Selective laser bonding on fabric

Abstract

This application relates to selective laser bonding on fabrics. Aspects herein relate to applying electromagnetic radiation emitted by a laser to a nonwoven fabric that includes first fibers having a first propensity to absorb electromagnetic radiation and second fibers having a second propensity to absorb electromagnetic radiation that is lower than the first propensity. The electromagnetic radiation can be used to form discrete bonded structures within a volume of the nonwoven fabric, where the bonded structures are not generally present on a face of the nonwoven fabric.

Description

Technical Field

[0001] This article relates to various aspects of creating adhesive structures within the volume of nonwoven materials to reduce pilling and / or to adhere two or more nonwoven fabrics to each other. Background Technology

[0002] Because nonwoven fabrics are typically formed from fibers, fiber ends can migrate across one side of the nonwoven fabric and become entangled with other fiber ends to form pilling. While pilling can be reduced by treating the surface of the nonwoven fabric with different methods (such as calendering and / or with different materials including adhesive-type materials) to bond the fiber ends together, overall surface treatment can affect the surface of the nonwoven fabric by, for example, potentially reducing the softness or hand feel of the nonwoven fabric, and may also affect its drape. This may not be desirable when the nonwoven fabric is used in garment articles where a soft hand feel and drape are desired characteristics.

[0003] In addition, traditional methods for securing nonwoven webs or fabrics together include, for example, using adhesives or films, sewing, entanglement, etc. While these methods may be effective securing mechanisms, they can increase manufacturing costs, increase the carbon footprint associated with manufacturing, and / or reduce the recyclability of the resulting composite nonwoven fabric due to the use of different materials (e.g., adhesives, films, or threads used for sewing). Attached Figure Description

[0004] The following describes examples of various aspects of this article in detail with reference to the accompanying drawings, in which:

[0005] Figure 1 The illustration shows an example process for finishing nonwoven fabrics to reduce pilling, based on various aspects of this article.

[0006] Figure 2 The diagram illustrates various aspects based on this article. Figure 1 The first side of the nonwoven fabric;

[0007] Figure 3 The diagram illustrates various aspects based on this article. Figure 1 The opposite second side of a nonwoven fabric;

[0008] Figure 4 The diagram illustrates various aspects based on this article. Figure 1 nonwoven fabric along Figure 2 The plane section cut by the cutting line shown in 4-4;

[0009] Figure 5 The diagram illustrates various aspects based on this article. Figure 1 nonwoven fabrics in Figure 2 The cross-section taken at point 5-5 of the cutting line;

[0010] Figure 6 The illustration shows an example bicomponent fiber according to various aspects of this article, which has two materials with different propensities for absorbing electromagnetic radiation emitted by lasers positioned side by side;

[0011] Figure 7 The illustration shows an example pattern of applying electromagnetic radiation to a nonwoven fabric using a laser, according to various aspects of this article.

[0012] Figure 8 The diagram illustrates the various aspects of this article. Figure 1 Examples of upper garments formed from nonwoven fabrics;

[0013] Figure 9 The diagram illustrates the various aspects of this article. Figure 1 Examples of lower garments made from nonwoven fabrics;

[0014] Figure 10 The diagram illustrates the various aspects of this article. Figure 1 Example of a shoe upper made of nonwoven fabric;

[0015] Figure 11 The diagram illustrates the organization of various aspects of this article as follows: Figure 1 Example flowchart of a method for producing nonwoven fabrics;

[0016] Figure 12 The illustration shows an example process of forming composite nonwoven fabrics using laser bonding according to various aspects of this article;

[0017] Figure 13 The diagram illustrates various aspects based on this article. Figure 12 The first side of the composite nonwoven fabric;

[0018] Figure 14 The diagram illustrates various aspects based on this article. Figure 12 The opposite second side of the composite nonwoven fabric;

[0019] Figure 15 The diagram illustrates various aspects based on this article. Figure 12 Composite nonwoven fabric along Figure 13 The plane section cut by the cutting line shown in 15-15;

[0020] Figure 16 The diagram illustrates various aspects based on this article. Figure 12 Composite nonwoven fabric along Figure 13 The cross-section cut by the cutting line 16-16;

[0021] Figure 17The diagram illustrates the various aspects of this article. Figure 12 Examples of upper garments formed from composite nonwoven fabrics;

[0022] Figure 18 The diagram illustrates the various aspects of this article. Figure 12 Examples of lower garments formed from composite nonwoven fabrics;

[0023] Figure 19 The diagram illustrates the various aspects of this article. Figure 12 Example of a footwear upper made of a composite nonwoven fabric;

[0024] Figure 20 The illustration shows a flowchart of an example method for forming composite nonwoven fabrics using laser bonding according to various aspects of this article;

[0025] Figure 21 The illustration shows an example nonwoven fabric with laser-bonded sites for dividing patterned patches, according to various aspects of this article;

[0026] Figure 22A The illustration shows an example patterned piece for a sleeve formed from a nonwoven fabric, according to various aspects of this article, wherein the patterned piece includes laser-bonded sites to increase drape.

[0027] Figure 22B The diagram shows... Figure 22A An example cross-section of the patterned sheet is shown, and the dimpling caused by the adhesive structure according to various aspects of this document is depicted; and

[0028] Figure 23 The illustration shows a schematic diagram of an example process for using fibers in response to electromagnetic radiation emitted by a laser to form graphics, letters, and / or care instructions, according to various aspects of this article. Detailed Implementation

[0029] 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 envision 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 in this document. 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 the order of the steps is expressly stated.

[0030] Because nonwoven fabrics are typically formed from fibers, fiber ends can migrate across one side of the nonwoven fabric and become entangled with other fiber ends to form pilling. While pilling can be reduced by treating the surface of the nonwoven fabric with different methods (such as calendering and / or with different materials including adhesive-type materials) to bond the fiber ends together, overall surface treatment can affect the surface of the nonwoven fabric by, for example, potentially reducing the softness or hand feel of the nonwoven fabric, and may also affect its drape. This may not be desirable when the nonwoven fabric is used in garment articles where a soft hand feel and drape are desired characteristics.

[0031] In addition, traditional methods for securing nonwoven webs or fabrics together include, for example, using adhesives or films, sewing, entanglement, etc. While these methods may be effective securing mechanisms, they can increase manufacturing costs, increase the carbon footprint associated with manufacturing, and / or reduce the recyclability of the resulting composite nonwoven fabric due to the use of different materials (e.g., adhesives, films, or threads used for sewing).

[0032] At a high level, aspects of this paper involve using electromagnetic radiation emitted by a laser (or some other bonding technique) to generate discrete, spaced-apart adhesive structures within the internal volume of a nonwoven fabric, while minimizing impact on the surfaces of the nonwoven fabric. In other words, in exemplary aspects, the adhesive structure may be primarily located between a first surface and an opposing second surface of the nonwoven fabric, and within the internal volume of the nonwoven fabric. In some instances, the adhesive structure may be on at least one surface. The adhesive structure helps to secure fibers and / or fiber ends, thereby reducing the likelihood of fiber ends migrating across the surfaces of the nonwoven fabric and forming fuzz. In at least some instances, the adhesive structure can be formed by applying a laser alone. In at least some instances, the adhesive structure can be formed by applying a laser in conjunction with one or more other techniques for generating the adhesive structure (e.g., by applying an adhesive, by thermal bonding through melting at least some fibers, etc.).

[0033] In instances involving lasers, the formation of an adhesive structure can be achieved by selectively mixing or entangled fibers having different tendencies to absorb electromagnetic radiation emitted by the laser. For example, a first plurality of fibers having a relatively high tendency to absorb electromagnetic radiation emitted by the laser can be selectively mixed or entangled with a second plurality of fibers having a relatively low tendency to absorb electromagnetic radiation emitted by the laser to produce a non-uniform mixture of the first and second plurality of fibers. In one example, one or more of the first and second plurality of fibers comprise a polymer. In another example, the second plurality of fibers may be located or more towards the first surface, and the first plurality of fibers may be located or more towards the second surface. Both the first and second plurality of fibers can exist within the internal volume of the nonwoven fabric, wherein the fibers are in contact with and / or closely adjacent to each other.

[0034] Electromagnetic radiation emitted by a laser of a specified wavelength or wavelength range can be directed to the first side of a nonwoven fabric. Because the first side primarily comprises a second plurality of fibers with a relatively low tendency to absorb wavelengths of the electromagnetic radiation emitted by the laser, the electromagnetic radiation enters the volume of the nonwoven fabric, where it is absorbed by one or more of the first plurality of fibers. The electromagnetic radiation causes partial melting of the first plurality of fibers. When the laser stops emitting electromagnetic radiation, the molten portion of the first plurality of fibers re-solidifies to form amorphous polymer agglomerates. The amorphous polymer agglomerates can encapsulate or partially encapsulate adjacent fibers from the first plurality of fibers and / or the second plurality of fibers, thereby trapping these fibers and generally minimizing the migration of fibers and fiber ends from the first and second plurality of fibers to reduce pilling or increase anti-pilling properties at the nonwoven fabric surface. This is achieved without substantially affecting the fibers present on one or more sides of the nonwoven fabric. Therefore, these fibers retain their desired properties, such as softness, abrasion resistance, etc. Nonwoven fabrics can then be used to form clothing products, such as upper garments, lower garments, shoe uppers, headwear, etc.

[0035] The exemplary aspect of this paper also considers the use of laser bonding to produce composite nonwoven fabrics. In the exemplary aspect, the surface of a first fiber web formed of a first fiber having a relatively large tendency to absorb electromagnetic radiation of a specified wavelength can be positioned adjacent to the surface of a second fiber web formed of a second fiber having a relatively low tendency to absorb electromagnetic radiation; one or more of the first and second fibers comprise a polymer. Electromagnetic radiation emitted by a laser of a specified wavelength or wavelength range can be directed to the second fiber web. Because the second fiber forming the second fiber web has a relatively low tendency to absorb electromagnetic radiation emitted by the laser, the electromagnetic radiation enters the internal volume of the stacked fiber webs. At the interface between the first and second fiber webs, the electromagnetic radiation is absorbed by one or more of the first fibers, causing partial melting of the first fiber. When the laser stops emitting electromagnetic radiation, the molten portion of the first fiber re-solidifies to form an amorphous polymer agglomerate. The amorphous polymer agglomerate can encapsulate or partially encapsulate adjacent fibers from the first and / or second fibers, thereby trapping these fibers and creating an adhesive between the first and second fiber webs to form a composite nonwoven fabric. This method can be used in conjunction with the methods described above to produce composite nonwoven fabrics with increased pilling resistance. Similarly, because the bonding structure is located within the internal volume of the composite nonwoven fabric, the fibers on the surface of the composite nonwoven fabric are largely unaffected, allowing them to retain their desired properties. The composite nonwoven fabric can then be used to form garments, such as upper garments, lower garments, shoe uppers, headwear, etc.

[0036] Electromagnetic radiation emitted by a laser can be used in other ways on nonwoven fabrics. For example, it can be used to cut patterned pieces from nonwoven fabrics that include fibers that absorb electromagnetic radiation. Alternatively, it can be used to generate markings that depict the perimeter or shape of the patterned piece. The patterned piece can then be cut from the nonwoven fabric using, for example, conventional cutting techniques and used to construct garments.

[0037] In another example, electromagnetic radiation emitted by a laser can be used to increase the drape or hang of nonwoven fabrics. In one example, an adhesive structure located within the volume of the nonwoven fabric can create indentations or dimples on one or more surfaces of the nonwoven fabric due to fiber trapping within the adhesive structure, where the trapped fibers exert tension on fibers entangled with them. The dimples are axially aligned with the adhesive structure located within the volume of the nonwoven fabric. The dimples reduce the bulk and / or thickness of the nonwoven fabric in its area. By selectively positioning the adhesive structure, dimple patterns can be formed on one or more surfaces of the nonwoven fabric. Dimple patterns can be used to create fold lines to improve drape.

[0038] In another example, electromagnetic radiation emitted by a laser can be used to create graphics, logos, or letters on nonwoven fabrics. This is useful, for example, in generating care instructions for garment articles made of nonwoven fabrics, eliminating the need to attach separate care instruction labels to the garment articles. In this example, at least some of the fibers forming the first side of the nonwoven fabric may include a material that changes color when exposed to electromagnetic radiation emitted by a laser. An example material may be titanium dioxide (TiO2). The electromagnetic radiation emitted by the laser can be applied to the first side in a predetermined pattern. The TiO2 fibers exposed to the electromagnetic radiation will change color from a first color to a second color (e.g., from white to gray), thus forming an image corresponding to the pattern applied by the electromagnetic radiation.

[0039] Generally, the aspects described above reduce the overall carbon footprint of nonwoven fabrics and can also improve fabric recyclability. For example, using laser bonding to increase anti-pilling properties reduces pilling and may eliminate (in some cases) the need for surface treatments that can improve fabric recyclability. Using laser bonding to create adhesion between fiber webs eliminates the need for other fastening methods (such as sewing, using adhesives, or films), which reduces the fabric's carbon footprint and also increases its recyclability. Other aspects described herein, such as using TiO2 fibers to generate care instructions for nonwoven garments, eliminate the need for applying care labels, which reduces manufacturing costs, decreases the carbon footprint, and increases fabric recyclability.

[0040] In some instances, nonwoven fabrics can be treated (e.g., to reduce pilling) by applying an adhesive to form one or more chemical bonding sites / structures for trapping fibers and reducing fiber migration. For example, a rotary gravure printing system may be adapted to apply a chemical adhesive to a nonwoven fabric to reduce the formation of fuzz on one or more surfaces of the nonwoven fabric. In one example, the chemical adhesive may be applied to one or more fiber webs (e.g., before the fiber webs are incorporated into a composite nonwoven fabric). In other instances, the chemical adhesive may be applied to a finished composite nonwoven fabric (e.g., a composite nonwoven fabric after individual fiber webs have been stacked and entangled with each other). In this respect, because the fibers are already entangled with each other, when the chemical adhesive is applied, for example, to one of the outer surfaces, the chemical adhesive may bond one or more of the fibers present on the first surface together, and / or may flow into the central volume to bond the fibers between the surfaces together.

[0041] As used herein, the term "chemical bonding" refers to the use of a chemical adhesive (e.g., an adhesive material) to bond fibers together. The chemical adhesive joins the fibers together at fiber crossings and creates a fiber bonding effect. In one example aspect, the chemical adhesive can form an adhesive film that bonds the fibers together, for example, at fiber crossings. Because the fibers are bonded together, the ends of the fibers are less prone to migration and pilling, and the overall anti-pilling property of at least one side of the composite nonwoven fabric is increased. Suitable chemical adhesives include those composed of polymers and can include vinyl polymers and copolymers, acrylate polymers and copolymers, rubbers and synthetic rubbers, and natural adhesives such as starch. Chemical adhesives can be applied in the form of aqueous dispersions, oil-based dispersions, foam dispersions, etc. In one example aspect, a base coating or primer can be applied to the composite nonwoven fabric prior to the application of the chemical adhesive. In one example aspect, the chemical adhesive can include an oil-based polyurethane adhesive. As used herein, the term "chemical bonding site" refers to the location of the chemical bonding and also to the chemical adhesive itself applied to the composite nonwoven fabric.

[0042] In some instances, nonwoven fabrics can be treated by applying thermal bonding. As used herein, the term "thermal bonding" refers to a process that may include locally heating fibers to melt, partially melt, and / or soften them. This allows polymer chains to relax and diffuse, or polymer flows, across the fiber-fiber interface between two intersecting fibers. Subsequent cooling of the fibers causes them to re-solidify and trap polymer chain segments that have diffused across the fiber-fiber interface. Thermal bonding traps the ends of the fibers and makes the fiber ends less susceptible to interacting with other fiber ends to form fuzz. As used herein, the term "thermal bonding site" refers to a thermally bonded location on a composite nonwoven fabric, while the term "thermal bonding structure" refers to the actual structure formed by the re-solidified fibers and / or materials, typically including fibers and materials from different fiber webs used to form the composite nonwoven fabric.

[0043] As used herein, the term "clothing article" is intended to encompass articles worn by a wearer. Therefore, they can 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 can also include hats, gloves, sleeves (arm warmers, calf warmers), 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, opposite to the inward-facing surface. 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 furthest from the wearer's body surface relative to other layers of the clothing article.

[0044] As used herein, the term "nonwoven fabric" refers to fibers held together by mechanical and / or chemical interactions without exhibiting a knitted, woven, braided, or other structured construction. 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 forming a viscous structure, wherein different fiber webs may have different or similar fiber compositions and / or different properties. As used herein, "fiber web" includes fibers that have undergone carding and web-laying processes, which typically align the fibers in one or more common directions extending along the x, y plane and achieve a desired basis weight. Fiber webs can also undergo mechanical entanglement processes that entangle the fibers of the fiber web to a degree that allows the fiber web to form a workable cohesive structure (e.g., winding onto a roll, unwinding from a roll, stacking, etc.).

[0045] The various aspects of this paper anticipate that fibers can become entangled with other fibers. 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 (commonly referred to as hydraulic entanglement). Needling typically uses barbed or spiked needles to reposition a proportion of fibers from a generally horizontal orientation (an orientation extending along the x, y plane) to a generally vertical orientation (an orientation in the z direction). Barbed needles fixed to a needle plate pass through one or more fiber webs, and after the needles have moved in and out of one or more fiber webs, a stripping plate strips the fibers from the needles. As one or more fiber webs move along the conveyor system in the machine direction, the needle plate can repeatedly engage and disengage with one or more fiber webs, such that the length of one or more fiber webs is needle-punched. Each engagement of the needle plate with one or more fiber webs is referred to herein as a “stroke.” Parameters associated with a particular needle plate can be adjusted to obtain the desired properties (e.g., basis weight, thickness, etc.) of the resulting needle-punched nonwoven fabric. Different parameters can include thread density (SD) and penetration depth (PD). Thread density is the distance per centimeter of thread during entanglement. 2 Number of needles used (n / cm) 2 Penetration depth is the distance the needle travels through one or more fiber webs before being pulled out. Parameters associated with the needle punching process, such as the spacing between the base plate and the stripper plate, and the feed speed of one or more fiber webs, can also typically be adjusted.

[0046] This paper envisions the use of barbed needles (needles with a predetermined number of barbs arranged along the length of the needle), but other needle types are also envisioned. As the barbs move from a first face of one or more fiber webs to an opposing second face, the barbs on the needle "capture" fibers. The movement of the needle through one or more fiber webs effectively moves or pushes the barbed-captured fibers from a position near or at the first face to a position near or at the second face, and further induces physical interactions with other fibers, helping to "lock" the moved fibers in place by, for example, friction (often referred to as entanglement). This paper also envisions the needle moving from the second face towards the first face through one or more fiber webs.

[0047] Hydraulic entanglement is similar to needle entanglement, except that instead of barbed needles, fluid jets are used to reposition a proportion of fibers from a generally horizontal direction (orientation along the x, y plane) to a generally vertical direction (orientation in the z direction).

[0048] Nonwoven or composite nonwoven fabrics may include a first side and an opposing second side, both of which face outward relative to the fabric's internal volume and encompass the outermost part of the fabric. Thus, both the first and second sides are fully visible when the fabric is observed. Both the first and second sides may extend along the x- and y-planes, which are generally parallel to and offset from each other. For example, the first side may be oriented in a first x- and y-plane, and the second side may be oriented in a second x- and y-plane, which is substantially parallel to and offset from the first x- and y-planes.

[0049] When referring to fibers, the term denier, or denier per fiber, is a unit of measurement for the linear mass density of a fiber; more specifically, it is the mass in grams per 9000 meters of fiber. In one example aspect, the denier of a fiber can be measured using ASTM D1577-07. The fineness of a fiber is the mass in grams of each fiber per 10,000 meters of fiber length. The diameter of a fiber can be calculated based on its denier and / or fineness. For example, the fiber diameter d in millimeters can be calculated using the following formula: d = square root of fineness divided by 100. Generally, the diameter of a fiber is directly related to its denier (i.e., the smaller the denier, the smaller the diameter). 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, which is a polymer material. 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).

[0050] As used herein, the term "color," when referring to fibers, such as in nonwoven fabrics, generally refers to the observable color of fibers forming at least a portion of the fabric. These aspects contemplate that the color can be any color imparted to the fiber using dyes, material deposits, pigments, and / or colorants known in the art. Thus, fibers can be configured to have colors including, but not limited to, red, orange, yellow, green, blue, indigo, purple, white, black, and their hues. In one example aspect, 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).

[0051] The aspects related to color also envision determining whether one color differs from 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 by standardizing and / or quantifying factors that may affect color perception. Such instruments include, but are not limited to, spectroradiometers, spectrophotometers, etc. Therefore, the aspects herein envision that the “color” of a fabric provided by fibers can include digital color values ​​measured and / or calculated using spectroradiometers and / or spectrophotometers. Furthermore, digital color values ​​can be associated with a color space or color model, which is a specific color organization that provides the color representation of the digital color values, and thus, each digital color value corresponds to a single color represented in the color space or color model.

[0052] In these respects, if the digital color values ​​of each color are different, it can be determined that one color is different from another. 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 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 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.

[0053] Furthermore, it can be envisioned that the visual difference between two colors can be related to the percentage difference between the numerical color values ​​of the first and second colors, and that the visual difference will be greater as the percentage difference between the color values ​​increases. Additionally, the visual difference can 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).

[0054] As used herein, the term "pilling" or "pilling" refers to the formation of small balls or ends of fibers on the face of a nonwoven fabric. Pills can extend away from the surface plane of the fabric. Typically, during normal washing and abrasion, forces (e.g., abrasive forces) cause fiber ends to migrate across the face of the nonwoven fabric and become entangled with other fiber ends, thus forming pills. The pilling resistance of a fabric can be measured using standardized tests such as the Random Tumble and Martindale Pilling tests.

[0055] This paper discusses various aspects of using lasers to emit electromagnetic radiation that is absorbed by one or more fibers in a nonwoven fabric. Typically, lasers emit energy in the form of photons with specific wavelengths, which depend on the energy state of the electrons at the time of photon emission. The electromagnetic radiation emitted by a laser is generally monochromatic (i.e., it includes a specific wavelength), coherent, and directional. Typically, the dominant wavelengths associated with electromagnetic radiation fall within the ultraviolet, visible, and infrared regions of the electromagnetic spectrum. For example, electromagnetic radiation can have wavelengths between 100 nanometers (nm) and 400 nm (ultraviolet radiation), between approximately 400 nm and 700 nm (visible radiation), and between 700 nm and 1 mm (infrared radiation). When describing the tendency of fibers to absorb electromagnetic radiation emitted by lasers, this paper anticipates that the fibers possess properties that enable them to absorb electromagnetic radiation of a specified wavelength or wavelength range.

[0056] This paper anticipates using various types of commercially available lasers, including laser diodes, continuous-wave lasers, gas lasers, solid-state lasers, pulsed lasers such as femtosecond lasers, excimer lasers, semiconductor lasers, dye lasers, free-electron lasers, etc. Laser types may include, for example, argon fluoride, xenon chloride, xenon fluoride, helium-cadmium, rhodamine 6G, copper vapor, argon, frequency-doubled Nd:YAG, helium-neon, krypton, ruby, laser diodes, Ti:sapphire, alexandrite, Nd:YAG, hydrogen fluoride, erbium:glass, carbon monoxide, carbon dioxide, etc.

[0057] In an example context, parameters associated with a specific laser used according to various aspects of this document can be optimized to achieve desired properties in the nonwoven fabric. For example, the wavelength emitted by the laser can be selected to induce heating of the electromagnetic radiation-absorbing fibers used to form the nonwoven fabric. In an example context, the wavelength range contemplated herein is from about 400 nanometers (nm) to about 1070 nm. In a further example context, wavelengths contemplated herein include about 450 nm, 532 nm, 650 nm, and 1060 nm. These are merely examples, and other wavelengths are also contemplated within the scope of this document. The intensity and / or energy density of the laser can be adjusted to achieve the desired penetration level of the nonwoven fabric. For example, the intensity can be adjusted to penetrate at least 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% of the thickness of the nonwoven fabric. In terms of examples, the intensity can be adjusted such that the electromagnetic radiation emitted by the laser penetrates into the internal volume of the nonwoven fabric (e.g., between about 20% and about 80% of the nonwoven fabric thickness), but does not extend to the side of the nonwoven fabric opposite to the side to which the electromagnetic radiation is applied. Additional parameters to be adjusted include the duration for which the electromagnetic radiation is applied to the nonwoven fabric. The duration can be selected to achieve the desired melting of the fibers without causing overheating of the area surrounding the affected fibers and / or damaging the structural integrity of the nonwoven fabric. The aspects described herein envision durations from about 1 millisecond to about 5 seconds. The total power density is determined when the duration is multiplied by the energy density. The laser beam width can also be adjusted to produce a selected size or surface area of ​​the laser application site. The aspects described herein envision beam widths equal to or greater than 1 to 2 mm. This, in turn, affects the number of bonded structures formed in the nonwoven fabric, the spacing between adjacent bonded structures, and the size of each bonded structure.

[0058] In one example, electromagnetic radiation emitted by a laser can be applied to a nonwoven fabric in a predetermined pattern to create discrete adhesive structures within the fabric. The pattern can be designed to produce a desired density of adhesive structures in different areas of the nonwoven fabric. For example, when a nonwoven fabric is used to form garment articles, areas of the nonwoven fabric exposed to higher rates of wear or use (such as the elbows and collar areas of upper garments or the hips and knees of lower garments) can have a relatively larger number of adhesive structures per unit area compared to areas less prone to wear. The increased adhesive structures in high-wear areas can reduce pilling in these areas. In a further example, the application of electromagnetic radiation by a laser and the entanglement of the nonwoven fabric can both be digitized, such that, for example, the entanglement occurs in areas different from those of the nonwoven fabric forming the adhesive structures (e.g., areas within a specific x, y plane of the nonwoven fabric do not overlap). This prevents over-processing of the nonwoven fabric, thus maintaining its soft hand feel and drape, making it ideal for use in garment articles.

[0059] According to various aspects of this document, when electromagnetic radiation emitted by a laser is absorbed by a first fiber (such as a polymer fiber including carbon black (e.g., coated or impregnated with carbon black)) that has a tendency to absorb electromagnetic radiation, the radiation causes the temperature of the first fiber to rise, and in an example, causes the first fiber to melt. As used herein, when describing a fiber's tendency to absorb electromagnetic radiation, various aspects of this document contemplate that the tendency to absorb electromagnetic radiation may be specific to a certain wavelength or a certain wavelength range (e.g., wavelengths in the infrared spectrum, visible spectrum, and / or ultraviolet spectrum). When the molten first fiber comes into contact with an adjacent second fiber that has a lower tendency to absorb electromagnetic radiation, the molten first fiber may at least partially encapsulate a portion of the adjacent second fiber. When the molten polymer material of the first fiber re-solidifies, an adhesive structure is formed, which may include an amorphous polymer aggregate formed by the molten first fiber together with portions of the first and / or second fibers in fibrous form. The term "fibrous form" generally refers to a structure having fibrous properties including a length generally greater than the fiber diameter and a relatively constant diameter along the fiber length.

[0060] In another example, the first fiber, formed from a material with a relatively high melting temperature, may include a material that absorbs electromagnetic radiation, such as carbon black. For example, the first fiber may be coated with carbon black, impregnated with carbon black, or have carbon black incorporated therein. The first fiber (with carbon black) may be blended or mixed with a second fiber (e.g., a low-melting-point fiber) formed from a polymeric material with a relatively low melting temperature, which typically does not absorb electromagnetic radiation. When the first fiber with carbon black is exposed to electromagnetic radiation emitted by a laser, the carbon black can be heated to the temperature at which it melts the portion of the adjacent second fiber, while the first fiber remains intact. In this example, the adhesive structure may include an amorphous polymer aggregate consisting primarily of a re-cured polymeric material of the second fiber and portions of adjacent first and second fibers in fibrous form.

[0061] In yet another example, aspects of this paper envision using bicomponent fibers having, for example, an electromagnetic radiation absorbing material positioned side-by-side with a material having a relatively low tendency to absorb electromagnetic radiation. The bicomponent fibers can be blended with other fiber types that may also have a relatively low tendency to absorb electromagnetic radiation. When the laser emits electromagnetic radiation of a specified wavelength or wavelength range, the temperature of the electromagnetic radiation absorbing material of the bicomponent fibers may rise to its melting point. The molten material can encapsulate or partially encapsulate adjacent fibers with a relatively low tendency to absorb electromagnetic radiation. In this example, the bonded structure may include an amorphous aggregate comprising a re-cured electromagnetic radiation absorbing material from the bicomponent fibers, a bicomponent fiber material with a relatively low tendency to absorb electromagnetic radiation (wherein this material retains its fibrous form), and adjacent non-bicomponent fiber portions with a relatively low tendency to absorb electromagnetic radiation (wherein these fibers are also in fibrous form).

[0062] The aspects of this document envision fibers with a relatively high tendency to absorb electromagnetic radiation as including any number of known electromagnetic radiation absorbing materials. For example, additives, such as carbon black, and / or various other pigments, including pigments using porphyrin compounds, can be imparted to the fibers, as well as fillers that enhance the fibers' ability to absorb electromagnetic radiation. The carbon black and / or other various pigments and fillers can be inherent to the fibers themselves (i.e., extruded together with the fibers during fiber formation), or the carbon black and / or other various pigments and fillers can be applied as a coating that fully or partially coats the fibers. The aspects of this document also envision engineered fibers that do not absorb electromagnetic radiation, for example, by applying non-absorbent colorants. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0063] This document provides various measurements for nonwoven fabrics. The thickness of nonwoven fabrics can be measured using a precision thickness gauge. To measure thickness, for example, the fabric can be positioned on a flat anvil, and a presser 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, in grams per square meter (gsm). Fabric stiffness, which typically corresponds to drape, is measured using the ASTM D4032 (2008) test standard, in kilogram-forces (Kgf). Fabric growth and recovery are measured using the ASTM 2594 test standard and expressed as a percentage. The term “tension” as used herein refers to a fabric property measured as an increase of a specified distance under a specified tension and is typically expressed as a percentage of the original reference distance (i.e., rest length or width). The term “growth” as used herein refers to an increase of a specified reference distance (i.e., rest length or width) over a period of time after the tension is released after being stretched to a specified tension and is typically 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 expressed as a percentage of the original reference distance. Thermal resistance, which corresponds to insulation properties, is typically measured using the ISO 11092 test standard, and is measured in RCTs (m²). 2 *K / W).

[0064] Unless otherwise stated, all measurements provided herein are taken at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar) with the nonwoven or composite nonwoven fabric in a static (unstretched) state.

[0065] Figure 1 A schematic diagram of an example method 100 for finishing a nonwoven fabric is depicted. In step 110, a first plurality of fibers 112 (shown in solid lines) are provided, having a first tendency to absorb electromagnetic radiation emitted by a laser at a specified wavelength or wavelength range. The first plurality of fibers 112 may be in the form of loose fibers or may be in the form of a fiber web (including entangled fiber webs). In step 110, a second plurality of fibers 114 (shown in dashed lines) having a second tendency to absorb electromagnetic radiation at a specified wavelength or wavelength range are additionally provided. In an example aspect, the second tendency to absorb electromagnetic radiation may be lower than the first tendency to absorb electromagnetic radiation. The second plurality of fibers 114 may also be in the form of loose fibers or may be in the form of a fiber web (including entangled fiber webs).

[0066] Various aspects of this document contemplate that the first plurality of fibers 112 may comprise fibers that absorb electromagnetic radiation, and that the second plurality of fibers 114 may comprise fibers that do not absorb electromagnetic radiation. Fibers 112 and 114 may, in exemplary respects, comprise polyester or PET fibers (virgin, shredded, or re-extruded), but other polymeric materials such as thermoplastic polyurethane, polyamides (e.g., nylon), etc., are contemplated herein. In exemplary respects, the first plurality of fibers 112 may be coated or impregnated with carbon black, which increases their tendency to absorb electromagnetic radiation. Other aspects of this document contemplate that the first plurality of fibers 112 may comprise bicomponent fibers having an electromagnetic radiation absorbing material in parallel with a material having a low or no tendency to absorb electromagnetic radiation.

[0067] In examples, fibers 112 and 114 may have short fiber lengths from about 40 mm to about 120 mm, from about 50 mm to about 110 mm, or from about 70 mm to about 100 mm. As used herein, the term “about” means within ±5% of the indicated value, unless otherwise stated. Having short fiber lengths within this range ensures sufficient length to support one or more bonded structures.

[0068] In step 116, the first plurality of fibers 112 and the second plurality of fibers 114 are blended or mixed to produce a nonwoven fabric 118, as shown in step 120. The nonwoven fabric 118 includes a first face 122 and an opposing second face 124. In some examples, the blending or mixing may include using, for example, needle entanglement or hydroentanglement to entangle the fibers 112 and 114. In some examples, the mixing of fibers 112 and 114 may be selective to produce a non-uniform distribution of fibers 112 and 114 between the first face 122 and the second face 124. For example, fibers 112 and 114 may be blended from about 10% by weight or quantity to about 90% by weight or quantity. This non-uniform distribution of fibers 112 and 114 may result in more second fibers 114 present on the first face 122 relative to the second face 124, and more first fibers 112 present on the second face 124 relative to the first face 122. Within the internal volume of the nonwoven fabric 118, at least some of the first plurality of fibers 112 are adjacent to or in contact with at least some of the second plurality of fibers 114. Furthermore, within a portion of the internal volume of the nonwoven fabric 118, a uniform distribution of the first fibers 112 and the second fibers 114 is envisioned.

[0069] In step 126, a laser 128 is used to apply electromagnetic radiation of a specified wavelength or wavelength range, targeting, for example, the first plurality of fibers 112, to the nonwoven fabric 118. The electromagnetic radiation may be applied in a pattern including spaced-apart application sites. Although the electromagnetic radiation is shown as being applied as a beam perpendicular to the surface plane of the first face 122 of the nonwoven fabric 118, various aspects herein contemplate that the application angle may vary between approximately 1 degree and approximately 89 degrees relative to the surface plane of the first face 122.

[0070] In one example, electromagnetic radiation is initially directed through the first surface 122 of the nonwoven fabric 118. In another example, because some of the first fibers 112 may have migrated into the first surface 122, some adhesive structure, such as adhesive structure 130, can be formed on the first surface 122 at one or more laser application sites, as shown in step 131. However, because the first surface 122 and portions of the nonwoven fabric 118 located inside and adjacent to the first surface 122 primarily comprise second fibers 114 with a lower tendency to absorb electromagnetic radiation, the electromagnetic radiation can be directed primarily into the internal volume of the nonwoven fabric 118. As a result, the second fibers 114 located on the first surface 122 are generally unaffected by the electromagnetic radiation, allowing them to retain the same properties, including their fibrous form prior to the application of electromagnetic radiation to the nonwoven fabric 118.

[0071] Within the internal volume of the nonwoven fabric, due to the greater degree of mixing within the internal volume of the nonwoven fabric 118, there are more contact points between the first fiber 112 and the second fiber 114. As described above, at least a portion of the first fiber 112 absorbs electromagnetic radiation at the application site, causing the temperature to rise to and / or exceed the melting point of the polymer material forming the first fiber 112. Once melted, the polymer material of the first fiber 112 can contact and / or wet portions of other fibers in contact with the molten polymer material, including portions of adjacent second fibers 114 and portions of adjacent first fibers 112. When the laser 128 stops emitting electromagnetic energy, the molten polymer material of the first fiber 112 re-solidifies, forming an adhesive structure comprising an amorphous polymer aggregate that partially or completely encapsulates the portions of the first fiber 112 and / or the second fiber 114 that have been wetted by the molten polymer material. The portions of the first fiber 112 and / or the second fiber 114 retain their fibrous form. Thus, in this example, the fiber extends from the amorphous polymer aggregate. The result of the adhesive structure is a reduction in the number of free fiber ends at one or more of the first surface 122 and the second surface 124. This is achieved by capturing the fiber ends, or by holding the fibers in a fixed position within the adhesive structure, thereby reducing the tendency of fibers 112 and 114 to migrate within the nonwoven fabric 118 and form pills on the first surface 122 and the second surface 124 of the nonwoven fabric 118. Various aspects of this document envision that each of the first surface 122 and the second surface 124 exhibits at least a pilling resistance of 2 in the Martindale pilling test after electromagnetic energy is applied to the nonwoven fabric 118.

[0072] Figure 2 The first side 122 of the nonwoven fabric 118 is depicted, while Figure 3 The second surface 124 of the nonwoven fabric 118 is depicted. The volume 205 of the nonwoven fabric 118 extends between the first surface 122 and the second surface 124. Figure 2 and Figure 3Each of these figures depicts a unit area, denoted by reference numerals 210 and 310, respectively. The unit area can be a 1cm × 1cm square, but other sizes are also conceivable. As shown, relative to the second surface 124, there is a greater number of second multiple fibers 114 per unit area 210 at the first surface 122. Additionally, relative to the first surface 122, there is a greater number of first multiple fibers 112 per unit area 310 at the second surface 124. This is likely due to the non-uniform or selective mixing of the first multiple fibers 112 and the second multiple fibers 114. Because some first fibers 112 can move to the first surface 122, some adhesive structures (such as adhesive structure 130) can exist on the first surface 122. Regarding the second surface 124, in an example, parameters associated with the laser 128 can be adjusted such that electromagnetic radiation penetration at or through the second surface 124 is minimized to none. Thus, as... Figure 3 The relatively few adhesive structures 130 shown demonstrate that minimal or no discrete adhesive structures can exist.

[0073] Figure 4 Depicting along Figure 2 The plane cross-section is shown in line 4-4. Thus, Figure 4The planar cross-section shown is taken approximately midway between the first surface 122 and the second surface 124 within the volume 205 of the nonwoven fabric 118. The unit area is indicated by reference numeral 410. As shown, the first plurality of fibers 112 and the second plurality of fibers 114 have a more uniform distribution within the volume 205 of the nonwoven fabric 118, such that two or more fibers of the first plurality of fibers 112 are adjacent to or in contact with two or more fibers of the second plurality of fibers 114 within the volume 205 of the nonwoven fabric 118. In an example, parameters associated with the laser 128 can be adjusted such that the penetration depth of electromagnetic radiation is optimized within the volume 205 of the nonwoven fabric 118. Therefore, due to the greater number of first fibers 112 and second fibers 114 in contact with each other within the volume 205 of the nonwoven fabric 118, and due to the penetration depth of the electromagnetic radiation emitted by the laser 128, a significant portion of the adhesive structure 130 can exist within the volume 205 of the nonwoven fabric 118. For example, in a illustrative context, there are more discrete adhesive structures 130 per unit area 410 within the volume 205 of the nonwoven fabric 118 than there are discrete adhesive structures 130 per unit area 210 on the first surface 122 (e.g., three adhesive structures 130 per unit area 410 compared to one adhesive structure 130 per unit area 210). Furthermore, there are more discrete adhesive structures 130 per unit area 410 within the volume 205 of the nonwoven fabric 118 than there are discrete adhesive structures 130 per unit area 310 on the second surface 124 (e.g., three adhesive structures 130 per unit area 410 compared to one adhesive structure 130 per unit area 310). As previously described, this feature helps maintain the properties of the first surface 122 and the second surface 124, such as a soft hand feel, abrasion resistance, and / or drape.

[0074] Figure 4 An enlarged view of the adhesive structure 130 is also depicted, which includes an amorphous polymer aggregate 412 formed from a first fiber 112 that has been melted and re-cured. The remainder of the first fiber 112 is shown extending from the amorphous polymer aggregate 412. The amorphous polymer aggregate 412 also encapsulates or partially encapsulates a portion of a second fiber 114, which is also shown extending from the amorphous polymer aggregate 412. This is a schematic depiction, and the aspects herein envision that the adhesive structure 130 may have different configurations or forms.

[0075] Figure 5 Is Figure 2The cross-section of the nonwoven fabric 118 taken at the cutting line 5-5 is shown. The first surface 122 and the second surface 124 are shown together with the internal volume 205 located between the first surface 122 and the second surface 124. The cross-section depicts a non-uniform distribution of the first plurality of fibers 112 and the second plurality of fibers 114, such that more of the second fibers 114 are located in or adjacent to the first surface 122, and more of the first fibers 112 are located in or adjacent to the second surface 124. Compared with the first surface 122 and the second surface 124, the first fibers 112 and the second fibers 114 have a substantially equal distribution within the internal volume 205 of the nonwoven fabric 118, and have a correspondingly greater number of adhesive structures 130 within the internal volume of the nonwoven fabric 118.

[0076] Figure 6 An example bicomponent fiber 600 is depicted having an electromagnetic radiation absorbing material 610 positioned side-by-side with a second material 612. The second material 612 may include a material having a lower tendency to absorb electromagnetic radiation compared to material 610. In some aspects, the second material 612 may not absorb electromagnetic radiation. Regarding the electromagnetic radiation absorbing material 610, material 610 may include, for example, a polymer material impregnated or at least partially coated with carbon black or other dyes / pigments. As described above, when the bicomponent fiber 600 is exposed to electromagnetic radiation, all or part of the electromagnetic radiation absorbing material 610 may melt, while the second material 612 remains substantially intact in fibrous form. If the bicomponent fiber 600 is in contact with or adjacent to other fibers (including other bicomponent fibers 600), the molten material 610 may encapsulate or partially encapsulate the other fibers to form an adhesive structure as described above. In this example, the adhesive structure would comprise an amorphous polymer agglomerate formed from the molten and re-cured material 610, the second material 612 in fibrous form, and one or more other fibers in fibrous form.

[0077] Figure 7 An example pattern 700 is depicted for applications involving electromagnetic radiation from, for example, a laser 128. Pattern 700 includes a plurality of discrete, spaced-apart application sites 710, where each application site 710 represents an area of ​​a nonwoven fabric (such as nonwoven fabric 118) exposed to electromagnetic radiation. Pattern 700 is exemplary, and it is contemplated herein that a laser can be programmed to apply electromagnetic radiation in any desired pattern to achieve a desired functional effect.

[0078] Figures 8 to 10 An example garment article formed from nonwoven fabric 118 is depicted. (About...) Figure 8 , Figure 8An example upper garment 800 in the form of a jacket is depicted. Although shown as a jacket, the various aspects herein envision the upper garment 800 as a shirt, pullover, hoodie, vest, undershirt, etc., with sleeves (long or short sleeves). The upper garment 800 includes a torso portion 810 defining a neck opening 812 and a waist opening 814. A first sleeve 816 and a second sleeve 818 extend from the torso portion 810.

[0079] In this example, the first side 122 of the nonwoven fabric 118 forms the outward-facing surface 820 of the garment 800, and in this example, may form the outermost surface of the garment 800. In this example, the second side 124 forms the inward-facing surface (not shown) of the garment 800, and in this example, may form the innermost surface of the garment 800. An enlarged view of the nonwoven fabric 118 shows the first fiber 112, the second fiber 114, and the adhesive structure 130. Various aspects of this document also contemplate that the second side 124 forms the outward-facing surface of the garment 800, while the first side 122 forms the inward-facing surface of the garment 800.

[0080] This paper proposes adjusting parameters associated with lasers (such as laser 128) to create a higher density adhesive structure 130 in areas of the upper garment 800 that typically experience a higher rate of abrasion compared to the rest of the upper garment 800. For example, areas of the upper garment 800 that may typically experience higher abrasion and subsequent pilling include, for example, the elbow area, collar area, waistband area, and cuff area. In some examples, the areas of higher density adhesive structure 130 may be based on the specific activity for which the upper garment 800 is designed. In an example where the activity is running, a higher density adhesive structure 130 may be formed along the sides of the torso and underarms, as these areas may experience relatively higher abrasion and subsequent pilling due to the wearer's arm movements during running.

[0081] Figure 9 An example of lower garment 900 in the form of trousers is depicted. Although shown as trousers, various aspects herein envision the lower garment 900 as being in the form of leggings, capri pants, shorts, a skirt, a bodysuit, etc. The lower garment 900 includes a torso portion 910 defining a waist opening 912. A first leg portion 914 and a second leg portion 916 extend from the torso portion 910 and terminate at a first leg opening 918 and a second leg opening 920, respectively.

[0082] In this example, the first side 122 of the nonwoven fabric 118 forms the outward-facing surface 922 of the garment 900, and in this example, may form the outermost surface of the garment 900. In this example, the second side 124 forms the inward-facing surface (not shown) of the garment 900, and in this example, may form the innermost surface of the garment 900. An enlarged view of the nonwoven fabric 118 shows the first fiber 112, the second fiber 114, and the adhesive structure 130. Various aspects of this document also contemplate that the second side 124 forms the outward-facing surface of the garment 900, while the first side 122 forms the inward-facing surface of the garment 900.

[0083] This paper proposes adjusting parameters associated with lasers (such as laser 128) to create a higher density adhesive structure 130 in areas of the lower garment 900 that typically experience a higher rate of wear compared to the rest of the garment. Some example locations include the knee area, waist opening area, leg cuff area, and / or hip portion. Similar to the upper garment 800, the higher density areas of the adhesive structure 130 can be based on the specific activity for which the lower garment 900 is designed. For example, in the case of running or cycling, a higher density adhesive structure 130 may be formed along the inner thigh portion of the lower garment 900, as these areas may experience a relatively higher amount of wear due to leg movements during running and / or cycling.

[0084] Figure 10 The image depicts an upper 1000 for footwear product 1010. Footwear product 1010 can encompass any type of footwear, including athletic shoes, sandals, fashion shoes (men's and women's), etc. Figure 10 In the example shown, the first side 122 of the nonwoven fabric 118 forms the outward-facing surface 1012 of the upper 1000, and in the example aspect, may form the outermost surface of the upper 1000. In this example, the second side 124 forms the inward-facing surface (not shown) of the upper 1000, and in the example aspect, may form the innermost surface of the upper 1000. An enlarged view of the nonwoven fabric 118 shows the first fiber 112, the second fiber 114, and the adhesive structure 130. Various aspects of this document also envision the second side 124 forming the outward-facing surface of the upper 1000, while the first side 122 forms the inward-facing surface of the upper 1000.

[0085] This paper proposes adjusting parameters associated with lasers (such as laser 128) to create a higher density of adhesive structure 130 in areas of the upper 1000 that typically experience higher wear rates compared to the rest of the upper 1000. For example, a higher density of adhesive structure 130 may be present around the ankle opening of the upper 1000, at the toe end of the upper 1000, and along the inner and outer sides of the upper 1000. The location of the higher density of adhesive structure 130 may depend on the specific sport for which the footwear 1010 will be used. For example, in a soccer ball, a higher density of adhesive structure 130 may be located at the toe end of the upper, as this area has more contact with the soccer ball than other areas of the upper 1000.

[0086] Figure 11 A flowchart depicts an example method for processing a nonwoven fabric (such as nonwoven fabric 118), generally denoted by the numeral 1100. Similar to nonwoven fabric 118, the nonwoven fabric in method 1100 includes a first side (such as first side 122), an opposing second side (such as second side 124), and a volume (such as volume 205) between the first and second sides. The nonwoven fabric includes at least a first plurality of fibers (such as first plurality of fibers 112) having a first tendency to absorb electromagnetic radiation of a specified wavelength or wavelength range, and a second plurality of fibers having a second tendency to absorb electromagnetic radiation, the second tendency being lower than the first tendency. The second plurality of fibers may be second plurality of fibers 114. The first plurality of fibers are mixed and / or entangled with the second plurality of fibers to achieve a non-uniform distribution of fibers, such that there is a greater number of first plurality of fibers per unit area on the second side and a greater number of second plurality of fibers per unit area on the first side.

[0087] In step 1110, electromagnetic radiation of a specified wavelength or wavelength range is selectively applied to the nonwoven fabric using a laser (such as laser 128) to form multiple discrete adhesive structures (such as adhesive structure 130). Parameters associated with the laser can be adjusted such that the adhesive structures are located within the volume of the nonwoven fabric and are typically situated between a first and a second surface. Each adhesive structure comprises one or more amorphous polymer agglomerates formed from a first plurality of fibers, wherein the agglomerates encapsulate or partially encapsulate adjacent fibers, such as one or more of the first plurality of fibers and / or a second plurality of fibers, to form the adhesive structure. At least the second fibers in the adhesive structure retain their fibrous form. Because the adhesive structure helps to hold the first and second plurality of fibers in place, the fibers have a reduced tendency to migrate and form pills. Therefore, finishing method 1100 can be used to increase the pilling resistance of the nonwoven fabric, and in an example, the resulting fabric may have a Martindale pilling fraction of 2 or higher. This is achieved while maintaining the surface properties of at least the first surface, as the electromagnetic radiation typically passes through the first surface without affecting the second plurality of fibers present on the first surface.

[0088] This paper also envisions that electromagnetic radiation emitted by lasers could be used to bond different nonwoven layers or fiber webs together, thereby eliminating the need for other more labor-intensive and / or less sustainable fastening techniques (such as stitching, adhesives, membranes, etc.). Figure 12 A schematic diagram of an example method 1200 for forming a composite nonwoven fabric by using electromagnetic radiation emitted by a laser to generate an adhesive structure at the interface region of different fiber webs is depicted.

[0089] In step 1210, the surface of a first fiber web 1212 formed by a first fiber 1214 (shown in solid lines) having a first tendency to absorb electromagnetic radiation of a specified wavelength or wavelength range is positioned adjacent to the surface of a second fiber web 1216 formed by a second fiber 1218 (shown in dashed lines) having a second tendency to absorb electromagnetic radiation, wherein the second tendency is lower than the first tendency. In some example aspects, after the first fiber web 1212 and the second fiber web 1216 are positioned adjacent to each other, a laser-transmitting material such as glass may be positioned on the second fiber web 1216 to ensure high contact at the interface between the first fiber web 1212 and the second fiber web 1216.

[0090] In an example, each of the first fiber web 1212 and the second fiber web 1216 may comprise an entangled fiber web (e.g., using fibers entangled, such as needle-entangled or hydroentangled fibers). Each of the first fiber web 1212 and the second fiber web 1216 may comprise fibers other than the first fiber 1214 and the second fiber 1218. One or more of the first fiber web 1212 and the second fiber web 1216 may comprise meltblown or spunbond fiber webs. One or more of the first fiber web 1212 and the second fiber web 1216 may be selected to achieve desired performance in the resulting composite nonwoven fabric. For example, the first fiber web 1212 may be configured to better withstand abrasion by including fibers with a higher denier and / or a higher density bonding structure (such as those described with respect to nonwoven fabric 118). In an example, the second fiber web 1216 may be configured to have a soft hand feel by including fibers with a lower denier (including meltblown or spunbond fibers), fibers coated with silicone, etc. These are merely illustrative examples, and the various aspects of this paper envision selecting any number of properties (including color) to achieve the desired set of features in composite nonwoven fabrics.

[0091] Various aspects of this document contemplate that the first fiber 1214 may comprise fibers that absorb electromagnetic radiation, while the second fiber 1218 may comprise fibers that do not absorb electromagnetic radiation. The first fiber 1214 and the second fiber 1218 may, in exemplary respects, comprise polyester or PET fibers (virgin, shredded, or re-extruded), but other polymeric materials such as thermoplastic polyurethane, polyamides (e.g., nylon), etc., are contemplated herein. In exemplary respects, the first fiber 1214 may be coated or impregnated with carbon black, which increases its tendency to absorb electromagnetic radiation. Other aspects of this document contemplate that the first fiber 1214 may comprise a bicomponent fiber having an electromagnetic radiation absorbing material in parallel with a material having a low or no tendency to absorb electromagnetic radiation.

[0092] In step 1220, a laser 1222 is used to apply electromagnetic radiation of a specified wavelength or wavelength range, targeting, for example, the first fiber 1214, to the second fiber web 1216. The electromagnetic radiation may be applied in a pattern including spaced-apart application sites. Although the electromagnetic radiation is shown as being applied as a beam perpendicular to the surface plane of the second fiber web 1216, various aspects herein contemplate that the application angle may vary between approximately 1 degree and approximately 89 degrees relative to the surface plane of the second fiber web 1216.

[0093] In this example, electromagnetic radiation can pass through the second fiber web 1216 without affecting the structural integrity of the second fibers 1218 because they have a low tendency to absorb electromagnetic radiation. Thus, electromagnetic radiation can be primarily directed into the internal volume of the stacked configuration of the first fiber web 1212 and the second fiber web 1214. As a result, the second fibers 1218 located within the second fiber web 1216 are generally unaffected by electromagnetic radiation, allowing them to retain the same properties they possessed before electromagnetic radiation was applied to the second fiber web 1216.

[0094] At the interface 1224 between the first fiber web 1212 and the second fiber web 1216 within the internal volume of the nonwoven fabric, there are a greater number of contact points between the first fiber 1214 and the second fiber 1218. At the interface 1224, at least a portion of the first fiber 1214 absorbs electromagnetic radiation at the application site, causing the temperature to rise to and / or exceed the melting point of the polymer material forming the first fiber 1214. Once melted, the polymer material of the first fiber 1214 can contact and / or wet portions of other fibers in contact with the molten polymer material, including portions of adjacent second fibers 1218 and portions of adjacent first fibers 1214. When the laser 1222 stops emitting electromagnetic energy, the molten polymer material of the first fiber 1214 re-solidifies, forming an adhesive structure comprising amorphous polymer aggregates that encapsulate or partially encapsulate the portions of the first fiber 1214 and / or the second fiber 1218 that have been wetted by the molten polymer material. Portions of the first fiber 1214 and / or the second fiber 1218 retain their fibrous form. Therefore, in this example, the fibers extend from an amorphous polymer aggregate. An adhesive structure forms multiple adhesive points between the first fiber web 1212 and the second fiber web 1216 to form a composite nonwoven fabric 1226, as shown in step 1228. The composite nonwoven fabric 1226 includes a first surface 1232 formed by the second fiber web 1216 and an opposing second surface 1234 formed by the first fiber web 1212.

[0095] In some examples, the composite nonwoven fabric 1226 may include recesses or indentations 1230 in the first surface 1232. The indentation 1230 may represent an area where the underlying second fibers 1218 are part of the adhesive structure. Because these fibers cannot move freely, they may generate tension on other second fibers 1218 entangled with them, thus creating the indentation 1230. Similar indentations may be formed in the second surface 1234 of the composite nonwoven fabric 1226 due to the entrapment of the first fibers 1214 in the adhesive structure and the tension applied to other second fibers 1218 entangled with them. In some examples, the indentations 1230 on the first surface 1232 and / or the second surface 1234 may be axially aligned with the adhesive structure located at the interface 1224 between the first fiber web 1212 and the second fiber web 1216. Therefore, the thickness of the composite nonwoven fabric 1226 may be reduced in the area corresponding to the indentation 1230. As further described below, because the thickness of the composite nonwoven fabric 1226 decreases in the region corresponding to the indentation 1230, the indentation 1230 can be used to create fold lines to increase the drape of the nonwoven fabric. They can also be used to create markings on the nonwoven fabric to indicate patterns that can subsequently be cut or removed from the nonwoven fabric. Any and all aspects and any variations thereof are contemplated within the scope of this document. Similar indentations can be formed on the nonwoven fabric 118 if one or more of the first plurality of fibers 112 and / or the second plurality of fibers 114 are entangled together.

[0096] Figure 13 The first surface 1232 of the composite nonwoven fabric 1226 is depicted, and Figure 14 A second surface 1234 of the composite nonwoven fabric 1226 is depicted. A volume 1310 extends between the first surface 1232 and the second surface 1234. A recess 1230 is shown in the first surface 1232, and the exemplary aspects herein contemplate that the second surface 1234 may also include a recess 1230, although not shown. Figure 13 and Figure 14 Each of these figures depicts a unit area and is indicated by reference numerals 1312 and 1412, respectively. In an example, when the second fiber 1218 does not absorb or minimally absorbs the electromagnetic radiation emitted by the laser 1222, preventing the second fiber 1218 from melting, the adhesive structure is not present on the first surface 1232, as... Figure 13 As shown. In other words, the number of adhesive structures per unit area 1312 is zero. In an example, parameters such as intensity associated with the laser 1222 can be configured such that electromagnetic radiation is not transmitted or is transmitted to a minimum to the second surface 1234 of the composite nonwoven fabric 1226. If electromagnetic radiation is not transmitted to the second surface 1234, the number of adhesive structures per unit area 1412 can be zero.

[0097] Figure 15 Depicting along the route by Figure 13 The planar cross-section shown in line 15-15 is taken at the interface 1224 of the first fiber web 1212 and the second fiber web 1216 within the internal volume 1310 of the composite nonwoven fabric 1226. The unit area is indicated by reference numeral 1510. At the interface 1224 of the first fiber web 1212 and the second fiber web 1216, two or more first fibers 1214 are adjacent to or in contact with two or more second fibers 1218 within the volume 1310 of the composite nonwoven fabric 1226. In this example, parameters associated with the laser 1222 can be adjusted such that the intensity and / or penetration depth of the electromagnetic radiation are optimized within the volume 1310 of the composite nonwoven fabric 1226. More specifically, parameters associated with the laser 1222 can be adjusted such that the penetration depth is optimized to coincide with the position of the interface 1224 between the first fiber web 1212 and the second fiber web 1216.

[0098] Because there are more first fibers 1214 and second fibers 1218 in contact with each other at interface 1224, discrete adhesive structures such as adhesive structures 1512 can be formed at interface 1224. Therefore, in an example, there are more discrete adhesive structures 1512 per unit area 1510 within the volume 1310 of the composite nonwoven fabric 1226 than there are discrete adhesive structures 1512 per unit area 1312 on the first surface 1232 (e.g., three adhesive structures 1512 per unit area 1510 compared to zero adhesive structures 1512 per unit area 1312). Furthermore, compared to the number of discrete adhesive structures 1512 per unit area 1412 on the second surface 1234, there are a greater number of discrete adhesive structures 1512 per unit area 1510 within the volume 1310 of the composite nonwoven fabric 1226 (e.g., three adhesive structures 1512 per unit area 1510 compared to zero adhesive structures 1512 per unit area 1412). This feature helps to maintain the properties of the first surface 1232 and the second surface 1234. The adhesive structures 1512 formed within the volume 1310 of the composite nonwoven fabric 1226 are structurally similar to the adhesive structure 130 described and depicted with respect to the nonwoven fabric 118.

[0099] Figure 16 Is Figure 13A cross-section of the composite nonwoven fabric 1226 is shown taken at cut lines 16-16. The first surface 1232 and the second surface 1234 are shown together with the internal volume 1310 located between the first surface 1232 and the second surface 1234. Interface 1224 is further depicted and indicates the location where the surface of the first fiber web 1212 contacts the surface of the second fiber web 1216. Multiple discrete adhesive structures 1512 are shown at spaced intervals at interface 1224 within the volume 1310 of the composite nonwoven fabric 1226. Adhesive structures 1512 are used to secure or bond the first fiber web 1212 and the second fiber web 1216 together. In this example aspect, adhesive structure 1512 represents the only securing structure for securing the first web 1212 and the second web 1216 together. Other examples envision other methods that can be used to secure the webs 1212 and 1216 together.

[0100] Figures 17 to 19 An example garment article formed from composite nonwoven fabric 1226 is depicted. (About...) Figure 17 , Figure 17 An example upper garment 1700 in the form of a jacket is depicted. Although shown as a jacket, the various aspects herein envision the upper garment 1700 as a shirt, pullover, hoodie, vest, undershirt, etc., with sleeves (long or short sleeves). The upper garment 1700 includes a torso portion 1710 defining a neck opening 1712 and a waist opening 1714. A first sleeve 1716 and a second sleeve 1718 extend from the torso portion 1710.

[0101] In this example, the first side 1232 of the composite nonwoven fabric 1226 forms the outward-facing surface 1720 of the garment 1700, and in this example, may form the outermost surface of the garment 1700. In this example, the second side 1234 forms the inward-facing surface (not shown) of the garment 1700, and in this example, may form the innermost surface of the garment 1700. An enlarged view of the first side 1232 of the composite nonwoven fabric 1226 having the second fiber 1218 is shown. Various aspects of this document also envision the second side 1234 forming the outward-facing surface of the garment 1700, while the first side 1232 forms the inward-facing surface of the garment 1700.

[0102] This paper proposes adjusting parameters associated with lasers (such as laser 1222) to create a higher density adhesive structure 1512 in areas of the upper garment 1700 that are typically subjected to stress, compared to the rest of the garment. A higher density adhesive structure 1512 in these areas helps reduce the chance of the first fiber web 1212 detaching from the second fiber web 1216. For example, with respect to the upper garment 1700, areas that are typically likely to experience higher stress include, for example, the upper back, which may experience stress or tension when the wearer extends their arms forward; areas along the sleeve seams; areas adjacent to the front closure mechanism; etc. In some examples, the areas with higher density adhesive structure 1512 may be based on the specific movement for which the upper garment 1700 is designed. In an example where the movement is running, a higher density adhesive structure 1512 may be formed along the mid-back to the upper back because these areas may experience a relatively higher amount of stress due to the wearer's arm movements during running.

[0103] Figure 18 An example of lower garment 1800 in the form of trousers is depicted. Although shown as trousers, various aspects herein envision the lower garment 1800 as possible in the form of leggings, capri pants, shorts, a skirt, a bodysuit, etc. The lower garment 1800 includes a torso portion 1810 defining a waist opening 1812. A first leg portion 1814 and a second leg portion 1816 extend from the torso portion 1810 and terminate at a first leg opening 1818 and a second leg opening 1820, respectively.

[0104] In this example, the first side 1232 of the composite nonwoven fabric 1226 forms the outward-facing surface 1822 of the garment 1800, and in this example, may form the outermost surface of the garment 1800. In this example, the second side 1234 forms the inward-facing surface (not shown) of the garment 1800, and in this example, may form the innermost surface of the garment 1800. An enlarged view of the first side 1232 of the composite nonwoven fabric 1226 having the second fiber 1218 is shown. Various aspects of this document also envision the second side 1234 forming the outward-facing surface of the garment 1800, while the first side 1232 forms the inward-facing surface of the garment 1800.

[0105] Various aspects of this paper envision adjusting parameters associated with lasers (such as laser 1222) such that a higher density adhesive structure 1512 is formed in areas of the lower garment 1800 that are typically subjected to stress, compared to the rest of the garment. A higher density adhesive structure 1512 in these areas helps reduce the chance that the first fiber web 1212 may detach from the second fiber web 1216. For example, with respect to the lower garment 1800, areas that may typically be subjected to higher stress include, for example, the hip, groin, and foregrip regions, which may experience stress or tension when the wearer sits and / or raises their legs. In some example aspects, the areas with higher density adhesive structure 1512 may be based on the specific sport for which the lower garment 1800 is designed. In an example where the sport is baseball and / or softball, a higher density adhesive structure 1512 may be formed along the waist opening region because this area may experience a relatively higher amount of stress due to the rotation of the wearer's torso when the bat is swung.

[0106] Figure 19 The image depicts an upper 1900 used for footwear 1910. Footwear 1910 can encompass any type of footwear, including athletic shoes, sandals, fashion shoes (men's and women's), etc. Figure 19 In the example shown, the first surface 1232 of the composite nonwoven fabric 1226 forms the outward-facing surface 1912 of the upper 1900, and in some aspects may form the outermost surface of the upper 1900. In this example, the second surface 1234 forms the inward-facing surface (not shown) of the upper 1900, and in some aspects may form the innermost surface of the upper 1900. An enlarged view of the first surface 1232 of the composite nonwoven fabric 1226 having the second fiber 1218 is shown. Various aspects of this document also envision the second surface 1234 forming the outward-facing surface of the upper 1900, while the first surface 1232 forms the inward-facing surface of the upper 1900.

[0107] This paper proposes adjusting parameters associated with lasers (such as laser 1222) to form a higher density adhesive structure 1512 in areas of the upper 1900 that typically experience higher stress compared to the rest of the upper 1900. The higher density adhesive structure 1512 in these areas helps reduce the chance of the first fiber web 1212 detaching from the second fiber web 1216. For example, with respect to the upper 1900, areas that may typically experience higher stress include, for example, the ankle collar, which is stretched when the wearer inserts their foot into the upper 1900. In some examples, the areas with higher density adhesive structure 1512 may be based on the specific movement for which the upper 1900 is designed. In one example, in ballet, the areas where the ballet ribbon extends may have an increased density adhesive structure 1512.

[0108] Figure 20 A flowchart illustrating an example method for forming a composite nonwoven fabric (such as composite nonwoven fabric 1226) is provided, and is generally indicated by the numeral 2000. Similar to composite nonwoven fabric 1226, the composite nonwoven fabric in method 2000 includes a first fiber web (such as first fiber web 1212) and a second fiber web (such as second fiber web 1216). The first fiber web includes first fibers, such as first fiber 1214 having a first tendency to absorb electromagnetic radiation of a specified wavelength or wavelength range. The second fiber web includes second fibers, such as second fiber 1218 having a second tendency to absorb electromagnetic radiation below the first tendency. The second fiber web forms a first surface, such as the first surface 1232 of the composite nonwoven fabric, and the first fiber web forms a second surface, such as the second surface 1234 of the composite nonwoven fabric. In an example aspect, one or more of the first and second fibers comprise a polymer material.

[0109] In step 2010, electromagnetic radiation of a specified wavelength or wavelength range is selectively applied to the composite nonwoven fabric using a laser (such as laser 1222) to form a plurality of discrete adhesive structures (such as adhesive structure 1512). Parameters associated with the laser can be adjusted such that the adhesive structures are located within the volume of the composite nonwoven fabric and typically at interfaces, such as interface 1224 between the first and second surfaces. Each adhesive structure includes one or more amorphous polymer agglomerates formed from the first fibers, wherein the agglomerates encapsulate or partially encapsulate adjacent fibers, such as one or more of the first and / or second fibers, to form the adhesive structure. At least the second fibers in the adhesive structure retain their fibrous form. The adhesive structure facilitates the bonding of the first and second fiber webs together. This is achieved while maintaining the surface properties of the first and second surfaces of the composite nonwoven fabric, as the electromagnetic radiation typically passes through the first surface without affecting the second fibers present in the second fiber web.

[0110] Based on various aspects of this article, laser bonding on nonwoven fabrics can be used in other ways. For example, Figure 21 Nonwoven fabric 2100 is described, which may be nonwoven fabric 118 or composite nonwoven fabric 1226. Nonwoven fabric 2100 may be formed from a first fiber (such as a first fiber 2105 (shown in solid lines) having a first tendency to absorb electromagnetic radiation of a specified wavelength or wavelength range) and a second fiber (such as a second fiber 2107 (shown in dashed lines) having a second tendency to absorb electromagnetic radiation), wherein the second tendency is less than the first tendency. The first fiber 2105 and the second fiber 2107 may be mixed or entangled with each other, as described with respect to nonwoven fabric 118. Alternatively or additionally, the first fiber 2105 and the second fiber 2107 may be in different fiber webs as described with respect to composite nonwoven fabric 1226. The first fiber 2105 and the second fiber 2107 may be any fiber described herein, including bicomponent fibers, such as bicomponent fiber 600.

[0111] In an example, laser bonding can be used to create markings 2112 on the surface 2113 of the nonwoven fabric 2100 to depict patterned pieces, such as patterned pieces 2114 for sleeves, patterned pieces 2116 for the uppers of footwear, and patterned pieces 2118 for the torso and leg portions of lower garments. Patterned pieces 2114, 2116, and 2118 can be removed from the nonwoven fabric 2100 using removal techniques known in the art, such as cutting, die-cutting, waterjet cutting, laser cutting, etc.

[0112] In one example aspect, mark 2112 may include a recess or indentation in the surface 2113 of the nonwoven fabric 2100, such as the recess 1230 described with respect to the composite nonwoven fabric 1226. As mentioned above, recesses may also be formed in the nonwoven fabric 118 when the first fiber 112 is entangled, when the second fiber 114 is entangled, or when the first fiber 112 is entangled with the second fiber 114. In another example aspect, mark 2112 may include an adhesive structure present on the surface 2113 of the nonwoven fabric 2100. In this example aspect, the beam width may be increased such that a visible adhesive structure having an approximate diameter from about 1 mm to about 5 mm can be formed on the surface 2113 of the nonwoven fabric 2100. In other example aspects, and as described with respect to Figure 23In more detail, the nonwoven fabric 2100 may include fibers that have been coated or impregnated with, for example, titanium dioxide (TiO2), giving the fibers a white color. The TiO2 fibers may be positioned to be present on surface 2113. When exposed to electromagnetic radiation from a laser, the TiO2 fibers change color. In an example, this could be due to degradation of the TiO2 caused by the electromagnetic radiation. For example, the color of the fibers changes from white to gray. Other exemplary methods of generating patterned markings are also contemplated within the scope of this document.

[0113] Figure 22A The text describes the use of laser bonding to create fold lines or drapes in patterned pieces (e.g., patterned piece 2200 for sleeves) or in garment articles formed from, for example, nonwoven fabric 118 or composite nonwoven fabric 1226. In one example aspect, and as described with respect to composite nonwoven fabric 1226, the bonded structure formed by electromagnetic radiation emitted by a laser can create indentations 2210, such as indentations 1230, in at least one face (e.g., face 2212) of patterned piece 2200. Figure 22B A schematic diagram depicting an example cross-section of one of the indentations 2210 is shown. As described with respect to indentation 1230, the interception of fibers within an adhesive structure such as adhesive structure 2230 can induce tension on adjacent fibers entangled with the intercepted fibers. In turn, this can create indentations on one or more surfaces, where indentation 2210 is axially aligned with adhesive structure 2230. Compared to fabric areas without indentation 2210, whether on one or both surfaces of the fabric, indentation 2210 reduces the thickness of the fabric. Therefore, indentations can be strategically positioned on pattern piece 2200 to create areas or "lines" of reduced thickness that can be folded or bent more easily than portions of pattern piece 2200 without indentation 2210.

[0114] Figure 23 Examples are depicted of creating graphics, letters, logos, etc., on a nonwoven fabric 2312, such as a nonwoven fabric 118 and / or a composite nonwoven fabric 1226, using electromagnetic radiation emitted by a laser 2316. In an example, the nonwoven fabric 2312 may include TiO2 fibers 2314 having a first color (such as white), wherein the fibers 2314 are present at least on a first side 2305 of the nonwoven fabric 2312. In step 2310, electromagnetic radiation is selectively applied to the nonwoven fabric 2312 by the laser 2316. The electromagnetic radiation can be applied in a programmable manner to create one or more of graphics, letters, logos, etc. As described above, applying electromagnetic radiation to the fibers 2314 causes them to change from a first color to a second color, such as gray.

[0115] In step 2318, letters, such as letter 2320, are depicted, wherein letter 2320 is formed by a color change in fiber 2314 caused by the programming application of electromagnetic radiation. In an example, the method can be used to form, for instance, care instructions on nonwoven fabrics used to form garment articles, thus eliminating the need for additional fabric material containing care instructions.

[0116] The following clauses represent exemplary aspects of the concepts envisioned herein. Any of the following clauses may be combined in multiple dependent ways 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.

[0117] Clause 1. A nonwoven fabric having a first side, an opposing second side, and a volume between the first side and the second side, the nonwoven fabric comprising: a first plurality of fibers having a first tendency to absorb electromagnetic radiation emitted by a laser; a second plurality of fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being less than the first tendency to absorb the electromagnetic radiation, at least some of the second plurality of fibers being mixed with the first plurality of fibers, wherein the fibers of at least one of the first plurality of fibers and the second plurality of fibers comprise a polymer; and a plurality of discrete adhesive structures positioned within the volume of the nonwoven fabric between the first side and the second side of the nonwoven fabric, at least some of the plurality of discrete adhesive structures comprising amorphous polymer agglomerates and fibers in fibrous form from one or more of the first plurality of fibers and the second plurality of fibers, wherein portions of the fibers from one or more of the first plurality of fibers and the second plurality of fibers are at least partially encapsulated by the amorphous polymer agglomerates.

[0118] Clause 2. The nonwoven fabric according to Clause 1, wherein the first plurality of fibers absorb the electromagnetic radiation and the second plurality of fibers do not absorb the electromagnetic radiation.

[0119] Clause 3. The nonwoven fabric according to any one of Clauses 1 to 2, wherein, relative to the second side, there is a greater number of the second plurality of fibers per unit area on the first side.

[0120] Clause 4. The nonwoven fabric according to any one of Clauses 1 to 3, wherein two or more of the first plurality of fibers are in contact with two or more of the second plurality of fibers within the volume of the nonwoven fabric.

[0121] Clause 5. The nonwoven fabric according to any one of Clauses 1 to 4, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

[0122] Clause 6. The nonwoven fabric according to any one of Clauses 1 to 5, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

[0123] Clause 7. The nonwoven fabric according to any one of Clauses 1 to 6, wherein one or more of the first plurality of fibers comprises a bicomponent fiber having an electromagnetic radiation absorbing material positioned in a side-by-side relationship with the non-electromagnetic radiation absorbing material.

[0124] Clause 8. The nonwoven fabric according to any one of Clauses 1 to 7, wherein the first plurality of fibers are entangled with the second plurality of fibers.

[0125] Clause 9. The nonwoven fabric according to any one of Clauses 1 to 8, wherein, in the Martindale pilling test, at least the first side has a pilling resistance of at least 2.

[0126] Clause 10. The nonwoven fabric according to any one of Clauses 1 to 9, wherein, in the Martindale pilling test, at least the second side has a pilling resistance of at least 2.

[0127] Clause 11. The nonwoven fabric according to any one of Clauses 1 to 10, wherein there is a non-uniform distribution of the first plurality of fibers and the second plurality of fibers between the first surface and the second surface.

[0128] Clause 12. The nonwoven fabric according to any one of Clauses 1 to 11, wherein the first plurality of fibers and the second plurality of fibers are present in a uniform or non-uniform distribution within the volume of the nonwoven fabric.

[0129] Clause 13. The nonwoven fabric according to any one of Clauses 1 to 12, wherein the short fiber length of one or more of the first plurality of fibers and the second plurality of fibers is from about 40 mm to about 120 mm.

[0130] Clause 14. A garment article comprising: a nonwoven fabric having an outward-facing surface, an inward-facing surface, and a volume between the inward-facing surface and the outward-facing surface, the nonwoven fabric comprising: a first plurality of fibers having a first tendency to absorb electromagnetic radiation emitted by a laser; a second plurality of fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being lower than the first tendency to absorb the electromagnetic radiation, at least some of the second plurality of fibers being mixed with the first plurality of fibers, wherein the first plurality of fibers... The fibers of at least one of the first and second plurality of fibers comprise a polymer; and a plurality of discrete adhesive structures are positioned within the volume of the nonwoven fabric between the inward-facing and outward-facing surfaces of the nonwoven fabric, at least some of the plurality of discrete adhesive structures comprising amorphous polymer agglomerates and fibers in the form of fibers from one or more of the first and second plurality of fibers, wherein portions of the fibers from one or more of the first and second plurality of fibers are at least partially encapsulated by the amorphous polymer agglomerates.

[0131] Clause 15. The garment article according to Clause 14, wherein the first plurality of fibers absorb the electromagnetic radiation and the second plurality of fibers do not absorb the electromagnetic radiation.

[0132] Clause 16. The garment article according to any one of Clauses 14 to 15, wherein a greater number of the second plurality of fibers are present per unit area on the outward-facing surface relative to the inward-facing surface.

[0133] Clause 17. A garment article according to any one of Clauses 14 to 16, wherein two or more of the first plurality of fibers are in contact with two or more of the second plurality of fibers within the volume of the nonwoven fabric.

[0134] Clause 18. The garment article according to any one of Clauses 14 to 17, wherein the number of discrete adhesive structures per unit area on the outward-facing surface of the nonwoven fabric is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

[0135] Clause 19. The garment article according to any one of Clauses 14 to 18, wherein the number of discrete adhesive structures per unit area on the inward-facing surface of the nonwoven fabric is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

[0136] Clause 20. The garment article according to any one of Clauses 14 to 19, wherein one or more of the first plurality of fibers comprises a bicomponent fiber having an electromagnetic radiation absorbing material positioned in a side-by-side relationship with a non-electromagnetic radiation absorbing material.

[0137] Clause 21. A garment article according to any one of Clauses 14 to 20, wherein the first plurality of fibers are entangled with the second plurality of fibers.

[0138] Clause 22. A garment article according to any one of Clauses 14 to 21, wherein, in the Martindale pilling test, at least the outward-facing surface has a pilling resistance of at least 2.

[0139] Clause 23. A garment article according to any one of Clauses 14 to 22, wherein, in the Martindale pilling test, at least the inward-facing surface has a pilling resistance of at least 2.

[0140] Clause 24. A garment article according to any one of Clauses 14 to 23, wherein there is a non-uniform distribution of the first plurality of fibers and the second plurality of fibers between the outward-facing surface and the inward-facing surface of the nonwoven fabric.

[0141] Clause 25. A garment article according to any one of Clauses 14 to 24, wherein the first plurality of fibers and the second plurality of fibers are present in a uniform or non-uniform distribution within the volume of the nonwoven fabric.

[0142] Clause 26. The garment article according to any one of Clauses 14 to 25, wherein the length of one or more of the first plurality of fibers and the second plurality of fibers is from about 40 mm to about 120 mm.

[0143] Clause 27. The garment article according to any one of Clauses 14 to 26, wherein the outward-facing surface of the nonwoven fabric forms the outermost surface of the garment article.

[0144] Clause 28. A garment article according to any one of Clauses 14 to 27, wherein the inner-facing surface of the nonwoven fabric forms the innermost surface of the garment article.

[0145] Clause 29. Clothing articles according to any one of Clauses 14 to 28, wherein the clothing articles include one of upper garments, lower garments or the upper of footwear articles.

[0146] Clause 30. A method for finishing a nonwoven fabric, the nonwoven fabric having a first side, an opposing second side, and a volume between the first side and the opposing second side, the nonwoven fabric comprising a first plurality of fibers and a second plurality of fibers, the first plurality of fibers having a first tendency to absorb electromagnetic radiation emitted by a laser, the second plurality of fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being lower than the first tendency to absorb the electromagnetic radiation, wherein at least some of the second plurality of fibers are mixed with the first plurality of fibers, and wherein at least one of the first plurality of fibers and the second plurality of fibers is woven into a fiber bundle. The method, which includes a polymer, comprises: selectively applying electromagnetic radiation from a laser to a nonwoven fabric to form a plurality of discrete adhesive structures within the volume of the nonwoven fabric, the plurality of discrete adhesive structures being positioned within the volume of the nonwoven fabric between a first surface and a second surface, at least some of the plurality of discrete adhesive structures comprising amorphous polymer agglomerates and fibers in the form of one or more of the first plurality of fibers and the second plurality of fibers, wherein portions of the fibers from one or more of the first plurality of fibers and the second plurality of fibers are at least partially encapsulated by the amorphous polymer agglomerates.

[0147] Clause 31. The method of finishing a nonwoven fabric according to Clause 30, wherein selectively applying the electromagnetic radiation from the laser causes partial melting of the first plurality of fibers, and wherein after the selective application of the electromagnetic radiation from the laser ceases, the molten portion of the first plurality of fibers is re-solidified to form the amorphous polymer agglomerate.

[0148] Clause 32. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 31, wherein the electromagnetic radiation is applied in a pattern comprising spaced-apart application sites.

[0149] Clause 33. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 32, wherein the first plurality of fibers absorb the electromagnetic radiation and the second plurality of fibers do not absorb the electromagnetic radiation.

[0150] Clause 34. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 33, wherein a greater number of the second plurality of fibers are present per unit area on the first surface relative to the second surface.

[0151] Clause 35. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 34, wherein two or more fibers of the first plurality of fibers are in contact with two or more fibers of the second plurality of fibers within the volume of the nonwoven fabric.

[0152] Clause 36. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 35, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

[0153] Clause 37. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 36, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

[0154] Clause 38. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 37, wherein one or more of the first plurality of fibers comprises a bicomponent fiber having an electromagnetic radiation absorbing material positioned in a side-by-side relationship with a non-electromagnetic radiation absorbing material.

[0155] Clause 39. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 38, wherein the first plurality of fibers are entangled with the second plurality of fibers.

[0156] Clause 40. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 39, wherein, in the Martindale pilling test, at least the first side has a pilling resistance of at least 2.

[0157] Clause 41. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 40, wherein, in the Martindale pilling test, at least the pilling resistance of the second side is at least 2.

[0158] Clause 42. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 41, wherein there is a non-uniform distribution of the first plurality of fibers and the second plurality of fibers between the first surface and the second surface.

[0159] Clause 43. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 42, wherein the first plurality of fibers and the second plurality of fibers are present in a uniform or non-uniform distribution within the volume of the nonwoven fabric.

[0160] Clause 44. A method for finishing a nonwoven fabric according to any one of Clauses 30 to 43, wherein the short fiber length of one or more of the first plurality of fibers and the second plurality of fibers is from about 40 mm to about 120 mm.

[0161] Clause 45. A composite nonwoven fabric having a first side, an opposing second side, and a volume between the first side and the second side, the composite nonwoven fabric comprising: a first fiber web forming the first side, the first fiber web including first fibers having a first tendency to absorb electromagnetic radiation emitted by a laser; a second fiber web forming the second side, the second fiber web including second fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being less than the first tendency to absorb the electromagnetic radiation, wherein the fibers of at least one of the first fibers and the second fibers comprise a polymer; and a plurality of discrete adhesive structures positioned within the volume of the composite nonwoven fabric between the first side and the second side of the composite nonwoven fabric, at least some of the plurality of discrete adhesive structures including amorphous polymer agglomerates and fibers in the form of one or more of the first fibers and the second fibers, wherein portions of one or more of the first fibers and the second fibers are at least partially encapsulated by the amorphous polymer agglomerates.

[0162] Clause 46. The composite nonwoven fabric according to Clause 45, wherein the plurality of discrete adhesive structures are located at the interface between the first fiber web and the second fiber web.

[0163] Clause 47. A composite nonwoven fabric according to any one of Clauses 45 to 46, wherein the first fiber absorbs the electromagnetic radiation and the second fiber does not absorb the electromagnetic radiation.

[0164] Clause 48. A composite nonwoven fabric according to any one of Clauses 45 to 47, wherein two or more fibers of the first fiber are in contact with two or more fibers of the second fiber within the volume of the composite nonwoven fabric.

[0165] Clause 49. The composite nonwoven fabric according to any one of Clauses 45 to 48, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

[0166] Clause 50. The composite nonwoven fabric according to Clause 49, wherein the number of discrete adhesive structures per unit area on the first surface is zero.

[0167] Clause 51. The composite nonwoven fabric according to any one of Clauses 45 to 50, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

[0168] Clause 52. The composite nonwoven fabric according to Clause 51, wherein the number of discrete adhesive structures per unit area on the second surface is zero.

[0169] Clause 53. A composite nonwoven fabric according to any one of Clauses 45 to 52, wherein one or more of the first fibers comprises a bicomponent fiber having an electromagnetic radiation absorbing material positioned side-by-side with a non-electromagnetic radiation absorbing material.

[0170] Clause 54. A composite nonwoven fabric according to any one of Clauses 45 to 53, wherein the first fiber web comprises a first entangled fiber web.

[0171] Clause 55. A composite nonwoven fabric according to any one of Clauses 45 to 54, wherein the second fiber web comprises a second entangled fiber web.

[0172] Clause 56. A garment article comprising: a composite nonwoven fabric having a first side, an opposing second side, and a volume between the first side and the second side, the composite nonwoven fabric comprising: a first fiber web forming the first side, the first fiber web comprising first fibers having a first tendency to absorb electromagnetic radiation emitted by a laser; a second fiber web forming the second side, the second fiber web comprising second fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being less than the first tendency to absorb the electromagnetic radiation, wherein the fibers of at least one of the first fibers and the second fibers comprise a polymer; and a plurality of discrete adhesive structures positioned within the volume of the composite nonwoven fabric between the first side and the second side of the composite nonwoven fabric, at least some of the plurality of discrete adhesive structures comprising amorphous polymer agglomerates and fibers in the form of one or more of the first fibers and the second fibers, wherein portions of one or more of the first fibers and the second fibers are at least partially encapsulated by the amorphous polymer agglomerates.

[0173] Clause 57. The garment article according to Clause 56, wherein the first side of the composite nonwoven fabric forms the outermost surface of the garment article.

[0174] Clause 58. A garment article according to any one of Clauses 56 to 57, wherein the second side of the nonwoven fabric forms the innermost surface of the garment article.

[0175] Clause 59. The garment article according to any one of Clauses 56 to 58, wherein the garment article is one of an upper garment, a lower garment, or the upper of a footwear article.

[0176] Clause 60. The garment article according to any one of Clauses 56 to 59, wherein the plurality of discrete adhesive structures are located at the interface between the first fiber web and the second fiber web.

[0177] Clause 61. A garment article according to any one of Clauses 56 to 60, wherein the first fiber absorbs the electromagnetic radiation and the second fiber does not absorb the electromagnetic radiation.

[0178] Clause 62. A garment article according to any one of Clauses 56 to 61, wherein two or more fibers of the first fiber are in contact with two or more fibers of the second fiber within the volume of the composite nonwoven fabric.

[0179] Clause 63. The garment article according to any one of Clauses 56 to 62, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

[0180] Clause 64. The garment article according to Clause 63, wherein the number of discrete adhesive structures per unit area on the first surface is zero.

[0181] Clause 65. The garment article according to any one of Clauses 56 to 64, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

[0182] Clause 66. The garment article according to Clause 65, wherein the number of discrete adhesive structures per unit area on the second surface is zero.

[0183] Clause 67. A garment article according to any one of Clauses 56 to 66, wherein one or more of the first fibers comprises a bicomponent fiber having an electromagnetic radiation absorbing material positioned side-by-side with a non-electromagnetic radiation absorbing material.

[0184] Clause 68. The garment article according to any one of Clauses 56 to 67, wherein the first fiber web comprises a first entangled fiber web.

[0185] Clause 69. The garment article according to any one of Clauses 56 to 68, wherein the second fiber web comprises a second entangled fiber web.

[0186] Clause 70. A method of forming a composite nonwoven fabric, the composite nonwoven fabric comprising a first fiber web and a second fiber web, the first fiber web comprising a first fiber having a first tendency to absorb electromagnetic radiation emitted by a laser, the second fiber web comprising a second fiber having a second tendency to absorb the electromagnetic radiation, the second tendency being lower than the first tendency, the first fiber web and the second fiber web forming a first face and an opposing second face of the composite nonwoven fabric and a volume between the first face and the second face, wherein fibers from at least one of the first fiber and the second fiber comprise a polymer, the method comprising: selectively applying the electromagnetic radiation to the composite nonwoven fabric using the laser to form a plurality of discrete adhesive structures, the plurality of discrete adhesive structures being positioned within the volume of the composite nonwoven fabric between the first face and the second face, at least some of the plurality of discrete adhesive structures comprising amorphous polymer agglomerates and fibers in the form of one or more of the first fiber and the second fiber, wherein portions of one or more of the first fiber and the second fiber are at least partially encapsulated by the amorphous polymer agglomerates.

[0187] Clause 71. The method of forming a composite nonwoven fabric according to Clause 70, wherein the electromagnetic radiation is selectively applied using the laser to cause partial melting of the first fiber, and wherein after the selective application of the electromagnetic radiation from the laser ceases, the molten portion of the first fiber is re-solidified to form the amorphous polymer agglomerate.

[0188] Clause 72. A method for forming a composite nonwoven fabric according to any one of Clauses 70 to 71, wherein the electromagnetic radiation is applied in a pattern comprising spaced-apart application sites.

[0189] Clause 73. A method of forming a composite nonwoven fabric according to any one of Clauses 70 to 72, wherein the plurality of discrete adhesive structures are located at the interface between the first fiber web and the second fiber web.

[0190] Clause 74. A method for forming a composite nonwoven fabric according to any one of Clauses 70 to 73, wherein the first fiber absorbs the electromagnetic radiation and the second fiber does not absorb the electromagnetic radiation.

[0191] Clause 75. A method for forming a composite nonwoven fabric according to any one of Clauses 70 to 74, wherein two or more fibers of the first fiber are in contact with two or more fibers of the second fiber within the volume of the composite nonwoven fabric.

[0192] Clause 76. A method for forming a composite nonwoven fabric according to any one of Clauses 70 to 75, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

[0193] Clause 77. The method of forming a composite nonwoven fabric according to Clause 76, wherein the number of discrete adhesive structures per unit area on the first surface is zero.

[0194] Clause 78. A method for forming a composite nonwoven fabric according to any one of Clauses 70 to 77, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

[0195] Clause 79. The method of forming a composite nonwoven fabric according to Clause 78, wherein the number of discrete adhesive structures per unit area on the second surface is zero.

[0196] Clause 80. A method for forming a composite nonwoven fabric according to any one of Clauses 70 to 79, wherein one or more of the first fibers comprise bicomponent fibers having an electromagnetic radiation absorbing material positioned side-by-side with a non-electromagnetic radiation absorbing material.

[0197] Clause 81. A method for forming a composite nonwoven fabric according to any one of Clauses 70 to 80, wherein the first fiber web comprises a first entangled fiber web.

[0198] Clause 82. A method for forming a composite nonwoven fabric according to any one of Clauses 70 to 81, wherein the second fiber web comprises a second entangled fiber web.

[0199] Clause 83. A nonwoven fabric having a first side and an opposing second side, the nonwoven fabric comprising: a first plurality of fibers including titanium dioxide, the first plurality of fibers at least partially forming the first side of the nonwoven fabric, wherein a first subset of the first plurality of fibers on the first side comprises a first color, and wherein a second subset of the first plurality of fibers on the first side comprises a second color different from the first color.

[0200] Clause 84. The nonwoven fabric according to Clause 82, wherein the second subset of the first plurality of fibers forms one or more of letters, logos, and graphics on the first surface of the nonwoven fabric.

[0201] Clause 85. The nonwoven fabric as described in Clause 84, wherein the second subset of the first plurality of fibers forms letters of the specified care instructions.

[0202] Clause 86. A garment article formed from a nonwoven fabric according to any one of Clauses 83 to 85.

[0203] Clause 87. The garment articles as described in Clause 86, wherein the garment articles include one of upper garments, lower garments or the upper of footwear articles.

[0204] Clause 89. A method for finishing a nonwoven fabric, the nonwoven fabric comprising a first side and an opposing second side, and a first plurality of fibers at least partially forming the first side of the nonwoven fabric, wherein the first plurality of fibers comprises a first color, the method comprising: selectively applying electromagnetic radiation of a specified wavelength or wavelength range to the first side of the nonwoven fabric, wherein the application of the electromagnetic radiation causes at least a subset of the first plurality of fibers to change from the first color to a second color, the second color being different from the first color.

[0205] Clause 90. The method of finishing a nonwoven fabric as described in Clause 89, wherein the subset of the first plurality of fibers forms one or more of letters, graphics, and symbols.

[0206] Clause 91. A method for finishing a nonwoven fabric according to any one of Clauses 89 to 90, wherein the first plurality of fibers comprises titanium dioxide.

[0207] Clause 92. A method of marking patterned patches on a nonwoven fabric, the nonwoven fabric comprising a first side, an opposing second side, and a volume between the first side and the opposing second side, the nonwoven fabric comprising a first plurality of fibers having a first tendency to absorb electromagnetic radiation emitted by a laser and a second plurality of fibers having a second tendency to absorb the electromagnetic radiation, the second tendency being lower than the first tendency, one or more of the first plurality of fibers and the second plurality of fibers comprising a polymer, the method comprising: selectively applying the electromagnetic radiation to the first side of the nonwoven fabric using a laser to define an application pattern that defines the peripheral shape of the patterned patch of one or more of the uppers of garments, clothing, and footwear articles, wherein the application pattern includes spaced-apart application sites.

[0208] Clause 93. The method of marking patterned pieces on a nonwoven fabric as described in Clause 92 further includes cutting off one or more of the patterned pieces from the nonwoven fabric.

[0209] Clause 94. A method of marking patterned patches on a nonwoven fabric according to any one of Clauses 92 to 93, wherein one or more discrete adhesive structures are formed at the application site, at least some of the one or more discrete adhesive structures comprising an amorphous polymer agglomerate and fibers in the form of one or more of the first plurality of fibers and the second plurality of fibers, wherein portions of the fibers from the first plurality of fibers and the second plurality of fibers are at least partially encapsulated by the amorphous polymer agglomerate.

[0210] Clause 95. A patterned sheet formed by any one of Clauses 92 to 94.

[0211] Clause 96. A garment article formed from a nonwoven fabric having an outward-facing surface, an inward-facing surface, and a volume between the inward-facing surface and the outward-facing surface, the nonwoven fabric comprising: a first plurality of fibers having a first tendency to absorb electromagnetic radiation emitted by a laser; a second plurality of fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being less than the first tendency to absorb the electromagnetic radiation, at least some of the second plurality of fibers being entangled with the first plurality of fibers, wherein the fibers of at least one of the first plurality of fibers and the second plurality of fibers comprise a polymer; a plurality of discrete An adhesive structure, comprising a plurality of discrete adhesive structures positioned within the volume of the nonwoven fabric between the inward-facing and outward-facing surfaces of the nonwoven fabric, wherein at least some of the plurality of discrete adhesive structures comprises amorphous polymer agglomerates and fibers in the form of one or more of the first plurality of fibers and the second plurality of fibers, wherein portions of the fibers from one or more of the first plurality of fibers and the second plurality of fibers are at least partially encapsulated by the amorphous polymer agglomerates; and a plurality of indentations formed in one or more of the first and second surfaces, each of the plurality of indentations being axially aligned with an adhesive structure in the plurality of discrete adhesive structures.

[0212] Clause 97. The garment article according to Clause 96, wherein the plurality of indentations are arranged in a pattern to form one or more fold lines, and the stiffness of the nonwoven fabric decreases along the fold lines.

[0213] Clause 98. A garment article according to any one of Clauses 96 to 97, wherein one or more fibers located in one or more of the plurality of indentations are entangled with one or more of the first plurality of fibers and the second plurality of fibers located within the adhesive structure.

[0214] Clause 99. A garment article according to any one of Clauses 96 to 98, wherein each of the plurality of indentations is offset inwardly from a surface plane defined by one or more of the first surface and the second surface.

[0215] Various aspects of this disclosure have been described in an illustrative rather than restrictive manner. Alternative aspects will become apparent to those skilled in the art without departing from its scope. Those skilled in the art can develop alternative means to achieve the above improvements without departing from the scope of this disclosure.

[0216] It should be understood that certain features and sub-combinations are useful and can be used without reference to other features and sub-combinations, and are contemplated to be within the scope of the claims. Not all steps listed in the various figures need to be performed in the specific order described.

Claims

1. A nonwoven fabric having a first side, an opposing second side, and a volume between the first side and the second side, the nonwoven fabric comprising: The first plurality of fibers have a first tendency to absorb electromagnetic radiation emitted by the laser. A second plurality of fibers, the second plurality of fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being lower than the first tendency to absorb the electromagnetic radiation, wherein at least some of the second plurality of fibers are mixed with the first plurality of fibers, wherein the fibers of at least one of the first plurality of fibers and the second plurality of fibers comprise a polymer; and Multiple discrete adhesive structures are positioned within the volume of the nonwoven fabric between the first and second surfaces of the nonwoven fabric. At least some of the multiple discrete adhesive structures include amorphous polymer aggregates and fibers in the form of one or more of the first and second plurality of fibers, wherein portions of the fibers from one or more of the first and second plurality of fibers are at least partially encapsulated by the amorphous polymer aggregates.

2. The nonwoven fabric according to claim 1, wherein the first plurality of fibers absorb the electromagnetic radiation and the second plurality of fibers do not absorb the electromagnetic radiation.

3. The nonwoven fabric according to claim 1, wherein, relative to the second side, there is a greater number of the second plurality of fibers per unit area on the first side.

4. The nonwoven fabric according to claim 1, wherein two or more of the first plurality of fibers are in contact with two or more of the second plurality of fibers within the volume of the nonwoven fabric.

5. The nonwoven fabric according to claim 1, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

6. The nonwoven fabric according to claim 1, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

7. The nonwoven fabric according to claim 1, wherein one or more of the first plurality of fibers comprises a bicomponent fiber having an electromagnetic radiation absorbing material positioned side-by-side with the non-electromagnetic radiation absorbing material.

8. The nonwoven fabric according to claim 1, wherein the first plurality of fibers are entangled with the second plurality of fibers.

9. The nonwoven fabric of claim 1, wherein, in the Martindale pilling test, at least the first side has a pilling resistance of at least 2.

10. The nonwoven fabric of claim 1, wherein, in the Martindale pilling test, at least the pilling resistance of the second side is at least 2.

11. The nonwoven fabric according to claim 1, wherein there is a non-uniform distribution of the first plurality of fibers and the second plurality of fibers between the first surface and the second surface.

12. The nonwoven fabric according to claim 1, wherein the volume of the nonwoven fabric contains either a uniform or non-uniform distribution of the first plurality of fibers and the second plurality of fibers.

13. The nonwoven fabric according to claim 1, wherein the short fiber length of one or more of the first plurality of fibers and the second plurality of fibers is from about 40 mm to about 120 mm, wherein, Approximately refers to within ±5% of the indicated value.

14. A garment article, comprising: A nonwoven fabric having an outward-facing surface, an inward-facing surface, and a volume between the inward-facing surface and the outward-facing surface, the nonwoven fabric comprising: The first plurality of fibers have a first tendency to absorb electromagnetic radiation emitted by the laser. A second plurality of fibers, the second plurality of fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being lower than the first tendency to absorb the electromagnetic radiation, at least some of the second plurality of fibers being mixed with the first plurality of fibers, wherein the fibers of at least one of the first plurality of fibers and the second plurality of fibers comprise a polymer; and A plurality of discrete adhesive structures are positioned within the volume of the nonwoven fabric between the inward-facing surface and the outward-facing surface of the nonwoven fabric, at least some of the plurality of discrete adhesive structures comprising an amorphous polymer aggregate and fibers in the form of one or more of the first plurality of fibers and the second plurality of fibers, wherein a portion of the fibers from one or more of the first plurality of fibers and the second plurality of fibers is at least partially encapsulated by the amorphous polymer aggregate.

15. The garment article of claim 14, wherein the first plurality of fibers absorb the electromagnetic radiation and the second plurality of fibers do not absorb the electromagnetic radiation.

16. The garment article of claim 14, wherein, relative to the inward-facing surface, there is a greater number of the second plurality of fibers per unit area on the outward-facing surface.

17. The garment article of claim 14, wherein two or more of the first plurality of fibers are in contact with two or more of the second plurality of fibers within the volume of the nonwoven fabric.

18. The garment article of claim 14, wherein the number of discrete adhesive structures per unit area on the outward-facing surface of the nonwoven fabric is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

19. The garment article of claim 14, wherein the number of discrete adhesive structures per unit area on the inward-facing surface of the nonwoven fabric is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

20. The garment article according to claim 14, wherein one or more of the first plurality of fibers comprises a bicomponent fiber having an electromagnetic radiation absorbing material positioned side-by-side with a non-electromagnetic radiation absorbing material.

21. The garment article according to claim 14, wherein the first plurality of fibers are entangled with the second plurality of fibers.

22. The garment article of claim 14, wherein, in the Martindale pilling test, at least the outward-facing surface has a pilling resistance of at least 2.

23. The garment article of claim 14, wherein, in the Martindale pilling test, at least the inward-facing surface has a pilling resistance of at least 2.

24. The garment article of claim 14, wherein there is a non-uniform distribution of the first plurality of fibers and the second plurality of fibers between the outward-facing surface and the inward-facing surface of the nonwoven fabric.

25. The garment article according to claim 14, wherein the volume of the nonwoven fabric contains either a uniform or non-uniform distribution of the first plurality of fibers and the second plurality of fibers.

26. The garment article of claim 14, wherein the short fiber length of one or more of the first plurality of fibers and the second plurality of fibers is from about 40 mm to about 120 mm, wherein, Approximately refers to within ±5% of the indicated value.

27. The garment article of claim 14, wherein the outward-facing surface of the nonwoven fabric forms the outermost surface of the garment article.

28. The garment article of claim 14, wherein the inward-facing surface of the nonwoven fabric forms the innermost surface of the garment article.

29. The garment article according to claim 14, wherein the garment article includes one of upper garment, lower garment or upper of footwear.

30. A method for finishing a nonwoven fabric, the nonwoven fabric having a first side, an opposing second side, and a volume between the first side and the second side, the nonwoven fabric comprising a first plurality of fibers and a second plurality of fibers, the first plurality of fibers having a first tendency to absorb electromagnetic radiation emitted by a laser, the second plurality of fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being lower than the first tendency to absorb the electromagnetic radiation, wherein at least some of the second plurality of fibers are mixed with the first plurality of fibers, and wherein the fibers of at least one of the first plurality of fibers and the second plurality of fibers comprise a polymer, the method comprising: The electromagnetic radiation from the laser is selectively applied to the nonwoven fabric to form a plurality of discrete adhesive structures within the volume of the nonwoven fabric. The plurality of discrete adhesive structures are positioned within the volume of the nonwoven fabric between the first and second surfaces. At least some of the plurality of discrete adhesive structures include amorphous polymer aggregates and fibers in the form of one or more of the first and second plurality of fibers, wherein a portion of the fibers from one or more of the first and second plurality of fibers is at least partially encapsulated by the amorphous polymer aggregates.

31. The method of finishing a nonwoven fabric according to claim 30, wherein selectively applying the electromagnetic radiation from the laser causes partial melting of the first plurality of fibers, and wherein after the selective application of the electromagnetic radiation from the laser ceases, the molten portion of the first plurality of fibers re-solidifies to form the amorphous polymer aggregate.

32. The method of finishing a nonwoven fabric according to claim 30, wherein the electromagnetic radiation is applied in a pattern comprising spaced-apart application sites.

33. The method for finishing a nonwoven fabric according to claim 30, wherein the first plurality of fibers absorb the electromagnetic radiation and the second plurality of fibers do not absorb the electromagnetic radiation.

34. The method of finishing a nonwoven fabric according to claim 30, wherein, relative to the second side, there is a greater number of the second plurality of fibers per unit area on the first side.

35. The method of finishing a nonwoven fabric according to claim 30, wherein two or more fibers of the first plurality of fibers are in contact with two or more fibers of the second plurality of fibers within the volume of the nonwoven fabric.

36. The method for finishing a nonwoven fabric according to claim 30, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

37. The method for finishing a nonwoven fabric according to claim 30, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the nonwoven fabric.

38. The method for finishing a nonwoven fabric according to claim 30, wherein one or more of the first plurality of fibers comprises a bicomponent fiber having an electromagnetic radiation absorbing material positioned side-by-side with a non-electromagnetic radiation absorbing material.

39. The method for finishing a nonwoven fabric according to claim 30, wherein the first plurality of fibers are entangled with the second plurality of fibers.

40. The method for finishing a nonwoven fabric according to claim 30, wherein in the Martindale pilling test, at least the pilling resistance of the first side is at least 2.

41. The method for finishing a nonwoven fabric according to claim 30, wherein in the Martindale pilling test, the pilling resistance of at least the second side is at least 2.

42. The method for finishing a nonwoven fabric according to claim 30, wherein there is a non-uniform distribution of the first plurality of fibers and the second plurality of fibers between the first surface and the second surface.

43. The method for finishing a nonwoven fabric according to claim 30, wherein the first plurality of fibers and the second plurality of fibers are present in a uniform or non-uniform distribution within the volume of the nonwoven fabric.

44. The method for finishing a nonwoven fabric according to claim 30, wherein the short fiber length of one or more of the first plurality of fibers and the second plurality of fibers is from about 40 mm to about 120 mm, wherein, Approximately refers to within ±5% of the indicated value.

45. A composite nonwoven fabric having a first side, an opposing second side, and a volume between the first side and the second side, the composite nonwoven fabric comprising: A first fiber web forming the first surface, the first fiber web comprising a first fiber having a first tendency to absorb electromagnetic radiation emitted by a laser; A second fiber web forming the second surface, the second fiber web comprising second fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being lower than the first tendency to absorb the electromagnetic radiation, wherein at least one of the first and second fibers comprises a polymer; and Multiple discrete adhesive structures are positioned within the volume of the composite nonwoven fabric between the first and second surfaces of the composite nonwoven fabric, at least some of the multiple discrete adhesive structures comprising amorphous polymer aggregates and fibers in the form of one or more of the first and second fibers, wherein portions of the fibers from one or more of the first and second fibers are at least partially encapsulated by the amorphous polymer aggregates.

46. ​​The composite nonwoven fabric of claim 45, wherein the plurality of discrete adhesive structures are located at the interface between the first fiber web and the second fiber web.

47. The composite nonwoven fabric of claim 45, wherein the first fiber absorbs the electromagnetic radiation and the second fiber does not absorb the electromagnetic radiation.

48. The composite nonwoven fabric of claim 45, wherein two or more fibers of the first fiber are in contact with two or more fibers of the second fiber within the volume of the composite nonwoven fabric.

49. The composite nonwoven fabric of claim 45, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

50. The composite nonwoven fabric of claim 49, wherein the number of discrete adhesive structures per unit area on the first surface is zero.

51. The composite nonwoven fabric of claim 45, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

52. The composite nonwoven fabric of claim 51, wherein the number of discrete adhesive structures per unit area on the second surface is zero.

53. The composite nonwoven fabric according to claim 45, wherein one or more of the first fibers comprise bicomponent fibers, the bicomponent fibers having electromagnetic radiation absorbing material positioned side-by-side with the non-electromagnetic radiation absorbing material.

54. The composite nonwoven fabric according to claim 45, wherein the first fiber web comprises a first entangled fiber web.

55. The composite nonwoven fabric of claim 45, wherein the second fiber web comprises a second entangled fiber web.

56. A garment article, comprising: A composite nonwoven fabric having a first side, an opposing second side, and a volume between the first side and the second side, the composite nonwoven fabric comprising: A first fiber web forming the first surface, the first fiber web comprising a first fiber having a first tendency to absorb electromagnetic radiation emitted by a laser; A second fiber web forming the second surface, the second fiber web comprising second fibers having a second tendency to absorb the electromagnetic radiation, the second tendency to absorb the electromagnetic radiation being lower than the first tendency to absorb the electromagnetic radiation, wherein at least one of the first and second fibers comprises a polymer; and Multiple discrete adhesive structures are positioned within the volume of the composite nonwoven fabric between the first and second surfaces of the composite nonwoven fabric, at least some of the multiple discrete adhesive structures comprising amorphous polymer aggregates and fibers in the form of one or more of the first and second fibers, wherein portions of the fibers from one or more of the first and second fibers are at least partially encapsulated by the amorphous polymer aggregates.

57. The garment article of claim 56, wherein the first side of the composite nonwoven fabric forms the outermost surface of the garment article.

58. The garment article of claim 56, wherein the second side of the composite nonwoven fabric forms the innermost surface of the garment article.

59. The garment article according to claim 56, wherein the garment article is one of an upper garment, a lower garment, or the upper of a footwear article.

60. The garment article of claim 56, wherein the plurality of discrete adhesive structures are located at the interface between the first fiber web and the second fiber web.

61. The garment article of claim 56, wherein the first fiber absorbs the electromagnetic radiation and the second fiber does not absorb the electromagnetic radiation.

62. The garment article of claim 56, wherein two or more fibers of the first fiber are in contact with two or more fibers of the second fiber within the volume of the composite nonwoven fabric.

63. The garment article of claim 56, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

64. The garment article of claim 63, wherein the number of discrete adhesive structures per unit area on the first surface is zero.

65. The garment article of claim 56, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

66. The garment article of claim 65, wherein the number of discrete adhesive structures per unit area on the second surface is zero.

67. The garment article according to claim 56, wherein one or more of the first fibers comprise bicomponent fibers, the bicomponent fibers having an electromagnetic radiation absorbing material positioned side-by-side with the non-electromagnetic radiation absorbing material.

68. The garment article of claim 56, wherein the first fiber web comprises a first entangled fiber web.

69. The garment article of claim 56, wherein the second fiber web comprises a second entangled fiber web.

70. A method of forming a composite nonwoven fabric, the composite nonwoven fabric comprising a first fiber web and a second fiber web, the first fiber web comprising a first fiber having a first tendency to absorb electromagnetic radiation emitted by a laser, the second fiber web comprising a second fiber having a second tendency to absorb the electromagnetic radiation, the second tendency being lower than the first tendency, the first fiber web and the second fiber web forming a first face and an opposing second face of the composite nonwoven fabric and a volume between the first face and the second face, wherein fibers from at least one of the first fiber and the second fiber comprise a polymer, the method comprising: The laser is used to selectively apply electromagnetic radiation to the composite nonwoven fabric to form a plurality of discrete adhesive structures, the plurality of discrete adhesive structures being positioned within the volume of the composite nonwoven fabric between the first and second surfaces, at least some of the plurality of discrete adhesive structures comprising amorphous polymer aggregates and fibers in the form of one or more of the first and second fibers, wherein portions of the fibers from one or more of the first and second fibers are at least partially encapsulated by the amorphous polymer aggregates.

71. The method of forming a composite nonwoven fabric according to claim 70, wherein the electromagnetic radiation is selectively applied using the laser to cause partial melting of the first fiber, and wherein after the selective application of the electromagnetic radiation from the laser ceases, the molten portion of the first fiber is re-solidified to form the amorphous polymer aggregate.

72. The method of forming a composite nonwoven fabric according to claim 70, wherein the electromagnetic radiation is applied in a pattern comprising spaced-apart application sites.

73. The method of forming a composite nonwoven fabric according to claim 70, wherein the plurality of discrete adhesive structures are located at the interface between the first fiber web and the second fiber web.

74. The method of forming a composite nonwoven fabric according to claim 70, wherein the first fiber absorbs the electromagnetic radiation and the second fiber does not absorb the electromagnetic radiation.

75. The method of forming a composite nonwoven fabric according to claim 70, wherein two or more fibers of the first fiber are in contact with two or more fibers of the second fiber within the volume of the composite nonwoven fabric.

76. The method of forming a composite nonwoven fabric according to claim 70, wherein the number of discrete adhesive structures per unit area on the first surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

77. The method of forming a composite nonwoven fabric according to claim 76, wherein the number of discrete adhesive structures per unit area on the first surface is zero.

78. The method of forming a composite nonwoven fabric according to claim 70, wherein the number of discrete adhesive structures per unit area on the second surface is less than the number of discrete adhesive structures per unit area within the volume of the composite nonwoven fabric.

79. The method of forming a composite nonwoven fabric according to claim 78, wherein the number of discrete adhesive structures per unit area on the second surface is zero.

80. The method of forming a composite nonwoven fabric according to claim 70, wherein one or more of the first fibers comprise bicomponent fibers having an electromagnetic radiation absorbing material positioned side-by-side with a non-electromagnetic radiation absorbing material.

81. The method of forming a composite nonwoven fabric according to claim 70, wherein the first fiber web comprises a first entangled fiber web.

82. The method of forming a composite nonwoven fabric according to claim 70, wherein the second fiber web comprises a second entangled fiber web.

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