Composite nonwoven fabric with asymmetric finish and method of making same

Abstract

The present application relates to composite nonwoven fabrics with asymmetric finishes and methods of making the same. Aspects herein relate to a recyclable composite nonwoven fabric with asymmetric finishes suitable for use in garments and other articles and methods of producing the same. In example aspects, the composite nonwoven fabric with asymmetric finishes includes a first face formed at least in part from a first web of entangled fibers and an opposing second face formed at least in part from a second web of entangled fibers. When incorporated into a garment article, the first face forms an outward-facing surface of the garment article and the second face forms an inward-facing surface of the garment article. The first face includes features that make it suitable for forming an outward-facing surface, such as abrasion resistance, and the second face includes features that make it suitable for forming an inward-facing surface, such as a soft hand.

Description

[0001] This application is a divisional application of the application filed on October 20, 2021, with application number 202180079005.6 and invention title "Asymmetric Finished Composite Nonwoven Fabric and Manufacturing Method Thereof". Technical Field

[0002] This article relates to a composite nonwoven fabric with a recyclable asymmetrical finish suitable for clothing and other articles, and a method for producing the same. Background Technology

[0003] Traditional nonwoven fabrics are generally unsuitable for apparel due to their lack of tensile and recovery properties, heavy weight, poor drape, rough hand feel, and lack of insulation performance in some applications requiring enhanced insulation. Furthermore, traditional nonwoven fabrics often have a symmetrical surface to provide a uniform fabric suitable for industries such as cleaning and personal hygiene. However, a uniform surface may not be suitable for apparel because the fabric surface facing the wearer's skin and the fabric surface exposed to the external environment may require different properties. Summary of the Invention

[0004] This application relates to the following aspects.

[0005] Project 1. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side, the first side including a plurality of discrete chemical bonding sites; a second entangled fiber web forming at least partially the second side; and an elastomer layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomer layer and are entangled with fibers of the second entangled fiber web.

[0006] Project 2. The composite nonwoven fabric according to Project 1, wherein the second surface does not have discrete chemical bonding sites.

[0007] Project 3. The composite nonwoven fabric according to any one of Projects 1 to 2, wherein the plurality of discrete chemical bonding sites comprises, in composition, an oil-based dispersion of polyurethane adhesive, a dispersion of polyurethane adhesive containing silica, and combinations thereof.

[0008] Item 4. A composite nonwoven fabric according to any one of Items 1 to 3, wherein at least the fibers of the first entangled fiber web are adhered together at the plurality of discrete chemical bonding sites.

[0009] Item 5. A composite nonwoven fabric according to any one of Items 1 to 4, wherein the first side comprises a first color, and the plurality of discrete chemical bonding sites comprise a second color different from the first color.

[0010] Item 6. The composite nonwoven fabric according to any one of Items 1 to 5, wherein the size of each of the plurality of discrete chemical bonding sites is in the range of about 0.1 mm to about 1 mm.

[0011] Item 7. The composite nonwoven fabric according to any one of Items 1 to 6, wherein the distance between adjacent bonding sites of the plurality of discrete chemical bonding sites is in the range of about 0.5 mm to about 6 mm.

[0012] Item 8. A composite nonwoven fabric according to any one of Items 1 to 7, wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the first entangled fiber web.

[0013] Item 9. The composite nonwoven fabric according to any one of Items 1 to 8 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0014] Item 10. The composite nonwoven fabric according to Item 9, wherein at least some fibers of the third entangled fiber web are entangled with fibers of the first entangled fiber web and fibers of the second entangled fiber web.

[0015] Item 11. A composite nonwoven fabric according to any one of Items 1 to 10, wherein the elastomer layer comprises one or more of a thermoplastic polyurethane meltblown layer or a thermoplastic polyether ester elastomer spunbond layer.

[0016] Item 12. A nonwoven garment article having an outward-facing surface and an opposing inward-facing surface, the nonwoven garment article comprising: a first entangled fiber web at least partially forming the outward-facing surface, the outward-facing surface including a first plurality of discrete chemical bonding sites located at a first position on the nonwoven garment article; a second entangled fiber web at least partially forming the inward-facing surface; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with at least some fibers of the second entangled fiber web.

[0017] Item 13. The nonwoven garment article according to Item 12, wherein the inward-facing surface does not have discrete chemical adhesive sites.

[0018] Item 14. The nonwoven garment article according to any one of Items 12 to 13, wherein the outward-facing surface further comprises a second plurality of discrete chemical adhesive sites located at a second position on the nonwoven garment article, the second position being different from the first position.

[0019] Item 15. The nonwoven garment article according to Item 14, wherein the density of the first plurality of discrete chemical adhesive sites is different from the density of the second plurality of discrete chemical adhesive sites.

[0020] Item 16. The nonwoven garment article according to any one of Items 12 to 15, wherein the first plurality of discrete chemical adhesive sites comprises, in composition, an oil-based dispersion of a polyurethane adhesive, a polyurethane adhesive in a dispersion containing silica, and combinations thereof.

[0021] Item 17. A method for finishing a composite nonwoven fabric, the composite nonwoven fabric comprising a first entangled fiber web forming at least partially a first side of the composite nonwoven fabric, a second entangled fiber web forming at least partially an opposing second side of the composite nonwoven fabric, and an elastomer layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers from the first entangled fiber web extend through the elastomer layer and become entangled with fibers of the second entangled fiber web, the method comprising: applying a chemical adhesive in a predetermined pattern to the first side of the composite nonwoven fabric to create a plurality of discrete chemical adhesive sites on the first side of the composite nonwoven fabric.

[0022] Item 18. A method for finishing composite nonwoven fabrics according to Item 17, wherein the chemical adhesive is applied using a gravure printing process.

[0023] Item 19. A method for finishing composite nonwoven fabrics according to any one of Items 17 to 18, wherein the chemical adhesive is applied using a digital printing process.

[0024] Item 20. A method for finishing a composite nonwoven fabric according to any one of Items 17 to 19, wherein the chemical adhesive is not applied to the second side of the composite nonwoven fabric.

[0025] Item 21. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side; a second entangled fiber web forming at least partially the second side; an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with fibers of the second entangled fiber web; and a plurality of discrete thermal bonding sites, each of the plurality of discrete thermal bonding sites comprising a thermal bonding structure located between the first side and the second side, wherein fibers from the first entangled fiber web extend from each of the thermal bonding structures.

[0026] Item 22. The composite nonwoven fabric according to Item 21, wherein each of the thermally bonded structures is offset relative to the first surface in a direction extending toward the second surface, and wherein each of the thermally bonded structures is offset relative to the second surface in a direction extending toward the first surface.

[0027] Item 23. A composite nonwoven fabric according to any one of Items 21 to 22, wherein the first average depth of the offset relative to the first surface is different from the second average depth of the offset relative to the second surface.

[0028] Item 24. A composite nonwoven fabric according to any one of items 21 to 23, wherein each of the thermally bonded structures comprises fibers in the form of a film from at least the first entangled fiber web.

[0029] Item 25. A composite nonwoven fabric according to any one of Items 21 to 24, wherein each of the thermally bonded structures comprises one or more of fibers in the form of a film from the second entangled fiber web and a portion of the film-formed portion of the elastomer layer.

[0030] Item 26. A composite nonwoven fabric according to any one of items 21 to 25, wherein the distance between adjacent discrete thermal bonding sites is less than the fiber length in at least the first entangled fiber web.

[0031] Item 27. A nonwoven garment article having an outward-facing surface and an opposing inward-facing surface, the nonwoven garment article comprising: a first entangled fiber web at least partially forming the outward-facing surface; a second entangled fiber web at least partially forming the inward-facing surface; an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with at least some fibers of the second entangled fiber web; and a first plurality of discrete thermal bonding sites located at a first position on the nonwoven garment article, each of the first plurality of discrete thermal bonding sites comprising a first thermal bonding structure offset relative to the outward-facing surface in a direction extending toward the inward-facing surface, each of the first thermal bonding structures comprising fibers in the form of a film from the first entangled fiber web.

[0032] Item 28. The nonwoven garment article according to Item 27, wherein the outward-facing surface further includes a second plurality of discrete thermal bonding sites located at a second position on the nonwoven garment article, the second position being different from the first position.

[0033] Item 29. The nonwoven garment article according to Item 28, wherein the density of the first plurality of discrete thermal bonding sites is different from the density of the second plurality of discrete thermal bonding sites.

[0034] Item 30. A nonwoven garment article according to any one of items 27 to 29, wherein the first average depth of the offset of the first thermally bonded structure relative to the outward-facing surface is different from the second average depth of the offset of the first thermally bonded structure relative to the inward-facing surface.

[0035] Item 31. A nonwoven garment article according to any one of items 27 to 30, wherein fibers from the first entangled fiber web extend from each of the first thermally bonded structures.

[0036] Item 32. The nonwoven garment article according to any one of items 27 to 31, wherein each of the first thermally bonded structures comprises one or more of fibers in the form of a film from the second entangled fiber web and a portion of the film-formed portion of the elastomer layer.

[0037] Item 33. A nonwoven garment article according to any one of items 27 to 32, wherein the distance between adjacent discrete thermal bonding sites of the first plurality of discrete thermal bonding sites is less than at least the fiber length in the first entangled fiber web.

[0038] Item 34. A method for finishing a composite nonwoven fabric, the composite nonwoven fabric comprising a first entangled fiber web forming at least partially a first side of the composite nonwoven fabric, a second entangled fiber web forming at least partially an opposing second side of the composite nonwoven fabric, and an elastomer layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers from the first entangled fiber web extend through the elastomer layer and become entangled with fibers of the second entangled fiber web, the method comprising: forming a plurality of discrete thermal bonding sites in a first predetermined pattern, each of the plurality of discrete thermal bonding sites comprising a thermal bonding structure offset relative to the first side in a direction extending toward the second side, each of the thermal bonding structures comprising fibers in the form of a film from at least the first entangled fiber web.

[0039] Item 35. A method for finishing composite nonwoven fabrics according to Item 34, wherein the plurality of discrete thermal bonding sites are formed using an ultrasonic bonding system comprising an impression roller and an ultrasonic welding head.

[0040] Item 36. The method for finishing a composite nonwoven fabric according to Item 35, wherein the composite nonwoven fabric is positioned in the ultrasonic bonding system such that the first side of the composite nonwoven fabric contacts the impression roller, and the second side of the composite nonwoven fabric contacts the ultrasonic welding head.

[0041] Item 37. The method for finishing a composite nonwoven fabric according to Item 35, wherein the composite nonwoven fabric is positioned in the ultrasonic bonding system such that the second side of the composite nonwoven fabric contacts the impression roller, and the first side of the composite nonwoven fabric contacts the ultrasonic welding head.

[0042] Item 38. A method for finishing a composite nonwoven fabric according to any one of items 34 to 37, wherein fibers from the first entangled fiber web extend from each of the thermally bonded structures.

[0043] Item 39. A method for finishing a composite nonwoven fabric according to any one of Items 34 to 38, wherein each of the thermally bonded structures is offset relative to the second surface in a direction extending toward the first surface.

[0044] Item 40. The method for finishing composite nonwoven fabrics according to Item 39, wherein the first average depth of the offset relative to the first surface is different from the second average depth of the offset relative to the second surface.

[0045] Item 41. A composite nonwoven fabric having an asymmetrical finish on a first side and an opposite second side, the asymmetrical finish composite nonwoven fabric comprising: a first entangled fiber web, the first entangled fiber web having a density of 1 cm... 2 Having the first number of fibers and per cm 2 A second number of fibers having a second denier, wherein the ratio of the first denier to the second denier is in the range of about 1.5:1 to about 2:1, the first entangled fiber web at least partially forming the first face; a second entangled fiber web, the second entangled fiber web per cm 2 The third number of fibers with a third denier and per cm 2 The second entangled fiber web at least partially forms the second face, wherein the ratio of the third denier to the fourth denier is in the range of about 0.3:1 to about 0.7:1; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the second entangled fiber web.

[0046] Item 42. A composite nonwoven fabric with an asymmetric finish according to Item 41, wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the first entangled fiber web.

[0047] Item 43. The composite nonwoven fabric with an asymmetric finish according to any one of Items 41 to 42 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0048] Item 44. A composite nonwoven fabric with an asymmetric finish according to Item 43, wherein the third entangled fiber web per cm 2 Including the fifth denier of the fifth number of fibers and per cm 2 The sixth number of fibers includes a sixth denier, wherein the ratio of the fifth denier to the sixth denier is in the range of about 1.5:1 to about 2:1.

[0049] Item 45. A composite nonwoven fabric with an asymmetric finish according to any one of items 43 to 44, wherein the third entangled fiber web is located between the first entangled fiber web and the elastomer layer.

[0050] Item 46. A composite nonwoven fabric with an asymmetric finish according to any one of items 43 to 44, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0051] Item 47. A composite nonwoven fabric with an asymmetric finish according to any one of items 43 to 46, wherein at least some fibers of the third entangled fiber web extend through the elastomeric layer.

[0052] Item 48. A composite nonwoven fabric with an asymmetric finish according to any one of items 43 to 47, wherein at least some fibers of the third entangled fiber web are entangled with fibers of the first entangled fiber web and fibers of the second entangled fiber web.

[0053] Item 49. A composite nonwoven fabric having an asymmetrical finish on a first side and an opposite second side, the asymmetrical finish composite nonwoven fabric comprising: a first entangled fiber web, the first entangled fiber web having a density of 1 cm... 2 The first number of fibers having a denier from about 1.2D to about 3.5D and per cm 2 The second number of fibers having a denier from about 0.6D to about 1D, per cm 2 The first number of fibers is more than per cm 2 The second number of fibers, wherein the first entangled fiber web at least partially forms the first surface; the second entangled fiber web, wherein the second entangled fiber web per cm 2 It has a third number of fibers with a denier ranging from about 0.6D to about 1D and per cm 2 Fibers with a denier ranging from about 1.2D to about 3.5D, per cm 2 The third number of fibers is more than per cm 2 The fourth number of fibers, wherein the second entangled fiber web at least partially forms the second surface; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the second entangled fiber web.

[0054] Item 50. A composite nonwoven fabric with an asymmetric finish according to Item 49, wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the first entangled fiber web.

[0055] Item 51. The composite nonwoven fabric with an asymmetric finish according to any one of Items 49 to 50, further comprising a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0056] Item 52. A composite nonwoven fabric with an asymmetric finish according to Item 51, wherein the third entangled fiber web per cm 2 This includes fibers with denier ranging from about 1.2D to about 3.5D and per cm 2Includes fibers with denier ranging from about 0.6D to about 1D, per cm 2 The fifth number of fibers is more than per cm 2 The sixth number of fibers.

[0057] Item 53. A composite nonwoven fabric with an asymmetric finish according to any one of Items 51 to 52, wherein the third entangled fiber web is located between the first entangled fiber web and the elastomer layer.

[0058] Item 54. A composite nonwoven fabric with an asymmetric finish according to any one of Items 51 to 52, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0059] Item 55. A composite nonwoven fabric with an asymmetric finish according to any one of items 51 to 54, wherein at least some fibers of the third entangled fiber web extend through the elastomeric layer.

[0060] Item 56. A composite nonwoven fabric with an asymmetric finish according to any one of items 51 to 55, wherein at least some fibers of the third entangled fiber web are entangled with fibers of the first entangled fiber web and fibers of the second entangled fiber web.

[0061] Item 57. A method of manufacturing a composite nonwoven fabric with an asymmetric finish, comprising: positioning an elastomer layer between a first fiber web having a denier of about 1.2D to about 3.5D and a second fiber web having a denier of about 0.6D to about 1D; and mechanically entangled a plurality of fibers of the first fiber web and a plurality of fibers of the second fiber web such that the first fiber web becomes a first entangled fiber web and the second fiber web becomes a second entangled fiber web, wherein after the mechanical entanglement step, at least some fibers of the first entangled fiber web and at least some fibers of the second entangled fiber web extend through the elastomer layer, and wherein the first entangled fiber web at least partially forms a first side of the composite nonwoven fabric with an asymmetric finish, and the second entangled fiber web at least partially forms an opposing second side of the composite nonwoven fabric with an asymmetric finish.

[0062] Item 58. The method for manufacturing a composite nonwoven fabric with an asymmetric finish according to Item 57 further includes: positioning a third fiber web between the first fiber web and the second fiber web before mechanically entangled the plurality of fibers of the first fiber web and the plurality of fibers of the second fiber web; and mechanically entangled the plurality of fibers of the third fiber web with the fibers of the first fiber web and the fibers of the second fiber web, such that the third fiber web becomes a third entangled fiber web.

[0063] Item 59. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to Item 58, wherein the third fiber web comprises a denier from about 1.2D to about 3.5D.

[0064] Item 60. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of Items 58 to 59, wherein at least some fibers of the third entangled fiber web extend through the elastomeric layer.

[0065] Item 61. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web at least partially forming the first side; a second entangled fiber web, wherein at least a portion of the fibers in the second entangled fiber web comprises silicone-coated fibers, the second entangled fiber web at least partially forming the second side; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers in the first entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the second entangled fiber web.

[0066] Item 62. The composite nonwoven fabric according to Item 61, wherein at least some fibers in the second entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the first entangled fiber web.

[0067] Item 63. The composite nonwoven fabric according to any one of Items 61 to 62, wherein at least a portion of the fibers of the first entangled fiber web comprises silicone-coated fibers.

[0068] Item 64. A composite nonwoven fabric according to any one of Items 61 to 63, wherein the second entangled fiber web per cm 2 The number of silicone-coated fibers is greater than that of the first entangled fiber web per cm. 2 The number of silicone-coated fibers.

[0069] Item 65. The composite nonwoven fabric according to Item 61 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers in the third entangled fiber web extend through the elastomeric layer and are entangled with one or more fibers of the first entangled fiber web and the second entangled fiber web.

[0070] Item 66. The composite nonwoven fabric according to Item 65, wherein at least a portion of the fibers of the third entangled fiber web comprises silicone-coated fibers.

[0071] Item 67. A composite nonwoven fabric according to any one of Items 65 to 66, wherein the third entangled fiber web per cm 2The number of silicone-coated fibers is less than that of the second entangled fiber web per cm. 2 The number of silicone-coated fibers.

[0072] Item 68. A composite nonwoven fabric comprising: two or more entangled fiber webs; and an elastomer layer, wherein at least some fibers of the two or more entangled fiber webs extend through the elastomer layer, and wherein the composite nonwoven fabric comprises, by weight, from about 10% to about 25% silicone-coated fibers.

[0073] Item 69. The composite nonwoven fabric according to Item 68, wherein the two or more entangled fiber webs include a first entangled fiber web that at least partially forms a first side of the composite nonwoven fabric and a second entangled fiber web that at least partially forms an opposing second side of the composite nonwoven fabric.

[0074] Item 70. The composite nonwoven fabric according to Item 69, wherein the elastomer layer is located between the first entangled fiber web and the second entangled fiber web.

[0075] Item 71. The composite nonwoven fabric according to any one of Items 68 to 70 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0076] Item 72. The composite nonwoven fabric according to Item 71, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0077] Item 73. A method of manufacturing a composite nonwoven fabric, comprising: positioning an elastomer layer between a first fiber web and a second fiber web, wherein the second fiber web comprises, by weight, from about 10% to about 100% silicone-coated fibers; and mechanically entangled at least some fibers of the first fiber web and at least some fibers of the second fiber web such that the first fiber web becomes a first entangled fiber web and the second fiber web becomes a second entangled fiber web, wherein after the mechanical entanglement step, at least some fibers of the first entangled fiber web extend through the elastomer layer, and wherein the first entangled fiber web at least partially forms a first side of the composite nonwoven fabric, and the second entangled fiber web at least partially forms an opposing second side of the composite nonwoven fabric.

[0078] Item 74. The method of manufacturing a composite nonwoven fabric according to Item 73, wherein the first fiber web does not include silicone-coated fibers.

[0079] Item 75. A method for manufacturing a composite nonwoven fabric according to any one of Items 73 to 74, wherein the silicone-coated fiber comprises polyethylene terephthalate (PET) silicone-coated fiber.

[0080] Item 76. A method for manufacturing a composite nonwoven fabric according to any one of items 73 to 75, further comprising: positioning a third fiber web between the first fiber web and the second fiber web before mechanically entangled said at least some fibers of the first fiber web and said at least some fibers of the second fiber web; and mechanically entangled said at least some fibers of the third fiber web with the fibers of the first fiber web and the fibers of the second fiber web, such that said third fiber web becomes a third entangled fiber web.

[0081] Item 77. The method of manufacturing a composite nonwoven fabric according to Item 76, wherein the third fiber web is located between the second fiber web and the elastomer layer.

[0082] Item 78. A method for manufacturing a composite nonwoven fabric according to any one of Items 76 to 77, wherein the third fiber web does not include silicone-coated fibers.

[0083] Item 79. A method for manufacturing a composite nonwoven fabric according to any one of Items 76 to 78, wherein the third fiber web comprises polyethylene terephthalate (PET) fibers.

[0084] Item 80. A method for manufacturing a composite nonwoven fabric according to any one of Items 73 to 79, wherein the first fiber web comprises polyethylene terephthalate (PET) fibers.

[0085] Item 81. A composite nonwoven fabric comprising: at least one fiber web and an elastomer layer, said composite nonwoven fabric having: a basis weight from about 40 g / m² to about 250 g / m²; thermal resistance from about 55 RCT to about 90 RCT; an increase of about 10% in the rest length in the machine direction less than or equal to that in the machine transverse direction; an increase of about 10% in the rest width less than or equal to that in the machine transverse direction; and resilience in the machine direction and the machine transverse direction within about 10% of said rest length and said rest width.

[0086] Item 82. The composite nonwoven fabric according to Item 81, wherein the basis weight is from about 150 gsm to about 190 gsm.

[0087] Item 83. A composite nonwoven fabric according to any one of Items 81 to 82, wherein the at least one fiber web comprises at least a first entangled fiber web and a second entangled fiber web, wherein the elastomeric layer is located between the first entangled fiber web and the second entangled fiber web.

[0088] Item 84. The composite nonwoven fabric according to Item 83, wherein the at least one fiber web further comprises a third entangled fiber web located between the second entangled fiber web and the elastomer layer.

[0089] Item 85. A composite nonwoven fabric according to any one of Items 83 to 84, wherein the first entangled fiber web at least partially forms a first side of the composite nonwoven fabric, and wherein the second entangled fiber web at least partially forms an opposing second side of the composite nonwoven fabric.

[0090] Item 86. A composite nonwoven fabric according to any one of items 83 to 85, wherein at least some fibers of the first entangled fiber web and at least some fibers of the second entangled fiber web extend through the elastomeric layer.

[0091] Item 87. The composite nonwoven fabric according to any one of items 81 to 86 further has a thickness from about 1.5 mm to about 3 mm.

[0092] Item 88. The composite nonwoven fabric according to any one of items 81 to 87 further has a stiffness from about 0.1 kgf to about 0.4 kgf.

[0093] Item 89. A composite nonwoven fabric comprising: at least one fiber web and an elastomer layer, said composite nonwoven fabric having: a thickness from about 1.5 mm to about 3 mm; thermal resistance from about 55 RCT to about 90 RCT; an increase of about 10% in the machine direction less than or equal to the rest length; an increase of about 10% in the machine transverse direction less than or equal to the rest width; and resilience in the machine direction and the machine transverse direction within about 10% of said rest length and said rest width.

[0094] Item 90. The composite nonwoven fabric according to Item 89 also has a basis weight between about 40 grams per square meter (gsm) and about 250 gsm.

[0095] Item 91. The composite nonwoven fabric according to Item 90, wherein the basis weight is from about 150 gsm to about 190 gsm.

[0096] Item 92. The composite nonwoven fabric according to any one of Items 89 to 91 further has a stiffness from about 0.1 kgf to about 0.4 kgf.

[0097] Item 93. A composite nonwoven fabric according to any one of Items 89 to 92, wherein the at least one fiber web comprises at least a first entangled fiber web and a second entangled fiber web, and wherein the elastomeric layer is located between the first entangled fiber web and the second entangled fiber web.

[0098] Item 94. The composite nonwoven fabric according to Item 93, wherein the at least one fiber web further comprises a third entangled fiber web located between the first entangled fiber web and the elastomer layer.

[0099] Item 95. A method of manufacturing a composite nonwoven fabric, comprising: positioning an elastomer layer between at least a first fiber web and a second fiber web; selecting entanglement parameters to produce the composite nonwoven fabric having a basis weight from about 40 g / m² to about 250 g / m² and a thermal resistance from about 55 RCT to about 90 RCT; and mechanically entangled the fibers of the first fiber web and the fibers of the second fiber web based on the selected entanglement parameters.

[0100] Item 96. The method for manufacturing a composite nonwoven fabric according to Item 95 further includes: positioning a third fiber web between the first fiber web and the second fiber web prior to the mechanical entanglement step; and mechanically entangled fibers from the third fiber web with fibers from the first fiber web and fibers from the second fiber web based on the selected entanglement parameters.

[0101] Item 97. The method of manufacturing a composite nonwoven fabric according to Item 96, wherein the basis weight of each of the elastomer layer, the first fiber web, the second fiber web and the third fiber web is from about 20 grams per square meter (gsm) to about 150 gsm.

[0102] Item 98. A method for manufacturing a composite nonwoven fabric according to any one of items 95 to 97, wherein the entanglement parameters are further selected to achieve a stiffness from about 0.1 kgf to about 0.4 kgf.

[0103] Item 99. A method for manufacturing a composite nonwoven fabric according to any one of Items 95 to 98, wherein the entanglement parameters are further selected to achieve a thickness from about 1.5 mm to about 3 mm.

[0104] Item 100. A method for manufacturing a composite nonwoven fabric according to any one of items 95 to 99, wherein at least some fibers in the first fiber web and at least some fibers in the second fiber web extend through the elastomeric layer after a mechanical entanglement step.

[0105] Item 101. A composite nonwoven fabric with an asymmetric finish, comprising: a first face at least partially formed of a first entangled fiber web, the first face having a first color characteristic and a second color characteristic different from the first color characteristic; an opposing second face at least partially formed of a second entangled fiber web, the second face having the first color characteristic and the second color characteristic, wherein a greater number of fibers having the second color characteristic per unit area are present on one of the first face or the second face compared to the opposing face; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the second entangled fiber web, and wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the first entangled fiber web.

[0106] Item 102. The composite nonwoven fabric with an asymmetric finish according to Item 101 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0107] Item 103. The composite nonwoven fabric with an asymmetric finish according to Item 102, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0108] Item 104. A composite nonwoven fabric with an asymmetric finish according to any one of Items 102 to 103, wherein at least some fibers of the third entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the second entangled fiber web.

[0109] Item 105. A composite nonwoven fabric with an asymmetric finish according to any one of items 102 to 104, wherein at least some fibers of the third entangled fiber web are entangled with the fibers of the first entangled fiber web.

[0110] Item 106. A composite nonwoven fabric with an asymmetric finish according to any one of items 101 to 105, wherein the elastomer layer includes the first color characteristic.

[0111] Item 107. A composite nonwoven fabric with an asymmetric finish, comprising: a first face at least partially formed of a first entangled fiber web, the first face having a first color characteristic and a second color characteristic different from the first color characteristic; an opposing second face at least partially formed of a second entangled fiber web, the second face having the first color characteristic and the second color characteristic, wherein a greater number of fibers having the second color characteristic per unit area are present on one of the first face or the second face compared to the opposing face; a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web, at least some fibers of the second entangled fiber web, and at least some fibers of the third entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the corresponding other entangled fiber webs.

[0112] Item 108. A composite nonwoven fabric with an asymmetric finish according to Item 107, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0113] Item 109. A method for manufacturing a composite nonwoven fabric with an asymmetric finish, comprising: positioning a third fiber web having a second color characteristic between a first fiber web having a first color characteristic and a second fiber web having the first color characteristic; positioning an elastomer layer having the first color characteristic between the first fiber web and the second fiber web; and mechanically entangled a first number of fibers of the third fiber web with at least some fibers of the first fiber web, and mechanically entangled a second number of fibers of the third fiber web with at least some fibers of the second fiber web.

[0114] Item 110. The method of manufacturing a composite nonwoven fabric with an asymmetric finish according to Item 109, wherein the third fiber web is located between the second fiber web and the elastomer layer.

[0115] Item 111. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of items 109 to 110, wherein the fibers of the third fiber web have a denier from about 1.2D to about 3.5D.

[0116] Item 112. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of items 109 to 111, wherein the fibers of the first fiber web have a denier from about 1.2D to about 3.5D.

[0117] Item 113. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of items 109 to 112, wherein the fibers of the second fiber web have a denier from about 0.6D to about 1D.

[0118] Item 114. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of items 109 to 113, wherein the fibers of each of the first fiber web, the second fiber web, and the third fiber web are pre-dyed such that the fibers of the first fiber web have the first color characteristic, the fibers of the second fiber web have the first color characteristic, and the fibers of the third fiber web have the second color characteristic.

[0119] Item 115. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of items 109 to 114, wherein the fibers of each of the first fiber web, the second fiber web, and the third fiber web are polyethylene terephthalate (PET) fibers.

[0120] Item 116. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of items 109 to 115, wherein the composite nonwoven fabric with the asymmetrical finish is not dyed after weaving.

[0121] Item 117. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of items 109 to 116, wherein mechanical entanglement includes needle punching.

[0122] Item 118. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of items 109 to 117, wherein after a mechanical entanglement step, the first fiber web becomes a first entangled fiber web having a first stitch density, and the second fiber web becomes a second entangled fiber web having a second stitch density less than the first stitch density.

[0123] Item 119. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to Item 118, wherein a first entangled fiber web at least partially forms a first side of the composite nonwoven fabric with an asymmetric finish, and wherein a second entangled fiber web at least partially forms a second side of the composite nonwoven fabric with an asymmetric finish.

[0124] Item 120. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to Item 119, wherein after a mechanical entanglement step, the first face has the first color characteristic and the second color characteristic, and the second face has the first color characteristic and the second color characteristic, wherein a greater number of fibers per unit area having the second color characteristic are present on one of the first face or the second face compared to the opposite face. Attached Figure Description

[0125] Examples of various aspects of this article are described in detail below with reference to the accompanying drawings, in which:

[0126] Figure 1 The illustration shows an example lifecycle of an example composite nonwoven fabric according to various aspects of this article;

[0127] Figure 2 The diagram illustrates the various aspects used in this article. Figure 1 Example of a composite nonwoven fabric with a first web of fibers;

[0128] Figure 3 The diagram illustrates the various aspects used in this article. Figure 1 Example of a second fiber web in a composite nonwoven fabric;

[0129] Figure 4 The diagram illustrates the various aspects used in this article. Figure 1 Example of a third fiber web in a composite nonwoven fabric;

[0130] Figure 5 The diagram illustrates the various aspects used in this article. Figure 1 An example of an elastomer layer in a composite nonwoven fabric;

[0131] Figure 6 The illustrations depict various aspects of manufacturing according to this article. Figure 1 Example manufacturing process of composite nonwoven fabrics;

[0132] Figure 7 The diagram illustrates various aspects based on this article. Figure 1 The first side of an example composite nonwoven fabric;

[0133] Figure 8 The diagram illustrates various aspects based on this article. Figure 1 Example of a composite nonwoven fabric with opposite second sides;

[0134] Figure 9 The diagram illustrates various aspects based on this article. Figure 7 Example cross-sectional view of a composite nonwoven fabric;

[0135] Figure 10 The illustration shows a cross-sectional view of an alternative construction of an example composite nonwoven fabric according to various aspects of this article;

[0136] Figure 11 The illustration depicts only silicone-coated fibers according to various aspects of this article. Figure 9 Cross-sectional view;

[0137] Figure 12 An example manufacturing process for manufacturing an example composite nonwoven fabric with pile, according to various aspects of this article, is illustrated.

[0138] Figure 13 The diagram illustrates the use of various aspects of this article. Figure 12 The first side of an example composite nonwoven fabric produced by the manufacturing process;

[0139] Figure 14 The diagram illustrates various aspects based on this article. Figure 13 The second side of an example composite nonwoven fabric;

[0140] Figure 15 The diagram illustrates various aspects based on this article. Figure 13 Example cross-sectional view of a composite nonwoven fabric;

[0141] Figure 16 The diagram illustrates various aspects based on this article. Figure 1 The first side of an example composite nonwoven fabric has a first color characteristic and a second color characteristic;

[0142] Figure 17 The diagram illustrates various aspects based on this article. Figure 16 Example of a composite nonwoven fabric with opposite second sides;

[0143] Figure 18 The diagram illustrates various aspects based on this article. Figure 16 Example cross-sectional view of a composite nonwoven fabric;

[0144] Figure 19 The diagram illustrates various aspects based on this article. Figure 1 Example of a composite nonwoven fabric on the first side at the first time point;

[0145] Figure 20 The diagram illustrates various aspects based on this article. Figure 19 The example composite nonwoven fabric shown is on the first side at the second time point;

[0146] Figure 21 The diagram illustrates various aspects based on this article. Figure 1 Example of a composite nonwoven fabric on the second side at the first time point;

[0147] Figure 22 The diagram illustrates various aspects based on this article. Figure 21 The example composite nonwoven fabric shown is on the second side at the second time point;

[0148] Figure 23 The diagram illustrates the various aspects of this article from the first time point. Figure 1 Example: the outward-facing surface of a garment article formed from a composite nonwoven fabric;

[0149] Figure 24 The diagram illustrates various aspects based on this article. Figure 23 The outward-facing surface of clothing items at the second point in time;

[0150] Figure 25 The diagram illustrates various aspects based on this article. Figure 23 The inward-facing surface of clothing and items at the first point in time;

[0151] Figure 26 The diagram illustrates various aspects based on this article. Figure 25 The inward-facing surface of the clothing item shown at the second time point;

[0152] Figure 27 The illustration shows an example upper garment formed from the example composite nonwoven fabric described herein, according to various aspects thereof;

[0153] Figure 28 The illustration shows an example lower garment formed from an example composite nonwoven fabric described herein, according to various aspects thereof;

[0154] Figure 29 An example gravure printing system for applying a chemical adhesive to the first side of an example composite nonwoven fabric described herein, according to various aspects thereof;

[0155] Figure 30 The diagram illustrates various aspects based on this article. Figure 29 Example pattern of the gravure printing roller in an example gravure printing system;

[0156] Figure 31 The diagram illustrates the use of various aspects according to this article. Figure 29 Example gravure printing system for the first side of composite nonwoven fabric after the application of chemical adhesives;

[0157] Figure 32 The diagram illustrates various aspects based on this article. Figure 31 The opposite second side of the composite nonwoven fabric;

[0158] Figure 33 The diagram illustrates various aspects based on this article. Figure 31 The cross-section of the composite nonwoven fabric;

[0159] Figure 34 The illustration shows a rear view of an upper garment with areas having chemical adhesive sites, according to various aspects of this article.

[0160] Figure 35 The illustration shows a front view of a lower garment with areas having chemical adhesive sites, according to various aspects of this article.

[0161] Figure 36 An example ultrasonic bonding system for forming thermal bonding sites on an example composite nonwoven fabric described herein, according to various aspects thereof;

[0162] Figure 37 The diagram illustrates the use of various aspects of this article. Figure 36 Example of an ultrasonic bonding system forming thermal bonding sites on the first side of a composite nonwoven fabric;

[0163] Figure 38 The illustration depicts the thermal bonding sites according to various aspects of this paper. Figure 37 The opposite second side of the composite nonwoven fabric;

[0164] Figure 39 The diagram illustrates various aspects based on this article. Figure 37 The cross-section of the composite nonwoven fabric;

[0165] Figure 40 The illustrations show the usability of various aspects according to this article. Figure 36 Example of an ultrasonic bonding system forming two sets of thermal bonding sites on the first side of an example composite nonwoven fabric;

[0166] Figure 41 The illustration depicts two sets of thermal bonding sites, based on various aspects described in this paper. Figure 40 The opposite second side of the composite nonwoven fabric;

[0167] Figure 42 The diagram illustrates various aspects based on this article. Figure 40 The cross-section of the composite nonwoven fabric;

[0168] Figure 43 The illustration shows a rear view of an upper garment with areas having thermal bonding sites, according to various aspects of this article.

[0169] Figure 44 The illustration shows a front view of a lower garment with thermal bonding sites applied according to various aspects of this article;

[0170] Figure 45 The illustration shows the first side of an example composite nonwoven fabric having thermal bonding sites and chemical bonding sites according to various aspects of this article;

[0171] Figure 46 The illustration depicts the thermal bonding sites according to various aspects of this paper. Figure 45 The opposite second side of the composite nonwoven fabric;

[0172] Figure 47 The diagram illustrates various aspects based on this article. Figure 45 The cross-section of the composite nonwoven fabric;

[0173] Figure 48 The illustration shows a schematic diagram of an example two-step mechanical entanglement process for reducing lint formation on the first surface of an example composite nonwoven fabric, according to various aspects of this article.

[0174] Figure 49 The diagram illustrates various aspects based on this article. Figure 48 The first side of the composite nonwoven fabric after the two-step mechanical entanglement process;

[0175] Figure 50 The diagram illustrates various aspects based on this article. Figure 49 The opposing second side of the composite nonwoven fabric; and

[0176] Figure 51 The diagram illustrates various aspects based on this article. Figure 49 The cross-section of the composite nonwoven fabric. Detailed Implementation

[0177] This document specifically describes the subject matter of the invention to meet 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” are used herein to refer to different elements of the method employed, these terms should not be construed as implying any particular order among or between the various steps disclosed herein, unless and except as expressly stated.

[0178] Traditional nonwoven fabrics are generally unsuitable for apparel due to their lack of tensile and recovery properties, heavy weight, poor drape, rough hand feel, and lack of insulation performance in some applications requiring enhanced insulation. Furthermore, traditional nonwoven fabrics often have symmetrical faces or sides to provide a uniform fabric suitable for industries such as cleaning and personal hygiene. However, having a uniform face may not be suitable for apparel because the fabric surface facing the wearer's skin and the fabric surface exposed to the external environment may require different properties.

[0179] This document relates to recyclable asymmetrical finish composite nonwoven fabrics suitable for clothing and other articles, and methods for producing the same. In an example, the asymmetrical finish composite nonwoven fabric comprises a first side formed at least partially of a first entangled fiber web and an opposing second side formed at least partially of a second entangled fiber web. When formed into clothing articles, the first side forms the outward-facing surface of the clothing article, and the second side forms the inward-facing surface. When the asymmetrical finish composite nonwoven fabric is formed into clothing articles, the first entangled fiber web may have characteristics that make it suitable for exposure to the external environment. For example, the fibers forming the first entangled web may have a denier approximately twice that of the fibers used to form the second entangled web, such that the first entangled web can better withstand abrasion forces without fiber breakage.

[0180] When asymmetrically finished composite nonwoven fabrics are formed into garment articles, the characteristics of the second entangled fiber web make it suitable for forming the skin-facing surface. For example, the fibers forming the second entangled web may have a denier that is about half that of the fibers used to form the first entangled web, because the second side may be less exposed to abrasive forces. Furthermore, a lower denier can produce a softer hand feel, making it comfortable for skin or near-skin contact. Additionally, the second entangled web may include silicone-coated fibers, which also impart a soft hand feel and improve the fabric's drape (i.e., make the fabric less stiff).

[0181] In a further example, the second side may include loops and / or fiber ends that extend away from the second side in a direction perpendicular to the surface plane of the second side to form a pile. For example, the loops and / or fiber ends may extend from the second side from about 1.5 mm to about 8.1 mm. The pile helps trap air heated by the wearer, thereby improving the thermal insulation properties of the nonwoven fabric. The pile also provides additional comfort for the wearer.

[0182] In a further aspect, asymmetrically finished composite nonwoven fabrics can also include different color characteristics associated with the first and second sides. In one aspect, the color characteristics can take the form of a more pronounced color blending effect on one side than on the other. Different color characteristics can impart the desired aesthetic to garments formed from nonwoven fabrics and can also provide the wearer with a visual indication of which side of the garment faces outwards and which side faces inwards. Different color characteristics may also make garments suitable for reversible wear (i.e., "inside out"). For example, different color characteristics can be imparted to the sides by selecting specific colors for the fibers forming different layers of the fabric and / or by selecting entanglement parameters, such that colored fibers selectively move to the first side relative to the second side, or vice versa.

[0183] Asymmetric finish composite nonwoven fabrics may also include an elastomeric layer located between a first entangled fiber web and a second entangled fiber web. The elastomeric layer imparts tensile and recovery properties to the composite nonwoven fabric, making it suitable for apparel products such as tops and bottoms. The elastomeric layer itself may lack sufficient tensile strength to withstand normal abrasion and tearing. Therefore, the elastomeric layer is integrated into the composite nonwoven fabric by using an entanglement process to extend fibers from different webs through the elastomeric layer to create a cohesive structure.

[0184] In some examples, composite nonwoven fabrics include additional entangled webs (e.g., third entangled fiber webs, fourth entangled fiber webs, etc.) layered together with elastomer layers. The weight of the web before entanglement can be selected to achieve a lightweight composite nonwoven fabric with minimal thickness after entanglement. Furthermore, the selection of the number of entangled webs, fiber denier, fiber type, fiber length, etc., results in a composite nonwoven fabric that provides enhanced thermal insulation by trapping air between the fibers forming the fabric. Additionally, the properties and / or number of different fiber webs used to form the composite nonwoven fabric can be adjusted to achieve different desired final properties of the nonwoven fabric, including different desired final characteristics for each facet of the composite nonwoven fabric. The result is a lightweight, asymmetrically finished composite nonwoven fabric with excellent thermal properties, tensile and recovery properties, good drape, interesting visual appeal, good abrasion resistance, and a soft hand feel, making composite nonwoven fabrics ideal for making apparel suitable for sportswear.

[0185] The composite nonwoven fabrics envisioned in this paper can be finished in various ways. For example, the fabric can be printed with one or more patterns, graphics, logos, etc., using selected printing techniques. In one example, printing can be applied to one or more fiber webs before entanglement, allowing the printed components to be integrated into the nonwoven fabric during entanglement. When the nonwoven fabric is formed into a garment, different techniques can be used to sew the fabric edges together. For example, the fabric edges can overlap, and an entanglement process can be used to entangle the fibers from the fabric edges together, thereby forming a seam.

[0186] This paper further envisions that asymmetric-finished composite nonwoven fabrics are recyclable, and in some respects, the fabrics can be fully recyclable. Therefore, in various aspects, the fibers selected for forming the entangled web can include recycled materials, including recycled polyethylene terephthalate (PET) fibers, commonly referred to as polyester fibers. Additionally, the materials selected for forming the elastomer layer can also be fully recyclable. The use of recycled fibers and materials reduces the carbon footprint of the composite nonwoven fabric.

[0187] Asymmetric-finished composite nonwoven fabrics are formed by setting an elastomer layer between two or more fiber webs. The selection of different web properties, such as the number of webs, fiber denier, weight of a single web, fiber length, fiber color, and fiber coating, is based on the desired final properties of the asymmetric-finished composite nonwoven fabric. Once the elastomer layer is in place between the two or more fiber webs, a mechanical entanglement process is performed. In one example, the mechanical entanglement process is needle punching. Based on the desired final properties of the asymmetric-finished composite nonwoven fabric, different parameters associated with the needle punching process are selected, such as needle selection, needle density, penetration depth, penetration direction, and needle passes. For example, parameters can be selected to produce nonwoven fabrics with desired thickness, desired tensile and resilience, desired weight, desired drape, or desired stiffness, etc.

[0188] The choice of different web properties, combined with needle-punching parameters, can result in asymmetry in nonwoven fabrics after washing and / or abrasion. In some respects, the asymmetry resulting from washing and / or abrasion may be a desired property. For example, the second side of a nonwoven fabric can pill to a greater extent than the first side. When nonwoven fabrics are incorporated into garment articles, this means that the inward-facing surface of the garment article can pill to a greater extent than the outward-facing surface. In an example, differential pilling may be due to the use of silicone-coated fibers for a second entangled web that partially forms the second side of the nonwoven fabric. The silicone coating can increase the tendency of fiber migration (i.e., reduce the frictional forces that keep the fibers entangled), causing the fiber ends to be exposed on the second side, thus forming pills. In an example, the presence of pills may be a desirable aesthetic, and factors and / or entanglement parameters associated with the choice of web can be adjusted to increase the likelihood of pill formation. Furthermore, having a greater number of pills on the inward-facing surface of garment articles formed from composite nonwoven fabrics can contribute to improved wearer comfort, similar to the comfort of wearing an old sweatshirt. In terms of examples, if pilling is not a desired property, composite nonwoven fabrics can undergo post-processing steps such as ironing, calendering, embossing, thermal bonding, and / or coating on the surface of the composite nonwoven fabric to increase pilling resistance.

[0189] Additional manufacturing steps can be implemented to achieve additional desired properties in the resulting nonwoven fabric. For example, the needle-punching process commonly used in the manufacture of Dilour carpets can be used to form pile on the second side of the nonwoven fabric instead of the first side. In this regard, in the needle-punching process, a brush is positioned adjacent to the second side of the nonwoven fabric. Needles are used to advance fibers and / or fiber loops from the fiber web into the brush and hold them in place until the needle-punching process is complete. When the nonwoven fabric is removed from the brush, the fibers and / or fiber loops held by the brush are oriented in a common direction perpendicular to the surface plane of the second side.

[0190] 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 sleeves, calf sleeves), footwear (such as shoe uppers), etc. The term "inward-facing surface" in relation to clothing articles refers to a surface configured to face the wearer's body surface, and the term "outward-facing surface" refers to a surface configured to face away from the wearer's body surface and towards the external environment, 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.

[0191] As used herein, the term "nonwoven fabric" refers to fibers held together by mechanical and / or chemical interactions without being knitted, woven, braided, or otherwise structured. In one specific aspect, a nonwoven fabric comprises an assembly of fibers mechanically manipulated to form a cushion-like material. In other words, a nonwoven fabric is made directly from fibers. Nonwoven fabrics can include different fiber webs forming a cohesive structure, wherein different fiber webs may have different or similar fiber compositions and / or different properties. The term "fiber web" refers to a layer prior to mechanical entanglement with one or more other fiber webs. A fiber web includes fibers that have undergone a carding and lapping process, which typically aligns the fibers in one or more common directions extending along the xy-plane and achieves the desired basis weight. Fiber webs may also undergo a light needle-punching process or a mechanical entanglement process, which entangles the fibers of the web to a degree that allows the fiber web to form a cohesive structure that can be manipulated (e.g., wound onto a roller, unwound from a roller, stacked, etc.). The fiber web may also undergo one or more additional processing steps, such as printing before entanglement with other fiber webs to form a composite nonwoven fabric. The term "entangled fiber web," when referring to composite nonwoven fabrics, refers to a fiber web that has been mechanically entangled with one or more other fiber webs. Therefore, an entangled fiber web can include fibers originally present in the fiber web of the forming layer, as well as fibers present in other fiber webs that have been moved into the entangled fiber web through the entanglement process.

[0192] The mechanical entanglement processes envisioned herein may include needle entanglement (commonly referred to as needle punching) using barbed or structured needles (e.g., forked needles), or fluid entanglement. In the aspects envisioned herein, needle punching can be utilized based on the small denier of the fibers used and the ability to fine-tune different parameters associated with the needle punching process. Needling typically uses barbed or spiked needles to reposition a proportion of fibers from a generally horizontal orientation (an orientation extending along the xy-plane) to a generally vertical orientation (z-direction orientation). Referring typically to the needle punching process, a carded, overlapped, and pre-needled fiber web can be stacked together with other carded, overlapped, and pre-needled fiber webs and other layers (such as elastomer layers), passing between a base plate and a stripper plate located on opposite sides of the stacked web configuration. Barbed needles fixed to the needle plate move in and out of the stacked web configuration, and after the needles have entered and exited the stacked web configuration, the stripper plate peels the fibers from the needles. The distance between the stripper plate and the base plate can be adjusted to control web compression during needle punching. As the stacked web configuration moves along the conveyor system in the machine direction, needle plates repeatedly engage and disengage with the stacked web configuration, thereby needle-punching the length of the stacked web configuration. Various aspects of this paper envision the use of multiple needle plates sequentially positioned at different points along the conveyor system, wherein as the stacked web configuration moves in the machine direction, different needle plates can engage the stacked web configuration from different faces (e.g., above and below the conveyor system). Each engagement of the needle plate with the stacked web configuration is referred to herein as a “pass”. Parameters associated with a particular needle plate can be adjusted to achieve desired properties of the resulting needle-punched nonwoven fabric (e.g., basis weight, thickness, etc.). Different parameters may include stitch density (SD) and penetration depth (PD), where stitch density is the depth per centimeter used during the entanglement process. 2 Number of stitches (n / cm) 2 Penetration depth is the distance the needle travels through the stacked mesh configuration before being pulled out. Parameters related to the needle punching process, such as the spacing between the base plate and the peeling plate, and the conveying speed of the stacked mesh configuration, can also typically be adjusted.

[0193] This paper envisions the use of barbed needles (needles with a predetermined number of barbs arranged along the length of the needle), although other needle types are also envisioned. As the barbs move from a first face to an opposing second face of a stacked mesh configuration, the barbs on the needle "capture" fibers. The movement of the needle through the stacked mesh configuration effectively moves or pushes the fibers captured by the barbs 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, thereby helping to "lock" the moved fibers into place by, for example, friction. This paper also envisions that these needles can pass through the stacked mesh configuration from the second face toward the first face. In an illustrative aspect, the number of barbs on the needle interacting with the fibers can be based on the depth of needle penetration. For example, when the penetration depth is a first amount, all barbs can interact with the fibers, while as the penetration depth decreases, fewer barbs can interact with the fibers. In a further illustrative aspect, the size of the barbs can be adjusted based on the denier of the fibers used in the mesh. For example, the barb size can be selected to engage with low denier (e.g., fine) fibers rather than high denier fibers, thereby causing selective movement of the low denier fibers rather than the high denier fibers. In another example, the barb size can be selected to engage with both low denier and high denier fibers, thereby causing both types of fibers to move through the web.

[0194] After entanglement, the nonwoven fabric may include a first face and an opposing second face, both of which face outward relative to the inner surface of the nonwoven fabric and encompass its outermost portion. Therefore, both the first and second faces are fully visible when the nonwoven fabric is observed. Both the first and second faces may extend along generally parallel and offset xy-planes. For example, the first face may be oriented in a first xy-plane, and the second face may be oriented in a second xy-plane, which is generally parallel to and offset from the first xy-plane.

[0195] As used herein, the term "elastomer layer" refers to a layer having tensile and recovery properties (i.e., elastic resilience) along at least one orientation axis, including layers having tensile and recovery properties along a single orientation axis and layers having tensile and recovery properties along multiple orientation axes. Examples of orientation axes include the length direction, width direction, x-direction, y-direction, and any direction offset at an angle from the length direction, width direction, x-direction, and y-direction. Elastomer layers can be formed from thermoplastic elastomers, such as thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), combinations of TPU and TPEE, etc. Elastomer layers can include spunbond layers, meltblown layers, films, webs, etc. In terms of examples, elastomer layers can include spunbond TPEE or meltblown TPU. Nonwoven elastomer materials, such as spunbond TPEE or meltblown TPU, allow for lower basis weights than elastomer films. Similarly, webs are generally more breathable and permeable due to their fibrous nature relative to films, and they are generally more flexible (i.e., less stiff) than films. These factors (low basis weight, breathability and permeability, flexibility) make them ideal for use in the example composite nonwoven fabrics described herein, especially in garments where these are desired characteristics.

[0196] 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 9,000 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 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. 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).

[0197] As used herein, the term "silicone-coated fiber" can refer to a fiber having a continuous silicone coating such that the silicone coating completely covers the fiber along its length. In one example, the fiber can form a core and the silicone can form a sheath surrounding the core. In other examples, the term "silicone-coated fiber" can refer to a fiber having an intermittent silicone coating in at least some regions along the fiber length. For example, the fiber can be sprayed with a silicone coating. In this regard, if a particular fiber web comprises 100% silicone-coated fiber by weight, it is contemplated that the fibers forming the web can have regions that do not contain a silicone coating. It is contemplated that the silicone-coated fiber is incorporated into the fiber web forming the composite nonwoven fabric. In other words, the silicone coating on the fiber is not applied to the fiber after the composite nonwoven fabric has been formed using, for example, a silicone spray finishing agent.

[0198] As used herein, the terms "color" or "color property" generally refer to the observable color of the fibers forming the fabric when referring to nonwoven fabrics. These aspects envision that the color can be any color that can be provided to the fiber using dyes, pigments, and / or colorants known in the art. Thus, fibers can be configured to have a color, including but not limited to red, orange, yellow, green, blue, indigo, purple, white, black, and their hues. In one example aspect, the fiber color can be imparted during fiber formation (often referred to as pre-spinning dyeing). In pre-spinning dyeing, the color is added to the fiber as it is extruded, such that the color is integrated into the fiber, rather than being added to the fiber in a post-forming step (e.g., by a post-weaving dyeing step).

[0199] 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.

[0200] 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.

[0201] 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).

[0202] 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, fiber ends migrate across the face of the nonwoven fabric and become entangled with other fiber ends due to forces (e.g., abrasive forces), thus forming pills. The pilling resistance of a fabric can be measured using standardized tests such as random tumbling and the Martindale pilling test. The term "pile" as used herein generally refers to the raised surface or pile of a fabric, consisting of upright loops and / or ends of fibers extending in a common direction from the fabric face.

[0203] This document provides various measurements of the web before entanglement and the resulting composite nonwoven fabric. The thickness of the resulting composite nonwoven fabric can be measured using a precision thickness gauge. For example, to measure thickness, the fabric can be placed on a flat anvil, and a pressure foot can be pressed onto the fabric from the top surface under a standard fixed load. The dial indicator on the precision thickness gauge provides a thickness indication in mm. Basis weight is measured using the ISO 3801 test standard 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 “stretch” 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 in this article, "resilience" refers to the ability of a fabric to recover to its original reference distance (i.e., its rest length or width), and is expressed as a percentage of the original reference distance. Thermal resistance, which typically corresponds to the insulation characteristic, is measured using the ISO 11092 test standard, with units of RCT (m²). 2 *K / W).

[0204] Unless otherwise stated, all measurements provided herein were taken at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar) with the nonwoven fabric in a static (unstretched) state.

[0205] Figure 1This is a schematic diagram of an example life cycle of the composite nonwoven fabric contemplated herein. Reference numeral 100 generally denotes a first fiber web 110, a second fiber web 112, a third fiber web 114, and an elastomer layer 116 in a stacked configuration prior to entanglement. Contemplated herein, in some example aspects, one or more fiber webs may be optional. In example aspects, the fibers used to form the first fiber web 110, the second fiber web 112, and the third fiber web 114 may include recycled fibers, specifically recycled PET fibers. Additionally, in example aspects, the elastomer layer 116 may be formed from recyclable materials. Arrow 118 schematically indicates the entanglement step, wherein the fibers in the first fiber web 110, the second fiber web 112, and the third fiber web 114 are entangled with each other such that one or more fibers extend through the elastomer layer 116 to form a cohesive composite nonwoven fabric 120. Arrow 122 schematically indicates the processing step, wherein the composite nonwoven fabric 120 is formed into a garment article 124. Although garment 124 is shown as upper garment, this document envisions that garment 124 could take other forms, such as lower garment, shoe uppers, hats, gloves, sleeves, etc. At the end of the service life of garment 124, it is envisioned that the wearer could return garment 124 to, for example, a manufacturer / retailer, where garment 124 could be fully recycled, as indicated by arrow 126, to form shredded fibers and / or re-extruded fibers, which are used to form fiber webs, such as fiber webs 110, 112, and 114, and possibly elastomer layers, such as elastomer layer 116, thereby forming a self-sustaining cycle. This self-sustaining cycle reduces the carbon impact typically associated with the manufacture of garments, including knitted, woven, and nonwoven garments.

[0206] Figure 2A first fiber web 110 is depicted prior to entanglement with other fiber webs. In an example aspect, properties associated with the first fiber web 110 can be selected to achieve the desired final properties of the composite nonwoven fabric 120. As described above, when entangled with other fiber webs, the first fiber web 110 is envisioned herein to form the first face of the composite nonwoven fabric 120. When the composite nonwoven fabric 120 is formed into a garment article, the first face is envisioned to form the outward-facing surface of the garment article, and in some respects, the outward-facing surface. Therefore, desired properties associated with the first fiber web 110 include, for example, durability and abrasion resistance, as well as humility. In an example aspect, the basis weight of the first fiber web 110 is from about 20 gsm to about 150 gsm, from about 35 gsm to about 65 gsm, from about 40 gsm to about 60 gsm, from about 45 gsm to about 55 gsm, or about 50 gsm. As used herein, unless otherwise stated, the term "about" generally means within ±10% of the indicated value. After the first fiber web 110 is bonded to other fiber webs and / or elastomer layers, a resulting nonwoven fabric with a basis weight within the desired range is provided for the first fiber web 110.

[0207] The first fiber web 110 is formed of fibers, such as fiber 210 (shown schematically), which may be oriented generally in a common direction or in two or more common directions due to carding and cross-lapping processes. In one example aspect, fiber 210 may include PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are contemplated herein. In one example aspect, fiber 210 may include 100% recycled fibers by weight, such as 100% recycled PET fibers by weight. However, in other aspects, fiber 210 may include 100% virgin fibers by weight, or other combinations of virgin and recycled fibers, as needed. The short fiber length of fiber 210 may range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. This use of fiber length provides optimal entanglement. For example, when below 40 mm, the fibers may not have sufficient length for entanglement, while when above 60 mm, the fibers may not be effectively entangled when the needles are withdrawn from the nonwoven fabric during the entanglement process. In one example, fiber 210 may include a consistent length, as when the fiber is formed from virgin extruded or re-extruded PET and cut to a defined length. In other aspects, fiber 210 may include variations in short fiber length, as when fiber 210 is derived from a shredded fiber source. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0208] Fiber 210 may include deniers greater than or equal to about 1.2D, or from about 1.2D to about 3.5D, from about 1.2D to about 1.7D, from about 1.3D to about 1.6D, or about 1.5D. Utilizing deniers within this range makes fiber 210 less prone to breakage, which in turn improves the durability and abrasion resistance of the first side of the composite nonwoven fabric 120. Furthermore, selecting a denier within this range while still achieving the basis weight of the first fiber web 110 provides good, uniform coverage of the first side, which helps enhance the durability characteristics of the first side. Selecting a denier greater than, for example, 3.5D while still maintaining the basis weight of the first fiber web 110 may not provide uniform coverage of the first side.

[0209] In one example, the fibers 210 used to form the first fiber web 110 may include a first color characteristic. This first color characteristic can be imparted to the fibers 210 during an extrusion process, for example, when the fibers 210 are formed such that they are pre-dyed before spinning. In one example, the color characteristic could be white, although other colors are also contemplated herein. Using pre-dyed fibers to form the composite nonwoven fabric 120 eliminates the need for post-processing dyeing steps, which further contributes to reducing the carbon footprint of the nonwoven fabric 120. For example, it is contemplated herein that the composite nonwoven fabric 120 is not post-dyed.

[0210] Figure 3 A second fiber web 112 is depicted prior to entanglement with other fiber webs. In an example aspect, properties associated with the second fiber web 112 can be selected to achieve the desired final properties of the composite nonwoven fabric 120. As described above, when entangled with other fiber webs, the second fiber web 112 is envisioned to form an opposing second side of the composite nonwoven fabric 120. When the composite nonwoven fabric 120 is formed into a garment article, the second side is envisioned to form the inward-facing surface of the garment article, and in some respects, the innermost surface. Therefore, properties associated with the second fiber web 112 include, for example, a soft hand feel or texture. In an example aspect, the basis weight of the second fiber web 112 is from about 20 gsm to about 150 gsm, from about 35 grams per square meter (gsm) to about 65 gsm, from about 40 gsm to about 60 gsm, from about 45 gsm to about 55 gsm, or about 50 gsm. In an example aspect, the second fiber web 112 has a basis weight substantially the same as the first fiber web 110. After the second fiber web 112 is combined with other fiber webs and / or elastomer layers, a resulting nonwoven fabric with a basis weight within the desired range is provided for the second fiber web 112.

[0211] In one example, the second fiber web 112 may be formed of two types of fibers, such as fiber 310 (shown schematically) and fiber 312 (shown schematically), which may be oriented generally in a common direction or in two or more common directions due to carding and cross-lapping processes. In one example, fiber 310 may include PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are contemplated herein. In one example, fiber 310 may include 100% recycled fibers by weight, such as 100% recycled PET fibers by weight. However, in other examples, fibers 310 and / or 312 may include 100% virgin fibers by weight, or other combinations of virgin and recycled fibers, as needed.

[0212] Fibers 312 are shown in dashed lines to indicate that they have characteristics different from those of fiber 310. For example, fiber 312 includes silicone-coated fibers. Fibers 312 may be coated with silicone before being incorporated into the second fiber web 112. In an example aspect, the second fiber web 112 may comprise about 10% to about 95% by weight of fiber 312, about 40% by weight of fiber 310 and about 60% by weight of fiber 312, about 45% by weight of fiber 310 and about 55% by weight of fiber 312, about 50% by weight of fiber 310 and about 50% by weight of fiber 312, about 55% by weight of fiber 310 and about 45% by weight of fiber 312, or about 60% by weight of fiber 310 and about 40% by weight of fiber 312. In a particular aspect, the second fiber web 112 may comprise approximately 50% by weight of fibers 310 and approximately 50% by weight of fibers 312. As described above, it is envisioned that fibers 312 may be intermittently coated with silicone along their length, or that fibers 312 may have a core / sheath configuration. The use of fibers 312 within the aforementioned range provides a good hand feel to the second surface formed by the second fiber web 112. It also provides good drape to the composite nonwoven fabric 120. In other words, the resulting nonwoven fabric 120 is not as stiff as conventional nonwoven fabrics used in cleanrooms and personal hygiene spaces. Furthermore, the use of fibers 310 and 312 within the aforementioned range reduces the needle force required to entangle the fiber web described herein, as the silicone-coated fibers may move more easily during entanglement. When silicone-coated fibers below the aforementioned range are incorporated, the second surface may feel dry and uncomfortable during wear. Conversely, when silicone-coated fibers above the aforementioned range are incorporated, the second surface may feel smooth, which may also cause discomfort to the wearer. Furthermore, using silicone-coated fibers with a viscosity exceeding the aforementioned range may make the carding process difficult, as the carding needles may not be able to engage with the fibers frictionally to achieve a uniform carded web. Additionally, using silicone-coated fibers with a viscosity exceeding the aforementioned range may also prevent sufficient entanglement between the fibers, as friction is reduced due to the silicone, thereby affecting the structural integrity of the composite nonwoven fabric 120.

[0213] The use of silicone-coated fiber 312 eliminates the need to add silicone finishing agents to the composite nonwoven fabric 120 in post-processing steps. As is known in the fabric industry, it is common practice to add silicone softening finishing agents to knitted or woven products in post-processing steps. By eliminating this step, the carbon footprint of the composite nonwoven fabric 120 is further reduced.

[0214] The short fiber lengths of fibers 310 and 312 can range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. Similar to fiber 210, this length provides optimal entanglement. In an exemplified respect, fibers 310 and / or 312 may include a consistent length, as when fibers are formed from virgin extruded or re-extruded PET and cut to a defined length. In other respects, fibers 310 and / or 312 may include variations in fiber length, as when fibers 310 and / or 312 are derived from a shredded fiber source. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0215] Each of fibers 310 and 312 may include a denier of about 1D or less. For example, the denier may be about 0.1D, about 0.2D, about 0.3D, about 0.4D, about 0.5D, about 0.6D, about 0.7D, about 0.8D, or about 0.9D. In a specific example, the denier of fibers 310 and 312 may be from about 0.6D to about 1D, from about 0.7D to about 0.9D, or about 0.8D. Utilizing a denier within this range helps to provide a soft feel or hand texture to the second surface formed by the second fiber web 112. Furthermore, selecting a denier within this range provides good coverage of the second surface while still achieving the basis weight of the second fiber web 112.

[0216] In one example, each of fibers 310 and 312 used to form the second fiber web 112 may include color characteristics that may be the same or different. In another example, both fibers 310 and 312 include the first color characteristics of fiber 210. Similar to fiber 210, each of fibers 310 and 312 may be pre-dyed, thereby further reducing the need for post-processing dyeing steps on the resulting composite nonwoven fabric.

[0217] Figure 5An elastomer layer 116 is depicted. In illustrative aspects, the basis weight of the elastomer layer 116 can be from about 20 gsm to about 150 gsm, from about 50 gsm to about 70 gsm, from about 55 gsm to about 65 gsm, or about 60 gsm. The basis weight of the elastomer layer 116 can be selected to achieve the desired basis weight of the resulting composite nonwoven fabric. Various aspects of this document envision the elastomer layer 116 being formed from a thermoplastic elastomer, such as thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), combinations of TPU and TPEE, etc. The elastomer layer can include a spunbond layer, a meltblown layer, a film, a web, etc. In a particular illustrative aspect, the elastomer layer 116 can include a TPEE spunbond layer, while in another particular aspect, the elastomer layer 116 can include a TPU meltblown layer. Typically, the elastomer layer 116 is selected to provide the composite nonwoven fabric 120 with the desired tensile and recovery properties while generally maintaining structural integrity during entanglement. The elastomer layer 116 may also be selected to have a low basis weight to maintain the low basis weight, breathability, and permeability of the resulting composite nonwoven fabric 120, which contributes to the comfort characteristics of clothing articles formed from the composite nonwoven fabric 120, and to have flexibility to reduce the stiffness of the composite nonwoven fabric 120. It is envisioned herein that the elastomer layer 116 has color properties. In an example aspect, the color property could be a first color property associated with fibers 210, 310, and 312, although different color properties (e.g., a second color property) are envisioned herein.

[0218] Figure 4An optional third fiber web 114 is depicted prior to entanglement with other fiber webs. When incorporated into the composite nonwoven fabric 120, the third fiber web 114 is envisioned to be located between the first fiber web 110 and the second fiber web 112. In an example, properties associated with the third fiber web 114 can be selected to achieve the desired final properties of the composite nonwoven fabric 120. In an example, the third fiber web 114 can be incorporated into the composite nonwoven fabric 120 to achieve the desired basis weight, the desired thickness, the desired thermal insulation performance, the desired pile, etc. of the composite nonwoven fabric 120. As further explained below, to impart visual appeal to the composite nonwoven fabric 120, the fibers forming the third fiber web 114 can have different color characteristics than the fibers used to form the first fiber web 110 and the second fiber web 112. Similar to the first fiber web 110 and the second fiber web 112, the basis weight of the third fiber web 114 is from about 20 gsm to about 150 gsm, from about 35 gsm to about 65 gsm, from about 40 gsm to about 60 gsm, from about 45 gsm to about 55 gsm, or about 50 gsm. After the third fiber web 114 is bonded to other fiber webs and / or elastomer layers, a resulting nonwoven fabric with a basis weight within the desired range is provided for the third fiber web 110 at this range.

[0219] The third fiber web 114 is formed of fibers such as fiber 410 (shown schematically), which may be oriented generally in a common direction or in two or more common directions due to carding and cross-lapping processes. In one example aspect, fiber 410 may comprise PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are contemplated herein. In one example aspect, fiber 410 may comprise 100% recycled fibers by weight, such as 100% recycled PET fibers by weight. However, in other aspects, fiber 410 may comprise 100% virgin fibers by weight, or other combinations of virgin and recycled fibers, as needed. Similar to fibers 210, 310, and 312, the short fiber length of fiber 410 may range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. In one example aspect, fiber 410 may comprise a uniform length, as when the fiber is formed from virgin extruded PET or re-extruded PET and cut to a defined length. In other respects, fiber 410 may include variations in short fiber length, such as when fiber 410 is derived from a shredded fiber source. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0220] Fiber 410 may include deniers greater than or equal to about 1.2D, from about 1.2D to about 3.5D, from about 1.3D to about 1.6D, or about 1.5D. Utilizing deniers within this range makes fiber 410 less prone to breakage, which in turn improves the durability and abrasion resistance of the composite nonwoven fabric 120. Since the third fiber web 114 is located between the first fiber web 110 and the second fiber web 112 during use, a soft hand feel is not as important as, for example, the second fiber web 112. Choosing a denier within this range while still achieving the basis weight of the third fiber web 114 improves the overall coverage and / or opacity of the composite nonwoven fabric 120.

[0221] In an example, the fibers 410 used to form the third fiber web 114 may include a second color characteristic different from the first color characteristic. This is in Figure 4 The description uses diagonal shading. This paper envisions dyeing of fiber 410 before spinning, thereby further reducing the carbon footprint of the composite nonwoven fabric 120. As will be explained in more detail below, during the entanglement of the first fiber web 110, the second fiber web 112, and the third fiber web 114, fiber 410 can move more towards one side than the other, making the second color characteristic more visually distinguishable or differentiated on one side compared to the other side. This paper envisions that fibers 210 of the first fiber web 110, fibers 310 of the second fiber web 112, and fibers 410 of the third fiber web 114 are not coated with silicone.

[0222] Figure 6 An example manufacturing process for producing an example composite nonwoven fabric 120 is illustrated, generally indicated by reference numeral 600. Figure 6 The depiction of the manufacturing components in the text is merely exemplary and intended to convey the general characteristics of the manufacturing process 600. Figure 6A conveying system 610 is depicted that conveys a stacked configuration 612 of a first fiber web 110, a second fiber web 112, a third fiber web 114, and an elastomer layer 116 in a machine direction. In one example aspect, the third fiber web 114 is located between the first fiber web 110 and the elastomer layer 116, as shown. In another example aspect, the third fiber web 114 is located between the second fiber web 112 and the elastomer layer 116. As described above, each of the first fiber web 110, the second fiber web 112, and the third fiber web 114 has been combed and overlapped to achieve the desired basis weight. Similarly, each of the webs 110, 112, and 114 has been lightly needled to achieve a cohesive structure. Since the fibers in each of the first fiber web 110, the second fiber web 112, and the third fiber web 114 are generally in a loose web state, they can move during needle entanglement. In an example, the conveying system 610 may convey the stack configuration 612 at a rate from about 2 m / min to about 2.5 m / min, from about 2.1 m / min to about 2.4 m / min, or about 2.3 m / min. This rate provides the desired level of entanglement via the needle bed to produce the desired final properties of the composite nonwoven fabric (e.g., basis weight, thickness, growth, and resilience). Slower rates may result in increased entanglement, thus affecting the desired final properties of the composite nonwoven fabric 120, while increased rates may result in insufficient entanglement, which also affects the desired final properties of the composite nonwoven fabric 120.

[0223] The stacking configuration 612 is indicated by the first needle plate of the first step at reference numeral 614. The needles used in the needle plate of manufacturing process 600 can be selected to optimally interact with a specific denier of the fibers used in the first fiber web 110, the second fiber web 112, and the third fiber web 114. They can also be selected to include a desired number of barbs to achieve a desired degree of entanglement. In an example, the first step 614 proceeds from the first fiber web 110 in a direction toward the second fiber web 112 and functionally has the effect of moving fiber 210 from the first fiber web 110 and winding it into the third fiber web 114 and the second fiber web 112, and further moving fiber 410 from the third fiber web 114 and winding it into the second fiber web 112. Performing the first step 614 in this direction helps ensure that the barbs are fully covered with fibers from the first fiber web 110 and optionally the third fiber web 114 before contacting the elastomer layer 116, thereby reducing the chance of empty barbs cutting the elastomer layer 116 and affecting the growth and recovery properties of the resulting composite nonwoven fabric 120.

[0224] In terms of examples, the first step 614 can have a strength of approximately 40 N / cm. 2 Approximately 60 N / cm 2 From approximately 45 N / cm 2 Approximately 55 N / cm2 or approximately 50 N / cm 2 The needle density. The penetration depth of step 614 can be from about 10 mm to about 14 mm, from about 11 mm to about 13 mm, or about 12 mm. In an example aspect, this amount of penetration depth will typically engage all the barbs of the needle. In an example aspect, all the barbs may include five barbs. This penetration depth ensures that the needle completely passes through the stack configuration 612, such that the fibers in each of the fiber webs 110, 112, and 114 are engaged with the needle. In other words, having a penetration depth as described in step 614 ensures that at least some of the fibers 210 from the first fiber web 110 are entangled with the fibers 410 of the third fiber web 114 and with the fibers 310 and 312 of the second fiber web 112, and that at least some of the fibers 410 of the third fiber web 114 are entangled with the fibers 310 and 312 of the second fiber web 112. In an example aspect, there is an inverse relationship between needle density and penetration depth. This is to avoid over-processing of the fibers and possible breakage. In other words, when the penetration depth is as high as in step 614, the stitch density is lower to avoid potential fiber breakage. After step 614 is completed, the thickness of the stack configuration 612 may decrease due to the z-direction movement and entanglement of fibers from different fiber webs. The stack configuration 612 may also increase slightly in the transverse direction of the machine due to transverse drafting.

[0225] The second step, indicated by reference numerals 616 and 618, is performed alternately from both sides of the stacked configuration 612, following the first step (i.e., temporarily following the first step). In other words, the second step is performed from the first fiber web 110 to the second fiber web 112 (reference numeral 616) and from the second fiber direction 112 to the first fiber web 110. Thus, the second step 616 is used to move fiber 210 from the first fiber web 110 to the third fiber web 114 and the second fiber web 112. It also moves fiber 410 from the third fiber web 114 through the elastomer layer 116 and into the second fiber web 112. The second step 618 moves fibers 310 and 312 through the elastomer layer 116 and into the third fiber web 114 and into the first fiber web 110.

[0226] Both the second process 616 and the second process 618 have a strength of approximately 40 N / cm. 2 Approximately 60 N / cm 2 From approximately 45 N / cm 2 Approximately 55 N / cm 2 or approximately 50 N / cm 2The stitch density. Maintaining a relatively low stitch density helps prevent over-processing of the elastomer layer 116 and thus helps maintain the desired growth and recovery properties of the resulting composite nonwoven fabric 120. The penetration depth of steps 616 and 618 is from about 6 mm to about 8 mm. In one example aspect, the penetration depth of step 616 is about 6 mm, and the penetration depth of step 618 is about 8 mm. In another example aspect, the penetration depth of step 616 is about 8 mm, and the penetration depth of step 618 is about 6 mm. Since step 614 reduces the thickness of the stack configuration 612, the penetration depth of steps 616 and 618 is reduced. It is envisioned that the penetration depth of steps 616 and 618 is sufficient to allow the needle to completely pass through the stack configuration 612. In one example aspect, when the penetration depth is 8 mm, it is envisioned that three needles are hooked together, and when the penetration depth is 6 mm, it is envisioned that two needles are hooked together. After steps 216 and 218 are completed, the thickness of the stacked configuration 612 is further reduced compared to the stacked configuration 612 after step 1 614, and may increase slightly in the transverse direction of the machine. The final result of steps 216 and 218 is that the fibers forming the first fiber web 110, the second fiber web 112, and the third fiber web 114 are further entangled together.

[0227] The third step, indicated by reference numeral 620, is performed after steps 616 and 618, and proceeds from the second fiber web 112 toward the first fiber web 110. The stitch density of the third step 620 is approximately 175 n / cm². 2 Approximately 225 N / cm 2 From approximately 180 N / cm 2 Approximately 220 N / cm 2 From approximately 190 N / cm 2 Approximately 210 N / cm 2 or approximately 200 N / cm 2 Compared to processes with lower stitch density such as steps 614, 616, and 618, the higher stitch density of step 620 achieves a more uniform texturing or finishing of the stacked configuration 612. The penetration depth of step 620 is from about 1 mm to about 5 mm, from about 2 mm to about 4 mm, or about 3 mm. In an example, this joins a barb of the needle. The purpose of step 620 is to fold some fibers present on the surface of the second fiber web 112 into the stacked configuration 612 without creating more entanglement. In other words, step 620 helps to reduce fuzz on the surface of the second fiber web 112.

[0228] The fourth step, indicated by reference numeral 622, is performed after the third step 620 and proceeds from the first fiber web 110 toward the second fiber web 112. Similar to the third step 620, the stitch density of the fourth step 622 is approximately 175 n / cm². 2 Approximately 225 N / cm 2 From approximately 180 N / cm 2 Approximately 220 N / cm 2 From approximately 190 N / cm 2 Approximately 210 N / cm 2 or approximately 200 N / cm 2 Similar to step 3 620, the penetration depth of step 4 622 is from about 1 mm to about 5 mm, from about 2 mm to about 4 mm, or about 3 mm. In an example, this involves a barb of the joining needle. The purpose of step 4 622 is to pleat some fibers present on the surface of the first fiber web 110 into the stacking configuration 612 without creating further entanglement. In other words, step 4 622 helps reduce fuzz on the surface of the first fiber web 110. In summary, the total stitch density of the composite nonwoven fabric 120 is about 550, with about 300 stitches on the first surface formed at least partially by the first fiber web 110 and about 250 stitches on the second surface formed at least partially by the second fiber web 112. The total stitch density of 550 is lower than that associated with typical nonwoven materials such as felt, in order to achieve greater bulk and a better hand feel. Furthermore, the lower total stitch density results in fewer fibers being utilized, leading to an uneven distribution of fibers from different fiber webs 110, 112, and 114 within the composite nonwoven fabric 120. This at least partially produces asymmetric features associated with different surfaces. Due to varying numbers of entanglements, some fibers forming the composite nonwoven fabric 120 may break, resulting in short fiber lengths of at least some fibers forming the composite nonwoven fabric 120 that may range from about 30 mm to about 45 mm.

[0229] Following step 4 622, in the example aspect, the entanglement process is completed and a composite nonwoven fabric 120 is formed. This is schematically shown by dashed line 624. Following step 4 622, in the example aspect, the composite nonwoven fabric 120 may have grown in both the machine direction (i.e., the length direction) and the machine transverse direction (i.e., the width direction). This concept is called machine drafting. For example, as needles pass through the fiber webs 110, 112, and 114, they create fiber-filled voids, which can cause the width to gradually increase according to the needle density, thus potentially leading to growth in the machine transverse direction. Growth in the machine direction generally depends on the feed rate and penetration depth. The stacking configuration 612 continues to move during the entanglement process, so an increase in penetration depth can cause fiber deflection based on the needle dwell time (i.e., the feed rate). This stretches the composite nonwoven fabric 120 in the machine direction.

[0230] In a further example, the composite nonwoven fabric 120 exhibits greater tensile strength in the length direction (i.e., the machine direction) compared to the width direction (i.e., the machine direction). In other words, fabric 120 exhibits anisotropic tensile properties. This difference may be due to the machine drafting discussed above. For example, growth in the machine direction can place the fibers forming the first fiber web 110, the second fiber web 112, and the third fiber web 114 under tension, thereby generating greater tensile resistance in the machine direction. This anisotropic tensile property may affect the cutting of patterns and their positioning on garment articles. For example, for garment articles such as bodices, greater stretch in the horizontal direction (e.g., from the first cuff to the second cuff) is generally desired compared to the vertical direction (e.g., from the neck opening to the waist opening). Therefore, patterns for bodices will be cut and positioned such that the width of fabric 120 will extend in the horizontal direction and the length of fabric 120 will extend in the vertical direction. In other words, the machine transverse of fabric 120 will extend horizontally, while the machine direction of fabric 120 will extend vertically.

[0231] In one example, after entanglement, the composite nonwoven fabric 120 is ironed. In another example, the ironing process helps to flatten the fiber ends extending from the surface of the composite nonwoven fabric 120, so that the fiber ends are approximately planar with the surface of the composite nonwoven fabric 120. This, in turn, reduces the tendency to pill. Furthermore, the ironing process can utilize rollers, and as the composite nonwoven fabric 120 is wound under tension on the rollers and pre-stretched, some of the fiber entanglement caused by the manufacturing process 600 can be loosened, which can improve the drape and resilience of the composite nonwoven fabric 120. After ironing, the composite nonwoven fabric 120 is wound to form a wound product 626, which can then be used to form garment articles. This document also envisions that the composite nonwoven fabric 120 can undergo further processing steps. For example, the composite nonwoven fabric 120 can be conveyed to a pattern-making station, where different pattern shapes can be cut from the nonwoven fabric 120. The composite nonwoven fabric 120 can also be conveyed to a printing station where various prints are applied to the surface of the nonwoven fabric 120. When this property is required, the nonwoven fabric 120 can also be subjected to calendering, embossing, or different coatings to increase anti-pilling properties. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0232] Typically, the composite nonwoven fabric 120 includes the desired properties based on the characteristics selected for each of the first fiber web 110, second fiber web 112, and third fiber web 114 (basis weight, fiber denier, fiber length, silicone coating, fiber type, etc.), the characteristics selected for the elastomer layer 116 (type of thermoplastic elastomer, construction (film, spunbond, meltblown, web, etc.)), and the selection of entanglement parameters. For example, the composite nonwoven fabric 120 may have a final thickness from about 1.8 mm to about 2.7 mm, from about 1.9 mm to about 2.6 mm, or from about 2 mm to about 2.5 mm. The composite nonwoven fabric 120 may have a basis weight from about 40 gsm to about 450 gsm, from about 100 gsm to about 350 gsm, from about 150 gsm to about 190 gsm, or about 180 gsm. The final basis weight may be affected by the number of layers (fiber webs) used in the structure, fiber loss due to peeling, machine drafting, etc. In an example, the composite nonwoven fabric 120 may have a thermal resistance ranging from about 50 RCT to about 95 RCT, from about 55 RCT to about 90 RCT, from about 60 RCT to about 85 RCT, or from about 65 RCT to about 80 RCT. Therefore, as shown, the composite nonwoven fabric 120 may exhibit insulation properties associated with typical knitted fleece, but with a lower basis weight and / or thickness.

[0233] Due to the elastomer layer 116, the composite nonwoven fabric 120 can exhibit minimal growth and good recovery properties. Using ASTM D2594 testing standards, the growth of the composite nonwoven fabric 120 in the length direction (i.e., the machine direction) can be less than or equal to about 5%, less than or equal to about 4%, less than or equal to about 3%, less than or equal to about 2%, less than or equal to about 1%, less than or equal to about 0.1%, or less than or equal to 0%. The growth of the composite nonwoven fabric 120 in the width direction (i.e., the machine transverse direction) can be less than or equal to about 10%, less than or equal to about 9%, less than or equal to about 8%, less than or equal to about 7%, less than or equal to about 6%, less than or equal to about 5%, less than or equal to about 4%, less than or equal to about 3%, less than or equal to about 2%, less than or equal to about 1%, less than or equal to about 0.1%, or less than or equal to 0%. Using ASTM D2594 testing standards, the resilience of the composite nonwoven fabric 120 is within approximately 10% of its rest length and width, approximately 9% of its rest length and width, approximately 8% of its rest length and width, approximately 7% of its rest length and width, approximately 6% of its rest length and width, approximately 5% of its rest length and width, approximately 4% of its rest length and width, approximately 3% of its rest length and width, approximately 2% of its rest length and width, or approximately 1% of its rest length and width. The stiffness of the composite nonwoven fabric 120, related to the drape of the fabric 120, is less than or equal to approximately 0.4 kgf, less than or equal to approximately 0.3 kgf, less than or equal to approximately 0.2 kgf, less than or equal to approximately 0.1 kgf, or from approximately 0.1 kgf to approximately 0.4 kgf.

[0234] In some examples, the aforementioned characteristics (basis weight, thickness, heat resistance, growth and recovery, and stiffness) can make the composite nonwoven fabric 120 suitable for lightweight, warm clothing items (e.g., pullovers, hoodies, sweatpants, etc.) for use in cool to cold weather conditions. In other examples, the aforementioned characteristics can make the composite nonwoven fabric 120 suitable for other items requiring asymmetry, such as the uppers of footwear.

[0235] Figure 7 and Figure 8 The illustration shows different sides of the composite nonwoven fabric 120. Figure 7A first surface 710 of a composite nonwoven fabric 120 and layers of the composite nonwoven fabric 120 are depicted. The first surface 710 is formed of a first entangled fiber web 712. The first entangled fiber web 712, in turn, includes fibers 210 from a first fiber web 110, fibers 310 and 312 from a second fiber web 112, and fibers 410 from a third fiber web 114. In an example, due to the entanglement parameters, the first entangled fiber web 712 mainly comprises fibers 210 from the first fiber web 110, while fibers 310, 312, and 410 are present in smaller quantities. Therefore, the area (cm²) of the first entangled fiber web 712 is defined herein as 1 cm x 1 cm. 2 The unit area of ​​the first entangled fiber web 712 comprises a first number of fibers, such as fibers 210 and 410, having a first denier of about 1.2D to about 3.5D, or about 1.5 denier, and a second number of fibers, such as fibers 310 and 312, having a second denier of about 0.6D to about 1D, or about 0.8D, wherein the first number of fibers is greater than the second number of fibers. In other words, the ratio of the first denier to the second denier of the unit area of ​​the first entangled fiber web 712 is in the range of about 1.5:1 to about 2:1 or about 1.9:1. Another way to describe this is that the first entangled fiber web 712 per cm 2 It has a first average denier. The first average denier can be determined by the number of deniers per centimeter. 2 Take a set number of fibers (e.g., 100 fibers), determine the denier of the fibers, and determine the average denier to determine the final density. For example, per cm... 2 The first average number of dendrites can be from about 1.1D to about 1.4D.

[0236] Figure 7 It also describes the formation as Figure 8The second entangled fiber web 718 of the second face 810 of the composite nonwoven fabric 120 shown. The second entangled fiber web 718 includes fibers 310 and 312 from a second fiber web 112, fibers 410 from a third fiber web 114, and fibers 210 from a first fiber web 110. In an example, due to the entanglement parameters, the second entangled fiber web 718 mainly comprises fibers 310 and 312 from the second fiber web 112, while fibers 210 and 410 are present in smaller quantities. Therefore, the unit area of ​​the second entangled fiber web 718 includes a third number of fibers, such as fibers 310 and 312, with a third denier from about 0.6 to about 1D, or about 0.8D, and a fourth number of fibers, such as fibers 210 and 410, with a fourth denier from about 1.2D to about 3.5D, or about 1.5D, wherein the third number of fibers is greater than the fourth number of fibers. In other words, the ratio of the third denier to the fourth denier per unit area of ​​the second entangled fiber web 718 is in the range of about 0.3:1 to about 0.7:1 or about 0.5:1. Another way to describe this is that the second entangled fiber web 718 per cm... 2 It has the second average denier. (per cm) 2 The second average denier can be less than per cm 2 The first average denier. For example, per cm... 2 The second average number of dans can be from about 0.9D to about 1D.

[0237] like Figure 7 and Figure 8As shown, the composite nonwoven fabric 120 also includes a third entangled fiber web 714. The third entangled fiber web 714 includes fibers 410 from a third fiber web 114, fibers 310 and 312 from a second fiber web 112, and fibers 210 from a first fiber web 110. In an example, due to the entanglement parameters, the third entangled fiber web 714 primarily comprises fibers 410 from the third fiber web 114, while fibers 310, 312, and 210 are present in smaller quantities. More specifically, because the needle passes through the first fiber web 110 and / or the second fiber web 112 before contacting the third fiber web 114, the needle barbs are typically covered with fibers, and therefore there may not be significant movement of fibers 410 during the entanglement process. Therefore, the third entangled fiber web 714 comprises, per unit area, a fifth number of fibers with a fifth denier ranging from about 1.2D to about 3.5D, or about 1.5 denier, such as fibers 410 and 210, and a sixth number of fibers with a sixth denier ranging from about 0.6D to about 1D, or about 0.8D, such as fibers 310 and 312, wherein the fifth number of fibers is greater than the sixth number of fibers. In other words, the ratio of the fifth denier to the sixth denier per unit area of ​​the third entangled fiber web 714 is in the range of about 1.5:1 to about 2:1 or about 1.9:1. Another way to describe this is that the third entangled fiber web 714 per cm 2 It has a third average denier. For example, per cm 2 The third average number of deniers can be greater than per cm. 2 The second average denier. For example, per cm... 2 The third average number of dendrites can range from about 1.1D to about 1.4D.

[0238] Figure 7 and Figure 8 The composite nonwoven fabric 120 shown also includes an elastomer layer 116. Figure 7 and Figure 8 In the configuration shown, an elastomer layer 116 is located between a second entangled fiber web 718 and a third entangled fiber web 714. At least some fibers from the first entangled fiber web 712 and the third entangled fiber web 714 extend through the elastomer layer 116 and become entangled with the fibers of the second entangled fiber web 718. Similarly, at least some fibers from the second entangled fiber web 718 extend through the elastomer layer 116 and become entangled with the fibers of the first entangled fiber web 712 and the third entangled fiber web 714. In an example, portions of the elastomer layer 116 do not move significantly in the z-direction during the entanglement process. In other words, the elastomer layer 116 generally extends uniformly along the xy-plane and generally maintains a cohesive, integral structure except through holes through which the fibers of the different entangled webs 712, 714, and 718 extend.

[0239] Although different entanglement networks 712, 714 and 718 are in Figure 7 and Figure 8 While shown as different layers, this paper envisions entangled webs 712, 714, and 718 entangled to form a cohesive structure. That is, in the example, each of the webs 712, 714, and 718 retains the characteristics of a different layer, making the entangled webs 712, 714, and 718 clearly visible in the cross-section of the composite nonwoven fabric 120, thus providing a unique aesthetic to the cut edges of the composite nonwoven fabric 120.

[0240] like Figure 7 and Figure 8 As further shown, the second surface 810 formed by the second entangled fiber web 718 includes silicone-coated fibers 312 (shown in dashed lines), in greater quantity than the silicone-coated fibers 312 present on the first surface 710 formed by the first entangled fiber web 712. In other words, the second entangled fiber web 718 comprises a greater number of silicone-coated fibers 312 per unit area than the first entangled fiber web 712. Furthermore, the third entangled fiber web 714 comprises a smaller number of silicone-coated fibers 312 per unit area than the second entangled fiber web 718. In an example aspect, this document envisions that the composite nonwoven fabric 120 may include silicone-coated fibers 312 ranging from about 10% to about 25% by weight. As previously stated, including silicone-coated fibers on the second surface 810 of the composite nonwoven fabric 120 provides a soft hand feel to the second surface 810 and reduces the stiffness of the composite nonwoven fabric 120 (i.e., increases drape).

[0241] Figure 9 Depicting Figure 7 A cross-section of the composite nonwoven fabric 120 is shown, illustrating fiber entanglement from different entangled fiber webs. As shown, the composite nonwoven fabric 120 includes a first entangled fiber web 712 forming a first surface 710, a second entangled fiber web 718 forming a second surface 810, a third entangled fiber web 714, and an elastomer layer 116. Figure 9 In the cross-section shown, the third tangled fiber web 714 is located between the first tangled fiber web 712 and the elastomer layer 116, although other aspects contemplate that the third tangled fiber web 714 is located between the second tangled fiber web 718 and the elastomer layer 116. As previously stated, this document contemplates that one or more of the tangled fiber webs 712, 714, and / or 718 may be optional.

[0242] Moving from left to right, fibers 210 from the first entangled fiber web 712 are shown entangled with fibers 310 and / or 312 from the second entangled fiber web 718, and fibers 210 from the first entangled fiber web 712 are shown entangled with fibers 410 from the third entangled fiber web 714. Fibers 410 from the third entangled fiber web 714 are shown entangled with fibers 310 and / or 312 from the second entangled fiber web 718, and fibers 410 from the third entangled fiber web 714 are shown entangled with fibers 210 from the first entangled fiber web 712. Fibers 310 and / or 312 from the second entangled fiber web 718 are shown entangled with fibers 210 from the first entangled fiber web 712, and fibers 310 and / or 312 are shown entangled with fibers 410 from the third entangled fiber web 714. As shown in the figure, one or more of fibers 210, 310, 312 and 410 extend through the elastomer layer 116. Figure 9 Some fibers are shown as darkened, but this is for illustrative purposes only.

[0243] Figure 10 Another cross-section of the composite nonwoven fabric 120 is depicted. (As shown) Figure 10 As shown, the elastomeric layer 116 is located between the third entangled fiber web 714 and the second entangled fiber web 718, and the elastomeric layer 116 is located between the first entangled fiber web 712 and the third entangled fiber web 714. Figure 9 The fibers of different layers are shown to be entangled together and extend through the elastomer layer 116.

[0244] Figure 11 Depicting Figure 9 The cross-section shows only the silicone-coated fiber 312. (See diagram). Figure 11 As shown, the silicone-coated fiber 312 exists in a larger quantity in the second entangled fiber web 718, but extends through the elastomer layer 116 into the first entangled fiber web 712 and the third entangled fiber web 714.

[0245] Figure 12 An example manufacturing process for producing pile on the second side of a composite nonwoven fabric is illustrated, generally indicated by reference numeral 1200. Aspects of the manufacturing process 1200 described below have traditionally been used to form, for example, Dilour carpets used in the automotive industry. In the more conventional Dilour process, needles are pierced through perforations in a single-layer fiber web, and the perforated fibers are retained by a set of brushes. The web is then pulled from the brushes, forming pile on one side of the web. This paper describes an improvement to this conventional Dilour process to produce a resulting composite nonwoven fabric with characteristics suitable for garment articles (e.g., a drapeable, fluffy, and soft fabric with stretch and recovery characteristics). Figure 12The depiction of the manufacturing components in the diagram is merely exemplary and intended to convey the general characteristics of manufacturing process 1200. Some features of manufacturing process 1200 are the same as those of manufacturing process 600, and therefore, the disclosure regarding these steps is consistent with the disclosure regarding manufacturing process 600. Figure 6 The publicly available information described is the same. Regarding Figure 12 The publicly available information typically focuses on the differences between manufacturing process 600 and manufacturing process 1200 and how these differences affect the properties of the resulting composite nonwoven fabric.

[0246] Figure 12 A conveying system 1209 is depicted that conveys a stacked configuration 1218 of a first fiber web 1210, a second fiber web 1212, a third fiber web 1214, and an elastomer layer 1216 in a machine direction. Each of the first fiber web 1210, the second fiber web 1212, and the third fiber web 1214 has been combed and overlapped to achieve the desired basis weight. Similarly, each of the webs 1210, 1212, and 1214 has been lightly needled to achieve a cohesive structure. The number of webs shown is exemplary, and it is contemplated that the number of webs may differ from (below or above) the number shown, as the fibers in each of the first fiber web 1210, the second fiber web 1212, and the third fiber web 1214 are typically in a loose web state, and therefore can move during needle entanglement. In some examples, the first fiber web 1210, the second fiber web 1212, and the third fiber web 1214 may be the same as the first fiber web 110, the second fiber web 112, and the third fiber web 114 used in manufacturing process 600, and the elastomer layer 1216 may be the same as the elastomer layer 116 used in manufacturing process 600. In some examples, the short fiber length of the fibers used to form the first fiber web 1210, the second fiber web 1212, and the third fiber web 1214 may be slightly longer than the short fiber length of the fibers used to form the first fiber web 110, the second fiber web 112, and the third fiber web 114. For example, the short fiber length may be from about 60 mm to about 70 mm, from about 62 mm to about 68 mm, or about 64 mm. In other respects, the fibers used to form the first fiber web 1210, the second fiber web 1212, and the third fiber web 1214 may be the same as those used to form the first fiber web 110, the second fiber web 112, and the third fiber web 114 (e.g., the same fiber type, denier, coating, color characteristics, etc.). In an example aspect, the conveying rate may be the same as or different from the conveying rate described for manufacturing process 600. In an example aspect, the conveying rate is selected to achieve the desired entanglement and pile of the resulting composite nonwoven fabric.

[0247] The stacking configuration 1218 is indicated by reference numeral 1220 as the first needle plate of the first step. The entanglement parameters associated with the first step 1220 can be the same as those of the first step 614, and therefore the description of the first step 614 is the same as that of the first step 1220, and will not be repeated here. Similarly, the second steps 1222 and 1224 are the same as the second steps 616 and 618 of the manufacturing process 600, and therefore the descriptions of the second steps 616 and 618 are the same as those of the second steps 1222 and 1224, and will not be repeated here.

[0248] In some examples, step 1226 may differ from step 620 of manufacturing process 600. For instance, in some aspects, as further explained below, step 1226 may be completely eliminated. In other examples, step 1226 may have a reduced pin density, for example, between approximately 30 n / cm. 2 Approximately 175 N / cm 2 Between, or between approximately 100 N / cm 2 Approximately 150 N / cm 2 between.

[0249] Step 4, 1228, also known as the Dilour step, is performed after step 3, 1226, or, if step 3, 1226, after steps 2, 1222 and 1224. In an example, one or more specialized needles may be used in step 4, 1228. For instance, one or more needles, or all needles, may include forked tips that capture fibers along their length as the needles pass through the stacked configuration 1218 to form loops. Step 4, 1226, proceeds from the first fiber web 1210 toward the second fiber web 1212. A set of brushes 1230 is positioned adjacent to one face of the second fiber web 1212. As shown in the enlarged view, when fibers from the first fiber web 1210, the second fiber web 1212, and the third fiber web 1214 are pushed past the surface of the second fiber web 1212 by the needle 1231, the ends of the fibers (such as fiber 1232) and / or the apexes of the fiber loops (such as loop 1234) are pushed into the brush assembly 1230, where they are held during the fourth step 1228. As the stack configuration 1218 continues to move in the machine direction, the fibers held by the brush assembly 1230 are pulled off the brush 1230. After being pulled off the brush assembly 1230, the fibers and fiber loops held by the brush assembly 1230 have a common orientation in the z-direction relative to, for example, the surface plane of the second fiber web 1212. (As per the...) Figure 15 In more detail, the distal ends of the fibers and fiber loops held by the brush assembly 1230 extend a predetermined distance from the surface of the second fiber web 1212.

[0250] To ensure that a sufficient number of fibers and / or fiber loops are pushed into the brush assembly 1230 to produce a sufficient pile with uniform coverage on the surface of the resulting composite nonwoven fabric, the stitch density of step 4 1228 is greater than that of the previous steps. For example, the stitch density of step 4 1228 is approximately 300 n / cm. 2 Approximately 1200 N / cm 2 From approximately 400 N / cm 2 Approximately 800 N / cm 2 From approximately 500 N / cm 2 Approximately 700 N / cm 2 or approximately 600 N / cm 2 In some examples, it has been found that subjecting the first surface to a high stitch density (such as that used in step 4 1228) can reduce the formation of fuzz on the first surface of the resulting composite nonwoven fabric. The penetration depth of step 4 1228 can be adjusted to produce longer or shorter pile. In examples, the penetration depth can be from about 3 mm to about 10 mm, from about 3.5 mm to about 8 mm, from about 4 mm to about 6 mm, or about 4 mm. After step 4 1228, the resulting composite nonwoven fabric can be wound to form a wound product 1236, although other processing steps discussed above with respect to manufacturing process 600 (e.g., ironing, pattern cutting, printing, calendering, embossing, coating, etc.) are contemplated herein.

[0251] In an example, due to the higher stitch density in step 4 1228, the stitch density prior to step 4 1228 is reduced compared to the stitch density in manufacturing process 600 to ensure that the elastomer layer 1216 is not over-needled prior to step 4 1228. Over-needling of the elastomer layer 1216 could affect the structural integrity of the elastomer layer 1216 and negatively impact the growth and recovery properties of the resulting composite nonwoven fabric. The final result of manufacturing process 1200 is a composite nonwoven fabric with the desired basis weight, desired bulk, and a uniformly covered pile on the second side of the fabric, wherein the cover may include fiber ends and fiber loops, fiber ends only, or fiber loops only, depending on the choice of needles.

[0252] Figure 13 and Figure 14 The first side 1310 and the opposing second side 1410 of the composite nonwoven fabric 1300 produced by manufacturing process 1200 are depicted respectively. The composite nonwoven fabric 1300 includes a first entangled fiber web 1312, a second entangled fiber web 1314, a third entangled fiber web 1316, and an elastomer layer 1216. The description of the different layers of the composite nonwoven fabric 1300 is generally associated with the bonding... Figure 7 and Figure 8The descriptions of the different layers of the composite nonwoven fabric 120 are the same, and therefore will not be repeated here.

[0253] about Figure 14 The second surface 1410 includes the end of the fiber 1412 and a predetermined amount of loops 1414 extending from the second surface 1410. Figure 14 The number of fibers 1412 and loops 1414 shown is merely exemplary, and it is contemplated herein that the second surface 1410 may include all loops 1414, all ends of fibers 1412, and any combination thereof. Fibers 1412 may include fibers from the first fiber web 1210, the second fiber web 1212, and / or the third fiber web 1214. Similarly, loops 1414 may be formed from fibers of the first fiber web 1210, the second fiber web 1212, and / or the third fiber web 1214. Therefore, the denier of fibers 1412 may be from about 0.6D to about 1D, or about 0.8D. Alternatively, the denier of fibers 1412 may be from about 1.3D to about 3.5D, or about 1.5D. Similarly, the denier of the fibers forming loops 1414 may be from about 0.6D to about 1D, or about 0.8D. Alternatively, the denier of the fibers forming the loop 1414 can be from about 1.3D to about 3.5D, or about 1.5D.

[0254] Figure 15 This is a cross-section of the composite nonwoven fabric 1300, and includes a first entangled fiber web 1312, a second entangled fiber web 1314, a third entangled fiber web 1316, and an elastomer layer 1216. In an example, each of the first entangled fiber web 1312, the second entangled fiber web 1314, and the third entangled fiber web 1316 extends in its respective xy plane, which are generally parallel and offset from each other. As shown, fibers 1412 and fiber loops 1414 extend away from the second surface 1410 of the composite nonwoven fabric 1300 in the z-direction. More specifically, at least a portion of the fibers forming the second entangled fiber web 1314 has a longitudinal length extending from the elastomer layer 1216 to the distal end of the respective fiber, wherein the distal end of the respective fiber (darkened for illustrative purposes) extends a predetermined amount away from the second surface 1410 in the z-direction. The distal end of the corresponding fiber may include an end having fiber 1412 or a apex of a loop such as loop 1414. In example, the predetermined amount may be from about 1.5 mm to about 8.1 mm, from about 3.5 mm to about 6.5 mm, from about 3 mm to about 6 mm, or about 4 mm.

[0255] Returning to the example composite nonwoven fabric 120, the fibers forming the different layers of the composite nonwoven fabric 120 can have different color characteristics, which gives the nonwoven fabric 120 a unique aesthetic appeal, such as... Figures 16 to 18 As shown. Figure 16The first side 710 of the composite nonwoven fabric 120 is depicted, and Figure 17 The second surface 810 of the composite nonwoven fabric 120 is depicted. As previously described, in terms of example, it is envisioned that the fibers 210 of the first fiber web 110 have a first color characteristic, the fibers 310 and 312 of the second fiber web 112 have a first color characteristic, and the elastomer layer 116 may have the first color characteristic or may have a different color characteristic (e.g., a second color characteristic). The fibers 410 of the third fiber web 114 have a second color characteristic different from the first color characteristic. During the manufacturing process 600, the fibers 410 of the third entangled fiber web 114 are pushed unevenly toward the first surface 710 and the second surface 810 of the composite nonwoven fabric 120, at least in part based on the order and entanglement parameters of the webs in the stacking configuration 612. Figure 16 and Figure 17 The dark spots shown represent the second color characteristic imparted by fiber 410 (denoted by numeral 1610), while the blank areas represent the first color characteristic imparted by fibers 210, 310, 312, and 410 (denoted by numeral 1612). In an example, when the third fiber web 1214 is located between the first fiber web 1210 and the elastomer layer 1216, the second color characteristic 1610 is more visually distinguishable or discernible on the first surface 710 compared to the second surface 810. In other words, in an example, fibers 410 having the second color characteristic 1610 can include a greater number of fibers per unit area on the first surface 710 compared to the second surface 810. It is envisioned that the first color characteristic 1612 on the second surface 810 can be enhanced (or more visually perceived) because the elastomer layer 116 has the first color characteristic 1612, since the elastomer layer is visible in some areas of the second surface 810. The overall appearance of the first surface 710 and the second surface 810 imparted by fiber 410 is a similar color mixing effect, which is more pronounced on the first surface 710. In an example, when the third fiber web 1214 is located between the second fiber web 1212 and the elastomer layer 1216, the thermoplastic color mixing effect may be more pronounced on the second surface 810.

[0256] Figure 16 and Figure 17The patterning of the first color characteristic 1612 and the second color characteristic 1610 shown is merely exemplary, and it is contemplated herein that the patterning may differ from the patterning shown. For example, the manufacturing process 600 produces random entanglement of different fibers in the composite nonwoven fabric 120, such that the pattern is variable on the first side 710 and the second side 810 of the nonwoven fabric 120. Furthermore, the overall color characteristics of the different sides 710 and 810 of the composite nonwoven fabric 120 can be adjusted by changing the color characteristics of the fibers forming different layers of the fabric 120, changing the entanglement parameters, changing the stacking order of the carding web before entanglement, etc. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0257] Figure 18 Depicting Figure 16 The cross-section of the composite nonwoven fabric 120 is shown. As illustrated, fibers 410 having a second color characteristic 1610 are pushed toward the first surface 710 and the second surface 810 of the composite nonwoven fabric 120, such that the second color characteristic 1610 is visually perceived on the opposing first surface 710 and second surface 810. Figure 18 As further illustrated, in an example, more fibers 410 can be pushed onto the first surface 710 compared to the second surface 810, making the second color characteristic 1610 more visually distinguishable on the first surface 710 compared to the second surface 810. When incorporating fabrics into garment articles, composite nonwoven fabrics with different color characteristics on opposing surfaces can be useful. For example, different color characteristics can provide the wearer with a visual indication of which side of the garment is facing outwards or inwards. In another example, different color characteristics can allow the garment to be worn in two different configurations (front side outwards and inside side outwards), with different visual appearances associated with each configuration.

[0258] This paper envisions that the composite nonwoven fabric 120 exhibits different pilling resistance on the first side 710 compared to the second side 810 in response to washing and abrasion. In some examples, the different pilling resistance between the first side 710 and the second side 810 can be a desired characteristic for producing a desired aesthetic and hand feel. Properties associated with the first fiber web 110, the second fiber web 112, and the third fiber web 114, properties associated with the stacking order of the fiber webs 110, 112, and 114, and entanglement parameters can be adjusted to design different resistance to pilling on the first side 710 and the second side 810. Generally, the first side 710 is more pill-resistant than the second side 810. In other words, the second side 810 can exhibit different pilling resistance per cm compared to the first side 710 in response to washing and abrasion. 2More pilling occurs. The difference in pilling resistance between the first face 710 and the second face 810 of the nonwoven fabric 120 can be caused by a number of factors. For example, the presence of a greater number of silicone-coated fibers 312 on the second face 810 increases the likelihood that fiber ends will migrate out of the second face 810 and become entangled with other fiber ends to form pills extending away from the second face 810. Additionally, the second face 810 has a lower stitch density (250 vs. 300) than the first face 710, which can result in less entanglement compared to the first face 710. Because the fibers may be less entangled, the likelihood of fiber ends migrating out of the second face 810 may increase. Another reason could be that the fourth process 622 proceeds from the first face 710 toward the second face 810. This process can push some fiber ends through the second face 810 to entangle there and form pills.

[0259] exist Figures 19 to 21 The diagram illustrates the difference in balling between the first surface 710 and the second surface 810 over time. Figure 19 The illustration shows the first surface 710 of the composite nonwoven fabric 120 at a first time point. In an illustrative aspect, the first time point may immediately follow the formation of the nonwoven fabric 120. The fibers forming the first surface 710 are not depicted in the illustration to better illustrate fuzz. In an illustrative aspect, the first surface 710 may not include any fuzz (as shown), or it may include fuzz per cm. 2 The first number of hairballs. Figure 21 The illustration shows the second side 810 of the composite nonwoven fabric 120 at a first time point. The second side 810 is also shown, but the fibers forming the second side 810 are not depicted to better illustrate the pompom. For example, the second side 810 may not include any pompoms (as shown), or it may include pompoms per cm. 2 The second number of hairballs.

[0260] Figure 20 The illustration shows the first surface 710 at a second time point following the first time point. The second time point can be after one or more washes or after a certain amount of wear or use. At the second time point, the first surface 710 comprises [data missing - likely referring to a unit of area] cm. 2 The third number of fuzz balls, such as fuzz ball 2010, of which each cm 2 The third number of hairballs is more than per cm 2 The first number of hairballs. Figure 22 The diagram illustrates the second surface 810 at a second time point. At the second time point, the second surface 810 comprises [a portion] cm. 2 The fourth number of hairballs, such as hairball 2210, of which each cm 2 The fourth number of hairballs is more than per cm 2 The second number of hairballs. Additionally, at the second time point, per cm2 The fourth number of hair balls is more than the number present per cm on the first surface 710. 2 The third number of hairballs.

[0261] When the composite nonwoven fabric 120 is incorporated into a garment, it is envisioned that the first surface 710 forms the outward-facing surface of the garment, and in an example, it can form the outward-facing surface of the garment. The second surface 810 forms the inward-facing surface of the garment, and in an example, it can form the inward-facing surface of the garment. Therefore, in an example, a larger pilling rate (or lower pilling resistance) of the second surface 810 may result in the inward-facing surface of the garment having a lower pilling rate per cm compared to the outward-facing surface of the garment. 2 It has a greater number of lint balls, which is somewhat contrary to typical garment articles where lint balls tend to form preferentially on outward-facing surfaces in areas exposed to greater wear (e.g., the elbow area).

[0262] Figures 23 to 26 The illustration shows the difference in pilling over time between the outward-facing and inward-facing surfaces of a garment. Figure 23 The illustration shows the outward-facing surface 2310 of a garment article 2300 at a first time point, wherein the garment article 2300 is formed of a composite nonwoven fabric 120 such that a first side 710 of the composite nonwoven fabric 120 forms the outward-facing surface 2310. In an example, the first time point may immediately follow the formation of the garment article 2300. The fibers forming the outward-facing surface 2310 are not depicted in the illustration to better illustrate fuzz. In an example, the outward-facing surface 2310 may not include any fuzz (as shown), or it may include fuzz per cm. 2 The first number of hairballs. Figure 25 The illustration shows the inward-facing surface 2510 of garment article 2300 at a first time point, wherein the inward-facing surface 2510 is formed by the second side 810 of composite nonwoven fabric 120. The inward-facing surface 2510 is also shown, but the fibers forming the inward-facing surface 2510 are not depicted to better illustrate pom-poms. In an example, the inward-facing surface 2510 may not include any pom-poms (as shown), or it may include pom-poms per cm. 2 The second number of hairballs.

[0263] Figure 24 The diagram illustrates the outward-facing surface 2310 at a second time point following the first time point. The second time point can be after one or more washes or after a certain amount of wear. At the second time point, the outward-facing surface 2310 comprises [a certain number of units per cm]. 2 The third number of hairballs, such as hairball 2410, of which each cm 2The third number of hairballs is more than per cm 2 The first number of hairballs. Figure 26 The diagram illustrates the inward-facing surface 2510 at a second time point. At the second time point, the inward-facing surface 2510 comprises [a certain number of units] per cm. 2 The fourth number of hairballs, such as 2610 hairballs, of which each cm 2 The fourth number of hairballs is more than per cm 2 The second number of hairballs. Additionally, at the second time point, per cm 2 The fourth number of hair balls is more than that present on the outward-facing surface of 2310 cm. 2 The third number of hairballs.

[0264] In other examples, it may be necessary to reduce the number of pills formed on the first side 710 and / or the second side 810 of the composite nonwoven fabric 120 to achieve different aesthetics and / or different hand feel. In this regard, the composite nonwoven fabric 120 may undergo multiple post-processing steps that increase pilling resistance on the first side 710 and the second side 810. Example post-processing steps may include calendering (hot or cold), embossing, coating the first side 710 and / or the second side 810 with a coating such as an oil-based polyurethane, etc. Any and all aspects and any variations thereof are contemplated within the scope of this document.

[0265] Figure 27An example garment article 2700 formed from composite nonwoven fabric 120 and / or composite nonwoven fabric 1300 is illustrated. The garment article 2700 is in the form of a short-sleeved upper garment, although other configurations such as jackets, hoodies, long-sleeved shirts, sleeveless shirts, vests, etc., are also contemplated herein. The garment article 2700 includes an outward-facing surface 2710 and an inward-facing surface (not visible). As shown, the outward-facing surface 2710 is the outermost surface of the garment article. In the example, the inward-facing surface is the innermost surface of the garment article 2700. Regarding the composite nonwoven fabric 120, a first surface 710 forms the outward-facing surface 2710 of the garment article 2700, and a second surface 810 forms the inward-facing surface. Regarding the composite nonwoven fabric 1300, a first surface 1310 forms the outward-facing surface 2710 of the garment article 2700, and a second surface 1410 forms the inward-facing surface. In an example, composite nonwoven fabrics 120 and / or 1300 are oriented such that the width direction (i.e., machine transverse) of fabrics 120 and / or 1300 is oriented to extend between the first cuff 2712 and the second cuff 2714, and the length direction (i.e., machine direction) of fabrics 120 and / or 1300 is oriented to extend between the neck opening 2716 and the waist opening 2718 of garment article 2700. This reflects that the width direction of fabrics 120 and / or 1300 has less tensile resistance than the length direction of fabrics 120 and / or 1300. This orientation can be switched if different tensile characteristics are required for different parts of garment article 2700.

[0266] The garment article 2700 formed from the composite nonwoven fabrics 120 and / or 1300 imparts different properties to the outward-facing surface 2710 and the inward-facing surface. For example, the outward-facing surface 2710 may have greater abrasion resistance due to the presence of a greater number of fibers 210 compared to, for example, fibers 310 and 312. The outward-facing surface 2710 may also have different color characteristics than the inward-facing surface due to the uneven movement of fibers 410 between the first and second surfaces of the composite nonwoven fabrics 120 and / or 1300. For example, the inward-facing surface of the garment article 2700 may have a softer hand feel compared to, for example, the outward-facing surface 2710 due to the greater amount of silicone-coated fibers 312. Similarly, the soft hand feel may be due to the lower denier of the fibers 310 and 312 that primarily form the inward-facing surface of the garment article 2700.

[0267] Figure 28Another example garment article 2800 formed from composite nonwoven fabric 120 or composite nonwoven fabric 1300 is depicted. The garment article 2800 is in the form of lower garments. Although shown as trousers, it is envisioned that the garment article 2800 could be in the form of shorts, capri pants, leggings, etc. The garment article 2800 includes an outward-facing surface 2810 and an inward-facing surface (not visible). As shown, the outward-facing surface 2810 is the outermost surface of the garment article. In the example, the inward-facing surface is the innermost surface of the garment article 2800. Regarding the composite nonwoven fabric 120, a first surface 710 forms the outward-facing surface 2810 of the garment article 2800, and a second surface 810 forms the inward-facing surface. Regarding the composite nonwoven fabric 1300, a first surface 1310 forms the outward-facing surface 2810 of the garment article 2800, and a second surface 1410 forms the inward-facing surface. In an example, the composite nonwoven fabrics 120 and / or 1300 are oriented such that the width direction (i.e., machine transverse) of the fabrics 120 and / or 1300 is oriented to extend between a first transverse side 2812 and a second transverse side 2814, and the length direction (i.e., machine direction) of the fabrics 120 and / or 1300 is oriented to extend between a waist opening 2816 and a leg opening 2818 of the garment article 2800. This reflects that the width direction of the fabrics 120 and / or 1300 has less tensile resistance than the length direction of the fabrics 120 and / or 1300. This orientation can be switched if different tensile characteristics are required for different parts of the garment article 2800.

[0268] Similar to garment article 2700, the asymmetrical finish of composite nonwoven fabrics 120 and / or 1300 imparts different desired characteristics to the outward-facing surface 2810 and the inward-facing surface of garment article 2800. Composite nonwoven fabrics 120 and / or 1300 can be used in other garment articles in which different characteristics are required on the outward-facing and inward-facing surfaces. Such garment articles may include, for example, the uppers of footwear articles.

[0269] As mentioned above, it may be necessary to reduce the number of pills formed on the first side 710 and / or the second side 810 of the composite nonwoven fabric 120 to achieve different aesthetics and / or different hand feel. In this regard, the composite nonwoven fabric 120 may undergo a preforming step and / or one or more post-processing steps to increase pilling resistance on the first side 710 and / or the second side 810.

[0270] Figure 29An example gravure printing system 2900 is illustrated, suitable for applying a chemical adhesive to a composite nonwoven fabric 120 to reduce fuzz formation on at least a first side 710 of the composite nonwoven fabric 120. In one example, the chemical adhesive may be applied to one or more fiber webs, such as a first fiber web 110, a second fiber web 112, and / or a third fiber web 114, before the webs 110, 112, and / or 114 are bonded to the composite nonwoven fabric 120. In this respect, the chemical adhesive may be applied only to the fibers constituting a single web, such as fibers 210 of the first fiber web 110, fibers 310 and 312 of the second fiber web 112, and / or fibers 410 of the third fiber web 114. In other examples, the chemical adhesive may be applied to the finished composite nonwoven fabric 120 (after the individual fiber webs 110, 112, and / or 114 have been stacked and entangled with each other). In this respect, since fibers 110, 310 and 312 and / or 410 are already entangled with each other, when a chemical adhesive is applied to, for example, the first surface 710, the chemical adhesive can bond one or more of the fibers 210, 310 and 312 and / or 410 present on the first surface 710 together.

[0271] As used herein, the term "chemical bonding" refers to the use of a chemical adhesive (e.g., an adhesive material) to hold fibers together. The chemical adhesive bonds 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 properties of at least the first side 710 of the composite nonwoven fabric 120 are improved. Suitable chemical adhesives include those composed of polymers and may 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 may be applied to the composite nonwoven fabric prior to the application of the chemical adhesive. In one example aspect, the chemical adhesive may include an oil-based polyurethane adhesive. As used herein, the term "chemical bonding site" refers to the location of a chemical bond and also to the chemical adhesive itself applied to the composite nonwoven fabric at the chemical bonding site. Figure 29 The components depicted are exemplary and intended to convey general concepts associated with the gravure printing system 2900. The system 2900 may include additional or fewer components, and these components may have different configurations than those shown.

[0272] The gravure printing system 2900 includes a gravure printing roller 2910 adapted to rotate in a first direction 2912. The gravure printing roller 2910 has an engraved pattern 2914. In one example, the gravure printing roller 2910 is supplied with a chemical adhesive 2916. For example, the gravure printing roller 2910 may be partially immersed in a tray 2918 containing the chemical adhesive 2916. As the gravure printing roller 2910 rotates in the first direction 2912, the chemical adhesive 2916 fills the engraved pattern 2914. In one example, excess chemical adhesive 2916 is scraped off the gravure printing roller 2910 before it comes into contact with the composite nonwoven fabric 120 to remove excess chemical adhesive 2916. In one example, the viscosity of the chemical adhesive 2916 prior to application can be selected to achieve the desired level of penetration into the composite nonwoven fabric 120 after the chemical adhesive 2916 is applied, for example, to the first side 710 of the composite nonwoven fabric 120. For example, when chemical adhesive 2916 is in the form of an oil-based polyurethane, its viscosity range at an application temperature of about 28 degrees Celsius to about 33 degrees Celsius and at a relative humidity of about 50% to about 80% can be from about 960 mPa·s to about 1020 mPa·s, from about 970 mPa·s to about 1010 mPa·s, or from about 980 mPa·s to about 1000 mPa·s.

[0273] The gravure printing system 2900 also includes an impression roller 2920 rotating in a second direction 2922 opposite to the first direction 2912. A composite nonwoven fabric 120 is positioned between the impression roller 2920 and the gravure printing roller 2910, such that a first surface 710 of the composite nonwoven fabric 120 contacts the gravure printing roller 2910, and a second surface 810 contacts the impression roller 2920. The gravure printing roller 2910 and the impression roller 2920 can each be adapted to apply a certain amount of pressure and heat to the composite nonwoven fabric 120. For example, the pressure applied by each of the gravure printing roller 2910 and the impression roller 2920 can range from about 20 kg to about 60 kg, from about 25 kg to about 55 kg, or from about 30 kg to about 50 kg. Various aspects of this document also envision that the gravure printing roller 2910 and the impression roller 2920 can apply different amounts of pressure. For example, the gravure printing roller 2910 can apply a pressure of 30 kg, and the impression roller 2920 can apply a pressure of 50 kg. In another example, the gravure printing roller 2910 can apply a pressure of 50 kg, and the impression roller 2920 can apply a pressure of 30 kg. As the composite nonwoven fabric 120 advances in the machine direction, the chemical adhesive 2916 is transferred from the engraved pattern 2914 to the first surface 710. The impression roller 2920 applies force to ensure that the entire first surface 710 is in contact with the gravure printing roller 2910, such that a uniform coverage of the chemical adhesive 2916 is applied to the first surface 710 in a pattern corresponding to the engraved pattern 2914.

[0274] Although the gravure printing system 2900 is depicted as applying the chemical adhesive 2916 only to the first side 710, various aspects herein envision that the chemical adhesive 2916 could also be applied to the second side 810. For example, after applying the chemical adhesive 2916 to the first side 710, the composite nonwoven fabric 120 can be run through the gravure printing system 2900 again, such that the second side 810 contacts the gravure printing roller 2910, while the first side 710 contacts the impression roller 2920. Furthermore, or alternatively, additional gravure printing systems can be aligned in series to contact the different sides 710 and 810 of the composite nonwoven fabric 120.

[0275] In an example aspect, the chemical adhesive 2916 may be an oil-based dispersion of a polyurethane adhesive, a dispersion containing silica, or a combination thereof. In an example aspect, the use of silica reduces friction between fibers to which the chemical adhesive 2916 is applied, making the fibers less likely to pill when exposed to abrasion or external friction (i.e., they are more likely to slide relative to each other). As described above, the chemical adhesive 2916 acts as an adhesive, helping to hold the fibers together in the area of ​​application. Because the fibers are adhered together, the ends of the fibers are less prone to pilling, and the overall pilling resistance of at least the first side 710 of the composite nonwoven fabric 120 is improved. For example, in a Martindale pilling test, the pilling resistance may be about 2, 2.5, or greater. As previously stated, in an example aspect, when the composite nonwoven fabric 120 is incorporated into clothing, the first side 710 of the composite nonwoven fabric 120 forms the outward-facing surface of the clothing. Therefore, the application of chemical adhesive 2916 helps to increase the pilling resistance of the outer surface of the garment, which is more prone to wear than, for example, the inner surface of the garment formed by the second side 810.

[0276] Figure 30 A portion of a gravure printing roller 2910, including an engraved pattern 2914, is depicted. The engraved pattern 2914 is depicted as a regular pattern of recessed holes (such as holes 3010) having similar sizes. Various aspects herein envision the engraved pattern 2914 being configured to include discrete shapes that are separate and distinct from each other, as opposed to continuous patterns (e.g., continuous lines or shapes extending from each other). In an example, the holes 3010 may have different depths. For example, deeper holes may transfer a larger amount of chemical adhesive 2916 to the composite nonwoven fabric 120 (i.e., a thicker coating), while shallower holes may transfer a smaller amount of chemical adhesive 2916 to the composite nonwoven fabric 120 (i.e., a thinner coating). Figure 30 The engraved pattern 2914 depicted herein is exemplary, and it is contemplated herein that other patterns, including irregular or organic patterns, may be used. Furthermore, the size of each hole 3010 may vary relative to each other to achieve the desired pattern on the composite nonwoven fabric 120. In illustrative terms, different engraved patterns may be used when the chemical adhesive 2916 is applied to the second surface 810. For example, to maintain the feel imparted by the small denier fibers 310 and 312 and the silicone-coated fiber 312 applied to the second surface 810, the engraved pattern may include smaller holes spaced further apart from each other.

[0277] In an example, an engraved pattern 2914 can be selected such that the average size 3012 of each hole 3010 and its corresponding chemical bonding site on the composite nonwoven fabric 120 are in the range of about 0.1 mm to about 1 mm. As used herein, the term "size" when referring to a chemical bonding site generally refers to the surface area occupied by the chemical bonding site. For example, if the chemical bonding site has a circular shape, the size of the chemical bonding site is generally equal to Πr. 2 Furthermore, the distance 3014 between adjacent holes 3010 and the corresponding chemical bonding sites on the composite nonwoven fabric 120 range from about 0.5 mm to about 6 mm, from about 1 mm to about 5 mm, or from about 1.1 mm to about 4 mm. As used herein, the term "distance" is generally measured from the center of the first chemical bonding site to the center of the second chemical bonding site. In an example, the size 3012 of the holes 3010 and / or the distance 3014 between adjacent holes 3010 may be selected based on, for example, the average short fiber length of the fibers forming the first surface 710 (e.g., fibers 210, 310, 312, and when 410 is used) and / or the fibers forming the second surface 810 (e.g., fibers 210, 310, 312, and when 410 is used). As previously mentioned, the short fiber lengths of fibers 210, 310, and 312 may range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. In this example, the size 3012 and / or distance 3014 between adjacent holes 3010 can be less than about 60 mm, less than about 55 mm, or less than about 51 mm. This ensures that different sections of a single fiber length are secured by the chemical adhesive 2916.

[0278] By configuring the engraved pattern 2914 to include discrete shapes having the stated size and spacing, the desired amount of surface area occupied by the resulting chemically bonded sites in the composite nonwoven fabric 120 is achieved. In an example, the surface area occupied by the resulting chemically bonded sites in the composite nonwoven fabric 120 is balanced by the need to maintain the drape, hand feel, and growth and recovery properties of the composite nonwoven fabric 120. For example, if the surface area occupied by the chemically bonded sites in the composite nonwoven fabric 120 exceeds a threshold, the drape and growth and recovery properties of the composite nonwoven fabric 120 may be reduced due to the adhesive properties of the chemical adhesive 2916, despite increased pilling resistance. Furthermore, the hand feel of the composite nonwoven fabric 120 may become more rubbery, which could reduce its desirability for use in clothing. Conversely, if the surface area occupied by the chemically bonded sites is below a threshold, the pilling resistance of at least the first side 710 of the composite nonwoven fabric 120 may be lower than desired. In an example, the amount of surface area occupied by chemically bonded sites in the composite nonwoven fabric 120 may be between about 10% and about 70%, or between about 40% and about 60%, to produce 2 or greater anti-pilling properties while still maintaining the desired drape, hand feel, and growth and recovery properties.

[0279] Using a gravure printing system (such as gravure printing system 2900) is merely one example of applying the chemical adhesive 2916 in liquid form to the composite nonwoven fabric 120. Other application methods may include spraying the chemical adhesive 2916 and / or applying it in foam or powder form. In these example aspects, masks may be used in areas of the composite nonwoven fabric 120 where the chemical adhesive 2916 is not required. Additional application methods include digitally printing the chemical adhesive 2916 onto the composite nonwoven fabric 120. Digital printing may be desirable in some aspects of application to areas where the chemical adhesive 2916 is required. For example, a computer program may be used to instruct a digital printer to print the chemical adhesive 2916 in a desired pattern, the pattern comprising a pattern in which the density of chemical adhesive sites in a first region of the composite nonwoven fabric 120 is greater than the density of chemical adhesive sites in a second region of the composite nonwoven fabric 120. As used with respect to adhesive sites, the term "density" refers to per cm². 2 The number of discrete adhesion sites. The following will be based on... Figure 34 and Figure 35 Further description of the regional application of chemical bonding sites.

[0280] Figure 31 Exemplary schematic diagrams depict composite nonwoven fabric 120 after processing by gravure printing system 2900 or other application methods described herein. For example, Figure 31A first surface 710 of the composite nonwoven fabric 120 is depicted, having a plurality of chemical bonding sites 3110, the pattern of which generally corresponds to, for example, the engraved pattern 2914 of a gravure printing roller 2910. As described above, the size and spacing between adjacent chemical bonding sites 3110 generally correspond to the size 3012 of the aperture 3010 of the gravure printing roller 2910 and the distance 3014 between adjacent apertures 3010 of the gravure printing roller 2910. In one example aspect, the first surface 710 of the composite nonwoven fabric 120 may have a first color characteristic, and the chemical bonding sites 3110 may have a second color characteristic different from the first color characteristic. In this respect, the combination of the second color characteristic of the plurality of chemical bonding sites 3110 with the first color characteristic of the first surface 710 can provide an interesting visual aesthetic.

[0281] Figure 31 An enlarged view of one of the chemical bonding sites 3110 is also depicted. Chemical adhesive 2916 is used as an adhesive to chemically bond fibers to each other at intersections. For example, chemical adhesive 2916 can chemically bond one or more of fibers 210, 310, and 312 and / or 410 present on the first face 710 due to entanglement. This reduces or eliminates the tendency for fiber ends to extend away from the first face 710 and entangle with other fiber ends to form a ball of fibers. To illustrate this differently, multiple discrete chemical bonding sites 3110 represent isolated or discrete areas of chemically bonded fibers, while the remainder of the first face 710 includes fibers that are not chemically bonded to each other.

[0282] Figure 32An exemplary schematic diagram of the second side 810 of the composite nonwoven fabric 120 is depicted. In this example, chemical bonding sites 3110 may not be present in the second side 810. In other words, the second side 810 may not include any chemical bonding sites 3110. As previously described, when the composite nonwoven fabric 120 is bonded to clothing, the second side 810 forms the inward-facing surface of the resulting garment. In this example, since the inward-facing surface is generally not visible when the resulting garment is worn, the presence or absence of pilling may not be so important from an aesthetic point of view, and therefore, the chemical adhesive 2916 may not be applied to the second side 810 to reduce material costs. Similarly, by not applying the chemical adhesive 2916 to the second side 810, the soft hand feel imparted by the low denier fibers 310 and 312, and by using the silicone-coated fiber 312, is retained. However, various aspects herein envision that the chemical adhesive 2916 may be applied to the second side 810 to increase pilling resistance when needed. In this respect, the surface area of ​​the second surface 810 occupied by the multiple chemical adhesive sites 3110 can be reduced compared to the first surface 710. In other words, the surface area of ​​the second surface 810 occupied by the multiple chemical adhesive sites 3110 can be smaller than the surface area of ​​the first surface 710 occupied by the multiple chemical adhesive sites 3110. This is done to ensure that the soft hand feel imparted by the use of silicone-coated fibers 312 and low denier fibers 310 and 312 is relatively maintained.

[0283] Figure 33 A cross-section of a portion of a composite nonwoven fabric 120 having chemical bonding sites 3110 is depicted. In one example aspect, and as... Figure 33As shown, the chemical adhesive 2916 at the chemical bonding site 3110 is depicted as being located on top of the first surface 710 of the composite nonwoven fabric 120. In one example, the chemical adhesive 2916 may have an application thickness 3310 between about 0.1 mm and about 0.2 mm to achieve the desired degree of chemical bonding to the fibers. Furthermore, in some examples, the application thickness 3310 may allow the chemical adhesive 2916 to extend outward from the first surface 710 at the chemical bonding site 3110 to form a micro-recessed structure. The application thickness 3310 of the chemical adhesive 2916 can be adjusted based on, for example, the depth of the hole 3010 of the gravure printing roller 2910 (i.e., a deeper hole equals an increased thickness). In an example, the temperatures of the gravure printing rollers 2910 and embossing rollers 2920, the amount of pressure applied by the gravure printing rollers 2910 and embossing rollers 2920 to the composite nonwoven fabric 120, and parameters associated with the chemical adhesive 2916, such as the applied temperature and viscosity, can be adjusted to achieve more or less penetration of the chemical adhesive 2916 into the thickness of the composite nonwoven fabric 120 relative to the first side 710. For example, increased pressure and decreased viscosity may be associated with relatively greater penetration of the chemical adhesive 2916 into the composite nonwoven fabric 120, while decreased temperature and increased viscosity may be associated with relatively less penetration of the chemical adhesive 2916 into the composite nonwoven fabric 120. The penetration level of the chemical adhesive 2916 can be adjusted based on the desired drape, hand feel, and growth and recovery characteristics of the composite nonwoven fabric 120, where greater penetration may be associated with reduced drape and reduced growth and recovery characteristics, but increased anti-pilling properties. In an example, due to the material properties of the elastomer layer 116 (e.g., spunbond or meltblown), the chemical adhesive 2916 may not extend beyond the elastomer layer 116 when applied to the first surface 710. In other words, when the chemical adhesive 2916 is applied to the first surface 710, it does not penetrate into the second entangled fiber web 718.

[0284] Figure 34 and Figure 35The illustration shows the application of chemical adhesive 2916 to specific areas. The application of chemical adhesive 2916 to specific areas can be performed in a variety of different ways. For example, a digital printing press can be used to apply chemical adhesive 2916 according to a computer program that can specify areas for applying larger density chemical adhesive sites and areas for applying smaller density chemical adhesive sites. Application can also be performed using spray, foam, or powder application, where different portions of the composite nonwoven fabric are masked to create areas with larger and smaller density chemical adhesive sites. Additionally, gravure printing rollers (such as gravure printing roller 2910) can be configured to have a larger pore density in one portion of the gravure printing roller and a smaller pore density in another portion. In another example, the application of chemical adhesive 2916 to specific areas can be achieved by cutting and sewing, where the first composite nonwoven fabric can include a larger density of chemical adhesive sites compared to the second composite nonwoven fabric. Patterns can be cut from each of the first and second composite nonwoven fabrics, and garments can be formed from the patterns. In this respect, the pattern from the first composite nonwoven fabric can be located in areas of the garment that experience a relatively high rate of abrasion.

[0285] Figure 34 A rear view of an example upper garment 3400 is depicted, which has a rear torso portion 3410 and a front torso portion ( Figure 34 (Not shown in the image), together they define a neck opening 3412 and a waist opening 3414. The upper garment 3400 also includes a first sleeve 3416 and an opposing second sleeve 3418. Although described as a long-sleeved upper garment, various aspects herein envision the upper garment 3400 potentially including other forms such as a pullover, hoodie, jacket / coat, vest, short-sleeved upper garment, etc. The upper garment 3400 may be formed from a composite nonwoven fabric 120. A first side 710 of the composite nonwoven fabric 120 forms the outward-facing surface 3401 of the upper garment 3400, and a second side 810 of the composite nonwoven fabric 120 forms the inward-facing surface of the upper garment 3400.

[0286] The garment 3400 includes a plurality of chemical adhesive sites 3415 located on at least the outward-facing surface 3401. The depiction of the chemical adhesive sites is exemplary in nature and need not be drawn to scale. For example, the number of chemical adhesive sites, the size of the chemical adhesive sites, and the spacing between the chemical adhesive sites are exemplary. In an example aspect, chemical adhesive sites 3415 may not be present on the inward-facing surface of the garment 3400. In an example aspect, a higher density of chemical adhesive sites 3415 may be applied to areas of the garment 3400 that typically experience higher rates of abrasion. For example, areas of the garment 3400 that may typically experience higher rates of abrasion include, for example, the elbow area, collar area, waistband area, and cuff area. In some example aspects, the application area of ​​the higher density of chemical adhesive sites may be based on the specific movement in which the garment 3400 is designed. In one example of running, a higher density of chemical adhesive sites may be applied along the sides of the torso and under the armpits, as these areas may experience relatively higher amounts of abrasion during running due to the wearer's arm movements.

[0287] exist Figure 34 In the example shown, the elbow region 3420, as shown in box 3422, has a higher density of chemical adhesive sites 3415 compared to other portions of, for example, the rear torso portion 3410, the front torso portion, and the first sleeve 3416 and the second sleeve 3418 (as shown in box 3424). The density difference of the chemical adhesive sites 3415 on the upper garment 3400 is exemplary, and it is envisioned herein that other portions of the upper garment 3400 may include relatively high densities of chemical adhesive sites 3415 based on the aforementioned wear pattern.

[0288] Figure 35 A front view of an example lower garment 3500 is depicted, which has a front torso portion 3510 and a rear torso portion that together define a waist opening 3512. Figure 35 (Not shown in the image). The lower garment 3500 also includes a first leg portion 3514 having a first leg opening 3516 and a second leg portion 3518 having a second leg opening 3520. Although depicted as trousers, various aspects herein envision the lower garment 3500 including other forms such as shorts, leggings, capri pants, etc. The lower garment 3500 may be formed of a composite nonwoven fabric 120. A first side 710 of the composite nonwoven fabric 120 forms the outward-facing surface 3501 of the lower garment 3500, while a second side 810 of the composite nonwoven fabric 120 forms the inward-facing surface of the lower garment 3500.

[0289] The lower garment 3500 includes a plurality of chemical adhesive sites 3515 located on at least the outward-facing surface 3501. The depiction of the chemical adhesive sites is exemplary in nature and need not be drawn to scale. For example, the number of chemical adhesive sites, the size of the chemical adhesive sites, and the spacing between the chemical adhesive sites are exemplary. In an example, chemical adhesive sites 3515 may not be present on the inward-facing surface of the lower garment 3500. In an example, a higher density of chemical adhesive sites 3515 may be applied to areas of the lower garment 3500 that typically experience higher rates of wear. Some example locations include the knee area, waist opening area, leg cuff area, and / or hip portion. Similar to the upper garment 3400, the application area of ​​the higher density of chemical adhesive sites may be based on the specific movement in which the lower garment 3500 is designed. For example, in the case of running or cycling, a higher density of chemical adhesive sites may be applied along the inner thigh portion of the lower garment 3500 because these areas may experience relatively higher rates of wear due to the wearer's leg movements during running and / or cycling.

[0290] exist Figure 35 In the example shown, the knee region 3522, as shown by box 3524, may have a higher density of chemical adhesive sites 3515 compared to other portions of, for example, the front torso portion 3510, the rear torso portion, and the first leg portion 3514 and the second leg portion 3518 (as shown by box 3526). The density difference of the chemical adhesive sites 3515 on the lower garment 3500 is exemplary, and it is envisioned herein that other portions of the lower garment 3500 may include relatively high densities of chemical adhesive sites 3515 based on the aforementioned wear pattern.

[0291] Figure 36An example ultrasonic bonding system 3600 suitable for forming a thermally conductive bond on a composite nonwoven fabric 120 to reduce the formation of lint on at least a first side 710 of the composite nonwoven fabric 120 is illustrated. While an ultrasonic bonding system has been described herein, other methods of forming a thermal bond are contemplated, such as the direct application of heat (e.g., heated air) and / or pressure. In an example aspect, a thermal bonding process may be applied to one or more fiber webs, such as a first fiber web 110, a second fiber web 112, and / or a third fiber web 114, prior to bonding webs 110, 112, and / or 114 to the composite nonwoven fabric 120. In this respect, the thermal bonding of a single web will only involve the fibers constituting the single web, such as fibers 210 of the first fiber web 110, fibers 310 and 312 of the second fiber web 112, and / or fibers 410 of the third fiber web 114. In other examples, thermal bonding can be applied to the finished composite nonwoven fabric 120 (a composite nonwoven fabric after the individual webs 110, 112, and / or 114 have been stacked and entangled with each other). In this respect, since fibers 110, 310, and 312, and / or 410 are already entangled with each other, thermal bonding will, for example, bond one or more of fibers 210, 310, and 312, and / or 410 together.

[0292] As used herein, the term “thermally bonded” 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 flow at 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. Thermobonding traps the ends of the fibers and makes the fiber ends less susceptible to interaction with other fiber ends to form fuzz. As used herein, the term “thermally bonded site” refers to the location of thermal bonding on a composite nonwoven fabric, and the term “thermally bonded structure” refers to the actual structure formed by re-cured fibers and / or materials, and typically includes fibers and materials from different fiber webs used to form the composite nonwoven fabric 120. The term “membrane form” as used herein also refers to a structure formed by re-cured fibers and / or materials. Figure 36 The components depicted are exemplary and intended to convey general concepts associated with the ultrasonic bonding system 3600. The system 3600 may include additional or fewer components, and these components may have different configurations than those shown.

[0293] The ultrasonic bonding system 3600 may include an impression roller 3610 having an impression pattern 3612. In an exemplary embodiment, the impression pattern 3612 may include a plurality of discrete protrusions extending away from the impression roller 3610. As further described below, the size of the protrusions and the spacing between adjacent protrusions can be selected to provide the desired thermal bonding pattern. Although the protrusions are depicted as having a rectangular shape, this is exemplary, and other shapes (e.g., circles, triangles, squares, etc.) are contemplated herein. The impression roller 3610 is configured to rotate in a first direction 3614.

[0294] The ultrasonic bonding system 3600 also includes an ultrasonic welding electrode or ultrasonic welding head 3616. A composite nonwoven fabric 120 is positioned between the impression roller 3610 and the ultrasonic welding head 3616, such that, in one example aspect, a first surface 710 of the composite nonwoven fabric 120 contacts the impression roller 3610, while a second surface 810 contacts the ultrasonic welding head 3616. Various aspects of this document also envision a second surface 810 of the composite nonwoven fabric 120 contacting the impression roller 3610, while the first surface 710 contacts the ultrasonic welding head 3616.

[0295] As the composite nonwoven fabric 120 advances in the machine direction, the impression roller 3610 applies pressure to discrete areas of the composite nonwoven fabric 120 based on the impression pattern 3612. In other words, pressure is applied to the composite nonwoven fabric 120 in areas corresponding to the protrusions forming the impression pattern 3612. For example, the pressure applied to the composite nonwoven fabric 120 can be approximately 2 kg / cm². 2 Approximately 4.6 kg / cm 2 The pressure causes discrete regions of the composite nonwoven fabric 120 to come into firm contact with the ultrasonic welding head 3616, which transmits ultrasonic vibrations to heat the fibers forming the composite nonwoven fabric 120 to a molten, partially molten, and / or softened state, thereby forming a plurality of thermal bonding sites 3618 (described further below). Pressure below these values ​​may result in insufficient contact with the ultrasonic welding head 3616, and the resulting thermal bond may be weakened. At the thermal bonding sites 3618, fibers 210, 310, and 312, as well as fiber 410 (when used), may melt or soften together and have a film form at the thermal bonding sites 3618. Additionally, a portion of the elastomer layer 116 may melt or soften together with fibers 210, 310, and 312, as well as fiber 410 (when used), at the thermal bonding sites 3618. Since fibers 210, 310, and 312, as well as fiber 410 (when used), are melted or softened together at the thermal bonding site 3618, the number of fiber ends available for pilling is reduced, and thus the anti-pilling properties of the composite nonwoven fabric 120 on the first side 710 and the second side 810 are increased.

[0296] By configuring the embossed pattern 3612 to include discrete shapes with specific sizes and spacings, the desired amount of surface area occupied by the resulting thermal bonding sites in the composite nonwoven fabric 120 is achieved. In an example aspect, the surface area occupied by the resulting thermal bonding sites in the composite nonwoven fabric 120 is balanced by the need to maintain the drape, growth, and recovery properties of the composite nonwoven fabric 120. For example, if the surface area occupied by the thermal bonding sites in the composite nonwoven fabric 120 exceeds a threshold, the drape, growth, and recovery properties of the composite nonwoven fabric 120 decrease, despite increased anti-pilling properties. Conversely, if the surface area occupied by the thermal bonding sites is below a threshold, the anti-pilling properties of at least the first side 710 of the composite nonwoven fabric 120 may be lower than desired. In an example aspect, the amount of surface area occupied by the thermal bonding sites in the composite nonwoven fabric 120 can be between about 5% and about 50%, between about 5% and about 30%, or between about 6% and about 25% to achieve anti-pilling properties of 2 or greater.

[0297] Figure 37 An exemplary schematic diagram is depicted of the first surface 710 of a composite nonwoven fabric 120 after processing by an ultrasonic bonding system 3600. In this example, the first surface 710 is positioned to contact an impression roller 3610, while the second surface 810 is positioned to contact an ultrasonic welding head 3616. The composite nonwoven fabric 120 includes a plurality of thermal bonding sites 3618. Each thermal bonding site 3618 includes a thermal bonding structure (described further below) that is offset relative to the first surface 710 in a direction extending toward the second surface 810. In other words, the thermal bonding structure is located between the first surface 710 and the second surface 810. Thus, the first surface 710 maintains a generally smooth planar configuration, which may be desirable from a comfort and aesthetic point of view. In an example, the distance 3710 between adjacent thermal bonding sites 3618 may be less than or equal to the average fiber length of the fibers present on the first surface 710 (e.g., fibers 210, 310 and 312, and / or fiber 410). For example, the spacing can be less than or equal to about 60 mm, less than about 55 mm, or less than about 51 mm. In an example, the size of the thermally bonded site 3618 can be between about 0.75 mm and about 4 mm, between about 1 mm and about 3.5 mm, or between about 1 mm and about 3 mm. The distance 3710 between adjacent thermally bonded sites 3618 can be between about 3 mm and about 7 mm, or between about 4 mm and 6 mm.

[0298] Figure 38An exemplary schematic diagram depicts the second side 810 of the composite nonwoven fabric 120 after processing by an ultrasonic bonding system 3600. The second side 810 also includes a plurality of thermal bonding sites 3618. The thermal bonding structure associated with the thermal bonding sites 3618 is further offset relative to the second side 810 in a direction extending toward the first side 710. Thus, the thermal bonding structure is located between the first side 710 and the second side 810. Similar to the first side 710, the second side 810 maintains a generally smooth planar configuration, which is desirable at least from a comfort point of view, as the second side 810 forms the inward-facing surface of the resulting garment.

[0299] about Figure 37 and Figure 38 The illustrated thermal bonding pattern has its primary direction of thermal bonding aligned with the machine orientation of the composite nonwoven fabric 120. This is based on an embossed pattern 3612, which includes shapes with long and short axes, and aligns the long axes of these shapes with the machine orientation of the composite nonwoven fabric 120. In this example, aligning the primary direction of thermal bonding with the machine orientation helps maintain the tensile and resilience properties of the composite nonwoven fabric 120 in the machine transverse direction. In other words, as described above, the tensile and resilience of the composite nonwoven fabric 120 in the machine orientation may be less than in the machine transverse direction due to the overall orientation of the fibers in each layer and the strain or tension applied to the fibers of the composite nonwoven fabric 120 during needle punching. Therefore, aligning the primary direction of thermal bonding with the machine orientation helps limit the thermal bonding effect of the composite nonwoven fabric 120 in the machine transverse direction and maintains the tensile and resilience of the fabric 120 in the machine transverse direction.

[0300] Figure 39A cross-section of the composite nonwoven fabric 120, taken at the thermal bonding site 3618, is depicted. The thermal bonding site 3618 includes a thermal bonding structure 3910 offset relative to the first surface 710 in a direction extending toward the second surface 810, and further offset relative to the second surface 810 in the direction extending toward the first surface 710. The bidirectional offset of the thermal bonding structure 3910 may be due to a combination of the pressure and depth of the protrusions of the embossed pattern 3612 forming the embossing roller 3610 and the melting of all layers of the composite nonwoven fabric caused by the ultrasonic welding head 3616 at the thermal bonding site 3618. The thermal bonding structure 3910 is a cohesive structure formed at least by molten, partially molten, and / or softened and re-cured fibers 210. The thermal bonding structure 3910 may also include molten, partially molten, and / or softened and re-cured fibers 310 and 312, and when used, may also include molten, partially molten, and / or softened and re-cured fibers 410. Additionally, the thermally bonded structure 3910 may include molten, partially molten, and / or softened and re-cured material from the elastomeric layer 116, including fibers. In other words, fibers 210, 310, and 312, fiber 410 (when used), and / or portions from the elastomeric layer 116 are in film form at the thermally bonded structure 3910. As shown, in an example aspect, fiber 210 from the first entangled fiber web 712 extends from the thermally bonded structure 3910. Figure 39 Fibers 310 and 312 from a second entangled fiber web 718 extending from the thermally bonded structure 3910 are also depicted. Additionally, fiber 410 from a third entangled fiber web 714 (when in use) extends from the thermally bonded structure 3910. In some examples, the melting of fibers 210, 310, 312, and 410, as well as the elastomer layer 116, can cause the formation of pores or pinholes, the formation of which allows air and water vapor to flow from the second side 810 of the composite nonwoven fabric 120 to the first side 710, while substantially preventing fluid communication paths for liquids (e.g., sediment) from flowing from the first side 710 to the second side 810.

[0301] In some examples, the thermally bonded structure 3910 is offset relative to the first surface 710 by a first average depth 3912, and further offset relative to the second surface 810 by a second average depth 3914, wherein the first average depth 3912 may be greater than the second average depth 3914. In other words, the thermally bonded structure 3910 is offset relative to both the first surface 710 and the second surface 810, and also relative to the central plane 3915 of the composite nonwoven fabric 120, wherein the central plane 3915 is located approximately halfway between the first surface 710 and the second surface 810. Figures 37 to 39In the example shown, the thermally bonded structure 3910 is located between the central plane 3915 and the second surface 810. Various aspects of this document also envision a first average depth 3912 being less than a second average depth 3914. In this respect, the thermally bonded structure 3910 will be located between the central plane 3915 and the first surface 710.

[0302] like Figure 39 As shown, the composite nonwoven fabric 120 is thinner at the location corresponding to the thermal bonding structure 3910. As a functional result, the permeability and / or breathability of the fabric 120 can be increased at the thermal bonding site 3618 compared to the region of the composite nonwoven fabric 120 excluding the thermal bonding site 3618. The permeability and / or breathability of the fabric 120 at the thermal bonding site 3618 can be enhanced by the aforementioned pores. Increased permeability and / or breathability near the thermal bonding site 3618 can be an ideal characteristic of the resulting garment, allowing moisture or sweat generated by the wearer to be converted into vapor and dissipated through the pores.

[0303] Figure 40 An exemplary schematic diagram depicts a first surface 710 of a composite nonwoven fabric 120, wherein the composite nonwoven fabric 120 includes a first plurality of heat-dissipating adhesive sites 4010 and a second plurality of heat-dissipating adhesive sites 4012. In an example embodiment, the first plurality of heat-dissipating adhesive sites 4010 may be formed using an ultrasonic bonding system 3600, wherein the first surface 710 is positioned to contact an impression roller 3610, and the second surface 810 is positioned to contact an ultrasonic welding head 3616. The second plurality of heat-dissipating adhesive sites 4012 may be formed using the ultrasonic bonding system 3600, wherein the second surface 810 is positioned to contact an impression roller having a pattern different from that of the impression roller 3610, and the first surface 710 is positioned to contact the ultrasonic welding head 3616.

[0304] In an example, the first plurality of heat-dissipating adhesive sites 4010 are arranged in a first pattern, and the second plurality of heat-dissipating adhesive sites 4012 are arranged in a second pattern different from the first pattern. For example, the first plurality of heat-dissipating adhesive sites 4010 may be different from and separate from the second plurality of heat-dissipating adhesive sites 4012, such that the first plurality of heat-dissipating adhesive sites 4010 do not overlap with or only partially overlap with the second plurality of heat-dissipating adhesive sites 4012. Furthermore, as... Figure 40 As shown, various aspects of this document envision that the shape of the first plurality of heat dissipation adhesive sites 4010 may differ from the shape of the second plurality of heat dissipation adhesive sites 4012 (rectangle versus circle), although various aspects of this document also envision that the shape of each of the first plurality of heat dissipation adhesive sites 4010 and the second plurality of heat dissipation adhesive sites 4012 is the same (e.g., two rectangles or two circles).

[0305] Figure 41 Depicting Figure 40 An exemplary schematic diagram of the second surface 810 of the composite nonwoven fabric 120. As shown, the second surface 810 also includes a first plurality of thermal bonding sites 4010 and a second plurality of thermal bonding sites 4012. Figure 42 A cross-section taken through thermal adhesive sites 4010 and 4012 is depicted. Thermal adhesive site 4010 includes a first thermal adhesive structure 4210 offset from the first surface 710 by a first depth 4212 in a direction extending toward the second surface 810. Thermal adhesive site 4012 includes a second thermal adhesive structure 4215 offset from the first surface 710 by a second depth 4214 in a direction extending toward the second surface 810. In this example, the first depth 4212 is greater than the second depth 4214.

[0306] From the perspective of the second surface 810, the first thermally bonded structure 4210 is offset by a third depth 4216 relative to the second surface 810 in the direction extending toward the first surface 710. The second thermally bonded structure 4215 is offset by a fourth depth 4218 relative to the second surface 810 in the direction extending toward the first surface 710. In an example, the third depth 4216 is less than the first depth 4212 and the fourth depth 4218 is greater than the second depth 4214. In addition, the fourth depth 4218 is greater than the third depth 4216.

[0307] Applying heat-bonding sites to both sides of the composite nonwoven fabric 120 can increase the pilling resistance of the first side 710 and the second side 810. For example, the heat-bonding sites 4010 generated when the first side 710 is positioned against the impression roller 3610 can help capture a larger proportion of fibers from the first entangled fiber web 712 in the first heat-bonding structure 4210, and the heat-bonding sites 4012 generated when the second side 810 is positioned against the impression roller can help capture a larger proportion of fibers from the second entangled fiber web 718 in the second heat-bonding structure 4215. As a result, a smaller proportion of fibers from the first entangled fiber web 712 and a smaller proportion of fibers from the second entangled fiber web 718 can be used for pilling.

[0308] Figure 43 and Figure 44The illustration shows the application of thermal bonding sites in specific areas. The application of thermal bonding sites in specific areas can be performed in a variety of different ways. For example, an impression roller, such as impression roller 3610, can be configured to have a higher density of protrusions in one part of the roller and a lower density of protrusions in another part. The application of thermal bonding sites in specific areas can also be achieved by ultrasonic, thermal, and / or pressure application. The application of thermal bonding sites in specific areas can also be achieved using a cut-and-sewn method, where the first composite nonwoven fabric can include a higher density of thermal bonding sites compared to the second composite nonwoven fabric. Patterns can be cut from each of the first and second composite nonwoven fabrics, and garments can be formed from the patterns. In this respect, the pattern from the first composite nonwoven fabric can be located in areas of the garment that experience a relatively high rate of abrasion. The application of these areas can be based on, for example, a pattern of garment areas susceptible to moderate to high abrasion.

[0309] Figure 43 A rear view of an example upper garment 4300 is depicted, which has a rear torso portion 4310 and a front torso portion ( Figure 43 (Not shown in the image), together they define a neck opening 4312 and a waist opening 4314. The upper garment 4300 also includes a first sleeve 4316 and an opposing second sleeve 4318. Although described as a long-sleeved upper garment, various aspects herein envision the upper garment 4300 potentially including other forms such as a pullover, hoodie, jacket / coat, vest, short-sleeved upper garment, etc. The upper garment 4300 may be formed of a composite nonwoven fabric 120. A first side 710 of the composite nonwoven fabric 120 forms the outward-facing surface 4301 of the upper garment 4300, and a second side 810 of the composite nonwoven fabric 120 forms the inward-facing surface of the upper garment 4300.

[0310] The upper garment 4300 includes a plurality of thermally bonded points 4315 located on at least the outward-facing surface 4301. The depiction of the thermally bonded points is exemplary in nature and need not be drawn to scale. For example, the number of thermally bonded points, the size of the thermally bonded points, and the spacing between the thermally bonded points are exemplary. In illustrative aspects, a larger density of thermally bonded points 4315 may be applied to areas of the upper garment 4300 that typically experience a higher rate of abrasion. For example, areas of the upper garment 4300 that may typically experience a higher rate of abrasion include, for example, the elbow area, collar area, waistband area, and cuff area. In some illustrative aspects, the application area of ​​the larger density of thermally bonded points may be based on the specific movement in which the upper garment 4300 is designed. In one example of running, a larger density of thermally bonded points may be applied along the sides of the torso and under the armpits, as these areas may experience a relatively high amount of abrasion during running due to the wearer's arm movements.

[0311] exist Figure 43 In the example shown, the elbow region 4320, as shown in box 4322, has a higher density of thermally bonded sites 4315 compared to other portions of, for example, the rear torso portion 4310, the front torso portion, and the first sleeve 4316 and the second sleeve 4318 (as shown in box 4344). The density difference of the thermally bonded sites 4315 on the upper garment 4300 is exemplary, and it is envisioned herein that other portions of the upper garment 4300 may include relatively high-density thermally bonded sites 4315 based on the aforementioned wear pattern.

[0312] Figure 44 A front view of an example lower garment 4400 is depicted, which has a front torso portion 4410 and a rear torso portion that together define a waist opening 4412. Figure 44 (Not shown in the image). The lower garment 4400 also includes a first leg portion 4414 having a first leg opening 4416 and a second leg portion 4418 having a second leg opening 4420. Although depicted as trousers, various aspects herein envision the lower garment 4400 potentially including other forms, such as shorts, leggings, capri pants, etc. The lower garment 4400 may be formed from a composite nonwoven fabric 120. A first side 710 of the composite nonwoven fabric 120 forms the outward-facing surface 4401 of the lower garment 4400, while a second side 810 of the composite nonwoven fabric 120 forms the inward-facing surface of the lower garment 4400.

[0313] The lower garment 4400 includes a plurality of thermally bonded points 4415 located on at least an outward-facing surface 4401. The depiction of the thermally bonded points is exemplary in nature and need not be drawn to scale. For example, the number of thermally bonded points, the size of the thermally bonded points, and the spacing between the thermally bonded points are exemplary. In illustrative terms, a larger density of thermally bonded points 4415 may be applied to areas of the lower garment 4400 that typically experience higher rates of wear and tear. Some example locations include the knee area, leg cuff area, waist opening area, and / or hip portion. Similar to the upper garment 4300, the application area of ​​the larger density of thermally bonded points may be based on the specific movement in which the lower garment 4400 is designed. For example, in the case of running or cycling, a larger density of thermally bonded points may be applied along the inner thigh portion of the lower garment 4400, as these areas may experience relatively higher rates of wear and tear due to the wearer's leg movements during running and / or cycling.

[0314] exist Figure 44In the example shown, the knee region 4422, as shown in box 4424, may have a higher density of thermally bonded sites 4415 compared to other portions of, for example, the front torso portion 4410, the rear torso portion, and the first leg portion 4414 and the second leg portion 4418 (as shown in box 4426). The density difference of the thermally bonded sites 4415 on the lower garment 4400 is exemplary, and it is envisioned herein that other portions of the lower garment 4400 may include relatively higher density thermally bonded sites 4415 based on the aforementioned wear pattern.

[0315] In an example, thermally bonded sites created using the ultrasonic bonding system 3600 can be combined with chemically bonded sites created, for example, using the gravure printing system 2900, to further improve the anti-pilling properties of the composite nonwoven fabric 120. In this respect, the composite nonwoven fabric 120 can be treated first using the gravure printing system 2900 and then treated using the ultrasonic bonding system 3600. In this respect, at least some of the thermally bonded sites created using the ultrasonic bonding system 3600 can be located in the same or nearly the same location as the chemically bonded sites created using the gravure printing system 2900 (e.g., they can partially overlap). In an example, thermal bonding can help to thermally cure the chemical adhesive at the chemically bonded sites, thereby improving the durability and lifespan of the chemically bonded sites, especially after repeated washing and abrasion. Conversely, the composite nonwoven fabric 120 can be treated first using the ultrasonic bonding system 3600 and then treated using the gravure printing system 2900.

[0316] In an example, the engraved pattern 2914 of the gravure printing roller 2910 and the imprinted pattern 3612 of the impression roller 3610 can be configured such that the resulting chemically bonded and thermally bonded sites on the composite nonwoven fabric 120 are distinct, separate from each other, and do not overlap. This facilitates the desired amount of surface area of ​​the composite nonwoven fabric 120 to include both chemically and thermally bonded sites, while minimizing the use of the chemical adhesive 2916 and reducing the energy consumption of the gravure printing system 2900 and the ultrasonic bonding system 3600.

[0317] Figure 45 An exemplary schematic diagram depicts a first surface 710 of a composite nonwoven fabric 120. A plurality of thermally bonded sites 4510 are present at first locations on the first surface 710, and a plurality of chemically bonded sites 4512 are present at second locations on the first surface 710. In one example, the second location differs from the first location. In another example, the first location does not overlap with the second location, as... Figure 45As shown. Thermal adhesive site 4510 may have features similar to thermal adhesive site 3618, and chemical adhesive site 4512 may have features similar to chemical adhesive site 3110. The depicted patterns of thermal adhesive site 4510 and chemical adhesive site 4512 are exemplary, and it is envisioned herein that thermal adhesive site 4510 and chemical adhesive site 4512 may have different patterns.

[0318] Figure 46 Depicting Figure 45 An exemplary schematic diagram of the second side 810 of the composite nonwoven fabric 120. The second side 810 includes thermal bonding sites 4510. In an example aspect, the second side 810 may not include any chemical bonding sites, such as chemical bonding sites 4512. Figure 47 An example cross-section taken through thermal bonding sites 4510 and chemical bonding sites 4512 is depicted. As shown, thermal bonding site 4510 includes a thermally bonded structure 4710 located between the first surface 710 and the second surface 810. Chemical bonding site 4512 is shown to be present on the first surface 710 but not on the second surface 810. As described above, the use of thermal bonding sites 4510 and chemical bonding sites 4512 increases at least the pilling resistance of the first surface 710. Various aspects of this document also envision forming thermal bonding sites by positioning the second surface 810 against the impression roller 3610 of the ultrasonic bonding system 3600, forming chemical bonding sites on the second surface 810 of the composite nonwoven fabric 120, and combinations thereof. This may be useful when increased pilling resistance of the second surface 810 is required.

[0319] Figure 48 A schematic diagram depicts an example process 4800 for further reducing pilling on at least the first side 710 of the composite nonwoven fabric 120. Process 4800 can be used alone or in combination with one or more of the aforementioned chemical bonding and thermal bonding processes. As described above, the composite nonwoven fabric 120 may include different fiber webs, such as webs 110, 112, and 114, formed as cohesive structures, wherein the different webs may have different or similar fiber compositions and / or different properties. The term "fiber web" refers to a layer prior to mechanical entanglement with one or more other fiber webs. The web comprises fibers that have undergone carding and overlapping processes, typically aligning the fibers in one or more common directions extending along the xy plane and achieving the desired basis weight. The fiber web may also undergo a light needle-punching process or a mechanical entanglement process, which entangles the fibers of the fiber web to a degree such that the fiber web forms a manipulable cohesive structure (e.g., wound onto a roller, unwound from a roller, stacked, etc.). For example, webs 112 and 114 may each have approximately 50 N / cm. 2The stitch density. Various aspects of this paper envision increasing the stitch density of at least the first fiber web 110 to increase the pilling resistance of at least the first side 710 of the composite nonwoven fabric 120, as described below.

[0320] In step 4810, the first fiber web 110 undergoes a first mechanical entanglement process 4816, which is performed unidirectionally from the first surface 4812 of the first fiber web 110 to the opposite second surface 4814. The stitch density of the first mechanical entanglement process 4816 can be greater than 50 n / cm. 2 Approximately 75 N / cm 2 Approximately 100 N / cm 2 Or approximately 200 N / cm 2 In one example, the stitch density of the first fiber web 110 after the first mechanical entanglement process 4816 may be at least twice the stitch density of the second fiber web 112, and, when used, at least twice the stitch density of the third fiber web 114. In this example, the first fiber web 110 does not undergo a mechanical entanglement process in the direction from the second surface 4814 toward the first surface 4812.

[0321] Step 4818 depicts the first fiber web 110 after the first mechanical entanglement process 4816. Since the first mechanical entanglement process 4816 is performed unidirectionally from the first surface 4812 towards the second surface 4814, the fibers 210 forming the first fiber web 110 are pushed by the entanglement needles, causing the fibers 210 (including the ends 4820 of the fibers 210) to extend outward from the second surface 4814 of the first fiber web 110. In other words, the fibers 201 extend in a direction away from the first surface 4812 of the first fiber web 110.

[0322] In step 4822, the first fiber web 110 is stacked with the second fiber web 112, an optional third fiber web 114, and the elastomer layer 116. In this example, the first fiber web 110 is stacked such that the second face 4814 faces outward and away from, for example, the elastomer layer 116 and the third fiber web 114 (when in use). Therefore, the ends 4820 of the fibers 210 extend in the stacked configuration in a direction away from the elastomer layer 116 and the third fiber web 114 (when in use).

[0323] In step 4824, a second mechanical entanglement process 4826 is performed on the stacked configuration of the first fiber web 110, the second fiber web 112, the third fiber web 114 (when in use), and the elastomer layer 116. The second mechanical entanglement process 4826 is performed in a direction from the first fiber web 110 toward the second fiber web 112, and effectively pushes the ends 4920 of the fibers 210 back into at least the first fiber web 110 to form, for example, a loop structure. Step 4824 may include, for example, regarding... Figure 7 The additional entanglement process described includes a mechanical entanglement process performed in the direction from the second fiber web 112 toward the first fiber web 110.

[0324] Step 4828 depicts the composite nonwoven fabric 120 after the second mechanical entanglement process 4826, wherein the composite nonwoven fabric 120 includes a first entangled fiber web 712, a second entangled fiber web 718, a third entangled fiber web 714 (when in use), and an elastomer layer 116. As shown, the second face 4814 of the first fiber web 110 forms the first face 710 of the composite nonwoven fabric 120 (also referred to as the first face surface) and includes a plurality of loops 4830 representing fibers 210 whose ends 4820 are pushed back into the first fiber web 110 after the second mechanical entanglement process 4826. Because the fiber ends 4820 do not extend outward from the first face 710 and therefore cannot interact with other fiber ends to form pills, the anti-pilling property of at least the first face 710 is increased to 2 or greater.

[0325] Step 4832 describes the composite nonwoven fabric 120 forming the upper garment 4834, wherein a plurality of loops 4830 extend from the outward-facing surface of the upper garment 4834. Various aspects of the process 4800 described herein envision that can be configured to produce a regional distribution of the plurality of loops 4830, wherein a higher density of loops 4830 is positioned in areas of the garment prone to increased wear, similar to the description of… Figures 34 to 35 and Figures 43 to 44 As described. For example, the first mechanical entanglement step 4816 and the second mechanical entanglement step 4826 may be positioned in discrete regions of the first fiber web 110 and / or in the stacking configuration shown in step 4824 to form loops 4830 in the discrete regions.

[0326] Figure 49 An exemplary schematic diagram depicts the first face 710 of the composite nonwoven fabric 120 after undergoing process 4800. The first face 710 includes a plurality of loops 4830 representing fibers 210, the ends 4820 of which are pushed back into the first fiber web 110 after a second mechanical entanglement process 4826. The first face 710 also includes fiber ends, such as fiber ends 4820. Fiber ends may include the ends of fibers 210 forming the first fiber web 110, and may also include the ends of fibers from other webs (e.g., webs 112 and 114) that are pushed over the first face 710 after the mechanical entanglement process.

[0327] Figure 50An exemplary schematic diagram depicts a second side 810 of a composite nonwoven fabric 120 after undergoing process 4800. The second side 810 includes fiber ends 5010 and loops 5012. Fiber ends 5010 and loops 5012 may include fibers 210, 310, and 312, and fiber 410 (when used). In an example aspect, the first side 710 may include a relatively high density of loops (e.g., per cm). 2 More loops), such as loops 4830 shown in box 4910, and the second side 810 may include loops of relatively low density, such as loops 5012. To describe this differently, the first side 710 may include fiber ends of relatively low density, such as ends 4820, while the second side 810 may include fiber ends of relatively high density, such as ends 5010.

[0328] Figure 51 Depicting Figure 49 The cross-section of the composite nonwoven fabric 120 is shown. As illustrated, loops 4830 and ends 4820 on the first surface 710 extend away from the first surface 710 in a direction away from the central plane 5110 of the composite nonwoven fabric 120. Similarly, ends 5010 and loops 5012 extend away from the second surface 810 in a direction away from the central plane 5110 of the composite nonwoven fabric 120. Compared to the second surface 810, the first surface 710 includes a relatively large number of loops, such as loops 4830, thereby giving the first surface 710 increased anti-pilling properties.

[0329] The following clauses represent example 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.

[0330] Clause 1. A composite nonwoven fabric having an asymmetrical finish on a first side and an opposing second side, said asymmetrical finish composite nonwoven fabric comprising: a first entangled fiber web, the first entangled fiber web per cm 2 Having the first number of fibers and per cm 2 A second number of fibers having a second denier, wherein the ratio of the first denier to the second denier is in the range of about 1.5:1 to about 2:1, the first entangled fiber web at least partially forming the first face; a second entangled fiber web, the second entangled fiber web per cm 2 The third number of fibers with a third denier and per cm 2The second entangled fiber web at least partially forms the second face, wherein the ratio of the third denier to the fourth denier is in the range of about 0.3:1 to about 0.7:1; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the second entangled fiber web.

[0331] Clause 2. A composite nonwoven fabric with an asymmetric finish as described in Clause 1, wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the first entangled fiber web.

[0332] Clause 3. The composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 1 to 2 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0333] Clause 4. A composite nonwoven fabric with an asymmetric finish as described in Clause 3, wherein the third entangled fiber web per cm 2 Including the fifth denier of the fifth number of fibers and per cm 2 The sixth number of fibers includes a sixth denier, wherein the ratio of the fifth denier to the sixth denier is in the range of about 1.5:1 to about 2:1.

[0334] Clause 5. A composite nonwoven fabric with an asymmetric finish according to any one of Clauses 3 to 4, wherein the third entangled fiber web is located between the first entangled fiber web and the elastomer layer.

[0335] Clause 6. A composite nonwoven fabric with an asymmetric finish according to any one of Clauses 3 to 4, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0336] Clause 7. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 3 to 6, wherein at least some fibers of the third entangled fiber web extend through the elastomeric layer.

[0337] Clause 8. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 3 to 7, wherein at least some fibers of the third entangled fiber web are entangled with fibers of the first entangled fiber web and fibers of the second entangled fiber web.

[0338] Clause 9. A composite nonwoven fabric having an asymmetrical finish on a first side and an opposing second side, said asymmetrical finish composite nonwoven fabric comprising: a first entangled fiber web, the first entangled fiber web per cm 2The first number of fibers having a denier from about 1.2D to about 3.5D and per cm 2 The first entangled fiber web has a second number of fibers with a denier of about 0.6D to about 1D, the first number of fibers being greater than the second number of fibers, wherein the first entangled fiber web at least partially forms the first face; the second entangled fiber web has a density of [missing information - likely a density value per cm]. 2 It has a third number of fibers with a denier ranging from about 0.6D to about 1D and per cm 2 The second entangled fiber web has a fourth number of fibers with a denier of about 1.2D to about 3.5D, the third number of fibers being more than the fourth number of fibers, wherein the second entangled fiber web at least partially forms the second face; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the second entangled fiber web.

[0339] Clause 10. A composite nonwoven fabric with an asymmetric finish as described in Clause 9, wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the first entangled fiber web.

[0340] Clause 11. The composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 9 to 10 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0341] Clause 12. A composite nonwoven fabric with an asymmetric finish as described in Clause 11, wherein the third entangled fiber web per cm 2 This includes fibers with denier ranging from about 1.2D to about 3.5D and per cm 2 It includes a sixth number of fibers with a denier ranging from about 0.6D to about 1D, wherein the fifth number of fibers is greater than the sixth number of fibers.

[0342] Clause 13. A composite nonwoven fabric with an asymmetric finish according to any one of Clauses 11 to 12, wherein the third entangled fiber web is located between the first entangled fiber web and the elastomer layer.

[0343] Clause 14. A composite nonwoven fabric with an asymmetric finish according to any one of Clauses 11 to 12, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0344] Clause 15. A composite nonwoven fabric with an asymmetric finish according to any one of Clauses 11 to 14, wherein at least some fibers of the third entangled fiber web extend through the elastomeric layer.

[0345] Clause 16. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 11 to 15, wherein at least some fibers of the third entangled fiber web are entangled with fibers of the first entangled fiber web and fibers of the second entangled fiber web.

[0346] Clause 17. A method of manufacturing an asymmetric-finished composite nonwoven fabric, comprising: positioning an elastomer layer between a first fiber web having a denier of about 1.2D to about 3.5D and a second fiber web having a denier of about 0.6D to about 1D; and mechanically entangled a plurality of fibers of the first fiber web and a plurality of fibers of the second fiber web such that the first fiber web becomes a first entangled fiber web and the second fiber web becomes a second entangled fiber web, wherein after the mechanical entanglement step, at least some fibers of the first entangled fiber web and at least some fibers of the second entangled fiber web extend through the elastomer layer, and wherein the first entangled fiber web at least partially forms a first side of the asymmetric-finished composite nonwoven fabric, and the second entangled fiber web at least partially forms an opposing second side of the asymmetric-finished composite nonwoven fabric.

[0347] Clause 18. The method of manufacturing a composite nonwoven fabric with an asymmetric finish according to Clause 17 further comprises: positioning a third fiber web between the first fiber web and the second fiber web before mechanically entangled the plurality of fibers of the first fiber web and the plurality of fibers of the second fiber web; and mechanically entangled the plurality of fibers of the third fiber web with the fibers of the first fiber web and the fibers of the second fiber web, such that the third fiber web becomes a third entangled fiber web.

[0348] Clause 19. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish as described in Clause 18, wherein the third fiber web comprises fibers with a denier from about 1.2D to about 3.5D.

[0349] Clause 20. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of Clauses 18 to 19, wherein at least some fibers of the third entangled fiber web extend through the elastomeric layer.

[0350] Clause 21. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web at least partially forming the first side; a second entangled fiber web, wherein at least a portion of the fibers in the second entangled fiber web comprises silicone-coated fibers, the second entangled fiber web at least partially forming the second side; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers in the first entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the second entangled fiber web.

[0351] Clause 22. The composite nonwoven fabric according to Clause 21, wherein at least some fibers in the second entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the first entangled fiber web.

[0352] Clause 23. A composite nonwoven fabric according to any one of Clauses 21 to 22, wherein at least a portion of the fibers of the first entangled fiber web comprises silicone-coated fibers.

[0353] Clause 24. The composite nonwoven fabric according to Clause 23, wherein the second entangled fiber web per cm 2 The number of silicone-coated fibers is greater than that of the first entangled fiber web per cm. 2 The number of silicone-coated fibers.

[0354] Clause 25. The composite nonwoven fabric according to any one of Clauses 21 to 24 further comprises a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers in the third entangled fiber web extend through the elastomeric layer and are entangled with one or more fibers of the first entangled fiber web and the second entangled fiber web.

[0355] Clause 26. The composite nonwoven fabric according to Clause 25, wherein at least a portion of the fibers of the third entangled fiber web comprises silicone-coated fibers.

[0356] Clause 27. The composite nonwoven fabric according to Clause 26, wherein the third entangled fiber web per cm 2 The number of silicone-coated fibers is less than that of the second entangled fiber web per cm. 2 The number of silicone-coated fibers.

[0357] Clause 28. A composite nonwoven fabric comprising: two or more entangled fiber webs; and an elastomer layer, wherein at least some fibers of the two or more entangled fiber webs extend through the elastomer layer, and wherein the composite nonwoven fabric comprises, by weight, from about 10% to about 25% silicone-coated fibers.

[0358] Clause 29. The composite nonwoven fabric according to Clause 28, wherein the two or more entangled fiber webs comprise a first entangled fiber web that at least partially forms a first side of the composite nonwoven fabric and a second entangled fiber web that at least partially forms an opposing second side of the composite nonwoven fabric.

[0359] Clause 30. The composite nonwoven fabric according to Clause 29, wherein the elastomer layer is located between the first entangled fiber web and the second entangled fiber web.

[0360] Clause 31. The composite nonwoven fabric according to any one of Clauses 29 to 30 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0361] Clause 32. The composite nonwoven fabric according to Clause 31, wherein the third entangled fiber web is located between the first entangled fiber web and the elastomer layer.

[0362] Clause 33. A method of manufacturing a composite nonwoven fabric, comprising: positioning an elastomer layer between a first fiber web and a second fiber web, wherein the second fiber web comprises, by weight, from about 10% to about 95% silicone-coated fibers; and mechanically entangled at least some fibers of the first fiber web and at least some fibers of the second fiber web such that the first fiber web becomes a first entangled fiber web and the second fiber web becomes a second entangled fiber web, wherein after the mechanical entanglement step, at least some fibers of the first entangled fiber web extend through the elastomer layer, and wherein the first entangled fiber web at least partially forms a first side of the composite nonwoven fabric, and the second entangled fiber web at least partially forms an opposing second side of the composite nonwoven fabric.

[0363] Clause 34. The method of manufacturing a composite nonwoven fabric as described in Clause 33, wherein the first fiber web does not include silicone-coated fibers.

[0364] Clause 35. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 33 to 34, wherein the silicone-coated fiber comprises polyethylene terephthalate (PET) silicone-coated fiber.

[0365] Clause 36. The method of manufacturing a composite nonwoven fabric according to any one of Clauses 33 to 35 further comprises: positioning a third fiber web between the first fiber web and the second fiber web before mechanically entangled said at least some fibers of the first fiber web and said at least some fibers of the second fiber web; and mechanically entangled said at least some fibers of the third fiber web with the fibers of the first fiber web and the fibers of the second fiber web, such that said third fiber web becomes a third entangled fiber web.

[0366] Clause 37. The method of manufacturing a composite nonwoven fabric according to Clause 36, wherein the third fiber web is located between the second fiber web and the elastomer layer.

[0367] Clause 38. A method for manufacturing a composite nonwoven fabric according to any one of Clauses 36 to 37, wherein the third fiber web does not include silicone-coated fibers.

[0368] Clause 39. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 36 to 38, wherein the third fiber web comprises polyethylene terephthalate (PET) fibers.

[0369] Clause 40. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 33 to 39, wherein the first fiber web comprises polyethylene terephthalate (PET) fibers.

[0370] Clause 41. A composite nonwoven fabric having an asymmetrical finish on a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side; a second entangled fiber web forming at least partially the second side; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with fibers of the second entangled fiber web, and wherein the second side comprises a plurality of loops formed from one or more of the fibers of the first entangled fiber web and the fibers of the second entangled fiber web, and wherein the apex of each of the plurality of loops extends a predetermined distance away from the second side.

[0371] Clause 42. A composite nonwoven fabric with an asymmetrical finish as described in Clause 41, wherein the plurality of loops extend in a direction away from the first face.

[0372] Clause 43. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 41 to 42, wherein the predetermined distance is from about 1.5 mm to about 8.1 mm.

[0373] Clause 44. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 41 to 43, wherein the predetermined distance is from about 4 mm to about 6 mm.

[0374] Clause 45. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 41 to 44, wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the first entangled fiber web.

[0375] Clause 46. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 41 to 45, wherein the denier of the fibers forming the plurality of loops is from about 0.6D to about 3.5D.

[0376] Clause 47. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 41 to 46, wherein the elastomer layer has a basis weight from about 20 grams per square meter (gsm) to about 150 gsm.

[0377] Clause 48. A composite nonwoven fabric with an asymmetric finish according to any one of Clauses 41 to 47, wherein the elastomeric layer comprises one of a thermoplastic polyurethane meltblown layer or a thermoplastic polyether ester elastomer spunbond layer.

[0378] Clause 49. A composite nonwoven fabric having an asymmetrical finish on a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side; a second entangled fiber web forming at least partially the second side; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with fibers of the second entangled fiber web, and wherein at least some fibers of the second entangled fiber web have a longitudinal length extending from the elastomeric layer to a distal end of a corresponding fiber, wherein the distal end of the corresponding fiber extends in a direction away from the second side.

[0379] Clause 50. A composite nonwoven fabric with an asymmetrical finish as described in Clause 49, wherein the distal end of the respective fiber comprises one of the ends or apexes of a loop.

[0380] Clause 51. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 49 to 50, wherein the distal end of the respective fiber extends about 1.5 mm to about 8.1 mm away from the second face.

[0381] Clause 52. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 49 to 51, wherein at least a portion of the fibers of the second entangled fiber web extending from the elastomer layer to the distal end of the respective fiber has a denier from about 0.6D to about 3.5D.

[0382] Clause 53. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 49 to 52, wherein the elastomer layer has a basis weight from about 20 grams per square meter (gsm) to about 150 gsm.

[0383] Clause 54. A composite nonwoven fabric with an asymmetric finish according to any one of Clauses 49 to 53, wherein the elastomeric layer comprises one of a thermoplastic polyurethane meltblown layer or a thermoplastic polyether ester elastomer spunbond layer.

[0384] Clause 55. A method of manufacturing a composite nonwoven fabric with an asymmetric finish, comprising: positioning an elastomeric layer between a first fiber web and a second fiber web; mechanically entangled at least some fibers of the first fiber web and at least some fibers of the second fiber web such that the first fiber web becomes a first entangled web and the second fiber web becomes a second entangled web, wherein at least some fibers of the first fiber web extend through the elastomeric layer; and oriented at least a portion of the fibers of the second entangled web to have a longitudinal length extending from the elastomeric layer to a distal end of a corresponding fiber, wherein the distal end of the corresponding fiber extends in a direction away from the face of the second entangled web.

[0385] Clause 56. A method of manufacturing a composite nonwoven fabric with an asymmetrical finish as described in Clause 55, wherein the distal end of the respective fiber comprises one of the ends or apexes of a loop.

[0386] Clause 57. A method of manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 55 to 56, wherein the distal end of the respective fiber extends about 1.5 mm to about 8.1 mm away from the face of the second entangled web.

[0387] Clause 58. A method of manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of Clauses 55 to 57, wherein at least a portion of the fibers of the second entangled fiber web extending from the elastomer layer to the distal end of the respective fibers have a denier from about 0.6D to about 3.5D.

[0388] Clause 59. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of Clauses 55 to 58, wherein the elastomer layer has a basis weight of from about 20 grams per square meter (gsm) to about 150 gsm.

[0389] Clause 60. A method for manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of Clauses 55 to 59, wherein the elastomeric layer comprises one of a thermoplastic polyurethane meltblown layer or a thermoplastic polyether ester elastomer spunbond layer.

[0390] Clause 61. A composite nonwoven fabric comprising: at least one fiber web and an elastomer layer, said composite nonwoven fabric having: a basis weight from about 40 g / m² to about 250 g / m²; thermal resistance from about 55 RCT to about 90 RCT; an increase of about 10% in the rest length in the machine direction less than or equal to that in the machine transverse direction; an increase of about 10% in the rest width in the machine transverse direction less than or equal to that in the rest length and the rest width; and resilience in the machine direction and the machine transverse direction within about 10% of said rest length and said rest width.

[0391] Clause 62. The composite nonwoven fabric as described in Clause 61, wherein the basis weight is from about 150 gsm to about 190 gsm.

[0392] Clause 63. A composite nonwoven fabric according to any one of Clauses 61 to 62, wherein the at least one fiber web comprises at least a first entangled fiber web and a second entangled fiber web, wherein the elastomeric layer is located between the first entangled fiber web and the second entangled fiber web.

[0393] Clause 64. The composite nonwoven fabric according to Clause 63, wherein the at least one fiber web further comprises a third entangled fiber web located between the second entangled fiber web and the elastomer layer.

[0394] Clause 65. A composite nonwoven fabric according to any one of Clauses 63 to 64, wherein the first entangled fiber web at least partially forms a first side of the composite nonwoven fabric, and wherein the second entangled fiber web at least partially forms an opposing second side of the composite nonwoven fabric.

[0395] Clause 66. A composite nonwoven fabric according to any one of Clauses 63 to 65, wherein at least some fibers of the first entangled fiber web and at least some fibers of the second entangled fiber web extend through the elastomeric layer.

[0396] Clause 67. The composite nonwoven fabric according to any one of Clauses 61 to 66 further has a thickness from about 1.5 mm to about 3 mm.

[0397] Clause 68. The composite nonwoven fabric according to any one of Clauses 61 to 67 also has a stiffness from about 0.1 kgf to about 0.4 kgf.

[0398] Clause 69. A composite nonwoven fabric comprising: at least one fiber web and an elastomer layer, said composite nonwoven fabric having: a thickness from about 1.5 mm to about 3 mm; thermal resistance from about 55 RCT to about 90 RCT; an increase of about 10% in the machine direction less than or equal to the rest length; an increase of about 10% in the machine transverse direction less than or equal to the rest width; and resilience in the machine direction and the machine transverse direction within about 10% of said rest length and said rest width.

[0399] Clause 70. The composite nonwoven fabric described in Clause 69 also has a basis weight between about 40 grams per square meter (gsm) and about 250 gsm.

[0400] Clause 71. A composite nonwoven fabric according to any one of Clauses 69 to 70, wherein the basis weight is from about 150 gsm to about 190 gsm.

[0401] Clause 72. The composite nonwoven fabric according to any one of Clauses 69 to 71 also has a stiffness from about 0.1 kgf to about 0.4 kgf.

[0402] Clause 73. A composite nonwoven fabric according to any one of Clauses 69 to 72, wherein the at least one fiber web comprises at least a first entangled fiber web and a second entangled fiber web, and wherein the elastomeric layer is located between the first entangled fiber web and the second entangled fiber web.

[0403] Clause 74. The composite nonwoven fabric according to Clause 73, wherein the at least one fiber web further comprises a third entangled fiber web located between the second entangled fiber web and the elastomer layer.

[0404] Clause 75. A method of manufacturing a composite nonwoven fabric, comprising: positioning an elastomer layer between at least a first fiber web and a second fiber web; selecting entanglement parameters to produce a composite nonwoven fabric having a basis weight from about 40 gsm to about 250 gsm and a thermal resistance from about 55 RCT to about 90 RCT; and mechanically entangled the fibers of the first fiber web and the fibers of the second fiber web based on the selected entanglement parameters.

[0405] Clause 76. The method of manufacturing a composite nonwoven fabric according to Clause 75 further comprises: positioning a third fiber web between the at least first fiber web and the second fiber web prior to the mechanical entanglement step; and mechanically entangled fibers from the third fiber web with fibers from the first fiber web and fibers from the second fiber web based on the selected entanglement parameters.

[0406] Clause 77. The method of manufacturing a composite nonwoven fabric according to Clause 76, wherein the basis weight of each of the elastomer layer, the first fiber web, the second fiber web and the third fiber web is from about 20 grams per square meter (gsm) to about 150 gsm.

[0407] Clause 78. A method for manufacturing a composite nonwoven fabric according to any one of Clauses 75 to 77, wherein the entanglement parameters are further selected to achieve a stiffness from about 0.1 kgf to about 0.4 kgf.

[0408] Clause 79. A method for manufacturing a composite nonwoven fabric according to any one of Clauses 75 to 78, wherein the entanglement parameters are further selected to achieve a thickness from about 1.5 mm to about 3 mm.

[0409] Clause 80. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 75 to 79, wherein at least some fibers in the first fiber web and at least some fibers in the second fiber web extend through the elastomeric layer after a mechanical entanglement step.

[0410] Clause 81. A composite nonwoven fabric with an asymmetrical finish, comprising: a first face at least partially formed of a first entangled fiber web, the first face having a first color characteristic and a second color characteristic different from the first color characteristic; an opposing second face at least partially formed of a second entangled fiber web, the second face having the first color characteristic and the second color characteristic, wherein a greater number of fibers having the second color characteristic per unit area are present on one of the first face or the second face compared to the opposing face; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the second entangled fiber web, and wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the first entangled fiber web.

[0411] Clause 82. The composite nonwoven fabric with an asymmetric finish as described in Clause 81 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0412] Clause 83. The composite nonwoven fabric with an asymmetric finish as described in Clause 82, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0413] Clause 84. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 82 to 83, wherein at least some fibers of the third entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the second entangled fiber web.

[0414] Clause 85. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 82 to 84, wherein at least some fibers of the third entangled fiber web are entangled with the fibers of the first entangled fiber web.

[0415] Clause 86. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 81 to 85, wherein the elastomer layer has the first color characteristic.

[0416] Clause 87. A composite nonwoven fabric with an asymmetrical finish, comprising: a first face at least partially formed of a first entangled fiber web, the first face having a first color characteristic and a second color characteristic different from the first color characteristic; an opposing second face at least partially formed of a second entangled fiber web, the second face having the first color characteristic and the second color characteristic, wherein a greater number of fibers having the second color characteristic per unit area are present on one of the first face or the second face compared to the opposing face; a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web, at least some fibers of the second entangled fiber web, and at least some fibers of the third entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the corresponding other entangled fiber webs.

[0417] Clause 88. A composite nonwoven fabric with an asymmetric finish as described in Clause 87, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0418] Clause 89. A method of manufacturing a composite nonwoven fabric, comprising: positioning a third fiber web having a second color characteristic between a first fiber web having a first color characteristic and a second fiber web having the first color characteristic; positioning an elastomer layer having one of the first color characteristic or the second color characteristic between the first fiber web and the second fiber web; and mechanically entangled a first number of fibers of the third fiber web with at least some fibers of the first fiber web, and mechanically entangled a second number of fibers of the third fiber web with at least some fibers of the second fiber web.

[0419] Clause 90. The method of manufacturing a composite nonwoven fabric with an asymmetric finish as described in Clause 89, wherein the third fiber web is located between the second fiber web and the elastomer layer.

[0420] Clause 91. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 89 to 91, wherein the fibers of the third fiber web have a denier from about 1.2D to about 3.5D.

[0421] Clause 92. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 89 to 91, wherein the fibers of the first fiber web have a denier from about 1.2D to about 3.5D.

[0422] Clause 93. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 89 to 93, wherein the fibers of the second fiber web have a denier from about 0.6D to about 1D.

[0423] Clause 94. A method of manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 89 to 93, wherein the fibers of each of the first fiber web, the second fiber web, and the third fiber web are dyed before spinning such that the fibers of the first fiber web have the first color characteristic, the fibers of the second fiber web have the first color characteristic, and the fibers of the third fiber web have the second color characteristic.

[0424] Clause 95. A method of manufacturing a composite nonwoven fabric with an asymmetric finish according to any one of Clauses 89 to 94, wherein the fibers of each of the first fiber web, the second fiber web, and the third fiber web are polyethylene terephthalate (PET) fibers.

[0425] Clause 96. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 89 to 95, wherein the composite nonwoven fabric with the asymmetrical finish is not dyed after weaving.

[0426] Clause 97. A method for manufacturing a composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 89 to 96, wherein mechanical entanglement comprises needle punching.

[0427] Clause 98. A method of manufacturing a composite nonwoven fabric with an asymmetric finish as described in Clause 89, wherein the first entangled fiber web at least partially forms a first side of the composite nonwoven fabric with the asymmetric finish, and wherein the second entangled fiber web at least partially forms a second side of the composite nonwoven fabric with the asymmetric finish.

[0428] Clause 99. A method for manufacturing a composite nonwoven fabric with an asymmetric finish as described in Clause 98, wherein after a mechanical entanglement step, the first face has the first color characteristic and the second color characteristic, and the second face has the first color characteristic and the second color characteristic, wherein a greater number of fibers per unit area having the second color characteristic are present on one of the first face or the second face compared to the opposite face.

[0429] Clause 100. A composite nonwoven fabric having an asymmetrical finish on a first side and an opposing second side, the first side having a greater stitch density than the second side, the asymmetrical finish composite nonwoven fabric comprising: at a first time point: the first side per cm 2 Having a first number of pom-poms; the second surface per cm2 Having a second number of hairballs; at a second time point later than the first time point: the first surface per cm 2 It has a third number of hair balls, per cm 2 The third number of hairballs mentioned is more than per cm 2 The first number of hairballs; and the second surface per cm 2 Having a fourth number of hairballs, per cm 2 The fourth number of hairballs mentioned is more than per cm 2 The second number of hair balls, per cm 2 The fourth number of hairballs mentioned is more than per cm 2 The third number of hairballs mentioned above.

[0430] Clause 101. A composite nonwoven fabric with an asymmetrical finish as described in Clause 100, wherein the first face is formed at least in part by a first entangled fiber web.

[0431] Clause 102. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 100 to 101, wherein the second face is formed at least in part by a second entangled fiber web.

[0432] Clause 103. A composite nonwoven fabric with an asymmetric finish as described in Clause 102, wherein the composite nonwoven fabric with an asymmetric finish comprises an elastomeric layer located between the first entangled fiber web and the second entangled fiber web.

[0433] Clause 104. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 100 to 103, wherein the second side comprises silicone-coated fibers.

[0434] Clause 105. A garment article comprising: a composite nonwoven fabric forming at least a portion of the garment article, the composite nonwoven fabric having an outward-facing surface and an inward-facing surface, the outward-facing surface having a greater stitch density than the inward-facing surface, wherein: at a first time point: the outward-facing surface has a stitch density of [number missing] stitches per cm. 2 Having a first number of hairballs; the inward-facing surface per cm 2 Having a second number of hairballs; at a second time point later than the first time point: the outward-facing surface per cm 2 It has a third number of hair balls, per cm 2 The third number of hairballs mentioned is more than per cm 2 The first number of hairballs; and the inward-facing surface per cm 2 Having a fourth number of hairballs, per cm 2 The fourth number of hairballs mentioned is more than per cm 2The second number of hair balls, per cm 2 The fourth number of hairballs mentioned is more than per cm 2 The third number of hairballs mentioned above.

[0435] Clause 106. The clothing article according to Clause 105, wherein the outward-facing surface of the composite nonwoven fabric is at least partially formed by a first entangled fiber web.

[0436] Clause 107. The garment article according to Clause 106, wherein the first tangled fiber web has a first stitch density.

[0437] Clause 108. The garment article according to any one of Clauses 105 to 107, wherein the outward-facing surface of the composite nonwoven fabric is the outermost surface of the garment article.

[0438] Clause 109. The garment article according to any one of Clauses 105 to 108, wherein the inward-facing surface of the composite nonwoven fabric is formed at least in part by a second entangled fiber web.

[0439] Clause 110. The garment article according to Clause 107, wherein the second tangled fiber web has a second stitch density less than the first stitch density.

[0440] Clause 111. The garment article according to any one of Clauses 105 to 110, wherein the inward-facing surface of the composite nonwoven fabric is the innermost surface of the garment article.

[0441] Clause 112. The clothing article according to any one of Clauses 106 to 111, wherein the composite nonwoven fabric comprises an elastomeric layer located between the first entangled fiber web and the second entangled fiber web.

[0442] Clause 113. The clothing article according to any one of Clauses 105 to 112, wherein the inward-facing surface of the composite nonwoven fabric comprises silicone-coated fibers.

[0443] Clause 114. A composite nonwoven fabric having an asymmetric finish on a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side of the composite nonwoven fabric having a first stitch density; and a second entangled fiber web forming at least partially the second side of the composite nonwoven fabric having a second stitch density less than the first stitch density, wherein the second entangled fiber web comprises silicone-coated fibers.

[0444] Clause 115. The composite nonwoven fabric with an asymmetric finish as described in Clause 114 further includes an elastomeric layer located between the first entangled fiber web and the second entangled fiber web.

[0445] Clause 116. A composite nonwoven fabric with an asymmetric finish as described in Clause 115, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the second entangled fiber web.

[0446] Clause 117. A composite nonwoven fabric with an asymmetric finish according to any one of Clauses 115 to 117, wherein at least some fibers of the second entangled fibers extend through the elastomer layer and become entangled with the fibers of the first entangled fiber web.

[0447] Clause 118. A composite nonwoven fabric with an asymmetrical finish according to any one of Clauses 114 to 117, wherein: at the first time point: the first surface per cm 2 Having a first number of pom-poms; the second surface per cm 2 Having a second number of hairballs; at a second time point later than the first time point: the first surface per cm 2 It has a third number of hair balls, per cm 2 The third number of hairballs mentioned is more than per cm 2 The first number of hairballs; and the second surface per cm 2 Having a fourth number of hairballs, per cm 2 The fourth number of hairballs mentioned is more than per cm 2 The second number of hair balls, per cm 2 The fourth number of hairballs mentioned is more than per cm 2 The third number of hairballs mentioned above.

[0448] Clause 119. A composite nonwoven garment article having an outward-facing surface and an opposing inward-facing surface, said asymmetrical composite nonwoven garment article comprising: per cm 2 A first entangled fiber web having a first average denier, the first entangled fiber web at least partially forming the outward-facing surface; per cm 2 With less than per cm 2 The first average denier and the second average denier of the second entangled fiber web, the second entangled fiber web forming at least partially the inward-facing surface; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with at least some fibers of the second entangled fiber web.

[0449] Clause 120. Composite nonwoven garment articles with asymmetrical finishes as described in Clause 119, wherein per cm 2 The first average number of deniers is from about 1.1D to about 1.4D.

[0450] Clause 121. Composite nonwoven garment articles with asymmetrical finishes according to any one of Clauses 119 to 120, wherein each cm 2 The second average number of dendrites is from about 0.9D to about 1D.

[0451] Clause 122. A composite nonwoven garment article with an asymmetrical finish according to any one of Clauses 119 to 121, wherein the first entangled fiber web per cm 2 Having the first number of fibers and per cm 2 The second denier is a second number of fibers, wherein the ratio of the first denier to the second denier is from about 1.5:1 to about 2:1.

[0452] Clause 123. Composite nonwoven garment articles with asymmetrical finishes as described in Clause 122, wherein per cm 2 The first number of fibers is more than per cm 2 The second quantity of fibers.

[0453] Clause 124. Composite nonwoven garment articles with asymmetrical finishes according to any one of Clauses 122 to 123, wherein each cm 2 The first quantity of fibers has a denier from about 1.2D to about 3.5D, and wherein each cm 2 The second number of fibers has a denier from about 0.6D to about 1D.

[0454] Clause 125. A composite nonwoven garment article with an asymmetrical finish according to any one of Clauses 122 to 124, wherein the second entangled fiber web per cm 2 The third number of fibers with a third denier and per cm 2 The fourth denier of the fourth number of fibers, wherein the ratio of the third denier to the fourth denier is in the range of about 0.3:1 to about 0.7:1.

[0455] Clause 126. Composite nonwoven garment articles with asymmetrical finishes as described in Clause 125, wherein per cm 2 The third number of fibers is more than per cm 2 The fourth number of fibers.

[0456] Clause 127. Composite nonwoven garment articles with asymmetrical finishes according to any one of Clauses 125 to 126, wherein each cm 2The third number of fibers has a denier from about 0.6D to about 1D, and wherein each cm 2 The fourth number of fibers has a denier ranging from about 1.2D to about 3.5D.

[0457] Clause 128. A composite nonwoven garment article having an outward-facing surface and an opposing inward-facing surface, said asymmetrical composite nonwoven garment article comprising: per cm 2 A first entangled fiber web having a first average denier, the first entangled fiber web at least partially forming the outward-facing surface; per cm 2 A second entangled fiber web having a second average denier less than the first average denier, the second entangled fiber web at least partially forming the inward-facing surface; a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with at least some fibers of the second entangled fiber web.

[0458] Clause 129. Composite nonwoven garment articles with asymmetrical finishes as described in Clause 128, wherein per cm 2 The first average number of deniers is from about 1.1D to about 1.4D.

[0459] Clause 130. Composite nonwoven garment articles with asymmetrical finishes according to any one of Clauses 128 to 129, wherein each cm 2 The second average number of dendrites is from about 0.9D to about 1D.

[0460] Clause 131. A composite nonwoven garment article with an asymmetrical finish according to any one of Clauses 128 to 130, wherein the third entangled fiber web per cm 2 With greater than per cm 2 The second average number of dan and the third average number of dan.

[0461] Clause 132. A composite nonwoven garment article with an asymmetrical finish according to any one of Clauses 128 to 131, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

[0462] Clause 133. A method of manufacturing a garment article, comprising: forming the garment article from a composite nonwoven fabric with an asymmetrical finish, the composite nonwoven fabric with an asymmetrical finish comprising a first entangled fiber web forming at least partially a first side, a second entangled fiber web forming at least partially an opposing second side, and an elastomeric layer located between the first side and the second side, wherein: the fibers forming the first entangled fiber web have a first set of properties, the fibers forming the second entangled fiber web have a second set of properties different from the first set of properties, the first side of the composite nonwoven fabric with an asymmetrical finish forms the outward-facing surface of the garment article, and the second side of the composite nonwoven fabric with an asymmetrical finish forms the inward-facing surface of the garment article.

[0463] Clause 134. The method of manufacturing garment articles according to Clause 133, wherein the first set of characteristics and the second set of characteristics include one or more of fiber denier, color, and coating.

[0464] Clause 135. The method of manufacturing garment articles as described in Clause 134, wherein the coating comprises a silicone coating.

[0465] Clause 136. A method of manufacturing a garment article according to any one of Clauses 133 to 135, wherein at least some fibers from the first tangled fiber web extend through the elastomeric layer.

[0466] Clause 137. A method of manufacturing garment articles according to any one of Clauses 133 to 136, wherein at least some fibers from the second entangled fiber web extend through the elastomeric layer.

[0467] Clause 138. A method of manufacturing garment articles according to any one of Clauses 133 to 137, wherein the composite nonwoven fabric with the asymmetrical finish comprises a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0468] Clause 139. The method of manufacturing garment articles according to Clause 138, wherein the fibers forming the third entangled fiber web have a third set of properties that are different from the first set of properties and the second set of properties.

[0469] Clause 140. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side, the first side including a plurality of discrete chemical bonding sites; a second entangled fiber web forming at least partially the second side; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with fibers of the second entangled fiber web.

[0470] Clause 141. The composite nonwoven fabric according to Clause 140, wherein the second surface does not have discrete chemical bonding sites.

[0471] Clause 142. The composite nonwoven fabric according to any one of Clauses 140 to 141, wherein the plurality of discrete chemical bonding sites comprise, in composition, an oil-based dispersion of a polyurethane adhesive, a polyurethane adhesive in a dispersion containing silica, and combinations thereof.

[0472] Clause 143. A composite nonwoven fabric according to any one of Clauses 140 to 142, wherein at least the fibers of the first entangled fiber web are adhered together at the plurality of discrete chemical bonding sites.

[0473] Clause 144. A composite nonwoven fabric according to any one of Clauses 140 to 143, wherein the first side comprises a first color, and the plurality of discrete chemical bonding sites comprise a second color different from the first color.

[0474] Clause 145. The composite nonwoven fabric according to any one of Clauses 140 to 144, wherein the size of each of the plurality of discrete chemical bonding sites is in the range of about 0.1 mm to about 1 mm.

[0475] Clause 146. The composite nonwoven fabric according to any one of Clauses 140 to 145, wherein the distance between adjacent adhesive sites of the plurality of discrete chemical adhesive sites is in the range of about 0.5 mm to about 6 mm.

[0476] Clause 147. A composite nonwoven fabric according to any one of Clauses 140 to 146, wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and are entangled with the fibers of the first entangled fiber web.

[0477] Clause 148. The composite nonwoven fabric according to any one of Clauses 140 to 147 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0478] Clause 149. The composite nonwoven fabric according to Clause 148, wherein at least some fibers of the third entangled fiber web are entangled with fibers of the first entangled fiber web and fibers of the second entangled fiber web.

[0479] Clause 150. A composite nonwoven fabric according to any one of Clauses 140 to 149, wherein the elastomeric layer comprises one or more of a thermoplastic polyurethane meltblown layer or a thermoplastic polyether ester elastomer spunbond layer.

[0480] Clause 151. A nonwoven garment article having an outward-facing surface and an opposing inward-facing surface, the nonwoven garment article comprising: a first entangled fiber web at least partially forming the outward-facing surface, the outward-facing surface including a first plurality of discrete chemical bonding sites located at a first position on the nonwoven garment article; a second entangled fiber web at least partially forming the inward-facing surface; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with at least some fibers of the second entangled fiber web.

[0481] Clause 152. The nonwoven garment article as described in Clause 151, wherein the inward-facing surface does not have discrete chemical adhesive sites.

[0482] Clause 153. The nonwoven garment article according to any one of Clauses 151 to 152, wherein the outward-facing surface further comprises a second plurality of discrete chemical adhesive sites located at a second location on the nonwoven garment article, the second location being different from the first location.

[0483] Clause 154. The nonwoven garment article according to Clause 153, wherein the density of the first plurality of discrete chemical adhesive sites at the first location is different from the density of the second plurality of discrete adhesive sites at the second location.

[0484] Clause 155. The nonwoven garment article according to any one of Clauses 151 to 154, wherein the first plurality of discrete chemical adhesive sites comprises, in composition, an oil-based dispersion of a polyurethane adhesive, a polyurethane adhesive in a dispersion containing silica, and combinations thereof.

[0485] Clause 156. A method for finishing a composite nonwoven fabric, the composite nonwoven fabric comprising a first entangled fiber web forming at least partially a first side of the composite nonwoven fabric, a second entangled fiber web forming at least partially an opposing second side of the composite nonwoven fabric, and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers from the first entangled fiber web extend through the elastomeric layer and become entangled with fibers of the second entangled fiber web, the method comprising: applying a chemical adhesive in a predetermined pattern to the first side of the composite nonwoven fabric to create a plurality of discrete chemical adhesive sites on the first side of the composite nonwoven fabric.

[0486] Clause 157. The method for finishing composite nonwoven fabrics according to Clause 156, wherein the chemical adhesive is applied using a gravure printing process.

[0487] Clause 158. A method for finishing composite nonwoven fabrics according to any one of Clauses 156 to 157, wherein the chemical adhesive is applied using a digital printing process.

[0488] Clause 159. A method for finishing a composite nonwoven fabric according to any one of Clauses 156 to 158, wherein the chemical adhesive is not applied to the second side of the composite nonwoven fabric.

[0489] Clause 160. A method for finishing composite nonwoven fabrics according to any one of Clauses 156 to 159, wherein the chemical adhesive comprises, in composition, an oil-based dispersion of a polyurethane adhesive, a polyurethane adhesive in a dispersion containing silica, and combinations thereof.

[0490] Clause 161. A method for finishing composite nonwoven fabrics according to any one of Clauses 156 to 160, wherein the chemical adhesive is applied to a thickness from about 0.1 mm to about 0.2 mm.

[0491] Clause 162. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side; a second entangled fiber web forming at least partially the second side; an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with fibers of the second entangled fiber web; and a plurality of discrete thermal bonding sites, each of the plurality of discrete thermal bonding sites comprising a thermal bonding structure located between the first side and the second side, wherein fibers from the first entangled fiber web extend from each of the thermal bonding structures.

[0492] Clause 163. The composite nonwoven fabric according to Clause 162, wherein each of the thermally bonded structures is offset relative to the first surface in a direction extending toward the second surface, and wherein each of the thermally bonded structures is offset relative to the second surface in a direction extending toward the first surface.

[0493] Clause 164. The composite nonwoven fabric according to Clause 163, wherein the first average depth of the offset relative to the first surface is different from the second average depth of the offset relative to the second surface.

[0494] Clause 165. A composite nonwoven fabric according to any one of Clauses 162 to 164, wherein each of the thermally bonded structures comprises fibers in the form of a film from at least the first entangled fiber web.

[0495] Clause 166. The composite nonwoven fabric according to any one of Clauses 162 to 165, wherein each of the thermally bonded structures comprises one or more of fibers in the form of a film from the second entangled fiber web and a portion of the film-formed portion of the elastomer layer.

[0496] Clause 167. The composite nonwoven fabric according to any one of Clauses 162 to 166, wherein the distance between adjacent discrete thermal bonding sites is less than the fiber length in at least the first entangled fiber web.

[0497] Clause 168. The composite nonwoven fabric according to any one of Clauses 162 to 167 further includes a plurality of discrete chemical bonding sites located on the first surface of the composite nonwoven fabric.

[0498] Clause 169. The composite nonwoven fabric according to Clause 168, wherein the second surface does not have discrete chemical bonding sites.

[0499] Clause 170. A composite nonwoven fabric according to any one of Clauses 168 to 169, wherein fibers from at least the first entangled fiber web are adhered together at the plurality of discrete chemical bonding sites.

[0500] Clause 171. A composite nonwoven fabric according to any one of Clauses 168 to 170, wherein the plurality of discrete chemical bonding sites are located at a first position on the first surface of the composite nonwoven fabric, and wherein the plurality of discrete thermal bonding sites are located at a second position on the composite nonwoven fabric, the first position being different from the second position.

[0501] Clause 172. The composite nonwoven fabric as described in Clause 171, wherein the first position is separate from and different from the second position.

[0502] Clause 173. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side; a second entangled fiber web forming at least partially the second side; an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with fibers of the second entangled fiber web; a first plurality of discrete thermal bonding sites, each of the first plurality of discrete thermal bonding sites comprising a first thermal bonding structure offset from the first side by a first depth in a direction extending toward the second side, each of the first thermal bonding structures comprising a film-formed fiber from the first entangled fiber web; and a second plurality of discrete thermal bonding sites, each of the second plurality of discrete thermal bonding sites comprising a second thermal bonding structure offset from the first side by a second depth in a direction extending toward the second side, the second depth being different from the first depth, each of the second thermal bonding structures comprising a film-formed fiber from the second entangled fiber web.

[0503] Clause 174. The composite nonwoven fabric according to Clause 173, wherein the first plurality of discrete thermal bonding sites are arranged at a plurality of first locations, and wherein the second plurality of discrete thermal bonding sites are arranged at a plurality of second locations different from the first locations.

[0504] Clause 175. A composite nonwoven fabric according to any one of Clauses 173 to 174, wherein each of the first thermally bonded structures is offset relative to the second surface by a third depth in a direction extending toward the first surface, the third depth being different from the first depth.

[0505] Clause 176. A composite nonwoven fabric according to any one of Clauses 173 to 175, wherein each of the second thermally bonded structures is offset relative to the second surface by a fourth depth in a direction extending from the first surface, the fourth depth being different from the second depth.

[0506] Clause 177. A composite nonwoven fabric according to any one of Clauses 175 to 176, wherein the third depth is different from the fourth depth.

[0507] Clause 178. The composite nonwoven fabric according to any one of Clauses 173 to 177, wherein each of the first thermally bonded structures further comprises fibers in the form of a film from the second entangled fiber web.

[0508] Clause 179. The composite nonwoven fabric according to any one of Clauses 173 to 178, wherein each of the second thermally bonded structures further comprises fibers in the form of a film from the first entangled fiber web.

[0509] Clause 180. A composite nonwoven fabric according to any one of Clauses 173 to 179, wherein the elastomeric layer comprises one or more of a thermoplastic polyurethane meltblown layer or a thermoplastic polyether ester elastomer spunbond layer.

[0510] Clause 181. A composite nonwoven fabric according to any one of Clauses 173 to 180, wherein each of the first thermal bonding structures and each of the second thermal bonding structures comprises a portion of the elastomeric layer in the form of a film.

[0511] Clause 182. A nonwoven garment article having an outward-facing surface and an opposing inward-facing surface, the nonwoven garment article comprising: a first entangled fiber web at least partially forming the outward-facing surface; a second entangled fiber web at least partially forming the inward-facing surface; an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with at least some fibers of the second entangled fiber web; and a first plurality of discrete thermal bonding sites located at a first position on the nonwoven garment article, each of the first plurality of discrete thermal bonding sites comprising a first thermal bonding structure offset relative to the outward-facing surface in a direction extending toward the inward-facing surface, each of the first thermal bonding structures comprising fibers in the form of a film from the first entangled fiber web.

[0512] Clause 183. The nonwoven garment article according to Clause 182, wherein the outward-facing surface further includes a second plurality of discrete thermal bonding sites located at a second location on the nonwoven garment article, the second location being different from the first location.

[0513] Clause 184. The nonwoven garment article according to Clause 183, wherein the density of the first plurality of discrete thermal bonding sites is different from the density of the second plurality of discrete thermal bonding sites.

[0514] Clause 185. A method for finishing a composite nonwoven fabric, the composite nonwoven fabric comprising a first entangled fiber web forming at least partially a first side of the composite nonwoven fabric, a second entangled fiber web forming at least partially an opposing second side of the composite nonwoven fabric, and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers from the first entangled fiber web extend through the elastomeric layer and become entangled with fibers of the second entangled fiber web, the method comprising: forming a plurality of discrete thermal bonding sites in a first predetermined pattern, each of the plurality of discrete thermal bonding sites comprising a thermal bonding structure offset relative to the first side in a direction extending toward the second side, each of the thermal bonding structures comprising fibers in the form of a film from at least the first entangled fiber web.

[0515] Clause 186. The method for finishing composite nonwoven fabrics according to Clause 185, wherein the plurality of discrete thermal bonding sites are formed using an ultrasonic bonding system comprising an impression roller and an ultrasonic welding head.

[0516] Clause 187. The method of finishing a composite nonwoven fabric according to Clause 186, wherein the composite nonwoven fabric is positioned in the ultrasonic bonding system such that a first side of the composite nonwoven fabric contacts the impression roller and a second side of the composite nonwoven fabric contacts the ultrasonic welding head.

[0517] Clause 188. A method for finishing a composite nonwoven fabric according to any one of Clauses 186, wherein the composite nonwoven fabric is positioned in the ultrasonic bonding system such that the second side of the composite nonwoven fabric contacts the impression roller, and the first side of the composite nonwoven fabric contacts the ultrasonic welding head.

[0518] Clause 189. The method of finishing a composite nonwoven fabric according to any one of Clauses 185 to 188 further comprises applying a chemical adhesive in a second predetermined pattern to the first surface of the composite nonwoven fabric to create a plurality of discrete chemical adhesive sites on the first surface of the composite nonwoven fabric.

[0519] Clause 190. The method of finishing a composite nonwoven fabric as described in Clause 189, wherein the second predetermined pattern is different from the first predetermined pattern.

[0520] Clause 191. A method for finishing a composite nonwoven fabric according to any one of Clauses 189 to 190, wherein the chemical adhesive is not applied to the second side of the composite nonwoven fabric.

[0521] Clause 192. A method for finishing a composite nonwoven fabric according to any one of Clauses 189 to 191, wherein the chemical adhesive is applied prior to the formation of the plurality of discrete thermal bonding sites.

[0522] Clause 193. A method for finishing a composite nonwoven fabric according to any one of Clauses 189 to 191, wherein the chemical adhesive is applied after the plurality of discrete thermal bonding sites are formed.

[0523] Clause 194. A method of manufacturing a composite nonwoven fabric, comprising: in a first mechanical entanglement step, mechanically entangled a plurality of fibers of a first fiber web in a direction extending from a first surface of a first fiber web to an opposing second surface of the first fiber web; after the first mechanical entanglement step, positioning an elastomeric layer between the first fiber web and a second fiber web such that the elastomeric layer is positioned adjacent to the first surface of the first fiber web; and in a second mechanical entanglement step, mechanically entangled a plurality of fibers of the first fiber web and a plurality of fibers of the second fiber web such that the first fiber web becomes a first entangled fiber web and the second fiber web becomes a second entangled fiber web, wherein after the second mechanical entanglement step, at least some fibers of the first entangled fiber web and at least some fibers of the second entangled fiber web extend through the elastomeric layer.

[0524] Clause 195. The method of manufacturing a composite nonwoven fabric according to Clause 194, wherein after the second mechanical entanglement step, the second face of the first fiber web at least partially forms the first face of the composite nonwoven fabric.

[0525] Clause 196. The method of manufacturing a composite nonwoven fabric according to Clause 195 further includes forming a garment article from the composite nonwoven fabric, wherein the first side of the composite nonwoven fabric forms the outward-facing surface of the garment article.

[0526] Clause 197. A method for manufacturing a composite nonwoven fabric according to any one of Clauses 194 to 196, wherein the stitch density of the first fiber web is greater than the stitch density of the second fiber web before the second mechanical entanglement step.

[0527] Clause 198. A method of manufacturing a composite nonwoven fabric according to any one of Clauses 194 to 197, wherein the stitch density of the first fiber web prior to the second mechanical entanglement step is at least twice the stitch density of the second fiber web prior to the second mechanical entanglement step.

[0528] Clause 199. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side, the first side having fiber ends of a first density; a second entangled fiber web forming at least partially the second side, the second side having fiber ends of a second density, the first density fiber ends being smaller than the second density fiber ends; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with fibers of the second entangled fiber web.

[0529] Clause 200. The composite nonwoven fabric according to Clause 199, wherein the fiber ends of the first face extend in a direction away from the first face and in a direction away from the central plane of the composite nonwoven fabric.

[0530] Clause 201. A composite nonwoven fabric according to any one of Clauses 199 to 200, wherein the fiber ends of the second surface extend in a direction away from the second surface and in a direction away from the central plane of the composite nonwoven fabric.

[0531] Clause 202. A composite nonwoven fabric according to any one of Clauses 199 to 201, wherein the first side has fiber loops of a first density and the second side has fiber loops of a second density, the fiber loops of the first density being larger than the fiber loops of the second density.

[0532] Clause 203. A composite nonwoven fabric according to any one of Clauses 199 to 202, wherein at least some fibers of the second entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the first entangled fiber web.

[0533] Clause 204. The composite nonwoven fabric according to any one of Clauses 199 to 203 further includes a third entangled fiber web located between the first entangled fiber web and the second entangled fiber web.

[0534] Clause 205. The composite nonwoven fabric according to Clause 204, wherein at least some fibers of the third entangled fiber web are entangled with fibers of the first entangled fiber web and fibers of the second entangled fiber web.

[0535] Clause 206. A composite nonwoven fabric according to any one of Clauses 199 to 205, wherein the elastomeric layer comprises one or more of a thermoplastic polyurethane meltblown layer or a thermoplastic polyether ester elastomer spunbond layer.

[0536] Clause 207. A composite nonwoven fabric having a first side and an opposing second side, the composite nonwoven fabric comprising: a first entangled fiber web forming at least partially the first side; a second entangled fiber web forming at least partially the second side, the first side having lower density fiber ends relative to the second side; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with fibers of the second entangled fiber web.

[0537] Clause 208. The composite nonwoven fabric according to Clause 207, wherein the fiber ends of the first face extend in a direction away from the first face and in a direction away from the central plane of the composite nonwoven fabric.

[0538] Clause 209. The composite nonwoven fabric according to any one of Clauses 207 to 208, wherein the fiber ends of the second surface extend in a direction away from the second surface and in a direction away from the central plane of the composite nonwoven fabric.

[0539] Clause 210. A composite nonwoven fabric according to any one of Clauses 207 to 209, wherein the first side comprises a higher density of fiber loops relative to the second side.

[0540] Various aspects of this disclosure have been described in an illustrative and not 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.

[0541] 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 garment article comprising an asymmetrically finished composite nonwoven fabric having an outward-facing surface and opposing inward-facing surfaces, the asymmetrically finished composite nonwoven fabric comprising: per cm 2 a first web of entangled fibers having a first average denier, the first web of entangled fibers at least partially forming the outward-facing surface; per cm 2 a second web of entangled fibers having a second average denier less than the first average denier per cm 2 of the first web of entangled fibers, the second web of entangled fibers at least partially forming the inward-facing surface; and an elastomeric layer positioned between the first web of entangled fibers and the second web of entangled fibers, wherein at least some fibers of the first web of entangled fibers extend through the elastomeric layer and entangle with at least some fibers of the second web of entangled fibers.

2. The garment article according to claim 1, wherein each cm 2 The first average number of dendrites ranges from 1.1 D to 1.4 D.

3. The garment article according to any one of claims 1 to 2, wherein each cm 2 The second average number of dendrites ranges from 0.9 D to 1 D.

4. The garment article according to any one of claims 1 to 3, wherein the first entangled fiber web per cm 2 Having the first number of fibers and per cm 2 The second denier is a second number of fibers, wherein the ratio of the first denier to the second denier is from 1.5:1 to 2:

1.

5. The garment article according to claim 4, wherein each cm 2 The first number of fibers is more than per cm 2 The second quantity of fibers.

6. The garment article according to claim 4 or 5, wherein each cm 2 The first quantity of fibers has a denier from 1.2 D to 3.5 D, and wherein each cm 2 The second number of fibers has a denier ranging from 0.6 D to 1 D.

7. The garment article according to any one of claims 4 to 6, wherein the second entangled fiber web per cm 2 The third number of fibers with a third denier and per cm 2 The fourth denier of the fourth number of fibers, wherein the ratio of the third denier to the fourth denier is in the range of 0.3:1 to 0.7:

1.

8. The garment article according to claim 7, wherein each cm 2 The third number of fibers is more than per cm 2 The fourth number of fibers.

9. The garment article according to claim 7 or 8, wherein each cm 2 The third number of fibers has a denier from 0.6 D to 1 D, and wherein each cm 2 The fourth number of fibers has a denier ranging from 1.2 D to 3.5 D.

10. The garment article according to any one of claims 1 to 9, wherein the garment article includes at least one of upper garment, lower garment, hat, gloves, sleeves and footwear.

11. The garment article of claim 10, wherein the garment article includes an upper for the footwear article.

12. A garment article comprising a composite nonwoven fabric with an asymmetrical finish, the composite nonwoven fabric having an outward-facing surface and opposing inward-facing surfaces, the composite nonwoven fabric comprising: per cm 2 A first entangled fiber web having a first average denier, the first entangled fiber web at least partially forming the outward-facing surface; per cm 2 A second entangled fiber web having a second average denier less than the first average denier, the second entangled fiber web at least partially forming the inward-facing surface; A third entangled fiber web located between the first entangled fiber web and the second entangled fiber web; and an elastomeric layer located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and are entangled with at least some fibers of the second entangled fiber web.

13. The garment article according to claim 12, wherein each cm 2 The first average number of dendrites ranges from 1.1 D to 1.4 D.

14. The garment article according to any one of claims 12 to 13, wherein each cm 2 The second average number of dendrites ranges from 0.9 D to 1 D.

15. The garment article according to any one of claims 12 to 14, wherein the third entangled fiber web per cm 2 With greater than per cm 2 The second average number of dan and the third average number of dan.

16. The garment article according to any one of claims 12 to 15, wherein the third entangled fiber web is located between the second entangled fiber web and the elastomer layer.

17. The garment article according to any one of claims 12 to 16, wherein the garment article comprises at least one of upper garment, lower garment, hat, gloves, sleeves and footwear.

18. The garment article of claim 17, wherein the garment article includes an upper for the footwear article.

19. A composite nonwoven fabric with an asymmetrical finish, having a first side and an opposing second side, said asymmetrical composite nonwoven fabric being used in garment articles and comprising: A first tangled fiber web, the first tangled fiber web per cm 2 Having the first number of fibers and per cm 2 A second number of fibers having a second denier, wherein the first denier is different from the second denier, and the first entangled fiber web per cm 2 Having a first average denier and at least partially forming the first surface, the first surface forming the outward-facing surface of the garment article; The second entangled fiber web, the second entangled fiber web per cm 2 The third number of fibers with a third denier and per cm 2 The second entangled fiber web has a fourth denier and a fourth number of fibers, wherein the third denier is different from the fourth denier. 2 With less than per cm 2 The first average denier and the second average denier and at least partially form the second surface, the second surface forming the inward-facing surface of the garment article; as well as An elastomeric layer is located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the second entangled fiber web.

20. A garment article comprising a composite nonwoven fabric with an asymmetrical finish as claimed in claim 19.

21. The garment article of claim 20, wherein the garment article comprises at least one of upper garment, lower garment, hat, gloves, sleeves and footwear.

22. The garment article of claim 21, wherein the garment article includes an upper for the footwear article.

23. A composite nonwoven fabric with an asymmetrical finish, having a first side and an opposing second side, said asymmetrical composite nonwoven fabric being used in garment articles and comprising: A first tangled fiber web, the first tangled fiber web per cm 2 Having a first number of fibers, the first entangled fiber web per cm 2 Having a first average denier and at least partially forming the first surface, the first surface forming the outward-facing surface of the garment article; The second entangled fiber web, the second entangled fiber web per cm 2 The second number of fibers with a second denier and per cm 2 The second entangled fiber web has a third number of fibers with a third denier, which is different from the second denier, per cm. 2 With less than per cm 2 The first average denier and the second average denier and at least partially form the second surface, the second surface forming the inward-facing surface of the garment article; as well as An elastomeric layer is located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the second entangled fiber web.

24. A garment article comprising a composite nonwoven fabric with an asymmetrical finish as claimed in claim 23.

25. The garment article of claim 24, wherein the garment article comprises at least one of upper garment, lower garment, hat, gloves, sleeves and footwear.

26. The garment article of claim 25, wherein the garment article includes an upper for the footwear article.

27. A composite nonwoven fabric with an asymmetrical finish, having a first side and an opposing second side, said asymmetrical composite nonwoven fabric being used in garment articles and comprising: A first tangled fiber web, the first tangled fiber web per cm 2 Having the first number of fibers and per cm 2 Fibers having a second denier, the second denier being different from the first denier, per cm 2 The first number of fibers is more than per cm 2 The second number of fibers, wherein the first entangled fiber web per cm 2 Having a first average denier and at least partially forming the first surface, the first surface forming the outward-facing surface of the garment article; The second entangled fiber web, the second entangled fiber web per cm 2 The third number of fibers with a third denier and per cm 2 Fibers having a fourth denier, the fourth denier being different from the third denier, per cm 2 The third quantity of fibers is more than per cm. 2 The fourth number of fibers, wherein the second entangled fiber web per cm 2 With less than per cm 2 The first average denier and the second average denier and at least partially form the second surface, the second surface forming the inward-facing surface of the garment article; as well as An elastomeric layer is located between the first entangled fiber web and the second entangled fiber web, wherein at least some fibers of the first entangled fiber web extend through the elastomeric layer and become entangled with the fibers of the second entangled fiber web.

28. A garment article comprising a composite nonwoven fabric with an asymmetrical finish as claimed in claim 27.

29. The garment article of claim 28, wherein the garment article comprises at least one of upper garment, lower garment, hat, gloves, sleeves and footwear.

30. The garment article of claim 29, wherein the garment article includes an upper for the footwear article.

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