one printing technique contemplated herein and is capable of including the printed part 130 with desired aesthetic characteristics. In one example, the inner layer 120 has a first color characteristic (white) and at least one side suitable for receiving one or more colored substances, which together form the printed part 130. In an example aspect, the inner layer 120 can be a fiber web formed from any selected fiber having characteristics associated with the fibers contemplated herein. In other example aspects, the inner layer 120 is a hydroentangled layer having features configured to provide the printed part 130 with desired aesthetic characteristics. Additional aspects associated with the inner layer 120 are discussed in more detail below.

[0088] Figures 4 to 6 Each depicts an example fiber web or example layer that may be included in one or more additional layers 140 of the printed composite nonwoven fabric 150. Figure 3 A second fiber web 112 is depicted prior to entanglement with other webs and / or lamination with other layers. In an example aspect, properties associated with the second fiber web 112 can be selected to achieve the desired final properties of the printed composite nonwoven fabric 150. As discussed above, when entangled with other webs, the second fiber web 112 is envisioned to form the opposing second facing side of the printed composite nonwoven fabric 150. When the printed composite nonwoven fabric 150 is formed into a garment article, the second facing side is envisioned to form the inward-facing surface of the garment article and, in some respects, the innermost facing surface. Accordingly, properties associated with the second fiber web 112 include, for example, a soft hand feel or texture. In an example aspect, the basis weight of the second fiber web 112 is approximately 20 gsm to approximately 150 gsm, approximately 35 gsm to approximately 65 gsm, approximately 40 gsm to approximately 60 gsm, approximately 45 gsm to approximately 55 gsm, or approximately 50 gsm. In an example, the second fiber web 112 has a basis weight that is substantially the same as that of the first fiber web 110. After the second fiber web 112 is combined with other webs and / or laminated with other layers, a resulting nonwoven fabric with a basis weight within the desired range is provided for the second fiber web 112.

[0089] The second fiber web 112 can be formed from two types of fibers, such as fiber 310 (schematically depicted) and fiber 312 (schematically depicted), which can be oriented generally in a common direction due to carding and cross-lapping processes. In one example aspect, fiber 310 may include PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also contemplated herein. In one example aspect, fiber 310 may include 100% by weight recycled fibers, such as 100% by weight recycled PET fibers. However, in other aspects, fiber 310 may include 100% by weight virgin fibers, or other combinations of virgin and recycled fibers, as needed.

[0090] Fibers 312 are shown in dashed lines to indicate that they have different characteristics from fibers 310. For example, fibers 312 include silicone-coated fibers. Fibers 312 may be coated with silicone before being incorporated into the second fiber web 112. In example aspects, the second fiber web 312 may comprise about 10% to about 100% by weight of fibers 312, about 40% by weight of fibers 310 and about 60% by weight of fibers 312, about 45% by weight of fibers 310 and about 55% by weight of fibers 312, about 50% by weight of fibers 310 and about 50% by weight of fibers 312, about 55% by weight of fibers 310 and about 45% by weight of fibers 312, or about 60% by weight of fibers 310 and about 40% by weight of fibers 312. When stating that the second fiber web 112 may comprise about 100% by weight of fibers 312, it is contemplated herein that fibers 312 may be intermittently coated with silicone along their length. The use of fibers 310 and 312 within the aforementioned range provides a good hand feel to the second surface formed by the second fiber web 112. It also provides good drape to the printed composite nonwoven fabric 150. In other words, the resulting printed composite nonwoven fabric 150 is not as stiff as conventional nonwovens used in the cleaning and personal hygiene fields. Furthermore, the use of fibers 310 and 312 within the aforementioned range reduces the needle force required to entangle the fiber web described herein, as the silicone-coated fibers may move more easily during the entanglement process. When silicone-coated fibers below the aforementioned range are incorporated, the second facing side may feel dry and uncomfortable during wear. Conversely, when silicone-coated fibers above the aforementioned range are incorporated, the second facing side may feel smooth, which may also cause discomfort to the wearer. Additionally, using silicone-coated fibers above the aforementioned range may make the combing process difficult, as the comb needles may not be able to engage the fibers frictionally to obtain a uniform combed web. In addition, using silicone-coated fibers with a higher range than mentioned above may also fail to form sufficient entanglement between the fibers, because the friction is reduced due to the silicone, thereby affecting the structural integrity of the printed composite nonwoven fabric 150.

[0091] The use of silicone-coated fiber 312 eliminates the need for adding silicone finishing to the printed composite nonwoven fabric 150 in post-processing steps. As is known in the fabric industry, it is common practice to add silicone softener finishes to knitted or woven products in post-processing steps. By eliminating this step, the carbon footprint of the printed composite nonwoven fabric 150 is further reduced.

[0092] The short fiber length of each of fibers 310 and 312 may be from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. Similar to fiber 210, this length provides optimal entanglement. In an example aspect, fibers 310 and / or 312 may include uniform lengths, such as when fibers are formed from virgin extruded or re-extruded PET and cut to defined lengths. In other aspects, fibers 310 and / or 312 may include variations in fiber length, such as when fibers 310 and / or 312 are derived from a shredded fiber source. Any and all aspects and any variations thereof are contemplated within the scope of these provisions.

[0093] Each of fibers 310 and 312 may include a denier of about 1D or less. For example, the denier may be about 0.1D, about 0.2D, about 0.3D, about 0.4D, about 0.5D, about 0.6D, about 0.7D, about 0.8D, or about 0.9D. In a illustrative context, the denier of fibers 310 and 312 may be about 0.6D to about 1D, about 0.7D to about 0.9D, or about 0.8D. Utilizing a denier within this range helps to provide a soft feel or hand texture to the second finish side formed by the second fiber web 112. Furthermore, selecting a denier within this range provides good coverage of the second finish side while still achieving the basis weight of the second fiber web 112.

[0094] In one example, each of the fibers 310 and 312 used to form the second fiber web 112 may include color characteristics that may be the same or different. In another example, both fibers 310 and 312 include the first color characteristics of fiber 210. Similar to fiber 210, each of fibers 310 and 312 may be pre-dyed, thereby further reducing the need for post-processing dyeing steps on the resulting composite nonwoven fabric.

[0095] Figure 5An optional third fiber web 114 is depicted prior to entanglement with other webs and / or lamination with other layers. When incorporated into a printed composite nonwoven fabric 150 as part of one or more additional layers 140, the third fiber web 114 is envisioned to be located between a first fiber web 110 and a second fiber web 112. In an example aspect, properties associated with the third fiber web 114 can be selected to achieve desired final properties of the printed composite nonwoven fabric 150. In an example aspect, the third fiber web 114 can be incorporated into the printed composite nonwoven fabric 150 to achieve a desired basis weight, a desired thickness, desired thermal insulation properties, desired pile, etc. As further explained below, in order to impart visual appeal to the printed composite nonwoven fabric 150, the fibers forming the third fiber web 114 may have different color characteristics than the fibers used to form the first fiber web 110 and the second fiber web 112. Similar to the first fiber web 110 and the second fiber web 112, the basis weight of the third fiber web 114 is approximately 20 gsm to about 150 gsm, approximately 35 gsm to about 65 gsm, approximately 40 gsm to about 60 gsm, approximately 45 gsm to about 55 gsm, or approximately 50 gsm. After the third fiber web 114 is combined with other webs and / or layers, a nonwoven fabric with a basis weight within the desired range is provided for the third fiber web 110.

[0096] The third fiber web 114 is formed of fibers, such as fiber 410 (schematically depicted), which may be oriented generally in a common direction due to carding and cross-lapping processes. In one example aspect, fiber 410 may comprise PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also contemplated herein. In one example aspect, fiber 410 may comprise 100% by weight of recycled fibers, such as 100% by weight of recycled PET fibers. However, in other aspects, fiber 410 may comprise 100% by weight of virgin fibers, or other combinations of virgin and recycled fibers, as needed. Similar to fibers 210, 310, and 312, the short fiber length of fiber 410 may range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. In one example aspect, fiber 410 may comprise a uniform length, such as when the fiber is formed from virgin extruded PET or re-extruded PET and cut to a defined length. In other respects, fiber 410 may include variations in short fiber length, such as when fiber 410 is derived from a shredded fiber source. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0097] Fiber 410 may include deniers greater than or equal to about 1.2D, about 1.2D to about 3.5D, about 1.3D to about 1.6D, or about 1.5D. Utilizing deniers within this range makes fiber 410 less prone to breakage, which in turn enhances the durability and abrasion resistance of the printed composite nonwoven fabric 150. Since the third fiber web 114 is located between the first fiber web 110 and the second fiber web 112 during use, a soft hand feel is not as important as, for example, the second fiber web 112. Choosing a denier within this range while still achieving the basis weight of the third fiber web 114 improves the overall coverage and / or opacity of the printed composite nonwoven fabric 150.

[0098] In some aspects, the fibers 410 used to form the third fiber web 114 may include a second color characteristic different from the first color characteristic. This is in Figure 4 The image is depicted using diagonal shading. This paper envisions fiber 410 being dyed before spinning, thereby further reducing the carbon footprint of the printed composite nonwoven fabric 150. As will be explained in more detail below, during the entanglement of the first fiber web 110, the second fiber web 112, and the third fiber web 114, fiber 410 can move more towards one finished side than the other, making the second color characteristic more visually distinguishable or differentiated on one finished side compared to the other. This paper envisions that fiber 210 of the first fiber web 110, fiber 310 of the second fiber web 112, and fiber 410 of the third fiber web 114 are not coated with silicone.

[0099] Figure 6An elastomeric layer 116 is depicted that can be included as part of one or more additional layers 140. In example aspects, the basis weight of the elastomeric layer 116 can be about 20 gsm to about 150 gsm, about 50 gsm to about 70 gsm, about 55 gsm to about 65 gsm, or about 60 gsm. The basis weight of the elastomeric layer 116 can be selected to achieve the desired basis weight of the resulting printed composite nonwoven fabric. Various aspects herein envision the elastomeric layer 116 being formed from a thermoplastic elastomer (such as thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), combinations of TPU and TPEE, etc.). The elastomeric layer can include a spunbond layer, a film, a web, etc. In certain example aspects, the elastomeric layer 116 can include a TPEE spunbond layer. In some example aspects, it has been found that spunbond layers withstand needle-punching processes better than, for example, films, while maintaining tensile and recovery properties. Typically, the elastomer layer 116 is chosen to provide the desired tensile and recovery properties to the printed composite nonwoven fabric 150 while maintaining substantial structural integrity during the entanglement process. This document envisions the elastomer layer 116 having color properties. In an example context, the color property could be a first color property associated with fibers 210, 310, and 312, although other color properties are also envisioned herein.

[0100] Figure 7 An example manufacturing process for producing an example printed composite nonwoven fabric 150 and incorporating it into a garment article 160 is illustrated, the process being generally indicated by reference numeral 700. Figure 7 The depiction of the manufactured parts is illustrative only and intended to convey the general characteristics of the various steps of manufacturing process 700. Furthermore, although these steps are depicted as being performed in a sequential order, various aspects herein envision that manufacturing process 700 may include any combination of one or more steps, any of which may be repeated or performed in a different order than depicted. At a high level, Figure 7 Several individual steps of the manufacturing process 700 are described, including forming a printed part 130 on an inner layer 120 using a printing technique to form a printed layer 170, positioning a first side of the printed layer 170 adjacent to a second side of a first fiber web 110 to form a composite structure 180, subjecting the composite structure 180 to an entanglement process to form a printed composite nonwoven fabric 150, and incorporating the printed composite nonwoven fabric 150 into a garment article 160.

[0101] Beginning at step 702, an inner layer 120 is obtained and / or provided. At step 704, a printing technique is used to form a printed part 130, which is generally described as applying a colored material 132 to a first surface of the inner layer 130. Step 706 describes optional and / or additional steps associated with the printing technique used, and in this example, step 706 generally describes a curing process in which the applied colored material 132 and the inner layer 120 are subjected to heat generated by a heat source 707. At step 708, the first surface of the printed layer 170 is positioned adjacent to a second surface of the first fiber web 110, and in an optional sub-step, the opposing second surface of the printed layer 170 is positioned adjacent to the first surface of one or more additional layers 140. The first fiber web 110 and the printed layer 170 form a composite structure 180, which may optionally include one or more additional layers 140. Step 710 generally describes subjecting the composite structure 180 to an entanglement process including a first condition 711 and a second condition 712. In the example, the first condition 711 is the first pass of needle punching associated with the first set of parameters, and the second condition 712 is the second pass of needle punching associated with the second set of parameters. Conditions 711 and 712 are merely illustrative, and it is envisioned herein that more or fewer needles may be used to achieve the desired printed composite nonwoven fabric. As depicted at step 714, upon completion of the entanglement process, the composite structure 180 is formed into the printed composite nonwoven fabric 150. Then, at step 716, the printed composite nonwoven fabric 150 is bonded to the garment article 160. Additional aspects related to the steps of the manufacturing process 700 are discussed in more detail below with reference to an example configuration of the printed layer 170 and the printed composite nonwoven fabric 150.

[0102] Figure 8An example printed layer 870 is depicted prior to combination with a first fiber web 110 and / or one or more additional layers 140. As shown, the printed layer 870 has a first surface 871 and includes an inner fiber web 820 and a printed component 130. In various aspects, the inner fiber web 820 has one or more features similar to the third fiber web 114, and therefore, the fibers 412 forming the inner fiber web 820 may also include one or more features similar to the fibers 410. However, in this example, the fibers 412 are depicted as having different color characteristics than the fibers 410, and it is envisioned that the color characteristics of the fibers 412 can be configured such that the printed component 130 is visually distinguishable or differentiable from the inner fiber web 820. In one example aspect, the color characteristics of the fibers 412 may be white, and in other example aspects, the color characteristics may be gray or lighter shades of red, orange, yellow, green, blue, indigo, or purple. Fiber 412 can be dyed before spinning, and during entanglement with other fiber webs, fiber 412 can move more towards one side than the other, making the color characteristics more visually distinguishable or differentiated on one finished side compared to the other finished side. This paper also envisions fiber 412 not being coated with silicone.

[0103] Other examples envision that, similar to the third fiber web 114, characteristics associated with the inner fiber web 820 can be selected to achieve the desired final characteristics of the printed composite nonwoven fabric 150. In examples, the inner fiber web 820 can be incorporated into the printed composite nonwoven fabric 150 to achieve desired basis weight, desired thickness, desired thermal insulation properties, desired pile, etc. Similar to the third fiber web 114, the basis weight of the inner fiber web 820 is approximately 20 gsm to approximately 150 gsm, approximately 35 gsm to approximately 65 gsm, approximately 40 gsm to approximately 60 gsm, approximately 45 gsm to approximately 55 gsm, or approximately 50 gsm. After the inner fiber web 820 is combined with other webs and / or layers, a resulting printed composite nonwoven fabric with a basis weight within the desired range is provided for the inner fiber web 820 within this range.

[0104] As described above, the internal fiber web 820 is formed of fibers, such as fiber 412 (schematically depicted), which can be oriented generally in a common direction due to carding and cross-lapping processes. In one example aspect, fiber 412 may comprise PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also contemplated herein. In one example aspect, fiber 412 may comprise 100% by weight of recycled fibers, such as 100% by weight of recycled PET fibers. However, in other aspects, fiber 412 may comprise 100% by weight of virgin fibers, or other combinations of virgin and recycled fibers, as needed. Similar to fiber 410, the short fiber length of fiber 412 can range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. In one example aspect, fiber 412 may comprise a uniform length, such as when the fiber is formed from virgin extruded PET or re-extruded PET and cut to a defined length. In other aspects, fiber 412 may comprise variations in short fiber length, such as when fiber 412 is derived from a shredded fiber source. Any and all aspects and any changes thereof are conceived as being within the scope of this article.

[0105] Fiber 412 may include deniers greater than or equal to about 1.2D, about 1.2D to about 3.5D, about 1.3D to about 1.6D, or about 1.5D. Utilizing deniers within this range makes fiber 412 less prone to breakage, which in turn enhances the durability and abrasion resistance of the printed composite nonwoven fabric 150. Since the inner fiber web 820 is located between the first fiber web 110 and the second fiber web 112 during use, a soft hand feel is not as important as, for example, the second fiber web 112. Choosing a denier within this range while still achieving the basis weight of the inner fiber web 820 improves the overall coverage and / or opacity of the printed composite nonwoven fabric 150.

[0106] like Figure 8 As shown, the printed part 130 is formed by a colorant 134 applied to the first surface 871 via a digital printing process. As discussed, the colorant 134 may provide the printed part 130 with one or more color properties, such as red, orange, yellow, green, blue, indigo, purple, and / or hues thereof. Furthermore, the printed part 130 is located in one or more areas (not identified) of the inner fiber web 412, and even though the printed part 130 is depicted as rectangular, the exemplary aspects herein envision that the printed part 130 may include images, graphics, designs, visual symbols, one or more shapes, including shapes associated with branding, such as logos, geometric shapes, organic shapes, patterns, letters, numbers, etc.

[0107] Figure 9 Depicting Figure 8The figure shows a cross-section of the printed layer 870. As shown, the colorant 134 forming the printed part 130 is located on the first surface 871 of the printed layer 870 and extends partially through the inner fiber web 814 toward the opposite second surface 872 of the printed layer 870. Although the colorant 134 is clearly delineated on the first surface 871 and the inner fiber web 814, it should be understood that this depiction of the colorant 134 is illustrative. Therefore, it is contemplated in various aspects herein that the colorant 134 may be included in the printed layer 870 in a less delineated and / or irregular manner. It is also contemplated that the colorant 134 may include the fibers 412 attached to the inner fiber web 814 and / or at least partially adsorbed by the fibers 412, and may also include other portions not attached to the fibers 412.

[0108] Figure 10 An alternative cross-section of the printed layer 870 is depicted, in which the printed parts are formed by sublimation dye 136 instead of a colorant. Accordingly, sublimation dye 136 can be applied to the first surface 871 via a sublimation printing process. Due to the differences between sublimation printing and digital printing processes, and between sublimation dye 136 and colorant 134, sublimation dye 136 is included in the printed layer 870 in a different manner than colorant 134. As shown, sublimation dye 136 is more absorbed into the printed layer 870. That is, sublimation dye 136 does not extend above the first surface 871, but extends partially through the inner fiber web 820 to a greater extent than colorant 134. Similarly, with Figure 9 Similarly, the depiction of sublimation dye 136 clearly demarcated on the first surface 871 and extending through the inner fiber web 820 is illustrative, and various aspects herein contemplate that sublimation dye 136 may be included in the printing layer 870 in a less demarcated and / or irregular manner. It is also contemplated that sublimation dye 136 may include portions bonded to, attached to, and / or at least partially adsorbed by fibers 412 of the inner fiber web 820, and may also include other portions not attached to fibers 412 and / or discrete from fibers 412.

[0109] Figures 11 to 14 The illustration shows aspects of an example printed composite nonwoven fabric 850 formed after performing an entanglement process on a first fiber web 110, a printed layer 870 (e.g., an inner fiber web 820 including a printed component 130), a second fiber web 112, and an elastomer layer 116. Figure 11 A first facing side 851 of a printed composite nonwoven fabric 850, at least partially formed from a first entangled fiber web 810, is depicted. (As shown) Figure 12As best shown (the figure depicts a cross-section of the printed composite nonwoven fabric 850), the first entangled fiber web 810 includes fibers 210 from the first fiber web 110, fibers 310 and 312 from the second fiber web 122, and fiber 412 from the inner fiber web 820. Furthermore, the second facing side 852 of the printed composite nonwoven fabric 850 is at least partially formed by the second entangled fiber web 812, which mainly comprises fibers 310 and 312. Additionally, an inner entangled fiber web 814, mainly comprising fiber 412, is located between the first entangled fiber web 810 and the second entangled fiber web 812. The inner entangled fiber web 814 also includes a printed component 130 on a first surface positioned adjacent to a second surface of the first entangled fiber web 814. Furthermore, an elastomer layer 116 is also located between the first entangled fiber web 810 and the second entangled fiber web 812, and adjacent to the inner entangled fiber web 814.

[0110] In one example, due to the entanglement parameters, the characteristics of fibers 110 and 412, and / or the characteristics of colorant 134, the printed part 130 is at least partially visible through the first entangled fiber web 810, making the printed part 130 visible on the first finishing side 851 of the printed composite nonwoven fabric 850. Additionally, for the same reason, different areas of the inner entangled fiber web 814 and different portions of the printed part 130 are incorporated into the first entangled fiber web 810 in different ways. In one example, the first entangled fiber web 810 may be at least partially translucent. In other examples, the parameters of the entanglement process may be configured such that discrete particles of colorant and / or sublimated dye, as well as the fibers comprising colorant and / or sublimated dye forming the printed part 130, migrate to the first entangled fiber web 810 and / or the first finishing side 151.

[0111] Figure 13 Depicting Figure 12 A magnified view of the cross-section of a printed composite nonwoven fabric 150. Figure 13The diagram illustrates a first region 821 of an internally entangled fiber web 814, and shows an example configuration of fibers 210, 310, 312, 412 and a printed component 130. The first region 821 includes a first portion 831 of the printed component 130, and at least some of the colorants 134 are attached to fibers 412 to form fibers 414. Furthermore, fibers 412 and 414, as well as fibers 310 and 312, are incorporated into the first entangled fiber web 810. Fibers 414 are incorporated such that at least one of the fibers 414 extends to a first finishing side 851 of the printed composite nonwoven fabric 850. Additionally, the first portion 831 of the printed component 130 includes at least some discrete particles of colorant 134 that are not attached to fibers 412. Accordingly, at the first region 821, the first finishing side 851 is at least partially formed by the colorant 134 and fibers 414 at the first portion of the printed component 130.

[0112] Figure 14 Depicting Figure 12 A magnified view of the cross-section of a printed composite nonwoven fabric 150. Figure 14 The diagram illustrates a second region 822 of the internally entangled fiber web 814, and shows an example configuration of fibers 210, 310, 312, 412, and the printing component 130. The second region 822 includes a second portion 832 of the printing component 130, and similar to the first region 821, in which colorant 134 is attached to fibers 412 to form fibers 414, and is also included as discrete particles 134 not attached to fibers 412. However, unlike the first region 821, fibers 412 and 414 are excluded from the first entangled fiber web 810 in the second region 822. Fibers 210, 310, and 312 have a similar configuration in both the first and second regions 821 and 822. Specifically, at least some of the fibers 210 extend into the internally entangled fiber web 814, while other fibers further extend through the internally entangled fiber web 814 and the elastomer layer 116 into the second entangled fiber web 812. Furthermore, at least some of the fibers 310 and 312 extend through the elastomer layer 116 and the internal entangled fiber web 814 and into the first entangled fiber web 810.

[0113] Figure 15An example printed layer 970 is depicted prior to combination with a first fiber web 110 and / or one or more additional layers 140. As shown, the printed layer 970 has a first surface 971 and includes a spunlace layer 920 and a printed part 130. In various aspects, the spunlace layer 920 is configured to provide a desired aesthetic to the printed part 130, and therefore, the spunlace layer 920 may include one or more features that make it suitable for printing and retaining the printed part 130. In one example aspect, the spunlace layer 920 may be configured such that the printed part 130 is visually distinguishable or discernible from the spunlace layer 920. In one example aspect, the color characteristic of the spunlace layer 920 may be white, and in other example aspects, the color characteristic may be gray or a lighter shade of red, orange, yellow, green, blue, indigo, or purple. In other example aspects, the spunlace layer 920 may include spunlace fibers, which may be in the form of a web. In another example, the basis weight of the spunlace layer 920 may be about 20 gsm to about 150 gsm, about 30 gsm to about 50 gsm, about 35 gsm to about 45 gsm, or about 40 gsm.

[0114] In an additional example, it is envisioned that the spunlace layer 920 may be formed of PET. Such an aspect also envisions the spunlace layer 920 comprising PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also envisioned herein. In one example aspect, the fibers of the spunlace layer 920 may comprise 100% by weight recycled fibers, such as 100% by weight recycled PET fibers. However, in other aspects, the fibers of the spunlace layer 920 may, as needed, comprise 100% by weight virgin fibers, or other combinations of virgin and recycled fibers. In another aspect, the short fiber length of the fibers of the spunlace layer 920 may be longer than the short fiber length of the fibers included in other fiber webs of the printed composite nonwoven fabric 950. In one example aspect, the fibers of the spunlace layer 920 may comprise variations in short fiber length, and in other example aspects, the fibers of the spunlace layer 920 may be continuous throughout the spunlace layer 920. In another aspect, it is envisioned that the fibers of the spunlace layer 920 may include a denier configured to provide properties of the spunlace layer 920 that impart a desired aesthetic to the printed part 130. In yet another example, the fibers of the spunlace layer 920 may be configured to provide hydrophobic properties to the spunlace layer 920 and consequently to the printed composite nonwoven fabric 950. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0115] Back Figure 15In one example, the printed part 130 is formed of sublimation dye 136, which is applied to the first surface 971 via a sublimation printing process. As discussed, the sublimation dye 136 can provide the printed part 130 with one or more color properties, such as red, orange, yellow, green, blue, indigo, purple, and / or hues thereof. Furthermore, the printed part 130 is located in one or more areas (unidentified) of the spunlace layer 920, and even though the printed part 130 is depicted as rectangular, the exemplary aspects herein envision that the printed part 130 may include images, graphics, designs, visual symbols, one or more shapes, including shapes associated with branding, such as logos, geometric shapes, organic shapes, patterns, letters, numbers, etc.

[0116] Figure 16 Depicting Figure 8 A cross-sectional view of the printed layer 970 is shown. As illustrated, sublimation dye 136 is applied to the first surface 971 and is at least partially adsorbed by the spunlace layer 920 onto the opposing second surface 972 of the printed layer 970. Although sublimation dye 136 is clearly demarcated as being flush with the first surface 971 and distributed throughout the printed layer 970, it should be understood that this depiction of sublimation dye is illustrative. Therefore, various aspects herein contemplate that sublimation dye 136 may be included in the printed layer 970 in a less demarcated and / or irregular manner. It is also contemplated that sublimation dye 136 may include portions bonded to, attached to, and / or at least partially adsorbed by the spunlace layer 920 and its fibers, and may also include other portions not attached to the spunlace layer 920 and its fibers and / or discrete from the spunlace layer 920 and its fibers.

[0117] Figure 17An alternative cross-section of the printed layer 970 is depicted, wherein the printed part 130 is formed by colorant 134 instead of sublimation dye 136. Accordingly, colorant 134 can be applied to the first surface 971 via a digital printing process. Due to the differences between digital printing and sublimation printing processes, and between colorant 134 and sublimation dye 136, colorant 134 is included in the printed layer 970 in a different manner than sublimation dye 136. As shown, colorant 134 extends partially over the first surface 971 of the printed layer 970 and partially through the spunlace layer 920 toward the opposite second surface 972 of the printed layer 970. Although colorant 134 is clearly demarcated on the first surface 971 and the spunlace layer 920, it should be understood that this depiction of colorant 134 is illustrative. Therefore, various aspects herein contemplate that colorant 134 may be included in the printed layer 970 in a less demarcated and / or irregular manner. It is also envisioned that the colorant 134 may include portions attached to the spunlace layer 920 and its fibers and / or at least partially adsorbed by the spunlace layer 920 and its fibers, and may also include other portions not attached to the spunlace layer 920 and its fibers.

[0118] Figures 18 to 21 The illustration shows aspects of an example printed composite nonwoven fabric 950 formed after performing an entanglement process on a first fiber web 110, a printed layer 970 (e.g., a hydroentangled layer 920 including printed parts 130), a second fiber web 112, a third fiber web 114, and an elastomer layer 116. Figure 18 A first facing side 951 of a printed composite nonwoven fabric 950, at least partially formed from a first entangled fiber web 910, is depicted. (As shown) Figure 19 As best shown (the figure depicts a cross-section of the printed composite nonwoven fabric 890), the first entangled fiber web 910 includes fibers 210 from the first fiber web 110, fibers 310 and 312 from the second fiber web 122, and fibers 410 from the third fiber web 114. Furthermore, the second facing side 952 of the printed composite nonwoven fabric 850 is at least partially formed by the second entangled fiber web 912, which mainly comprises fibers 310 and 312. A third entangled fiber web 914, mainly comprising fiber 410, is located between the first entangled fiber web 910 and the second entangled fiber web 912. A hydroentangled layer 920 is located between the first entangled fiber web 910 and the third entangled fiber web 914, and also includes a printed component 130 on a first surface positioned adjacent to a second surface of the first entangled fiber web 910. In addition, the elastomer layer 116 is located between the second entangled fiber web 912 and the third entangled fiber web 914.

[0119] In an example, due to the entanglement parameters, the characteristics of fiber 110, the characteristics of spunlace layer 920 and / or colorant 134, the printed part 130 is at least partially visible through the first entangled fiber web 910, such that the printed part 130 is visible on the first finished side 951 of the printed composite nonwoven fabric 950. Additionally, for the same reason, different areas of the spunlace layer 920 and different portions of the printed part 130 are incorporated into the first entangled fiber web 910 in different ways.

[0120] Figure 20 Depicting Figure 19 A magnified view of the cross-section of the printed composite nonwoven fabric 950. Figure 20 The diagram illustrates a first region 921 of the spunlace layer 920, and shows an example configuration of fibers 210, 310, 312, 410, fiber 416 of the spunlace layer 920, and the printing component 130. The first region 921 includes a first portion 931 of the printing component 130, and at the first region 921, at least some of the sublimated dyes 136 are attached to the fibers 416 to form fibers 418. Furthermore, fibers 416 and 418, as well as fibers 310, 312, 410, are incorporated into a first entangled fiber web 910. Fibers 418 are incorporated such that at least one of the fibers 418 extends to a first finishing side 951 of the printed composite nonwoven fabric 950. Additionally, the first portion 931 of the printing component 130 includes at least some discrete particles of sublimated dyes 136 that are not attached to the fibers 416. Accordingly, in the first area 921, the first decorative side 951 is formed at least in part by the sublimation dye 136 and fiber 418 at the first portion 931 of the printed part 130.

[0121] Figure 21 Depicting Figure 19 A magnified view of the cross-section of a printed composite nonwoven fabric 150. Figure 21The diagram illustrates a second region 922 of the spunlace layer 920, and shows an example configuration of fibers 210, 310, 312, 410, 416, 418, and the printing component 130. The second region 922 includes a second portion 932 of the printing component 130, and similar to the first region 921, in which sublimation dye 136 is attached to and / or bonded to fibers 416 to form fibers 418, and is also included as discrete particles 136 not attached to fibers 416. However, unlike the first region 921, fibers 416 and 418 are excluded from the first entangled fiber web 910 in the second region 922. Fibers 210, 310, 312, and 410 have similar configurations in both the first and second regions 921 and 922. Specifically, at least some of the fibers 210 extend through the spunlace layer 920 and into the third entangled fiber web 914, while other fibers further extend through the elastomer layer 116 and into the second entangled fiber web 912. Furthermore, at least some of the fibers 310 and 312 extend through the elastomer layer 116, the third entangled fiber web 914, and the spunlace layer 920 into the first entangled fiber web 910. Additionally, at least some of the fibers 410 extend through the spunlace layer 920 and into the first entangled fiber web 910, while others extend through the elastomer layer 116 and into the second entangled fiber web 912.

[0122] Figure 22 The illustration depicts an example upper garment 1000, in the form of a short-sleeved garment, although other configurations such as jackets, hoodies, long-sleeved shirts, sleeveless shirts, vests, etc., are also contemplated herein. As shown, the upper garment 1000 is formed from a first composite nonwoven fabric 1010 and a second composite nonwoven fabric 1020. Various aspects of this document contemplate that the first composite nonwoven fabric 1010 and / or the second composite nonwoven fabric 1020 may have the same or similar features as any of the printed composite nonwoven fabrics 150, 850, and 950. Although not depicted, various aspects of this document contemplate that the first composite nonwoven fabric 1010 and / or the second composite nonwoven fabric 1020 may include any of the printed layers 170, 870, and 970, and further, various aspects of this document also contemplate that the upper garment 1000 may include a printed component 130.

[0123] The upper garment 1000 includes several seam locations, wherein a first composite nonwoven fabric 1010 and / or a second composite nonwoven fabric 1020 are connected to each other or to other parts of the upper garment 1000 (e.g., sleeves, collars, etc.). A first seam location 1002 is located near a side portion of the upper garment 1000 (e.g., a side seam), and a second seam location 1004 is located near the upper portion of the upper garment 1000 (e.g., a seam extending between the collar and sleeves). Furthermore, a third seam location 1006 is located near the collar portion of the upper garment 1000, and a fourth seam location 1008 is located near the sleeve portion of the upper garment 1000.

[0124] Figure 23 An example lower garment article 1100 in the form of lower clothing is illustrated. Although shown as trousers, it is envisioned that garment article 1100 could be in the form of shorts, capri pants, leggings, etc. As shown, lower garment article 1100 is formed of a first composite nonwoven fabric 1110 and a second composite nonwoven fabric 1120. Various aspects of this document envision that the first composite nonwoven fabric 1110 and / or the second composite nonwoven fabric 1120 could have the same or similar features as any of the printed composite nonwoven fabrics 150, 850, and 950. Although not depicted, various aspects of this document envision that the first composite nonwoven fabric 1110 and / or the second composite nonwoven fabric 1120 could include any of the printed layers 170, 870, and 970, and further, various aspects of this document also envision that lower garment article 1100 could include a printed component 130.

[0125] The lower garment article 1100 includes several seam locations, wherein a first composite nonwoven fabric 1110 and / or a second composite nonwoven fabric 1120 are connected to each other or to other portions of the lower garment article 1100 (e.g., waist portion, pocket portion, etc.). A first seam location 1102 is located near an outer portion (e.g., a side seam) of the lower garment article 1100, and a second seam location 1104 is located near an inner portion (e.g., an inner seam) of the lower garment article 1100. Furthermore, a third seam location 1106 is located near a waist portion (e.g., a belt) of the lower garment article 1100, and a fourth seam location 1108 is located near a pocket of the lower garment article 1100.

[0126] Figure 24 Depicting Figure 22A cross-sectional view of an upper garment article 1000 is shown, depicting an example first seam 1001. Typically, the first seam 1001 is formed by the entanglement of fibers 1030 of a first composite nonwoven fabric 1010 and fibers 1040 of a second composite nonwoven fabric 1020. Furthermore, the first composite nonwoven fabric 1010 includes a first entangled fiber web 1031 that at least partially forms a first facing side 1011 of the first composite nonwoven fabric 1010, a second entangled fiber web 1032 that at least partially forms an opposing second facing side 1012 of the first composite nonwoven fabric 1010, and a third entangled fiber web 1033 located between the first entangled fiber web 1031 and the second entangled fiber web 1032. Similarly, the second composite nonwoven fabric 1020 also includes a first tangled fiber web 1041 that at least partially forms a first facing side 1021 of the second composite nonwoven fabric 1020, a second tangled fiber web 1042 that at least partially forms an opposing second facing side 1022 of the second composite nonwoven fabric 1020, and a third tangled fiber web 1043 located between the first tangled fiber web 1041 and the second tangled fiber web 1042. In an example aspect, forming the first seam 1001 may include positioning a first edge 1014 of the first composite nonwoven fabric 1010 adjacent to a second edge 1024 of the second composite nonwoven fabric 1020, such that the first facing side 1111 of the first composite nonwoven fabric 1010 abuts or contacts the first facing side 1021 of the second composite nonwoven fabric 1020. Then, while holding the first composite nonwoven fabric 1010 and the second composite nonwoven fabric 1020 in that position, the first edge 1014 and the second edge 1024 are subjected to an entanglement process, such that fibers 1030 from any one of the first entangled fiber web 1031, the second entangled fiber web 1032, or the third entangled fiber web 1033 are entangled with fibers 1040 from any one of the first entangled fiber web 1041, the second entangled fiber web 1042, or the third entangled fiber web 1043.

[0127] Figure 25 Depicting Figure 23The image shows a cross-sectional view of the lower garment article 1100, and depicts an example second seam 1101. Typically, the second seam 1101 is formed by the entanglement of fibers 1130 of a first composite nonwoven fabric 1110 and fibers 1140 of a second composite nonwoven fabric 1120. Furthermore, the first composite nonwoven fabric 1110 includes a first entangled fiber web 1131 that at least partially forms a first facing side 1111 of the first composite nonwoven fabric 1110, a second entangled fiber web 1132 that at least partially forms an opposing second facing side 1112 of the first composite nonwoven fabric 1110, and a third entangled fiber web 1133 located between the first entangled fiber web 1131 and the second entangled fiber web 1132. Similarly, the second composite nonwoven fabric 1120 also includes a first tangled fiber web 1141 that at least partially forms a first facing side 1121 of the second composite nonwoven fabric 1120, a second tangled fiber web 1142 that at least partially forms an opposing second facing side 1122 of the second composite nonwoven fabric 1120, and a third tangled fiber web 1143 located between the first tangled fiber web 1141 and the second tangled fiber web 1142. In an example aspect, forming the second seam 1101 may include positioning a first edge 1114 of the first composite nonwoven fabric 1110 adjacent to a second edge 1124 of the second composite nonwoven fabric 1120, such that the second facing side 1112 of the first composite nonwoven fabric 1110 abuts or contacts the first facing side 1121 of the second composite nonwoven fabric 1120. Then, while holding the first composite nonwoven fabric 1110 and the second composite nonwoven fabric 1120 in that position, the first edge 1114 and the second edge 1124 are subjected to an entanglement process, such that fibers 1130 from any one of the first entangled fiber web 1131, the second entangled fiber web 1132, or the third entangled fiber web 1133 are entangled with fibers 1140 from any one of the first entangled fiber web 1141, the second entangled fiber web 1142, or the third entangled fiber web 1143.

[0128] Figure 26 An exploded view of an example composite nonwoven fabric 1250 is illustrated in a manufacturing process for providing aesthetic and / or functional properties to a garment article incorporating the composite nonwoven fabric 1250. According to various aspects herein, the composite nonwoven fabric 1250 can be formed by performing an entanglement process on a first fiber web 110, a second fiber web 112, and an elastomer layer 116. Accordingly, in Figure 26 The image depicts a composite nonwoven fabric 1250 after the entanglement process is performed and before the manufacturing process for forming embossed portions or pleated structures is performed.

[0129] As shown in the figure, the composite nonwoven fabric 1250 includes a first entangled fiber web 1210, a second entangled fiber web 1212, and an elastomer layer 1216 located between the first entangled fiber web 1210 and the second entangled fiber web 1212. The first entangled fiber web 1210 includes fibers 210 from the first fiber web 110 and at least partially forms the first outer surface side 1251 of the composite nonwoven fabric 1250. Similarly, the second entangled fiber web 1212 includes fibers 310, 312 from the second fiber web 112 and at least partially forms the opposing second outer surface side 1252 of the composite nonwoven fabric 1250. Figure 26 (Not shown). The elastomer layer 1216 is formed of a thermoplastic elastomer, such as thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), a combination of TPU and TPEE, etc. In a particular example, the elastomer layer 1216 may include a TPU meltblown layer.

[0130] Various aspects herein envision that fibers 210, 310, and 312 may include any of their respective properties discussed herein. Such properties of fibers 210, 310, and 312 may be adjusted and / or selectively included to achieve the desired final properties of the composite nonwoven fabric 1250. Similarly, various aspects herein envision that the elastomer layer 1216 may include any of its properties discussed herein. Furthermore, such properties of the elastomer layer 1216 may be adjusted and / or selectively included to achieve the desired final properties of the composite nonwoven fabric 1250. Any and all aspects and any variations thereof are contemplated within the scope of these aspects.

[0131] Although not depicted, aspects herein envision that the composite nonwoven fabric 1250 may include one or more additional entangled fiber webs and / or layers, which may be any of the entangled fiber webs and / or layers discussed herein. More specifically, any of the one or more additional entangled fiber webs and / or layers of the composite nonwoven fabric 1250 may be a first entangled fiber web 810, 910, 1210; a second entangled fiber web 812, 912, 1212; an inner entangled fiber web 814; a third entangled fiber web 914; an elastomer layer 116, 1216; an inner layer 120; printed layers 170, 870, 970; or a hydroentangled layer 920. Further aspects envision that the properties of one or more additional entangled fiber webs and / or layers may be adjusted and / or selectively included to achieve desired final properties of the composite nonwoven fabric 1250. In another aspect, it is envisioned that the arrangement of one or more additional entangled fiber webs and / or layers, the first entangled fiber web 1210, the second entangled fiber web 1212, and the elastomer layer 1216 can be adjusted and / or configured to achieve the desired final properties of the composite nonwoven fabric 1250.

[0132] This document envisions that one or more properties of the first entangled fiber web 1210, the second entangled fiber web 1212, and / or the elastomer layer 1216 can be configured to make the composite nonwoven fabric 1250 suitable for manufacturing processes in which embossed portions are formed on the composite nonwoven fabric 1250. Examples of properties of the first entangled fiber web 1210, the second entangled fiber web 1212, and / or the elastomer layer 1216 include, but are not limited to, melt temperature, thickness, color, basis weight, material composition, hydrophobicity, hydrophilicity, fiber composition, short fiber length, and fiber denier.

[0133] In a particular example, the first entangled fiber web 1210, the second entangled fiber web 1212, and the elastomer layer 1216 each comprise a material having a corresponding melt temperature. Although not depicted illustratively, Figure 26In one example, the first entangled fiber web 1210 includes a first material having a first melting temperature, the second entangled fiber web 1212 includes a second material having a second melting temperature, and the elastomer layer 1216 includes a third material having a third melting temperature about 40°C lower than the first melting temperature of the first material. Additional aspects of this document contemplate that the first melting temperature of the first material can be about 210°C to about 190°C, about 205°C to about 195°C, or about 200°C, and also contemplate that the second melting temperature of the second material can be about 210°C to about 190°C, about 205°C to about 195°C, or about 200°C. Such aspects also contemplate that the third melting temperature of the third material can be about 170°C to about 150°C, about 165°C to about 155°C, or about 160°C. In a particular example aspect, the first melting temperature of the first material is about 200°C, the second melting temperature of the second material is about 200°C, and the third melting temperature of the third material is about 160°C. As used herein, the term “about” means approximately ±10% of the indicated value. Various aspects of this document also envision that the aforementioned first, second, and third materials, having their respective melt temperatures, can be associated with material layers different from those described above. For example, the first entangled fiber web 1210 can be formed of either the second or third material. Similarly, the second entangled fiber web 1212 can be formed of either the first or third material. Likewise, the elastomer layer 1216 can be formed of either the first or second material. Further aspects of this document envision that material layers formed of a third material having a correspondingly lower melt temperature (regardless of whether this third material is used to form the first entangled fiber web 1210), the second entangled fiber web 1212, or the elastomer layer 1216 can be situated between corresponding other layers formed of the first and second materials. Additionally, various aspects of this document envision that layers formed of a third material having a lower melt temperature include a color (referred to herein as a “third color”), which, as explained below, can be imparted during the extrusion of the fibers forming the layer or during post-extrusion steps (such as by printing).

[0134] Figures 27A to 28 The illustration shows various aspects of the composite nonwoven fabric 1250 after a manufacturing process in which a recessed portion 1230 is formed on the first outer surface side 1251 of the composite nonwoven fabric 1250 is performed. Figure 27A and Figure 27B In this illustration, the composite nonwoven fabric 1250 is depicted illustratively to represent the color characteristics of the first entangled fiber web 1210, the second entangled fiber web 1212, and the elastomer layer 1216. Therefore, in Figure 27A In the diagram, the diagonal line represents the first color 1241 of the first entangled fiber web 1210, and the dot represents the third color 1243 of the elastomer layer 1216. Figure 27B In the middle, the horizontal line represents the second color 1242 of the second entangled fiber web 1212.

[0135] Figure 27A The figure illustrates the first outer surface side 1251 of a composite nonwoven fabric 1250, and as shown, a recessed portion 1230 is visible on the first outer surface side 1251. The composite nonwoven fabric 1250 includes a first region 1221 and a second region 1222, both of which are also visible on the first outer surface side 1251. In the first region 1221, the first outer surface side 1251 is at least partially formed by a first entangled fiber web 1210, and consequently, a first color 1241 of the first entangled fiber web 1210 is visible on the first outer surface side 1251 in the first region 1221. In the second region 1222, the first outer surface side 1251 is at least partially formed by the recessed portion 1230. Thus, the recessed portion 1230 is visible on the first outer surface side 1251 in the second region 1222. Additionally, because at least some of the fibers 210 of the first entangled fiber web 1210 are integrated within the recessed portion 1230 at the second region 1222, the third color 1243 of the elastomer layer 1216 is visible on the first outer finish side 1251 at the second region 1222. The third color 1243 can be added during the extrusion of the fibers that can form the elastomer layer 1016 by a sustainable inkless process (e.g., also known as pre-spinning dyeing), or the third color 143 can be added after the extrusion of the fibers that can form the elastomer layer 1016 by a printing process, such as that envisioned herein.

[0136] Figure 27B The illustration shows opposing second outer surface sides 1252 of the composite nonwoven fabric 1250, and as shown, the embossed portion 1230 is not visible on the opposing second outer surface sides 1252. Unlike the first outer surface side 1251, the opposing second outer surface sides 1252 are at least partially formed by a second entangled fiber web 1212 in the first region 1221 and the second region 1222. Therefore, the second color 1242 of the second entangled fiber web 1212 is visible on the opposing second outer surface sides 1252 in the first region 1221 and the second region 1222.

[0137] This document posits that a first color 1241 is different from a third color 1243, and / or that a first color 1241 is different from both a second color 1242 and a third color 1243. In another example, the second color 1242 is different from the third color 1243. In other examples, the first color 1241 is substantially the same as the second color 1242, and the first color 1241 is substantially the same as the third color 1243. Based on the aspects discussed herein, one color can be determined to be different from another color. Furthermore, a color can be determined to be "similar" or "substantially the same" as another color based on the difference between the numerical color value of a color and the numerical color value as a percentage relative to any numerical color value. If the percentage difference between the numerical color values ​​of the first color and the second color is equal to or less than 5%, then the first color is "substantially the same" as the second color.

[0138] Figure 28 A cross-sectional view of the composite nonwoven fabric 1250 is shown. As shown, the second region 1222 is recessed relative to the first region 1221. In other words, the thickness of the composite nonwoven fabric 1250 at the first region 1221 is greater than the thickness of the composite nonwoven fabric 1250 at the second region 1222. More specifically, the thickness 1262 of the recessed portion 1230 is approximately 50% smaller than the thickness 1261 of the first entangled fiber web 1210 and the elastomer layer 1216 at the first region 1221. Additionally, the thickness 1263 of the second entangled fiber web 1212 in the composite nonwoven fabric 1250 is within approximately 95% of each other at the first region 1221 and the second region 1222. In other words, the thickness of the second entangled fiber web 1212 in the composite nonwoven fabric 1250 at the first zone 1221 is within about 95% of the thickness of the second entangled fiber web 1212 in the composite nonwoven fabric 1250 at the second zone 1222.

[0139] In various respects, the embossed portion 1230 may refer to a portion of the second region 1222, which includes the first entangled fiber web 1210 and the elastomer layer 1216, but does not include the second entangled fiber web 1212. Further aspects envision that the relationship and / or configuration of the first entangled fiber web 1210 and the elastomer layer 1216 at the embossed portion 1230 may be described in different ways. In one example aspect, the embossed portion 1230 may include the elastomer layer 1216 in the form of a film, which encapsulates a plurality of fibers 212 from the first entangled fiber web 1210. As used herein, when describing the configuration of fibers at the embossed portion, the term "encapsulation" means that at least half of the surface area of ​​the fibers is surrounded by the elastomer layer in the form of a film. In another example aspect, the embossed portion 1230 may include a matrix structure formed of a plurality of fibers 212 and a film.

[0140] Although the first entangled fiber web 1210, the second entangled fiber web 1212 and the elastomer layer 1216 are in Figures 26 to 28 While shown as different layers, this document envisions the first entangled fiber web 1210 and the second entangled fiber web 1212 entangled with each other and extending through the elastomer layer 1216 to form a cohesive structure. Nevertheless, in this example, each of the first entangled fiber web 1210, the second entangled fiber web 1212, and the elastomer layer 1216 retains the characteristics of a different layer at the first region 1221 of the composite nonwoven fabric 1250. Conversely, at the second region 1222 of the composite nonwoven fabric 1250, only the second entangled fiber web 1212 retains the characteristics of a different layer because the fibers of the first entangled fiber web 1210 are integrated into the elastomer layer 1216 at the indentation 1230.

[0141] Figure 29 The illustration depicts an example manufacturing process for forming the embossed portion 1230 of the composite nonwoven fabric 1250 and incorporating it into a garment article 1320, the process being generally indicated by reference numeral 1300. It should be understood that... Figure 29 Any depiction of the manufactured parts herein is illustrative and intended to convey the general characteristics of the various steps of manufacturing process 1300. Additionally, while the steps of manufacturing process 1300 are depicted as being performed in a sequential order, aspects herein contemplate that manufacturing process 1300 may include any combination of one or more steps, any of which may be repeated or performed in a different order than depicted. At a high level, Figure 29 The various steps of the manufacturing process 1300 are depicted, which generally involve applying one or more of heat and pressure to a second region 1222 of a first outer surface side 1251 of a composite nonwoven fabric 1250 to impart a pattern 1270 thereon.

[0142] Beginning at step 1302, a composite nonwoven fabric 1250 is obtained and / or provided. The composite nonwoven fabric 1250 includes a first entangled fiber web 1210 having a first color 1241, a second entangled fiber web 1212 having a second color 1242 (not visible), and an elastomer layer 1216 having a third color 1243 and located between the first entangled fiber web 1210 and the second entangled fiber web 1212. The first color 1241 and the third color 1243 are compatible with... Figure 27A and Figure 27B It is described and represented in the same illustrative way as in the text.

[0143] At step 1304, one or more of heat and pressure 1314 (illustrated by arrows) are applied to a second region 1222 on the first outer surface side 1251 of the composite nonwoven fabric 1250, such that the elastomeric layer 1216 forms a membrane encapsulating a plurality of fibers from the first entangled fiber web 1210. Figure 29 In this example, the embossing tool 1310 is used to apply one or more of heat and pressure 1314 to a second region 1222 of the composite nonwoven fabric 1250. The embossing tool 1310 is merely one example; other tooling methods are contemplated herein, including, for example, lasers, ultrasonic welding machines, etc. The embossing tool 1310 includes a tool component 1312 and is configured to transfer heat to a portion of the first outer surface side 1251 that contacts or nearly contacts the tool component 1312 and / or the surface (not visible) of the tool component 1312 during the application of one or more of heat and pressure 1314. Furthermore, while the tool component 1312 is depicted as having a circular shape, aspects herein contemplate that the tool component 1312 and / or its surface may include designs, visual markings, one or more shapes, and / or one or more linear or curved portions associated with branded commercial products, such as logos, geometric shapes, organic shapes, patterns, letters, numbers, etc.

[0144] To initiate the application of heat and pressure 1314 or more, the embossing tool 1310 is positioned such that the tool component 1312 and / or its surface contacts or nearly contacts the first outer finish side 1251 at the second region 1222. Then, while applying heat and pressure 1314 or more to the second region 1222 on the first outer finish side 1251 of the composite nonwoven fabric 1250, the embossing tool 1310 is held in place. To terminate the application of heat and pressure 1314 or more, the embossing tool 1310 is repositioned such that the tool component 1312 and its surface are spaced apart from the first outer finish side 1251 at the second region 1222.

[0145] In one example, the embossing tool 1310 is configured to apply heat and pressure 1314 at a temperature and duration sufficient to cause the elastomeric layer 1216 to form a film encapsulating a plurality of fibers from the first entangled fiber web 1210. In other examples, the embossing tool 1310 is configured to apply heat to a second region 1222 of the first outer surface side 1251 at a temperature of about 210°C to about 160°C, about 205°C to about 165°C, about 200°C to about 170°C, about 195°C to about 175°C, about 190°C to about 180°C, about 200°C to about 190°C, or about 195°C for a duration of about 80 seconds to about 20 seconds, about 75 seconds to about 25 seconds, about 70 seconds to about 30 seconds, about 65 seconds to about 35 seconds, about 60 seconds to about 40 seconds, about 55 seconds to about 45 seconds, or about 50 seconds. In one particular example, the embossing tool 1310 is configured to apply heat to the second region 1222 of the first exterior finish side 1251 at a temperature of about 190°C to about 170°C for a duration of about 32 seconds to about 28 seconds. In another particular example, the embossing tool 1310 is configured to apply heat to the second region 1222 of the first exterior finish side 1251 at a temperature of about 180°C for a duration of about 30 seconds. As used herein, the term "about" means within approximately ±10% of the indicated value. In yet another particular example, one or more of heat and pressure 1314 are applied simultaneously.

[0146] Step 1304 further includes positioning the composite nonwoven fabric 1250 on the deformable surface 1318 such that, during one or more of the application of heat and pressure 1314, the opposing second outer surface side 1252 of the composite nonwoven fabric 1250 is positioned adjacent to the deformable surface 1318. The deformable surface 1318 is configured to prevent and / or reduce any residual heat contacting the opposing second outer surface side 1252 during one or more of the application of heat and pressure 1314. Accordingly, the deformable surface 1318 includes thermal insulation properties and is formed of a highly thermally insulating material (e.g., rubber-coated foam). Additionally, the deformable surface 1318 is also configured to deform during one or more of the application of heat and pressure 1314 in a manner corresponding to the shape of the tool component 1312 and / or its surface.

[0147] At step 1306, the application of heat and pressure 1314 is stopped, and at the second region 1222 of the composite nonwoven fabric 1250, an elastomer layer 1216 forms a membrane 1330 encapsulating a plurality of fibers from the first entangled fiber web 1210. Accordingly, the color of the first outer surface side 1251 at the second region 1222 is a third color 1243, and the color of the first outer surface side 1251 at the first region 1221 is a first color 1241. Furthermore, a pattern 1270 is formed on the first outer surface side 1251 of the composite nonwoven fabric 1250 at the second region 1222. The pattern 1270 has a shape corresponding to the shape of the tool component 1312 and / or its surface. Although the pattern 1270 is... Figure 29 While the example features a circular shape, various aspects of this document envision that graphic 1270 may include designs, visual symbols, one or more shapes, and / or one or more linear or curved portions associated with a branded commercial product, such as logos, geometric shapes, organic shapes, patterns, letters, numbers, etc. Such aspects also envision that a graphic with a different shape from graphic 1270 can be formed using a debossing tool having a tool part with a different shape than tool part 1312.

[0148] In one example, the thickness of the composite nonwoven fabric 1250 in the second region 1222 is about 50% less than the thickness of the composite nonwoven fabric 1250 in the first region 1221. In other examples, the thickness of the composite nonwoven fabric in the second region 1222 is about 70% to about 30%, about 65% to about 35%, about 60% to about 40%, or about 55% to about 45% less than the thickness of the composite nonwoven fabric 1250 in the first region 1221. In yet another example, the thickness of the second entangled fiber web 1212 in the composite nonwoven fabric 1250 is about 95% to about 85%, about 90%, or about 95% of each other in the first region 1221 and the second region 1222. As used herein, the term “about” means within approximately ±10% of the indicated value.

[0149] At step 1308, the composite nonwoven fabric 1250 is incorporated into the garment article 1320. The composite nonwoven fabric 1250 may form at least a portion of the garment article 1320, and one example aspect envisions the composite nonwoven fabric 1250 as a garment piece of the garment article 1320, which is combined with one or more other fabrics (e.g., composite nonwoven fabrics, woven fabrics, and / or knitted fabrics) to form the garment article 1320.

[0150] Figure 30A and Figure 30B The illustration shows an example upper garment article 1400 incorporating a composite nonwoven fabric 1450. The upper garment article 1400 is... Figure 30AThe image shows a long-sleeved upper garment, indicating that the upper garment 1400 can be in the form of a jacket, hoodie, short-sleeved shirt, etc. Figure 30B The upper garment 1400 shown is sleeveless, indicating that it may be a sleeveless shirt, vest, or similar form. The upper garment 1400 includes an outward-facing surface 1401 and an inward-facing surface 1402. As shown, the outward-facing surface 1401 is the outermost surface of the upper garment 1400, and similarly, the inward-facing surface 1402 is the innermost surface of the upper garment 1400. Furthermore, a first outer facing side 1451 of the composite nonwoven fabric 1450 at least partially forms the outward-facing surface 1401 of the upper garment 1400, and an opposing second outer facing side 1452 of the composite nonwoven fabric 1450 at least partially forms the inward-facing surface 1402 of the upper garment 1400.

[0151] The composite nonwoven fabric 1450 includes the same features as the composite nonwoven fabric 1250, but includes additional regions with additional embossed portions. Accordingly, the composite nonwoven fabric 1450 includes a first region 1421, a second region 1422, and a third region 1423. The first region 1421 includes a first entangled fiber web, a second entangled fiber web, and an elastomer layer located between the first and second entangled fiber webs. At the second region 1422, the composite nonwoven fabric 1450 includes a first embossed portion 1431 and a second entangled fiber web, and the third region 1423 includes a second embossed portion 1432 and a first entangled fiber web.

[0152] The first embossed portion 1431 includes the same features as the embossed portion 1230, and therefore, the first embossed portion 1431 is formed on the first outer surface side 1451 of the composite nonwoven fabric 1450 and includes a plurality of fibers from the first entangled fiber web integrated within the elastomer layer. Furthermore, the first embossed portion 1431 forms a first pattern 1471, and as... Figure 30A and Figure 30B As shown, the first embossed portion 1431 is visible on the outward-facing surface 1401 of the upper garment 1400 and is not visible on the inward-facing surface 1402 of the upper garment 1400.

[0153] The second embossed portion 1432 includes features similar to those of the embossed portion 1230 but is formed on the opposing second outer surface side 1452 of the composite nonwoven fabric 1450. Accordingly, unlike the embossed portion 1230, the second embossed portion 1432 includes a plurality of fibers from the second entangled fiber web integrated within the elastomer layer. The second embossed portion 1432 forms a second pattern 1472, and in one example aspect, the second pattern 1472 has an appearance different from the first pattern 1471. In another example aspect, the second pattern 1472 may have a substantially identical appearance to the first pattern 1471. Furthermore, as... Figure 30A and Figure 30B As depicted, the second embossed portion 1432 is visible on the inward-facing surface 1402 of the upper garment article 1400, but not visible on the outward-facing surface 1401 of the upper garment article 1400.

[0154] In an example, the second embossed portion 1432 may be formed in a manner similar to the embossed portion 1230, but the embossing tool 1310 may be applied to the second entangled fiber web 1212 instead of the first entangled fiber web 1210. In this respect, the elastomeric layer 1216 forms a film encapsulating a plurality of fibers from the second entangled fiber web 1212, such that the color of the second embossed portion 1432 is a third color 1243 similar to that of the first embossed portion 1431. In an example, the second embossed portion 1432 may include, for example, care instructions for garment article 1400, which avoids additional manufacturing steps associated with sewing or attaching care labels, and may also facilitate easier recycling of garment article 1400.

[0155] Figure 31A and Figure 31B An example lower garment article 1500 incorporating a composite nonwoven fabric 1550 is illustrated. The lower garment article 1500 is in the form of lower clothing and is shown as trousers, although it is also envisioned that the lower garment article 1500 could be in the form of shorts, capri pants, leggings, etc. The lower garment article 1500 includes an outward-facing surface 1501 and an inward-facing surface 1502. As shown, the outward-facing surface 1501 is the outermost surface of the lower garment article 1500, and similarly, the inward-facing surface 1502 is the innermost surface of the lower garment article 1500. Furthermore, the first outer surface side 1551 of the composite nonwoven fabric 1550 at least partially forms the outward-facing surface 1501, and the opposing second outer surface side 1552 of the composite nonwoven fabric 1550 at least partially forms the inward-facing surface 1502.

[0156] Composite nonwoven fabric 1550 includes the same features as composite nonwoven fabric 1250, but includes additional regions with additional embossed portions. Therefore, composite nonwoven fabric 1550 includes a first region 1521, a second region 1522, a third region 1523, a fourth region 1524, and a fifth region 1525. First region 1521 includes a first entangled fiber web, a second entangled fiber web, and an elastomer layer located between the first and second entangled fiber webs. Second region 1522 and third region 1523 both include the second entangled fiber web and respectively include a first embossed portion 1531 and a second embossed portion 1532. Fourth region 1524 and fifth region 1525 both include the first entangled fiber web and respectively include a third embossed portion 1533 and a fourth embossed portion 1534.

[0157] The first embossed portion 1531 and the second embossed portion 1532 include the same features as the embossed portion 1230, and therefore, the first embossed portion 1531 and the second embossed portion 1532 are formed on the first outer surface side 1551 of the composite nonwoven fabric 1550 and include a plurality of fibers from the first entangled fiber web integrated within the elastomer layer. Furthermore, the first embossed portion 1531 forms a first pattern 1571, and the second embossed portion 1532 forms a second pattern 1572. Figure 31A and Figure 31B As shown, the first embossed portion 1531 and the second embossed portion 1532 are visible on the outward-facing surface 1501 of the lower garment article 1500, and are not visible on the inward-facing surface 1502 of the lower garment article 1500.

[0158] The third embossed portion 1533 and the fourth embossed portion 1534 include features similar to those of the embossed portion 1230 but are formed on the opposing second outer surface side 1552 of the composite nonwoven fabric 1550. Accordingly, unlike the embossed portion 1230, the third embossed portion 1533 and the fourth embossed portion 1534 include a plurality of fibers from the second entangled fiber web integrated within the elastomer layer. The third embossed portion 1533 forms a third pattern 1573, and the fourth embossed portion 1534 forms a fourth pattern 1574. It is envisioned that any of the first pattern 1571, the second pattern 1572, the third pattern 1573, and the fourth pattern 1574 can have the same or different appearances. Furthermore, as Figure 31A and Figure 31B As depicted, the third recessed portion 1533 and the fourth recessed portion 1534 are visible on the inward-facing surface 1502 of the lower garment article 1500, but not visible on the outward-facing surface 1501 of the lower garment article 1500.

[0159] Figures 32A to 33The illustration shows an example pleated construction 1600, which includes a composite nonwoven fabric 1850, an elastically resilient structured fabric 1620, and multiple pleats 1630. As used herein, the term "structured fabric" refers to a fabric having one of a knitted or woven construction, and the term "elastically resilient" refers to a fabric that substantially returns to its original length after being subjected to tension. Figure 32A The illustration shows the first side 1601 of the pleated structure 1600, which is at least partially formed by the composite nonwoven fabric 1850, and Figure 32B The illustration shows the second side 1602 of a pleated structure 1600, which is at least partially formed by an elastically resilient structured fabric 1620. Furthermore, as discussed below, the pleated structure 1600 is configured such that the peaks of the plurality of pleats 1630 are formed at the first side 1601 and the valleys of the plurality of pleats 1630 are formed at the second side 1602.

[0160] like Figure 33 As shown (illustrating an exploded view of the pleated structure 1600), the composite nonwoven fabric 1850 includes a first entangled fiber web 1810, a second entangled fiber web 1812, and an elastomer layer 1816 located between the first entangled fiber web 1810 and the second entangled fiber web 1812. The composite nonwoven fabric 1850 is formed by performing an entanglement process on the first fiber web 1810, the second fiber web 1812, and the elastomer layer 1816. Accordingly, the first entangled fiber web 1810 includes fibers 210 (not identified) from the first fiber web 1810 and at least partially forms the first outer facing side 1851 of the composite nonwoven fabric 1850 (in Figure 32A (As shown in the diagram). Similarly, the second entangled fiber web 1812 includes fibers 310, 312 (not identified) from the second fiber web 112 and at least partially forms the opposing second outer surface side 1852 of the composite nonwoven fabric 1850. The elastomer layer 1816 is formed of a thermoplastic elastomer, such as thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), a combination of TPU and TPEE, etc.

[0161] A resilient, structured fabric 1620 is positioned adjacent to the outermost surface 1881 of the second tangled fiber web 1812 and attached thereto via an adhesive layer 1610. In one example, the adhesive layer 1610 includes a pleating configuration 1600 such that the resilient, structured fabric 1620 is attached to the second tangled fiber web 1812 at intermittent areas on the outermost surface 1881. Figure 33In this example, the adhesive layer 1610 is included on the outermost surface 1881 at one or more first regions 1641 and is not present on the outermost surface 1881 at one or more second regions 1642. As a result of this configuration of the adhesive layer 1610, the elastic resilient structured fabric 1620 is attached to the second tangled fiber web 1812 at one or more first regions 1641 and is not attached to the second tangled fiber web 1812 at one or more second regions 1642.

[0162] This document envisions each of one or more first regions 1641 having a length and a width, wherein the length is greater than the width at the one or more first regions 1641. Continuing with these examples, each of one or more second regions 1642 has a length and a width, wherein the length is greater than the width at the one or more second regions. In other aspects, the one or more first regions 1641 are spaced apart from each other by the one or more second regions 1642.

[0163] In one example, adhesive layer 1610 may be a heat-activated adhesive configured to melt and flow when heated to a specified temperature. In one such example, the heat activation temperature of adhesive layer 1610 is from about 125°C to about 135°C. In another example, the heat activation temperature of adhesive layer 1610 is less than the melting temperature (as described above) of the materials forming each of the first entangled fiber web 1810, the second entangled fiber web 1812, and the elastomer layer 1816. Other aspects envision adhesive layer 1610 also being configured to chemically bond with composite nonwoven fabric 1850 and / or mechanically bond with elastically resilient structured fabric 1620. Further aspects envision adhesive layer 1610 as a thermoplastic film, and in one example, adhesive layer 1610 comprises a thermoplastic elastomer. In yet another example, adhesive layer 1610 may be Bemis tape.

[0164] In an additional example, the elastic-rebound structured fabric 1620 is configured to have stretch and recovery properties. Accordingly, applying tension causes the elastic-rebound structured fabric 1620 to transition to a tensioned state, and once the tension is released, the elastic-rebound structured fabric 1620 transitions out of tension and returns to its resting state. Other aspects of this document envision the elastic-rebound structured fabric 1620 comprising a warp-knitted or weft-knitted mesh construction and a material having stretch and recovery properties. In one example, the elastic-rebound structured fabric 1620 comprises: a first material comprising elastic yarns and / or a second material comprising polyester.

[0165] Another aspect of this document envisions that the composite nonwoven fabric 1850 may include one or more additional entangled fiber webs and / or layers, which may be any of the entangled fiber webs and / or layers discussed herein. More specifically, any of the one or more additional entangled fiber webs and / or layers of the composite nonwoven fabric 1850 may be a first entangled fiber web 810, 910, 1210, 1810; a second entangled fiber web 812, 912, 1212, 1812; an inner entangled fiber web 814; a third entangled fiber web 914; an elastomer layer 116, 1216, 1816; an inner layer 120; printed layers 170, 870, 970; or a hydroentangled layer 920. An additional aspect envisions that the properties of one or more additional entangled fiber webs and / or layers may be adjusted and / or selectively included to achieve the desired final properties of the composite nonwoven fabric 1850. Another aspect envisions is that the arrangement of one or more additional entangled fiber webs and / or layers, the first entangled fiber web 1810, the second entangled fiber web 1812, and the elastomer layer 1816 can be adjusted and / or configured to achieve the desired final characteristics of the composite nonwoven fabric 1850.

[0166] In one aspect, the first entangled fiber web 1810, the second entangled fiber web 1812, and the elastomer layer 1816 may each be configured to provide the composite nonwoven fabric 1850 with fabric stiffness, tensile strength, and / or resilience suitable for forming the pleated structure 1600. In one aspect, the composite nonwoven fabric 1850 may have fabric stiffness insufficient to resist the resilience of the elastically resilient structured fabric 1620. In another aspect, the first entangled fiber web 1810, the second entangled fiber web 1812, and the elastomer layer 1816 may each be configured to have a melt temperature higher than the activation temperature of the adhesive layer 1610. Further aspects of this document contemplate that the properties of fibers 210, 310, 312, and the elastomer layer 1816 may be adjusted and / or selectively included to achieve desired final properties of the composite nonwoven fabric 1850. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0167] Figure 34 The illustration depicts an example manufacturing process for forming the pleated structure 1600 and incorporating it into the garment article 1720, the process being generally indicated by reference numeral 1700. It should be understood that... Figure 34 Any depiction of the manufactured parts herein is illustrative and intended to convey the general characteristics of the various steps of manufacturing process 1700. Additionally, although the steps of manufacturing process 1700 are depicted as being performed in a sequential order, aspects herein contemplate that manufacturing process 1700 may include any combination of one or more steps, any of which may be repeated or performed in a different order than depicted.

[0168] At a high level, Figure 34 The various steps of the manufacturing process 1700 are described, which generally include tensioning the elastic rebound structured fabric 1620, positioning the elastic rebound structured fabric 1620 onto the surface of the composite nonwoven fabric 1850 while in a tensioned state, selectively attaching the composite nonwoven fabric 1850 to the elastic rebound structured fabric 1620 at one or more first regions 1641, and releasing the tension applied to the elastic rebound structured fabric 1620 to form a plurality of pleats 1630.

[0169] Starting from step 1702, a composite nonwoven fabric 1850 is obtained and / or provided. The composite nonwoven fabric 1850 includes a first entangled fiber web 1810 (not visible), a second entangled fiber web 1812, and an elastomeric layer 1816 (not visible) located between the first entangled fiber web 1810 and the second entangled fiber web 1812.

[0170] At step 1704, an adhesive layer 1610 is applied to the outermost surface 1881 of the second entangled fiber web 1812. The adhesive layer 1610 is applied in a manner aligned with one or more first regions 1641. In an illustrative aspect, each of the one or more first regions 1641 has a length and a width, wherein the length is greater than the width at that one or more first regions 1641. Continuing with these illustrative aspects, each of the one or more second regions 1642 has a length and a width, wherein the length is greater than the width at that one or more second regions 1642. In other aspects, the one or more first regions 1641 are spaced apart from each other by the one or more second regions 1642. In an illustrative aspect, the longitudinal axis of the one or more first regions 1641 is aligned parallel to the longitudinal axis of the one or more second regions 1642.

[0171] At step 1706, the elastic-rebound structured fabric 1620 is tensioned. In various aspects, the elastic-rebound structured fabric 1620 can be tensioned by elongating it in the warp or longitudinal direction or the machine direction indicated by the arrow. In one example, the tension applied to the elastic-rebound structured fabric 1620 is sufficient to elongate it by about 55%. In another aspect, the tension applied to the elastic-rebound structured fabric 1620 elongates it by about 75% to about 25%, about 70% to about 30%, about 65% to about 35%, about 60% to about 40%, or about 55% to about 45%. At step 1708, the elastic-rebound structured fabric 1620 is positioned on the outermost surface 1881 of the second entangled fiber web 1812 of the composite nonwoven fabric 1850. In addition, the elastic rebound structured fabric 1620 is positioned when it is under tension.

[0172] At step 1710, the composite nonwoven fabric 1850 is selectively attached to the elastic resilient structured fabric 1620 at one or more first regions 1641. In an example embodiment, the composite nonwoven fabric 1850 and the elastic resilient structured fabric 1620 can be selectively attached by applying heat at a temperature sufficient to activate the adhesive layer 1610. Figure 34 In one example, heating element 1716 is used to apply heat, and in one aspect, heating element 1716 is a hot press. In another example aspect, the composite nonwoven fabric 1850 and the elastic resilient structured fabric 1620 can be selectively attached by applying a first heat cycle at a temperature of about 150°C to about 160°C for a duration of about 10 seconds, and then applying a second heat cycle at a temperature of about 150°C to about 160°C for a duration of about 10 seconds. In other aspects, pressure can also be applied during the attachment of the composite nonwoven fabric 1850 and the elastic resilient structured fabric 1620. Various aspects of this document also envision that after the application of heat is stopped, the elastic resilient structured fabric 1620 remains in tension for about 20 seconds.

[0173] At step 1712, the tension applied to the elastically resilient structured fabric 1620 is released, thereby forming a plurality of pleats 1630 and further forming a pleated structure 1600 (e.g., a composite nonwoven fabric 1850 having a plurality of pleats 1630). Upon release, one or more first regions 1641 form valleys of the plurality of pleats 1630 at a second side 1602 of the pleated structure 1600, and one or more second regions 1642 form peaks of the plurality of pleats 1630 at a first side 1601 of the pleated structure 1600. Various aspects herein envision that at one or more first regions 1641, the elastically resilient structured fabric 1620 remains taut because the adhesive layer 1610 at least partially impregnates the elastically resilient structured fabric 1620 and “locks” the knitted or woven structure in these regions. As shown, the longitudinal axes of the plurality of pleats 1630 are aligned parallel to the longitudinal axes of one or more first regions 1641 and / or one or more second regions 1642.

[0174] At step 1714, the pleating structure 1600 is incorporated into the garment article 1720. The pleating structure 1600 may form at least a portion of the garment article 1720, and in one example aspect, the pleating structure 1600 is envisioned to form the cuff of the garment article 1720, wherein the cuff may be located at the distal end of, for example, a sleeve, a waist opening, a collar, a belt, a distal trouser leg, etc.

[0175] Figure 35An upper garment article 2000 is depicted having one or more portions formed of a composite nonwoven fabric 1850, wherein the garment article 2000 includes pleats 1600 at one or more locations on the garment article 2000. Similarly, Figure 36 A lower garment article 2100 is depicted having one or more portions formed of a composite nonwoven fabric 1850, wherein the garment article 2100 includes pleats 1600 at one or more locations on the garment article 2100. The outward-facing surfaces 2001 of both the garment article 2000 and the garment article 2100 are shown. With respect to the garment article 2000, the pleats 1600 form cuffs at the sleeve ends, and with respect to the garment article 2100, the pleats 1600 form cuffs at the leg openings of the garment article 2100. The pleats 1600 can also be used to form waist openings for the garment article 2000 and waistbands for the garment article 2100, as shown.

[0176] Each of the cuffs may include, for example, about Figure 34 The composite nonwoven fabric 1850, the elastic resilient structured fabric 1620, and the adhesive layer 1610 form a first plurality of pleats 1631. In one example aspect, the cuff can be formed by folding and pleating construction 1600 such that the surfaces of the elastic resilient structured fabric 1620 are positioned adjacent to each other (i.e., the surfaces are in a face-sharing relationship), and the composite nonwoven fabric 1850 forms both the outward-facing surface and the inward-facing surface of the cuff.

[0177] Figure 37 A cross-sectional view of the cuff of the upper garment 2000 is illustrated, and an enlarged view of a portion of the cross-section is also depicted. As shown, the pleating structure 1600 is folded or reconfigured such that the surfaces of the elastically resilient structured fabric 1620 (serving as the outward-facing surfaces of the pleating structure 1600) form two surfaces positioned adjacent to each other (i.e., these surfaces are in a face-sharing relationship). The composite nonwoven fabric 1850 forms both the outward-facing surface and the inward-facing surface of the cuff. Accordingly, a first plurality of pleats 1631 are located on the outermost surface 2001 of the upper garment 2000, and a second plurality of pleats 1632 are located on the innermost surface 2002 of the upper garment 2000.

[0178] A first plurality of pleats 1631 are included in a first portion of the pleated structure 1600 and are formed by a first composite nonwoven fabric 2050 (i.e., a portion of the composite nonwoven fabric 1850 forming the outward-facing surface of the cuff), a first elastically resilient structured fabric 1621, and a first adhesive layer 1611. Similarly, a second plurality of pleats 1632 are included in a second portion of the pleated structure 1600 and are formed by a second composite nonwoven fabric 1950 (i.e., a portion of the composite nonwoven fabric 1850 forming the inward-facing surface of the cuff), a second elastically resilient structured fabric 1622, and a second adhesive layer 1612. The first composite nonwoven fabric 2050 and the second composite nonwoven fabric 1950 are each a portion of the composite nonwoven fabric 1850 and therefore have the same characteristics. Accordingly, the first composite nonwoven fabric 2050 includes a first entangled fiber web 2010, a second entangled fiber web 2012, and a first elastomeric layer 2016 located between the first entangled fiber web 2010 and the second entangled fiber web 2012. Similarly, the second composite nonwoven fabric 1950 includes a third entangled fiber web 1910, a fourth entangled fiber web 1912, and a second elastomeric layer 1916 located between the third entangled fiber web 1910 and the fourth entangled fiber web 1912. In one example aspect, the first composite nonwoven fabric 2050 and the second composite nonwoven fabric 1950 may originate from different composite nonwoven fabrics and therefore may include one or more different features.

[0179] like Figure 37 As shown in the enlarged view, the second entangled fiber web 2012 has a first outermost surface 2081 attached to the third surface 1625 of the first resilient structured fabric 1621 at one or more first regions 1641, and the fourth entangled fiber web 1912 has a second outermost surface 1981 attached to the fourth surface 1626 of the second resilient structured fabric 1622 at one or more first regions 1641. At one or more second regions 1642, the first outermost surface 2081 and the second outermost surface 1981 are not attached to the first resilient structured fabric 1621 and the second resilient structured fabric 1622, respectively, which at least partially contributes to the formation of peaks and valleys in the first composite nonwoven fabric 2050 and the second composite nonwoven fabric 1950. Furthermore, the first elastic rebound structured fabric 1621 and the second elastic rebound structured fabric 1622 can be in a tensioned state at one or more first regions 1641 (i.e., held tensioned by the adhesive layer 1610) and can be untensioned at one or more second regions 1642, which can also help to form peaks and valleys in the first composite nonwoven fabric 2050 and the second composite nonwoven fabric 1950.

[0180] In all respects, throughout the cuff, the first elastic rebound structured fabric 1621 and the second elastic rebound structured fabric 1622 remain in adjacent positions, but may be spaced apart in different ways. Figure 37 In the design, the first surface 1623 of the first elastic rebound structured fabric 1621 is spaced apart from the second surface 1624 of the second elastic rebound structured fabric 1622 at one or more second regions 1642, and at one or more first regions 1641, the first surface 1623 and the second surface 1624 are shown to be in contact with each other. In other words, the first surface 1623 and the second surface 1624 are in a face-sharing relationship throughout the cuff.

[0181] It should be understood that Figure 37 The description is illustrative, and the various aspects herein envision that the pleated construction 1600 may have one or more different configurations throughout the cuff. In one instance, the first surface 1623 and the second surface 1624 may be spaced apart at one or more first regions 1641. In another instance, the first plurality of pleats 1631 may be offset from the second plurality of pleats 1632.

[0182] The following clauses represent exemplary aspects of the concepts envisioned herein. Any of the following clauses may be combined in a multi-dependent manner to depend on one or more other clauses. Furthermore, any combination of dependent clauses (clauses that explicitly depend on preceding clauses) may be combined while remaining within the scope of the aspects envisioned herein. The following clauses are examples and not limitations.

[0183] Clause 1. A method of manufacturing a printed composite nonwoven fabric, comprising: positioning a first side of a printed layer adjacent to a second side of a first fiber web to form a composite structure, wherein the printed layer includes printed components; and subjecting the composite structure to a needle entanglement process, wherein, after the entanglement process, at least a portion of the printed components is bonded to the first fiber web.

[0184] Clause 2. The method of manufacturing a printed composite nonwoven fabric according to Clause 1, wherein the printed layer is an inner fiber web having a first region including a first portion of the printed component and a second region including a second portion of the printed component.

[0185] Clause 3. The method of manufacturing a printed composite nonwoven fabric according to Clause 2, wherein the first region of the inner fiber web has greater mechanical entanglement with the first fiber web compared to the second region of the inner fiber web.

[0186] Clause 4. A method of manufacturing a printed composite nonwoven fabric according to any one of Clauses 2 to 3, wherein after the composite structure is subjected to the needle entanglement process, at least some of the fibers in the first region of the inner fiber web are mechanically entangled with the first fiber web, and at least some of the fibers in the second region of the inner fiber web are mechanically independent of the first fiber web.

[0187] Clause 5. The method of manufacturing a printed composite nonwoven fabric according to Clause 4, wherein the printed component comprises at least one selected from the group consisting of colorants and sublimation dyes.

[0188] Clause 6. A method for manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 5, wherein the printed layer is a hydroentangled layer.

[0189] Clause 7. The method of manufacturing a printed composite nonwoven fabric according to Clause 6, wherein after the composite structure is subjected to the needle entanglement process, at least some of the fibers of the first fiber web extend through the hydroentangled layer, a first portion of the printed part is bonded to the first fiber web, and a second portion of the printed part is bonded to the hydroentangled layer.

[0190] Clause 8. The method of manufacturing a printed composite nonwoven fabric as described in Clause 7, wherein the second portion of the printed component is not bonded to the first fiber web.

[0191] Clause 9. A method for manufacturing a printed composite nonwoven fabric according to Clauses 7 to 8, wherein the printed component comprises at least one selected from the group consisting of a colorant and a sublimation dye.

[0192] Clause 10. A method for manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 9, wherein the printed layer comprises spunlace fibers.

[0193] Clause 11. A method for manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 10, wherein the printed layer comprises a fiber web.

[0194] Clause 12. A method of manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 11, wherein the composite structure further comprises a second fiber web adjacent to a second side of an inner layer.

[0195] Clause 13. A method of manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 12, wherein the printed component is on the first surface of the printed layer.

[0196] Clause 14. The method of manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 13 further comprises: printing the printed component on an inner layer to form the printed layer before positioning the first side of the printed layer adjacent to the second side of the first fiber web to form the composite structure.

[0197] Clause 15. The method of manufacturing a printed composite nonwoven fabric according to Clause 14, wherein the printing of the printed part is a sublimation printing process.

[0198] Clause 16. The method of manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 15 further comprises: forming the printed layer prior to positioning the first side of the printed layer adjacent to the second side of the first fiber web to form the composite structure.

[0199] Clause 17. The method of manufacturing a printed composite nonwoven fabric according to Clause 16, wherein forming the printed layer comprises: applying a sublimated dye to an inner layer; and subjecting the applied sublimated dye and the inner layer to a temperature of about 185°C to about 205°C for a period of about 0.5 seconds to about 1.5 seconds.

[0200] Clause 18. A method for manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 17, wherein the needle entanglement process comprises a first needle entanglement process having a first condition and a second needle entanglement process having a second condition different from the first condition.

[0201] Clause 19. A method of manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 18, wherein at least a portion of the printed component incorporated into the first fiber web comprises one or more fibers of the printed layer, wherein the one or more fibers of the printed layer extend into the first fiber web.

[0202] Clause 20. A method of manufacturing a printed composite nonwoven fabric according to any one of Clauses 1 to 19, wherein the at least portion of the printed component incorporated into the first fiber web extends at least partially to a first surface of the first fiber web.

[0203] Clause 21. A method of manufacturing a printed asymmetric finish composite nonwoven fabric, comprising: forming a printed portion on an inner layer using a printing technique to form a printed layer; after using the printing technique, positioning a first side of the printed layer adjacent to a second side of a first fiber web to form a composite structure; and subjecting the composite structure to a variable entanglement process, wherein after the variable entanglement process, at least a portion of the printed portion and the first side of the first fiber web at least partially form a first finish side of the asymmetric finish composite nonwoven fabric.

[0204] Clause 22. A method for manufacturing a composite nonwoven fabric with a printed asymmetrical finish as described in Clause 21, wherein the printing technique includes applying a colorant to the first side of the inner layer.

[0205] Clause 23. The method of printing the asymmetrical finish of the composite nonwoven fabric according to Clause 22, wherein after subjecting the composite structure to the entanglement process, a first portion of the printed part is bonded to the first fiber web, and a second portion of the printed part is not bonded to the inner layer.

[0206] Clause 24. The method of printing the asymmetric finish of a composite nonwoven fabric according to Clause 23, wherein the inner layer is a fiber web.

[0207] Clause 25. The method of printing the asymmetrical finish of a composite nonwoven fabric according to Clause 23, wherein the inner layer is a hydroentangled layer.

[0208] Clause 26. The method of printing the asymmetric finish of the composite nonwoven fabric as described in Clause 22, wherein the printing technique comprises sublimating the printing dye onto the first surface of the inner layer.

[0209] Clause 27. The method of printing the asymmetrical finish of the composite nonwoven fabric according to Clause 26, wherein after subjecting the composite structure to the entanglement process, a first portion of the sublimated dyed inner layer is incorporated into the first fiber web more than a second portion of the sublimated dyed inner layer.

[0210] Clause 28. The method of printing the asymmetric finish of a composite nonwoven fabric as described in Clause 27, wherein the inner layer is a fiber web.

[0211] Clause 29. The method of printing the asymmetric finish of the composite nonwoven fabric as described in Clause 27, wherein the inner layer is a hydroentangled layer.

[0212] Clause 30. A printed composite nonwoven fabric having a first finished side, the printed composite nonwoven fabric comprising: a first entangled fiber web having a first side and an opposing second side, wherein the first side at least partially forms the first finished side; and an inner layer having a first side positioned adjacent to the second side of the first entangled fiber web, wherein the first side of the inner layer includes a printed member having a first portion and a second portion, wherein the first portion of the printed member is incorporated into the first fiber web more than the second portion of the printed member.

[0213] Clause 31. The printed composite nonwoven fabric as described in Clause 30, wherein the inner layer is a web of entangled fibers.

[0214] Clause 32. The printed composite nonwoven fabric as described in Clause 30, wherein the inner layer is a hydroentangled layer.

[0215] Clause 33. A printed composite nonwoven fabric according to any one of Clauses 30 to 32, wherein the printed component comprises sublimation dyes or colorants.

[0216] Clause 34. A composite nonwoven fabric with an asymmetrical finish printed on a first finishing side, the asymmetrical finish nonwoven fabric comprising: a first entangled fiber web having a first side and an opposing second side, wherein the first side at least partially forms the first finishing side; and an inner layer having a first side positioned adjacent to the second side of the first entangled fiber web, wherein the first side of the inner layer includes a printed member having a first portion and a second portion, wherein the first portion of the printed member at least partially forms the first finishing side, and wherein the second portion of the printed member is excluded from the first entangled fiber web.

[0217] Clause 35. A composite nonwoven fabric with a printed asymmetrical finish as described in Clause 34, wherein the inner layer comprises an internally entangled fiber web.

[0218] Clause 36. A composite nonwoven fabric with a printed asymmetrical finish as described in Clause 34, wherein the inner layer comprises an inner spunlace fiber web.

[0219] Clause 37. A composite nonwoven fabric with a printed asymmetrical finish according to any one of Clauses 34 to 36, wherein the printed component comprises a sublimation dye or colorant.

[0220] Clause 38. A composite nonwoven fabric with a printed asymmetrical finish according to any one of Clauses 34 to 37 further comprising a second entangled fiber web.

[0221] Clause 39. The composite nonwoven fabric with a printed asymmetrical finish as described in Clause 38 further includes an elastomeric layer located between the first entangled fiber web and the second entangled fiber web.

[0222] Clause 40. The composite nonwoven fabric with a printed asymmetrical finish as described in Clause 39 further includes a third entangled fiber web.

[0223] Clause 41. An upper garment article comprising: a first composite nonwoven fabric including a first entangled fiber web having a first edge; a second composite nonwoven fabric including a second entangled fiber web having a second edge; and a first seam formed along a portion of the first edge of the first composite nonwoven fabric, the first edge being adjacent to the second edge of the second composite nonwoven fabric, wherein at least some of the fibers of the first entangled fiber web are entangled with at least some of the fibers of the second entangled fiber web to form the first seam, wherein the first seam is formed at a first seam location of the upper garment article.

[0224] Clause 42. The upper garment article as described in Clause 41, wherein the first seam is located near the side portion of the upper garment article.

[0225] Clause 43. The upper garment article as described in Clause 41, wherein the first seam is located near the collar portion of the upper garment article.

[0226] Clause 44. The upper garment article as described in Clause 41, wherein the first seam is located near the sleeve of the upper garment article.

[0227] Clause 45. An upper garment article according to any one of Clauses 41 to 44, wherein the first composite nonwoven fabric further comprises an adhesive layer along the first edge.

[0228] Clause 46. An upper garment article according to any one of Clauses 41 to 45, wherein the first composite nonwoven fabric includes a third edge, and wherein the second composite nonwoven fabric includes a fourth edge adjacent to the third edge of the first composite nonwoven fabric.

[0229] Clause 47. The upper garment article according to Clause 46 further includes a second seam formed along a portion of the third edge of the first composite nonwoven fabric adjacent to the fourth edge of the second composite nonwoven fabric, wherein at least some of the fibers of the first entangled fiber web are entangled with at least some of the fibers of the second entangled fiber web to form the second seam, wherein the second seam is formed at the second seam location of the upper garment article.

[0230] Clause 48. The upper garment article as described in Clause 47, wherein the first seam is located near the side portion of the upper garment article, and wherein the second seam is located near the collar portion of the upper garment article.

[0231] Clause 49. The upper garment article according to Clause 47, wherein the first composite nonwoven fabric further comprises an adhesive layer along the third edge.

[0232] Clause 50. A lower garment article comprising: a first composite nonwoven fabric including a first entangled fiber web having a first edge; a second composite nonwoven fabric including a second entangled fiber web having a second edge; and a first seam formed along a portion of the first edge of the first composite nonwoven fabric, the first edge being adjacent to the second edge of the second composite nonwoven fabric, wherein at least some of the fibers of the first entangled fiber web are entangled with at least some of the fibers of the second entangled fiber web to form the first seam, wherein the first seam is formed at a first seam location of the lower garment article.

[0233] Clause 51. The lower garment article as described in Clause 50, wherein the first seam is located near the outer portion of the lower garment article.

[0234] Clause 52. The lower garment article as described in Clause 50, wherein the first seam is located near the inner portion of the lower garment article.

[0235] Clause 53. The lower garment article as described in Clause 50, wherein the first seam is located near the waist portion of the lower garment article.

[0236] Clause 54. The lower garment article according to any one of Clauses 50 to 53, wherein the first composite nonwoven fabric further comprises an adhesive layer along the first edge.

[0237] Clause 55. A lower garment article according to any one of Clauses 50 to 54, wherein the first composite nonwoven fabric includes a third edge, and wherein the second composite nonwoven fabric includes a fourth edge adjacent to the third edge of the first composite nonwoven fabric.

[0238] Clause 56. The lower garment article according to Clause 55 further includes a second seam formed along a portion of the third edge of the first composite nonwoven fabric adjacent to the fourth edge of the second composite nonwoven fabric, wherein at least some of the fibers of the first entangled fiber web are entangled with at least some of the fibers of the second entangled fiber web to form the second seam, wherein the second seam is formed at the second seam location of the lower garment article.

[0239] Clause 57. The lower garment article according to Clause 56, wherein the first composite nonwoven fabric further comprises an adhesive layer along the third edge.

[0240] Clause 58. A method of manufacturing a garment article, the garment article comprising a first composite nonwoven fabric and a second composite nonwoven fabric, the method comprising: positioning a first fiber web above a second fiber web; mechanically entangled fibers of the first fiber web and fibers of the second fiber web, such that the first fiber web becomes a first entangled web and the second fiber web becomes a second entangled web, wherein the first entangled web and the second entangled web form the first composite nonwoven fabric; positioning a third fiber web above a fourth fiber web; mechanically entangled fibers of the third fiber web and fibers of the fourth fiber web, such that the third fiber web becomes a third entangled web and The fourth fiber web becomes a fourth entangled web, wherein the third entangled web and the fourth entangled web form the second composite nonwoven fabric; the first composite nonwoven fabric and the second composite nonwoven fabric are positioned such that a first edge of the first composite nonwoven fabric is adjacent to a second edge of the second composite nonwoven fabric; and at least some of the fibers of the first entangled web and the second entangled web, and at least some of the fibers of the third entangled web and the fourth entangled web, are mechanically entangled together such that a first seam is formed at a position where the first edge of the first composite nonwoven fabric is positioned adjacent to the second edge of the second composite nonwoven fabric.

[0241] Clause 59. The method of manufacturing an article of clothing as described in Clause 58, wherein the article of clothing is an upper garment article.

[0242] Clause 60. The method of manufacturing an article of clothing as described in Clause 58, wherein the article of clothing is an article of lower garment.

[0243] Clause 61. A composite nonwoven fabric comprising: a first region including a first entangled fiber web, a second entangled fiber web, and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web; and a second region including a embossed portion and the second entangled fiber web, the embossed portion including a plurality of fibers from the first entangled fiber web integrated within the elastomeric layer.

[0244] Clause 62. The composite nonwoven fabric according to Clause 61, wherein the first entangled fiber web and the elastomer layer together have a first thickness in the first region, wherein the embossed portion has a second thickness different from the first thickness.

[0245] Clause 63. The composite nonwoven fabric according to Clause 62, wherein the second thickness is about 50% less than the first thickness.

[0246] Clause 64. A composite nonwoven fabric according to any one of Clauses 61 to 63, wherein the first entangled fiber web has a first color, and the elastomeric layer has a third color different from the first color.

[0247] Clause 65. The composite nonwoven fabric as described in Clause 64, wherein in the first region, the first color is visible and the third color is at least partially obscured visually.

[0248] Clause 66. A composite nonwoven fabric according to any one of Clauses 64 to 65, wherein the third color is visible in the second region.

[0249] Clause 67. A composite nonwoven fabric according to any one of Clauses 61 to 66, wherein in the first region, the first outer surface side of the composite nonwoven fabric is at least partially formed by the first entangled fiber web, and wherein in the second region, the first outer surface side is at least partially formed by the embossed portion.

[0250] Clause 68. A composite nonwoven fabric according to any one of Clauses 61 to 67, wherein the opposing second outer surface side of the composite nonwoven fabric is formed of the second entangled fiber web at the first region and the second region.

[0251] Clause 69. A method of patterning a composite nonwoven fabric, the composite nonwoven fabric comprising a first entangled fiber web having a first color, a second entangled fiber web having a second color, and an elastomeric layer having a third color and located between the first entangled fiber web and the second entangled fiber web, the method comprising: applying one or more of heat and pressure to a second region on a first outer surface side of the composite nonwoven fabric, such that the elastomeric layer forms a membrane encapsulating a plurality of fibers from the first entangled fiber web, wherein after applying one or more of the heat and pressure, the color on the first outer surface side at the second region is the third color, and the color on the first outer surface side at the first region is the first color, the second region forming the pattern on the first outer surface side of the composite nonwoven fabric.

[0252] Clause 70. The method of giving a pattern to a composite nonwoven fabric as described in Clause 69, wherein the color of the composite nonwoven fabric in the first and second regions is the second color on opposite second outer surface sides of the composite nonwoven fabric.

[0253] Clause 71. A method for patterning a composite nonwoven fabric according to any one of Clauses 69 to 70, wherein said heat and pressure are applied simultaneously.

[0254] Clause 72. A method for patterning a composite nonwoven fabric according to any one of Clauses 69 to 71, wherein during the application of one or more of the heat and pressure to a second region on the first outer surface side of the composite nonwoven fabric, a deformable surface is positioned adjacent to the opposing second outer surface side of the composite nonwoven fabric.

[0255] Clause 73. A method for patterning a composite nonwoven fabric according to any one of Clauses 69 to 72, wherein an indentation tool applies one or more of the heat and pressure to the second region of the composite nonwoven fabric.

[0256] Clause 74. The method of patterning a composite nonwoven fabric according to Clause 73, wherein the embossing tool is configured to apply heat to the second region of the first outer surface side of the composite nonwoven fabric at a temperature of about 170 degrees Celsius to about 190 degrees Celsius for a duration of about 28 seconds to about 32 seconds.

[0257] Clause 75. A method for patterning a composite nonwoven fabric according to any one of Clauses 73 to 74, wherein the embossing tool is configured to apply heat to a second region on the first outer surface side of the composite nonwoven fabric at a temperature of about 180 degrees Celsius for a duration of about 30 seconds.

[0258] Clause 76. A method for patterning a composite nonwoven fabric according to any one of Clauses 69 to 75, wherein the thickness of the composite nonwoven fabric in the second region is about 50% less than the thickness of the composite nonwoven fabric in the first region.

[0259] Clause 77. A method for patterning a composite nonwoven fabric according to any one of Clauses 69 to 76, wherein the thickness of the second entangled fiber web in the composite nonwoven fabric is within approximately 95% of each other in the first region and the second region.

[0260] Clause 78. A method for imparting a pattern to a composite nonwoven fabric according to any one of Clauses 69 to 77, wherein at least the first color is different from the third color.

[0261] Clause 79. A method of manufacturing a composite nonwoven fabric having a dented portion, the method comprising: positioning a denting tool on a first outer surface side of the composite nonwoven fabric, the composite nonwoven fabric including a first entangled fiber web, a second entangled fiber web, and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web; and applying the denting tool to the first outer surface side of the composite nonwoven fabric to form the dented portion.

[0262] Clause 80. A method of manufacturing a composite nonwoven fabric having a recessed portion as described in Clause 79, wherein the first outer surface side of the composite nonwoven fabric is formed at least partially from the first entangled fiber web.

[0263] Clause 81. A method of manufacturing a composite nonwoven fabric having a embossed portion according to any one of Clauses 79 to 80, wherein the embossed portion comprises a plurality of fibers from the first entangled fiber web integrated within the elastomer layer.

[0264] Clause 82. A method of manufacturing a composite nonwoven fabric having a recessed portion according to any one of Clauses 79 to 81, wherein the recessed portion is not present on the second outer surface side of the composite nonwoven fabric.

[0265] Clause 83. A method of manufacturing a composite nonwoven fabric having an embossed portion according to any one of Clauses 79 to 82, wherein the first outer surface side of the composite nonwoven fabric has a first color, and the embossed portion has a second color different from the first color.

[0266] Clause 84. A method of manufacturing a composite nonwoven fabric having a embossed portion according to any one of Clauses 79 to 83, wherein the embossing tool is configured to apply heat to the first outer surface side of the composite nonwoven fabric at a temperature of about 170 degrees Celsius to about 190 degrees Celsius for a duration of about 28 seconds to about 32 seconds.

[0267] Clause 85. A method of manufacturing a composite nonwoven fabric having a embossed portion according to any one of Clauses 79 to 84, wherein the embossing tool is configured to apply heat to the first outer surface side of the composite nonwoven fabric at a temperature of about 180 degrees Celsius for a duration of about 30 seconds.

[0268] Clause 86. A method of manufacturing a composite nonwoven fabric having a recessed portion according to any one of Clauses 79 to 85, wherein the thickness of the composite nonwoven fabric at the recessed portion is less than half the thickness of the composite nonwoven fabric in the area other than the recessed portion.

[0269] Clause 87. A method of manufacturing a composite nonwoven fabric having a recessed portion according to any one of Clauses 79 to 86, wherein the thickness of the second entangled fiber web in the composite nonwoven fabric is substantially similar at the recessed portion and in areas other than the recessed portion.

[0270] Clause 88. A garment article comprising: a composite nonwoven fabric forming at least a portion of the garment article, the composite nonwoven fabric including a first region and a second region, the first region including a first entangled fiber web, a second entangled fiber web, and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, the second region including a first embossed portion and the second entangled fiber web, the first embossed portion including a plurality of fibers from the first entangled fiber web integrated within the elastomeric layer.

[0271] Clause 89. The garment article according to Clause 88, wherein the first embossed portion forms a first pattern.

[0272] Clause 90. The garment article according to Clause 89, wherein the first embossed portion is visible on the outward-facing surface of the garment article.

[0273] Clause 91. The garment article according to any one of Clauses 89 to 90, wherein the first embossed portion is not visible on the inward-facing surface of the garment article.

[0274] Clause 92. The garment article according to any one of Clauses 89 to 91 further includes a second embossed portion, the second embossed portion comprising a plurality of fibers from the second entangled fiber web integrated within the elastomer layer.

[0275] Clause 93. The garment article according to Clause 92, wherein the second embossed portion forms a second pattern having an appearance different from the first pattern.

[0276] Clause 94. The garment article according to any one of Clauses 92 to 93, wherein the second embossed portion is visible on the surface of the garment article facing inward.

[0277] Clause 95. A garment article according to any one of Clauses 92 to 94, wherein the second embossed portion is not visible on the outward-facing surface of the garment article.

[0278] Clause 96. Clothing articles pursuant to any one of Clauses 88 to 95, wherein said clothing articles are upper garment articles.

[0279] Clause 97. Clothing articles pursuant to any one of Clauses 88 to 95, wherein said clothing articles are lower garment articles.

[0280] Clause 98. A garment article according to any one of Clauses 88 to 97, wherein the first entangled fiber web and the elastomer layer have a first thickness in the first region, and the first embossed portion has a second thickness in the second region that is about 50% less than the first thickness.

[0281] Clause 99. A composite nonwoven fabric comprising: a first entangled fiber web; a second entangled fiber web; an elastomer layer; a first region having the elastomer layer disposed between the first entangled fiber web and the second entangled fiber web; and a second region being recessed relative to the first region, wherein in the second region, the elastomer layer is in the form of a film, the elastomer layer encapsulating a plurality of fibers from the first entangled fiber web to form a recessed portion, and wherein the second entangled fiber web is disposed below the recessed portion.

[0282] Clause 100. The composite nonwoven fabric according to Clause 99, wherein the embossed portion comprises a matrix structure formed of the plurality of fibers and membranes.

[0283] Clause 101. A composite nonwoven fabric according to any one of Clauses 99 to 100, wherein the embossed portion has a different color from the first area on the first outer surface side of the composite nonwoven fabric.

[0284] Clause 102. A composite nonwoven fabric according to any one of Clauses 99 to 101, wherein the thickness of the second entangled fiber web in the composite nonwoven fabric is within about 95% of each other in the first region and the second region.

[0285] Clause 103. A composite nonwoven fabric having a first exterior surface side and an opposing second exterior surface side, the composite nonwoven fabric comprising: a first entangled fiber web having a first color; a second entangled fiber web having a second color; an elastomer layer having a third color different from at least the first color; a first region having the elastomer layer disposed between the first entangled fiber web and the second entangled fiber web; and a second region being recessed relative to the first region, wherein, viewed from the first exterior surface side, the color of the composite nonwoven fabric in the first region is substantially the same as the first color, and the color of the composite nonwoven fabric in the second region is substantially the same as the third color.

[0286] Clause 104. The composite nonwoven fabric according to Clause 103, wherein, viewed from the second outer surface side, the color of the composite nonwoven fabric in the first and second regions is substantially the same as the second color.

[0287] Clause 105. The composite nonwoven fabric according to any one of Clauses 103 to 104, wherein the thickness of the composite nonwoven fabric in the second region is about 50% less than the thickness of the composite nonwoven fabric in the first region.

[0288] Clause 106. A composite nonwoven fabric comprising: a first entangled fiber web including a first material having a first melting temperature; a second entangled fiber web including a second material having a second melting temperature; and an elastomer layer including a third material having a third melting temperature, wherein the third melting temperature is about 40 degrees Celsius lower than the first melting temperature, the composite nonwoven fabric comprising: a first region wherein the elastomer layer is disposed between the first entangled fiber web and the second entangled fiber web; and a second region being recessed relative to the first region, wherein in the second region, the elastomer layer is in the form of a film, the elastomer layer encapsulating a plurality of fibers from the first entangled fiber web to form a recessed portion, and wherein the second entangled fiber web is disposed below the recessed portion.

[0289] Clause 107. The composite nonwoven fabric according to Clause 106, wherein the embossed portion comprises a matrix structure formed of the plurality of fibers and a membrane.

[0290] Clause 108. A composite nonwoven fabric according to any one of Clauses 106 to 107, wherein the embossed portion has a different color from the first area on the first outer surface side of the composite nonwoven fabric.

[0291] Clause 109. The composite nonwoven fabric according to any one of Clauses 106 to 108, wherein the thickness of the embossed portion is about 50% less than the thickness of the first entangled fiber web and the elastomer layer in the first region.

[0292] Clause 110. A composite nonwoven fabric comprising: a first entangled fiber web; a second entangled fiber web; and an elastomeric layer formed of elastomeric fibers having a melting temperature lower than that of fibers forming at least the first entangled fiber web, the composite nonwoven fabric comprising: a first region wherein the elastomeric layer is disposed between the first entangled fiber web and the second entangled fiber web; and a second region being recessed relative to the first region, wherein in the second region, the elastomeric layer includes a membrane encapsulating a plurality of fibers from the first entangled fiber web to form a recessed portion, and wherein the second entangled fiber web is disposed below the recessed portion.

[0293] Clause 111. The composite nonwoven fabric according to Clause 110, wherein each of the first entangled fiber web and the second entangled fiber web comprises staple fibers with a length less than the length of the elastomeric fibers forming the elastomeric layer.

[0294] Clause 112. A composite nonwoven fabric according to any one of Clauses 110 to 111, wherein the elastomer fiber comprises at least one of meltblown fiber or spunbond fiber.

[0295] Clause 113. The composite nonwoven fabric according to any one of Clauses 108 to 112, wherein the embossed portion has a different color from the first area on the first outer surface side of the composite nonwoven fabric.

[0296] Clause 114. A pleated construction comprising: a composite nonwoven fabric including a first entangled fiber web, a second entangled fiber web, and an elastomer layer located between the first entangled fiber web and the second entangled fiber web; an elastically resilient structured fabric positioned adjacent to the outermost surface of the second entangled fiber web; and a plurality of pleats formed by the composite nonwoven fabric and the elastically resilient structured fabric.

[0297] Clause 115. The pleated construction according to Clause 114 further includes an adhesive layer that attaches the resilient, resilient structured fabric to the second entangled fiber web at one or more first regions.

[0298] Clause 116. The pleated construction as described in Clause 115, wherein the adhesive layer comprises a thermoplastic film.

[0299] Clause 117. The pleated construction according to any one of Clauses 115 to 116, wherein the adhesive layer is about 2 mm thick.

[0300] Clause 118. A pleated construction according to any one of Clauses 114 to 117, wherein the elastically resilient structured fabric is attached to the second tangled fiber web at one or more first regions and is not attached to the second tangled fiber web at one or more second regions.

[0301] Clause 119. The pleated construction according to Clause 118, wherein each of the one or more first regions has a length and a width, wherein the length is greater than the width at the one or more first regions, and wherein each of the one or more second regions has a length and a width, wherein the length is greater than the width at the one or more second regions.

[0302] Clause 120. The pleated construction according to any one of Clauses 118 to 119, wherein the one or more first regions are spaced apart from each other by the one or more second regions.

[0303] Clause 121. The pleated construction according to any one of Clauses 118 to 120, wherein each of the one or more first regions has a longitudinal axis aligned parallel to the longitudinal axis of the one or more second regions.

[0304] Clause 122. The pleated construction according to any one of Clauses 118 to 121, wherein each of the one or more first regions has a longitudinal axis aligned parallel to the longitudinal axis of one or more of the plurality of pleats.

[0305] Clause 123. A method of manufacturing a composite nonwoven fabric having multiple pleats, the method comprising: tensioning an elastically resilient structured fabric to bring the elastically resilient structured fabric into a tensioned state; positioning the elastically resilient structured fabric onto a surface of the composite nonwoven fabric while in the tensioned state; selectively attaching the composite nonwoven fabric to the elastically resilient structured fabric at one or more first regions; and releasing the tension applied to the elastically resilient structured fabric to form the multiple pleats.

[0306] Clause 124. The method according to Clause 123, wherein the elastic rebound structured fabric is tensioned to about 50% to about 60% of its resting length.

[0307] Clause 125. The method according to any one of Clauses 123 to 124, wherein the elastic resilient structured fabric is tensioned to about 55% of its resting length.

[0308] Clause 126. The method according to any one of Clauses 123 to 125, wherein the elastic rebound structured fabric comprises a knitted construction having a plurality of loop rows and a plurality of loop warps.

[0309] Clause 127. The method according to Clause 126, wherein the elastic resilient structured fabric is tensioned in the longitudinal direction.

[0310] Clause 128. The method according to any one of Clauses 126 to 127, wherein the elastic resilient structured fabric is tensioned in the machine direction.

[0311] Clause 129. The method according to any one of Clauses 123 to 128, wherein the composite nonwoven fabric comprises a first entangled fiber web, a second entangled fiber web, and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web.

[0312] Clause 130. The method according to Clause 129, wherein the elastic resilient structured fabric is attached to the outermost surface of the second entangled fiber web.

[0313] Clause 131. The method according to any one of Clauses 129 to 130, wherein the elastic resilient structured fabric is not attached to the second entangled fiber web at one or more second regions.

[0314] Clause 132. The method according to Clause 131, wherein each of the one or more first regions has a length and a width, wherein the length is greater than the width in the one or more first regions, and wherein each of the one or more second regions has a length and a width, wherein the length is greater than the width in the one or more second regions.

[0315] Clause 133. The method according to any one of Clauses 131 to 132, wherein the one or more first regions are spaced apart from each other by the one or more second regions.

[0316] Clause 134. The method according to any one of Clauses 123 to 133, wherein after the tension is released, the elastic rebound structured fabric remains in the tensioned state at one or more first regions.

[0317] Clause 135. A pleated construction at least in a first portion of a garment article, comprising: a first composite nonwoven fabric including a first entangled fiber web, a second entangled fiber web, and a first elastomeric layer located between the first entangled fiber web and the second entangled fiber web; a first elastically resilient structured fabric positioned adjacent to a first outermost surface of the first composite nonwoven fabric; and a first plurality of pleats formed by the first composite nonwoven fabric and the first elastically resilient structured fabric.

[0318] Clause 136. The pleated construction as described in Clause 135, wherein the garment article is an upper garment article.

[0319] Clause 137. The pleated construction as described in Clause 135, wherein the garment article is a lower garment article.

[0320] Clause 138. The pleated construction according to any one of Clauses 135 to 137 further comprises: a second composite nonwoven fabric, the second composite nonwoven fabric including a third entangled fiber web, a fourth entangled fiber web, and a second elastomeric layer located between the third entangled fiber web and the fourth entangled fiber web; a second elastically resilient structured fabric positioned adjacent to a second outermost surface of the second composite nonwoven fabric; and a second plurality of pleats formed by the second composite nonwoven fabric and the second elastically resilient structured fabric, wherein the second elastically resilient structured fabric and the first elastically resilient structured fabric share a surface.

[0321] Clause 139. The pleating construction according to any one of Clauses 135 to 137, wherein the first plurality of pleats are located on the outermost surface of the garment article.

[0322] Clause 140. The pleating construction according to Clause 138, wherein the first plurality of pleats are located on the outermost surface of the garment article.

[0323] Clause 141. The pleating construction according to Clause 138 or 140, wherein the second plurality of pleats are located on the innermost surface of the garment article.

Claims

1. A pleated construction comprising: a composite nonwoven fabric comprising a first entangled fiber web, a second entangled fiber web, and an elastomeric layer positioned between the first and second entangled fiber webs; an elastic resilient structured fabric positioned adjacent to an outermost surface of the second entangled fiber web; and a plurality of pleats formed from the composite nonwoven fabric and the elastic resilient structured fabric.

2. The pleated construction of claim 1, further comprising an adhesive layer attaching the elastic resilient structured fabric to the second entangled fiber web at one or more first regions.

3. The pleated construction of any of claims 1-2, wherein the elastic resilient structured fabric is attached to the second entangled fiber web at one or more first regions and is unattached to the second entangled fiber web at one or more second regions.

4. The pleated construction of claim 3, wherein each of the one or more first regions has a length and a width, the length being greater than the width at the one or more first regions, and wherein each of the one or more second regions has a length and a width, the length being greater than the width at the one or more second regions.

5. The pleated construction of claim 3, wherein the one or more first regions are spaced apart from each other by the one or more second regions.

6. The pleated construction of claim 4, wherein the one or more first regions are spaced apart from each other by the one or more second regions.

7. The pleated construction of claim 3, wherein each of the one or more first regions has a longitudinal axis that is aligned in parallel with a longitudinal axis of the one or more second regions.

8. The pleated construction of any of claims 4-6, wherein each of the one or more first regions has a longitudinal axis that is aligned in parallel with a longitudinal axis of the one or more second regions.

9. The pleated construction of claim 3, wherein each of the one or more first regions has a longitudinal axis that is aligned in parallel with a longitudinal axis of one or more of the plurality of pleats.

10. The pleated construction of any of claims 4-7, wherein each of the one or more first regions has a longitudinal axis that is aligned in parallel with a longitudinal axis of one or more of the plurality of pleats.

11. The pleated construction of claim 8, wherein each of the one or more first regions has a longitudinal axis that is aligned in parallel with a longitudinal axis of one or more of the plurality of pleats.

12. The pleated construction of claim 1, wherein the elastic resilient structured fabric is attached to the second entangled fiber web at intermittent regions.

13. The pleated construction of claim 12, further comprising an adhesive layer positioned at the intermittent regions and attaching the elastic resilient structured fabric to the second entangled fiber web. ​ 14. A method of making a composite nonwoven fabric having a plurality of pleats, the method comprising: tensioning an elastic resilient structured fabric to transform the elastic resilient structured fabric into a tensioned state, positioning the elastic resilient structured fabric onto a surface of the composite nonwoven fabric while in the tensioned state; selectively attaching the composite nonwoven fabric to the elastic resilient structured fabric at one or more first regions; and releasing the tension applied to the elastic resilient structured fabric to form the plurality of pleats.

15. The method of claim 14, wherein the composite nonwoven fabric comprises a first entangled fiber web, a second entangled fiber web, and an elastomeric layer positioned between the first entangled fiber web and the second entangled fiber web.

16. The method of claim 15, wherein the elastic resilient structured fabric is attached to an outermost surface of the second entangled fiber web.

17. The method of any one of claims 15-16, wherein the elastic resilient structured fabric is not attached to the second entangled fiber web at one or more second regions.

18. The method of claim 17, wherein each of the one or more first regions has a length and a width, the length being greater than the width at the one or more first regions, and wherein each of the one or more second regions has a length and a width, the length being greater than the width at the one or more second regions.

19. The method of claim 17, wherein the one or more first regions are spaced apart from each other by the one or more second regions.

20. The method of claim 18, wherein the one or more first regions are spaced apart from each other by the one or more second regions.

21. The method of any one of claims 14-16, 18-20, wherein the elastic resilient structured fabric remains in the tensioned state at the one or more first regions after the tension is released.

22. The method of claim 17, wherein the elastic resilient structured fabric remains in the tensioned state at the one or more first regions after the tension is released.

23. A pleated configuration at least at a first portion of an article of apparel, comprising: a first composite nonwoven fabric comprising a first entangled fiber web, a second entangled fiber web, a first elastomeric layer positioned between the first entangled fiber web and the second entangled fiber web; a first elastic resilient structured fabric positioned adjacent to a first outermost surface of the first composite nonwoven fabric; and a first plurality of pleats formed by the first composite nonwoven fabric and the first elastic resilient structured fabric.

24. The pleated configuration of claim 23, wherein the article of apparel is an upper body apparel article.

25. The pleated configuration of claim 23, wherein the article of apparel is a lower body apparel article.

26. The pleated configuration of any one of claims 23-25, further comprising: a second composite nonwoven fabric comprising a third entangled fibrous web, a fourth entangled fibrous web, a second elastomeric layer positioned between the third entangled fibrous web and the fourth entangled fibrous web; a second elastically resilient structured fabric positioned adjacent to a second outermost surface of the second composite nonwoven fabric; and a second plurality of pleats formed from the second composite nonwoven fabric and the second elastically resilient structured fabric, wherein the second elastically resilient structured fabric is in a face-sharing relationship with the first elastically resilient structured fabric.

27. The pleated construction of any of claims 23-25, wherein the first plurality of pleats is on an outermost facing surface of the apparel item.

28. The pleated construction of claim 26, wherein the first plurality of pleats is on an outermost facing surface of the apparel item.

29. The pleated construction of claim 26, wherein the second plurality of pleats is on an innermost facing surface of the apparel item.

30. The pleated construction of claim 28, wherein the second plurality of pleats is on an innermost facing surface of the apparel item.

31. The pleated construction of claim 23, wherein the first elastically resilient structured fabric is attached to the second entangled fibrous web at one or more first regions and is unattached to the second entangled fibrous web at one or more second regions.

32. The pleated construction of claim 31, wherein the first elastically resilient structured fabric is attached to the second entangled fibrous web at the one or more first regions by an adhesive layer.

33. The pleated construction of any of claims 23, 28-30, wherein the apparel item is an article of footwear.

34. The pleated construction of claim 26, wherein the apparel item is an article of footwear.

35. The pleated construction of claim 27, wherein the apparel item is an article of footwear.

36. The pleated construction of claim 33, wherein the apparel item is an upper of the article of footwear.

37. The pleated construction of claim 34 or 35, wherein the apparel item is an upper of the article of footwear.

38. An apparel item comprising the pleated construction of any of claims 1-13.

39. The apparel item of claim 38, wherein the apparel item comprises at least one of an upper body garment, a lower body garment, a hat, a glove, a sleeve, and an article of footwear.

40. The apparel item of claim 39, wherein the apparel item comprises an upper of the article of footwear.

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