Nonwoven fabric with nonlinear interlaced seams suitable for clothing

Abstract

To provide a composite nonwoven textile including nonlinear entangled seams; and to provide a method and a system for producing the same.SOLUTION: A composite nonwoven textile 100 includes a first nonwoven layer 110, a second layer 114, and a filling material 116 positioned between the first nonwoven layer and the second layer. When the composite nonwoven textile is formed into a garment, a region between nonlinear entangled seams 118 is helpful in storing and retaining heat to be capable of providing heat insulation. In addition, the nonlinear entangled seams can be helpful in preventing the filling material from shifting or drifting.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] Embodiments described herein contemplate composite nonwoven fabrics including nonlinear interlaced seams, as well as methods and systems for producing the same. Summary of the Invention [Problem to be solved by the invention]

[0002] Traditional insulating garments generally consist of adjacent textile materials (e.g., woven Baffles are typically formed by positioning panels of fabric (e.g., knitted or knitted fabric), optionally applying adhesive to the textile panels in predetermined locations, heat-pressing and / or stitching the textile together in predetermined locations to form linear seams separating the baffles, and filling the baffles with down or other types of insulating filler material. This construction method can be expensive and time-intensive due to the large number of different materials used to form the garment. Furthermore, the energy costs and carbon footprint associated with, for example, spinning the yarns used in the textile, weaving or knitting the textile with those yarns, applying adhesive, heat-pressing or stitching the seams to form the seams, and filling the baffles can be high, and the recyclability of the resulting garment can be limited due to the large number of individual materials. When the textile material used to form the garments includes a repeating sequence of any type of visual element (e.g., a visual array of printed components, a visual array of seams, etc.), ensuring that each garment in a garment lot includes the visual array of elements in consistent locations on the garment to provide a uniform appearance for each garment in the garment lot can result in wasted material. [Brief explanation of the drawings]

[0003] Examples of the aspects described herein are described in detail below with reference to the accompanying drawings. [Figure 1]1 illustrates a first surface of an exemplary composite nonwoven fabric having a nonlinear interlaced seam according to embodiments described herein. [Figure 2A] 2 illustrates the opposing second surface of the composite nonwoven fabric of FIG. 1, a first exemplary second surface formed from a nonwoven fabric according to embodiments described herein. [Figure 2B] 2 illustrates the opposing second surface of the composite nonwoven fabric of FIG. 1, a second exemplary second surface formed from a nonwoven fabric according to embodiments described herein. [Figure 3] 3 illustrates a cross-sectional view of a composite nonwoven fabric taken along line 3-3 in FIG. 1 according to an embodiment described herein. [Figure 4A] 1 illustrates an enlarged view of a portion of a first exemplary nonlinear interlaced seam according to embodiments described herein. [Figure 4B] 1 illustrates an enlarged view of a portion of a second exemplary nonlinear interlaced seam according to embodiments described herein. [Figure 5] FIG. 2 illustrates a side view of an exemplary entanglement system for producing the composite nonwoven fabric of FIG. 1 according to embodiments described herein. [Figure 6A] 6 illustrates a front view of a first exemplary interlacing station that is part of the interlacing system of FIG. 5 according to embodiments described herein. [Figure 6B] 6 illustrates a front view of an alternative exemplary interlacing station that is part of the interlacing system of FIG. 5 according to embodiments described herein. [Figure 7] 6 illustrates a front view of an additional exemplary interlacing station that is part of the interlacing system of FIG. 5 according to embodiments described herein. [Figure 8] 6 illustrates a front view of an additional exemplary interlacing station that is part of the interlacing system of FIG. 5 according to embodiments described herein. [Figure 9A] 6 illustrates an exemplary interlacing head for use in the interlacing system of FIG. 5, according to embodiments described herein. [Figure 9B] 6 illustrates an exemplary interlacing head for use in the interlacing system of FIG. 5, according to embodiments described herein. [Figure 10A]6B illustrates a schematic diagram of an exemplary process for forming a non-linear interlaced seam by use of the interlacing station of FIG. 6A according to embodiments described herein. [Figure 10B] 6C illustrates a schematic diagram of an exemplary process for forming a non-linear interlaced seam by use of the interlacing station of FIG. 6B, according to embodiments described herein. [Figure 11] 1 illustrates an exemplary process for manufacturing an array of garments having a common finish configuration, the array of garments including different visual arrangements of non-linear interlacing seams, according to embodiments described herein. [Figure 12] 12 illustrates an array of upper body garments formed using the exemplary process of FIG. 11 according to embodiments described herein. [Figure 13] 12 illustrates an array of lower body garments formed using the exemplary process of FIG. 11 according to embodiments described herein. [Figure 14] 1 illustrates a first surface of an exemplary composite nonwoven fabric having nonlinear interlacing seams that cross each other, according to embodiments described herein. [Figure 15] 15 illustrates a cross-sectional view of a composite nonwoven fabric taken along line 15-15 of FIG. 14, according to an embodiment described herein. [Figure 16] 15 illustrates an exemplary upper body garment having zoned insulating features formed using the composite nonwoven fabric of FIG. 14, according to embodiments described herein. [Figure 17] 1 illustrates an exemplary composite nonwoven fabric having discontinuous nonlinear interlaced seams according to embodiments described herein. [Figure 18] 1 illustrates an exemplary single layer nonwoven fabric having a non-linear interlaced seam, according to embodiments described herein. [Figure 19] 19 illustrates the exemplary single layer nonwoven fabric of FIG. 18, according to embodiments described herein. DETAILED DESCRIPTION OF THE INVENTION

[0004] The subject matter of the present invention is described with particularity to meet statutory requirements. However, the description itself is not intended to limit the scope of the present disclosure. Rather, the inventors believe that the claimed or disclosed subject matter may be embodied in other ways, including different steps or combinations of steps similar to those described herein, in conjunction with other existing or future technologies. Furthermore, although the terms "step" and / or "block" may be used herein to connote different elements of a method employed, these terms should not be construed to imply any particular order between the various steps unless the order of the individual steps is explicitly recited.

[0005] Traditional insulating garments generally consist of adjacent textile materials (e.g., woven or baffles are formed by positioning panels of fabric (e.g., knitted fabric), optionally applying adhesive to the fabric panels in predetermined locations, heat-pressing and / or sewing the fabric together in predetermined locations to form linear seams separating the baffles, and filling the baffles with down or other types of insulating filler material. This construction method can be costly and time-intensive due to the large number of different materials used to form the garment. Furthermore, there are high energy costs and carbon footprints associated with, for example, spinning the yarns used in the fabric, weaving or knitting the fabric with those yarns, applying adhesive, heat-pressing or sewing the seams to form the seams, and filling the baffles, and the recyclability of the resulting garment can be limited due to the large number of individual materials present. It is also possible that the fabric materials used to form the garment do not have any type of repeating arrangement of visual elements (e.g., plied or woven fabrics) that are part of a repeating sequence of visual elements. When fabrics include various visual alignments (visual alignment of blended components, visual alignment of seams, etc.), ensuring that each garment in a garment lot includes visual alignment of elements in consistent locations on the garment to provide a uniform appearance for each garment in the garment lot can result in wasted material.

[0006] At a high level, embodiments described herein contemplate composite nonwoven fabrics having nonlinear interlaced seams suitable for garments, as well as methods and systems for producing the same. In exemplary embodiments, an entanglement system can be used to form the composite nonwoven fabric. The entanglement system, in exemplary embodiments, can include one or more entanglement stations that can sequentially align layers of a laminate construct used to form the composite nonwoven fabric along a conveying system adapted to advance the layers along the conveying system surface in a material flow direction. Each entanglement station includes an actuator that, in one exemplary embodiment, is adapted to move in a direction perpendicular to the plane of the conveying surface. Each entanglement station further includes one or more entanglement heads coupled to the actuator. In one embodiment, the entanglement head includes one or more needles arranged in a structural configuration. In one example, the entanglement needles are engaged with the layers of the laminate construct by moving the actuator in a direction perpendicular to the plane of the conveying surface. In another embodiment, the actuator remains stationary but moves the entanglement head and / or entanglement needles up and down in a direction perpendicular to the conveying plane, thereby causing the entanglement needles to engage the layers of the laminated construct. In another exemplary embodiment, the entanglement head is adapted to emit one or more pressurized jets of a fluid, such as water. In this embodiment, the actuator can remain stationary and cause the fluid jets to be emitted from the entanglement head.

[0007] In exemplary embodiments, the entangling head can also be coupled, directly or indirectly by an actuator, to a carriage, which is adapted to move in a direction non-parallel to the material flow direction. Additionally or alternatively, the conveying system can be adapted to move in a direction non-parallel to the material flow direction. Thus, in exemplary embodiments, the entangling head and the conveying system can be adapted to move relative to one another in a direction non-parallel to the material flow direction.

[0008] In an exemplary embodiment, the entangling heads can be positioned at different locations at corresponding entangling stations to contact different locations of the laminated construct as it is conveyed along the surface of the conveying system. For example, a first entangling station can include a first entangling head positioned a first distance inward from a side edge of the surface of the conveying system, and a second entangling station positioned subsequent to the first entangling station can include a second entangling head positioned a second distance inward from the side edge of the conveying system, the second distance being different from the first distance.

[0009] In an exemplary embodiment, the laminate construct includes a first nonwoven layer, a second nonwoven layer, and a filler material positioned between the first and second nonwoven layers. The laminate construct is positioned on the surface of a conveying system with the first nonwoven layer facing upward or toward the actuator, and the entanglement head and second layer of the first entanglement station facing toward the surface of the conveying system. In one exemplary embodiment, when the entanglement head includes entanglement needles, the actuator moves the entanglement head and / or the entanglement needles in a direction perpendicular to the plane of the conveying surface while the composite nonwoven fabric is in the first stationary phase, thereby engaging the entanglement needles, and indirectly the entanglement head, with the laminate construct to form a first entangled region. When the entanglement needles engage the laminate construct, the needles drive fibers from the first nonwoven layer through the filler material and into the second layer. In another exemplary embodiment, when the entanglement head emits one or more fluid jets, the actuator operates the entanglement head to entangle the laminate while the composite nonwoven fabric is in the first stationary phase. One or more fluid jets are emitted that contact the construct to form a first entangled region. Alternatively, the laminate construct can be continuously advanced while the entangling head continuously emits one or more fluid jets. In these embodiments, as the fluid jets contact the laminate construct, the pressure of the jets drives fibers from the first nonwoven layer, through the filler material, and into the second layer.

[0010] When entangling needles are used, the conveying system then advances the laminated construct of the first nonwoven layer, the second layer, and the filler material a predetermined amount in the material flow direction. In exemplary embodiments, the predetermined amount of advancement can be less than or equal to a dimension of the entangling head in the material flow direction. Additionally, the entangling head and / or the conveying system can move a predetermined amount in a direction non-parallel to the material flow direction. In exemplary embodiments, the predetermined amount of movement can be less than or equal to a dimension of the entangling head in a direction non-parallel to the material flow direction. While the laminated construct is in the second stationary phase, and when the entangling head includes entangling needles, the actuator moves the entangling head and / or the entangling needles in a direction perpendicular to the plane of the conveying surface, thereby engaging the entangling needles with the structure to form a second entangled region. When the entangling head is adapted to emit one or more fluid jets, the actuator operates the entangling head to emit one or more fluid jets to form the second entangled region. The second interlaced region extends from the first interlaced region to form a non-linear interlaced seam.

[0011] As the laminated construct continues to advance through the first entanglement station, additional entangled regions are formed extending from the first and second entangled regions, forming an apparently continuous entangled seam in the material flow direction. By moving the entanglement head and / or conveying system in a direction non-parallel to the material flow direction, the continuous entangled seam becomes non-linear in the material flow direction. In exemplary embodiments, the first entangled region and the second entangled region partially overlap, and this overlapping region is where the entanglement needles and / or fluid jets engage the laminated construct at least two times. In other exemplary embodiments, the first entangled region and the second entangled region do not overlap but are positioned directly adjacent to each other to form a non-linear entangled seam. In still other embodiments, the first entangled region and the second entangled region can be spaced apart from each other to form a discontinuous non-linear entangled seam. Any and all embodiments, and any variations thereof, are considered within the scope of the present invention.

[0012] The laminated construct of the first nonwoven layer, the second layer, and the filler material can continue to advance through additional entangling stations, which form additional nonlinear entangled seams that are separate and distinct from the entangled seam formed by the first entanglement station. In other words, the additional nonlinear entangled seams can be located at different locations along a direction nonparallel to the material flow direction. Depending on the number of entanglement stations in the entanglement system, the resulting composite nonwoven fabric can have a short repeating visual sequence of entangled seams, a long repeating visual sequence of entangled seams, or even no repeating visual sequence.

[0013] The resulting composite nonwoven fabric may include a plurality of nonlinear interlaced seams extending in the material flow direction of the fabric. As described above, the interlaced seams represent regions where fibers extend from the first nonwoven layer through the filler material into the second layer. In an exemplary embodiment, the fibers may penetrate the second layer, causing the fibers to protrude outward from the second surface of the composite nonwoven fabric. The composite nonwoven fabric further includes regions where the first nonwoven layer, the second layer, and the filler material are substantially unentangled. The regions where the first nonwoven layer, the second layer, and the filler material are substantially unentangled have a greater thickness than the interlaced seams. When the composite nonwoven fabric is formed into a garment, the regions where the first nonwoven layer, the second layer, and the filler material are substantially unentangled correspond to the "baffles" found in traditional insulating garments and retain heat to accumulate heat and provide warmth, while the interlaced seams help prevent the filler material from drifting or shifting. .

[0014] The systems, methods, fabrics, and garments described herein offer numerous advantages. For example, the composite nonwoven fabric is easy and quick to manufacture, requiring minimal materials (e.g., no adhesives, no seams) and equipment (e.g., no hot presses), and eliminating the need for post-processing steps of placing filler material into baffles, as is done in traditional constructions. This, in turn, reduces the carbon footprint associated with the manufacturing process. Furthermore, the composite nonwoven fabric can be formed from the same or similar materials (e.g., materials of the same polymer grade). In one exemplary embodiment, the first nonwoven layer, the second layer, and the filler material Each of the nonwoven fabrics can be formed from recycled polyester fibers. This allows the entire fabric to be easily recycled, for example, by shredding, without the need for subsequent sorting to remove dissimilar materials. Furthermore, because the nonlinear seams are formed, for example, by an entanglement process using recycled polyester fibers, the composite nonwoven fabric does not contain adhesives and / or threads used in stitching, which reduces the need to remove these portions of the fabric before recycling.

[0015] In exemplary embodiments, because the composite nonwoven fabric can be formed from materials of the same polymer grade, and because the composite nonwoven fabric does not include dissimilar materials such as threads, adhesives, etc., the resulting garment formed from the composite nonwoven fabric can be easily recycled, for example, by shredding. Additionally, shredded material from the garment can be recycled to form the first nonwoven layer, the second layer, and the filler material to create a sustainable lifecycle for the garment. Along these lines, scrap pieces resulting from the fabrication of garments from the composite nonwoven fabric can also be easily recycled by shredding, with the shredded material from the scrap then being used to fabricate one or more of the first nonwoven layer, the second layer, and the like. , and a filler material.

[0016] An additional advantage of using the interlacing systems and manufacturing methods described herein is the ability to create complex visual arrangements of interlaced seams. As used herein, a visual arrangement of interlaced seams is collectively created by different shapes associated with each interlaced seam, the spacing between interlaced seams, the number of interlaced seams, the width of the interlaced seams, etc. To create complex visual arrangements of interlaced seams, interlacing heads can be positioned at different locations in the interlacing stations, the number and / or spacing of interlacing heads at different interlacing stations can be varied, the interlacing footprints created by the interlacing heads can be varied, and the interlacing heads and / or conveying systems can be moved in different directions nonparallel to the material flow direction. Complex visual arrangements of interlaced seams can include seams that cross over, intersect, or are positioned closely together. In addition to creating interesting aesthetics, the ability to create areas where seams cross over, intersect, or are positioned closely together allows for the production of composite nonwoven fabrics of different thicknesses. For example, areas where seams cross over or intersect each other represent instances where one or more entangling heads from an entangling station engage the composite nonwoven fabric multiple times. Thus, such areas may be more closely spaced than other entangled seams and may be more closely spaced between the first nonwoven layer, the second nonwoven layer, and the filling layer. The filler may have a reduced thickness compared to areas that are substantially unentangled. When the composite nonwoven is formed into a garment, these areas will be positioned adjacent to portions of the human body that require less insulation (e.g., based on a body heat map), i.e., these areas will have less loft and less insulating properties compared to other regions of the composite nonwoven.

[0017] Yet another advantage of using the interlacing systems and manufacturing methods described herein is the ability to produce fabrics with short repeat visual sequences of interlacing seams, long repeat visual sequences of interlacing seams, or no repeat visual sequences. This is achieved by varying the number of interlacing stations aligned in series along the conveying system. The ability to create long or no repeats using the interlacing systems described herein addresses a potential shortcoming in traditional garment construction. Traditional garment construction using fabrics with short, repeating visual sequences of elements can generate material waste because the pattern pieces used to form the garments are positioned to produce garments with the same visual sequence of elements in the same location on the garment. This often results in a high amount of scrap. The ability to create composite nonwoven fabrics with long or no repeating visual sequences of interlacing seams allows for the production of an array of garments with a common finish form, but with varied aesthetic appearances resulting from the unique visual sequences of the interlacing seams, minimizing material waste. When viewed as a garment array or lot, a consumer will recognize the garments as having a common origin and / or shared manufacturer, but will be able to select a garment from the array with their preferred visual sequence of the interlacing seams.

[0018] Another aspect related to the interlacing systems and methods described herein is the ability to create nonlinear interlaced seams on one or more single nonwoven layers. The ability to create interlaced seams on a single layer has additional advantages, including ease and speed of manufacturing with minimal materials (e.g., no adhesives, no seams) and equipment (e.g., no heat presses). This, in turn, reduces the carbon footprint associated with the manufacturing process. Furthermore, nonwoven fabrics can be formed from the same or similar materials (i.e., materials of the same polymer grade). This allows for the entire fabric to be easily recycled, for example, by shredding, without the need for subsequent sorting to remove dissimilar materials. Furthermore, because nonlinear seams are formed by an entanglement process using, for example, recycled polyester fibers, the composite nonwoven fabric does not contain adhesives and / or threads used in seams, reducing the need to remove these portions of the fabric before recycling.

[0019] A single nonwoven layer can include a single fiber layer (e.g., a lightly entangled fiber web), multiple fiber layers entangled with one another, a fiber layer entangled with other materials, such as an elastic layer, a textile layer, etc. In an exemplary embodiment, a nonlinear interlaced seam is created in the individual nonwoven layers, after which the nonwoven layers can be formed, for example, into a garment. In other exemplary embodiments, different nonwoven layers having nonlinear interlaced seams can be positioned adjacent to one another with optional additional layers (nonwoven, knitted, woven, film, etc.) positioned therebetween, and the different layers can be secured to one another using interlacing, sewing, bonding, etc. Any and all embodiments and variations thereof are contemplated as being within the scope of the present invention.

[0020] As used herein, the term "garment" or "article of apparel" refers to a ) is intended to encompass articles worn by a wearer. As such, they can include upper body garments (e.g., outerwear, t-shirts, pullovers, hooded sweatshirts, jackets, coats, etc.) and lower body garments (e.g., trousers, pants, tights, pants, unitards, etc.). Apparel articles can also include hats, gloves, sleeves (arm sleeves, calf sleeves), footwear articles such as shoe uppers, etc. When referring to apparel, the term "inner-facing surface" refers to the surface configured to face the body surface of the wearer, and the term "outer-facing surface" refers to the surface configured to face the external environment, away from the body surface of the wearer. The term "innermost-facing surface" refers to the surface closest to the body surface of the wearer relative to other layers of the apparel, and the term "outermost-facing surface" refers to the surface furthest from the body surface of the wearer relative to other layers of the apparel. The term "pattern" or "pattern piece" refers to the way in which pieces of fabric are combined to form a garment, for example, using traditional cut and sew construction. It is used when extracting, extracting, or cutting a fabric portion having a perimeter shape corresponding to a pattern or pattern piece.

[0021] As used herein, the term "composite nonwoven textile" encompasses any fabric comprising at least one nonwoven layer in combination with other layers, whether or not the layers are substantially unsecured to one another except for interlaced seams. Thus, it is contemplated herein that a composite nonwoven textile is formed entirely from nonwoven layers. It is further contemplated herein that nonwoven layers may be combined with other structures, such as fibrous materials, films, woven layers, knitted layers, braided layers, and the like. As used herein, the term "composite nonwoven textile" is contemplated to encompass a laminate construction of layers and one or more interlaced seams joining the layers to form a laminate construction at the seam area.

[0022] The term "nonwoven layer" refers to a layer in which fibers are held together by mechanical and / or chemical interactions and are not in the form of a knitted, woven, braided, or other structured structure. In certain embodiments, a nonwoven layer comprises a collection of fibers that are mechanically or chemically manipulated to form a mat-like material. In other words, the nonwoven layer is made directly from fibers. The composite nonwoven fabrics described herein comprise different layers formed as a conglomerate structure, and the different layers can have fibers or yarns of different or similar composition and / or different properties. In one embodiment, the first nonwoven layer and optionally the second layer can comprise spunbond layers. As used herein, spunbond layers are formed by spinning continuous filaments of molten polymeric material on a moving belt and bonding the polymeric material together, for example, by using a calendering process. Spunbond nonwoven fabrics typically have a soft hand and are strong and durable. Additionally, nonwoven fabrics generally have a smooth surface suitable for printing, including digital printing with a digital printing head. In other exemplary embodiments, the first nonwoven layer and optionally the second layer can be spunlace layers. As used herein, a spunlace layer includes a fibrous web that is entangled, for example, by hydroentanglement. The embodiments described herein contemplate that the filler material may include an entangled fibrous web that forms a sheet-like material. In exemplary embodiments, the fibers can be resin-bonded to form a compact structure. Other embodiments described herein contemplate that the filler material includes loose synthetic fibers / filaments, down, or any combination of the foregoing.

[0023] The term "substantially unentangled" when referring to a composite nonwoven fabric means that the layers are not entangled with one another, thereby allowing the layers to move independently of one another. The term "entangled seam" refers to an area of ​​a composite nonwoven fabric where one or more layers are lightly entangled with one another, or where one or more layers are lightly entangled with one another. The term "entangled seam," when referring to a composite nonwoven fabric, refers to an area of ​​the composite nonwoven fabric where the layers of the composite nonwoven fabric have been mechanically entangled with one another, for example, by needlepunching or hydroentangling. In this manner, different layers of the composite nonwoven fabric in the seam area may contain fibers originally present in that particular layer as well as fibers present in other layers, including additional nonwoven layers, or filler materials that have migrated into the layers through the entanglement process. When describing an entangled seam as "non-linear," this specification contemplates that the distance between the non-linear entangled seam and the linear edge of the composite nonwoven fabric may vary along the material flow direction of the nonwoven fabric. Embodiments described herein contemplate that the seam may include straight segments, curved segments, curvilinear segments, etc., alone or in combination to form the non-linear entangled seam. In an exemplary embodiment, the distance between adjacent nonlinear interlaced seams can vary along the material flow direction of the composite nonwoven fabric.

[0024] The mechanical entanglement process contemplated herein involves needle entanglement using barbed or structured needles (e.g., forked needles), known herein as entanglement needles. There may be entanglement (generally needle punching), or fluid entanglement, known herein as hydroentanglement. Needle punching is generally a type of entanglement. Needle punching is used to reposition a percentage of the fibers from a generally horizontal orientation (extending along the x-y plane) to a generally vertical orientation (z-direction orientation). Generally, the needlepunching process involves stacking the layers that form the composite nonwoven fabric, and passing the entanglement needles associated with the entanglement head through the laminated fabric. Thus, when we say that the entanglement head engages the nonwoven fabric, we are assuming that the entanglement needles associated with the entanglement head engage the nonwoven fabric. A stripper plate can be used to strip the fibers from the needles after they move in and out of the laminated fabric. Each pass of the entanglement head through the laminated fabric is known herein as a "pass." Parameters associated with the entanglement head can be adjusted to obtain desired properties (e.g., basis weight, thickness, etc.) of the resulting composite nonwoven fabric, as further described below.

[0025] The barbs on the entanglement needles "trap" fibers as they move from the first nonwoven layer through the laminated construct. The movement of the entanglement needles effectively moves or pushes the fibers captured by the barbs from a location at or near the surface of the first nonwoven layer to a location at or near the surface of the second layer, and further creates physical interactions with other fibers, for example, frictionally "locking" the displaced fibers in place. This specification also contemplates passing the entanglement needles through the laminated construct in a direction from the second layer toward the first nonwoven layer. In a hydroentanglement operation similar to needlepunching, pressurized fluid (e.g., water) jets move fibers through different layers. Parameters associated with the hydroentanglement process, such as fluid jet pressure, number of fluid jets, conveying speed, etc., can be adjusted to achieve a desired degree of entanglement.

[0026] As used herein, the term "entanglement head" refers to a defined arrangement of The term "entanglement footprint" is used to describe a structure including one or more entanglement needles and / or one or more orifices that emit one or more pressurized fluid jets in a defined arrangement. When the entanglement needles and / or fluid jets engage a composite nonwoven fabric through an entanglement head, an entanglement footprint can be formed. As used herein, the term "entanglement footprint" refers to the structured arrangement of entanglement points created on the composite nonwoven fabric by the entanglement head. For example, based on the defined arrangement of the entanglement needles and / or orifices in the entanglement head, the entanglement footprint can have a circular shape, a square shape, a rectangular shape, a triangular shape, etc.

[0027] As used herein, the term "material flow direction" means , refers to the direction in which the material advances along the conveying system. The material flow direction is also known as the machine direction. Thus, when describing a composite nonwoven fabric that includes a nonlinear entangled seam that extends in the material flow direction, the nonlinear entangled seam extends in the direction of advancement of the composite nonwoven fabric along the conveying system of the entanglement system. As noted above, the entanglement head, or the fluid jet when using hydroentanglement, can move in a direction perpendicular to the conveying plane of the conveying system. Another way to state this is that when the conveying plane extends along the x,y plane and the material flow direction extends in the positive x-direction, the entanglement head or fluid jet: The carriage or transport system can move in the positive or negative z-direction. When describing movement in a direction non-parallel to the y direction, this specification generally assumes that the carriage and / or transport system moves in the positive or negative y direction.

[0028] The fibers used to form the nonwoven layers and other layers contemplated herein can be made of many different materials (e.g., cotton, nylon, etc.), including polyethylene terephthalate (PET), commonly known as polyester. PET fibers are virgin PET fibers. It can include fibers (non-recycled fibers) and recycled PET fibers. Recycled PET fibers include shredded PET fibers derived from shredded materials and re-extruded PET fibers (re-extruded fibers using recycled PET chips).

[0029] Various measurements are performed on composite nonwoven fabrics. The thickness of the resulting composite nonwoven fabric can be measured using a precision thickness gauge. To measure thickness, for example, the fabric can be placed on a flat base (anvil) and a presser foot can be pressed onto the fabric from above with a standard fixed load. The dial indicator on the precision thickness gauge shows the thickness in mm. Basis weight is measured using the ISO 3801 test standard and has units of grams per square meter (gsm). Thermal resistance, which generally corresponds to thermal insulation characteristics, is measured using the ISO 11092 test standard and has units of RCT (Meters). 2 *K / W). Unless otherwise specified, all measurements made herein are taken with the nonwoven fabric in a rest (unstretched) state at standard ambient temperature and pressure (25°C or 298.15K, and 0.1 MPa (1 bar)).

[0030] FIG. 1 illustrates a first surface 101 of a composite nonwoven fabric 100, which is formed of a first nonwoven layer 110. In an exemplary embodiment, the first nonwoven layer 110 can include a spunbond or spunlace material, although other nonwoven structures are contemplated herein. The spunbond or spunlace material generally provides a soft feel and makes the material durable and suitable for incorporation into a garment. The first nonwoven layer 110 is formed from intertwined fibers, as indicated by reference numeral 112. When the composite nonwoven fabric 100 is incorporated into a garment, the first surface 101 can be positioned as the inward-facing surface or the innermost inward-facing surface of the garment. Alternatively, the first surface 101 can be positioned as the outward-facing surface or the outermost outward-facing surface of the garment.

[0031] 2A and 2B. A filler material 116 is positioned between the first nonwoven layer 110 and the second layer 114. The filler material 116 can include a fibrous sheet having intertwined fibers that can optionally be resin bonded to maintain a more compact structure, a lightly entangled fibrous web, a carded web, loose synthetic fibers, down, etc.

[0032] 1 , the composite nonwoven fabric 100 can include a plurality of nonlinear interlaced seams 118 extending in the material flow direction 105 of the composite nonwoven fabric 100. The interlaced seams 118 represent areas where fibers from different layers are interlaced with one another. In one exemplary embodiment, the interlaced seams 118 represent areas where fibers extend from the first nonwoven layer 110, through the filler material 116, and into the second layer 114. The regions 122 of the composite nonwoven fabric 100 located between the interlaced seams 118 represent areas where the first nonwoven layer 110, the second layer, and the filler material 116 are substantially unentangled, and the different layers are not, or are only lightly, secured or fixed to one another in the regions 122. As shown, regions 122 have loftier or greater thickness than interlaced seams 118 and may help store and retain heat when composite nonwoven fabric 100 is incorporated into a garment. Interlaced seams 118, in turn, may help prevent shifting or drifting of filler material 116 when a garment incorporating composite nonwoven fabric 100 is worn.

[0033] At least with respect to interlaced seam 118a, the distance between interlaced seam 118a and linear first edge 120 of composite nonwoven fabric 100 varies along the material flow direction 105 of composite nonwoven fabric 100. For example, first distance 124 between interlaced seam 118a and first edge 120 may be less than second distance 126 between interlaced seam 118a and first edge 120. This is also true for the other interlaced seams 118 shown in FIG. 1 . As shown, interlaced seams 118 may include linear segments extending from one another, curved portions, and combinations thereof. The shape of an individual interlaced seam 118, the shape of the interlaced seam 118, and the shape of the interlaced seam 118 may vary. The depiction of the number, spacing between adjacent interlaced seams 118, and overall visual arrangement of the interlaced seams 118 is illustrated, and it is contemplated herein that the interlaced seams 118 may include other non-linear shapes, different numbers of interlaced seams 118, different spacing, and different overall visual arrangements of the interlaced seams 118.

[0034] FIG. 2A illustrates the opposing second surface 201 of the composite nonwoven fabric 100, which is formed by the second layer 114. In one exemplary embodiment as shown in FIG. 2A , the second layer 114 can include a woven layer 210 interwoven with the exemplary warp and weft yarns. In this example, when the composite nonwoven fabric 100 is incorporated into a garment, the second layer 114 can be positioned as the garment's outer or outermost outer surface. Woven materials generally have high resistance to abrasion and can act as an effective windproof barrier due to the tight weave structure that makes them suitable for forming the outer surface of a garment. In an exemplary embodiment, the woven material can be treated with a water-resistant, water-repellent agent to impart waterproof properties to the composite nonwoven fabric 100. A nonlinear interlacing seam 118 is shown extending throughout the composite nonwoven fabric 100, as present on the second surface 201 of the fabric 100.

[0035] 2B illustrates a second embodiment in which the second layer 114 is formed from a nonwoven material, such as a spunbond or spunlace material. The interlaced fibers forming the second layer 114 are designated by reference numeral 212. A nonlinear interlaced seam 118 extends throughout the composite nonwoven fabric 100 and is present on the second surface 201 of the fabric 100 in FIG. 2B.

[0036] Figure 3 shows a cross section of the composite nonwoven fabric 100 taken along section line 3-3 in Figure 1. Shown are a first nonwoven layer 110, a second layer 114, and a filler material 116, which is a filler material that is a part of the first nonwoven layer. In region 122, the first nonwoven layer 110 is positioned between the second layer 114. The first nonwoven layer 110, the second layer 114, and the filler material 116 are substantially unentangled. The two layers 114 and the filler material 116 remain as separate and distinct layers overall and have a combined thickness 310 measured from the first surface 101 to the second surface 201 .

[0037] Fibers 112 from the first nonwoven layer 110 are shown penetrating the filler material 116 and the second layer 114 at the interlacing seams 118, which secure the different layers together at the seam area. In one exemplary embodiment, the fibers 112 can penetrate the second layer 114, thereby protruding from the second surface 201 of the composite nonwoven fabric 100, as shown in FIG. 3 . In this example, the fibers 112 can be left untreated so that the second surface 201 exhibits a fuzzy surface at the interlacing seams 118. In another example, the fibers 112 can be removed, compressed, or melted. For example, a calendering process can be used to compress the fibers 112 so that they do not protrude from the second surface 201. In another example, the filler material 116 can include low-melting fibers, and any low-melting fibers protruding from the second surface 201 can be removed by applying heat. Additionally, fibers 112 can be removed using a shaving process if desired. In another exemplary embodiment, fibers 112 can extend into but not penetrate second layer 114, and can be substantially absent from second surface 201 of composite nonwoven fabric 100.

[0038] The interlaced seam has a thickness 312 that is less than the thickness 310 in region 122. In one exemplary embodiment, thickness 310 can be from about 7 mm to about 15 mm, from about 8 mm to about 13 mm, from about 9 mm to about 11 mm, or about 10 mm. As used herein, the term "about" means within ±10% of the indicated value. In an exemplary embodiment, Thickness 312 can be about 5 mm to about 0.2 mm, about 4 mm to about 1 mm, about 3 mm to about 1.5 mm, or about 2 mm. Thus, in an exemplary embodiment, thickness 312 of interlaced seam 118 can be about 5% to 30% of thickness 310 of region 122.

[0039] FIG. 4A illustrates an enlarged view of one interlaced seam 118 in composite nonwoven fabric 100 as viewed from first surface 101 of composite nonwoven fabric 100. A view of interlaced seam 118 as viewed from second surface 201 of composite nonwoven fabric 100 would be similar. FIG. 4A illustrates a first exemplary manner in which interlaced seam 118 may be formed. In an exemplary embodiment, interlaced seam 118 may be formed from discrete interlaced areas 410 that partially overlap with overlap areas 412. Each of the discrete interlaced areas 410 has an interlaced footprint. For example, while the interlaced footprints of the discrete interlaced areas 410 are shown as having a circular configuration, this is for illustrative purposes only and is based on the structured arrangement of interlaced needles and / or orifices in the interlacing head used to form the interlaced areas 410. As shown, the interlaced areas 410 extend nonlinearly from one another to form an apparently continuous, nonlinear interlaced seam.

[0040] Individual dots within the entanglement area 410 represent entanglement points where either entanglement needles or fluid jets engage the composite nonwoven fabric 100 to entangle the fibers. 2 The number of interlacing points 414 per stitch may be known herein as stitch density. Stitch density may be based on, for example, the number of interlacing needles associated with the entanglement head, the number of fluid jets emitted from the entanglement head, the structured arrangement of the interlacing needles and / or fluid jets, etc. Higher stitch densities may result in a reduced thickness of the entangled seam 118 compared to lower stitch densities, since higher stitch densities generally mean a higher degree of fiber entanglement.

[0041] The overlap area 412 represents an area where the entanglement head engages the composite nonwoven fabric more than once. As such, the number and / or density of entanglement points 414 within the overlap area 412 is greater than the number and / or density of entanglement points 414 in the remainder of the entangled area 410. In other words, the stitch density in the overlap area 412 is greater than the stitch density in the remainder of the entangled area 410. This may result in the overlap area 412 having a reduced thickness compared to the remainder of the entangled area 410.

[0042] FIG. 4B illustrates a second exemplary manner in which the interlaced seam 118 may be formed. In this embodiment, the interlaced areas 410 extend from one another in a nonlinear manner to form a seemingly continuous interlaced seam, but do not partially overlap one another as shown in FIG. 4A. Instead, the interlaced areas 410 may be positioned directly adjacent to one another such that the interlaced points 414 of a first interlaced area 410 share a common boundary with the interlaced points 414 of an adjacent second interlaced area 410. With respect to the nonlinear interlaced seam 118, the interlaced seam 118 may include the configuration shown in FIG. 4A, the configuration shown in FIG. 4B, or a combination of the configurations shown in FIGS. 4A and 4B. It is also contemplated herein that the interlaced areas 410 may be separated from one another to form a discontinuous nonlinear interlaced seam.

[0043] 5 is a schematic side view of an exemplary interlacing system 500. The depiction of the different components of the interlacing system 500 is merely illustrative and does not represent the actual form or structure of the components. The interlacing system 500 may include, for example, a first nonwoven layer 110, a second nonwoven layer 111, a third nonwoven layer 112, a fourth nonwoven layer 113, a fifth nonwoven layer 114, a sixth nonwoven layer 116, a sixth nonwoven layer 118, a sixth nonwoven layer 119, a sixth nonwoven layer 119, a sixth nonwoven layer 120, a sixth nonwoven layer 122, a sixth nonwoven layer 124, a sixth nonwoven layer 126, a sixth nonwoven layer 128 ... The conveying system 512 includes a surface 514 adapted to advance the laminated construction of the two layers 114 and filler material 116 in a material flow direction indicated by arrow 516. In another embodiment, as further described with respect to Figures 18 and 19, the conveying system 512 can advance a single nonwoven layer, such as the first nonwoven layer 110, in the material flow direction 516. The conveying system 512 can include conventional conveying systems such as rollers, belts, and the like. The advancement of the conveying system 512, in an exemplary embodiment, can include stationary phases or positions and moving phases in the material flow direction 516. The stationary and moving phases can be The duration of the stationary phase can be adjusted to achieve one or more desired characteristics in the resulting composite nonwoven fabric. For example, the duration of the stationary phase can be adjusted to achieve more or less entanglement in the resulting entangled seam. In other words, a longer stationary phase allows for more passes of the entanglement needle in the entangled area, a higher stitch density in the entangled area, and a higher degree of entanglement in the entangled area. The advance distance during the moving phase can also be adjusted to achieve desired characteristics in the resulting composite nonwoven fabric. For example, increasing the advance distance during the moving phase can cause the entangled areas to not overlap or even be separated from each other, while decreasing the advance distance during the moving phase can increase the amount of overlap between adjacent entangled areas. The conveying speed during the moving phase can be adjusted to increase and / or decrease production time.

[0044] The entangling system 500 further includes multiple entangling stations, such as entangling stations 518, 520, and 522. While only three entangling stations are shown, it is contemplated that there may be more or fewer entangling stations than those shown in FIG. 5 . The entangling stations 518, 520, and 522 are aligned serially in the material flow direction 516 along the conveying system 512. In an exemplary embodiment, including more entangling stations in the entangling system 500 results in the resulting composite nonwoven fabric having a longer or no repeat of the visual array of the nonlinear entangled seam. Including fewer entangling stations in the entangling system 500 results in the resulting composite nonwoven fabric having a shorter repeat of the visual array of the nonlinear entangled seam. In this manner, the number of entangling stations that are part of the entangling system 500 can be customized to achieve a desired repeat length of the visual array of the nonlinear entangled seam.

[0045] Components associated with the different entangling stations 518, 520, 522 may be substantially similar, and therefore, although components associated with the entangling station 518 are described herein, it should be understood that the component description also applies to the entangling stations 520, 522. The entangling station 518 includes, for example, a carriage 524 slidably coupled to a mount 526. The carriage 524 is adapted to move in a direction non-parallel to the material flow direction 516. Alternatively, the carriage 524 may not be used when the transport system 512 is adapted to move in a direction non-parallel to the material flow direction 516. In an exemplary embodiment, the carriage 524 and / or the transport system 512 are adapted to move perpendicular to the material flow direction 516 toward both a first side edge and an opposite second side edge of the transport system 512 (i.e., in the positive and negative y-directions).

[0046] The entangling station 518 further includes an actuator 528 coupled to the carriage 524. In one exemplary embodiment, as shown in FIG. 5, the actuator 528 is adapted to move in a direction perpendicular to the conveying plane of the surface 514 of the entangling system 512, as indicated by arrow 530. In other exemplary embodiments, the actuator can remain stationary and actuate the entangling head and / or entangling needles to move in a direction perpendicular to the conveying plane of the surface 514 of the entangling system 512. In yet other exemplary embodiments, and as described with reference to FIG. 6B, the actuator can remain stationary and actuate the entangling head to emit a fluid jet. An entangling head 532 is coupled to the actuator 528 and can be indirectly coupled to the carriage 524 by the actuator 528. In the embodiment shown in FIG. 5, the entangling head 532 can include one or more entangling needles 534 that protrude toward the surface 514 of the conveying system 512. Although only one interlacing needle 534 is shown, it is contemplated herein that multiple interlacing needles may be included, as further described with respect to Figures 9A and 9B.

[0047] 6A shows a front view of the entanglement station 518, illustrating the mount 526, carriage 524, actuator 528, entanglement head 532, and entanglement needles 534. Arrow 610 indicates a first direction of movement of the carriage 524 and / or transport system 512 in a direction non-parallel to the material flow direction 516, and arrow 611 indicates an opposite second direction of movement of the carriage 524 and / or transport system 512 in a direction non-parallel to the material flow direction 516. In an exemplary embodiment, the first direction 610 and the second direction 611 are perpendicular to the material flow direction 516.

[0048] The front view of the entanglement head 518 shows three entanglement heads 532a, 532b, and 532c that are approximately evenly spaced from one another, each adapted to form a corresponding non-linear entanglement seam. This is for illustrative purposes only, and it is contemplated herein that there may be more than three entanglement heads 532a, 532b, and 532c, or fewer than three entanglement heads 532a, 532b, and 532c. Similarly, the spacing between the first and second entanglement heads 532a, 532b, and 532c may be greater than or equal to the spacing between the first and second entanglement heads 532a, 532b, and 532c. 9A and 9B, the interlacing heads 532a, 532b, and 532c can have different dimensions, different structured arrangements of interlacing needles and / or orifices, etc.

[0049] 6B shows a front view of an alternative entangling station 612 that may be part of an entangling system such as entangling system 500, which is adapted to hydroentangle layers to create a composite construct instead of needlepunching the layers to create a composite construct. Similarly, entangling station 612 may represent multiple entangling stations that are part of entangling system 500.

[0050] The entangling station 612 further includes a mount 614 to which a carriage 616 is slidably coupled, an actuator 618 coupled to the carriage 616, and an entangling head 620 coupled to the actuator 618. The carriage 616 and / or the transport system 512 move in a first direction of movement, as indicated by arrow 622, in a direction non-parallel to the material flow direction 516, and in an opposite second direction of movement 623, also non-parallel to the material flow direction 516. In an exemplary embodiment, directions 622 and 623 are orthogonal to material flow direction 516. In an exemplary embodiment, actuator 618 may be prevented from moving in direction 530 orthogonal to the conveying plane of surface 514. Instead, in an exemplary embodiment, actuator 618 is adapted to actuate entangling head 620 to emit one or more fluid jets 624 extending toward surface 514 of conveying system 512. With respect to this embodiment, it is contemplated herein that conveying system 512 may advance intermittently, as described above, and fluid jets 624 may be emitted when conveying system 512 is in a stationary phase. Alternatively, conveying system 512 may advance continuously, and fluid jets 624 may be emitted continuously from entangling head 620. As with the interlacing station 518, the number of interlacing heads 620 may differ from that shown, the spacing between the interlacing heads 620 may vary from that shown, and the interlacing heads 620 may have different dimensions, different structured arrangements of orifices, etc.

[0051] 7 shows a second interlacing station 520, which includes the same components as interlacing station 518 (e.g., mount 526, carriage 524, actuator 528, and interlacing head 532). Two interlacing heads 532d and 532e are shown for second interlacing station 520. In an exemplary embodiment, interlacing heads 532d and 532e are shown. Interlacing heads 532d and 532e can be positioned out of alignment with entanglement heads 532a, 532b, and 532c in material flow direction 516. As a result, entanglement heads 532d and 532e are adapted to engage the composite nonwoven fabric in a direction non-parallel to the material flow direction at different locations compared to entanglement heads 532a, 532b, and 532c. In other words, entanglement heads 532d and 532e form a distinct and separate set of non-linear entangled seams that are distinct from the non-linear entangled seam formed by entanglement heads 532a, 532b, and 532c. entanglement head 532d and 532e are adapted to form a non-linear entangled seam set. For example, entanglement head 532a may be offset from a first edge 660 of surface 514 of conveying system 512 by a first distance 613 in a direction perpendicular to material flow direction 516, and entanglement head 532d may be offset from the first edge 660 of surface 514 of conveying system 512 by a second distance 615 that is greater than first distance 613 in a direction perpendicular to material flow direction 516. Thus, the spacing arrangement between entanglement heads 532d and 532e is different from the spacing arrangement between entanglement heads 532a, 532b, and 532c. As shown, entanglement station 520 includes a different number of entanglement heads 532 than the number of entanglement heads 532 in entanglement station 518. It is contemplated herein that entanglement station 520 may include fewer or more entanglement heads than shown. The dimensions of interlacing heads 532e and 532d can be the same as or different from the dimensions of interlacing heads 532a, 532b, and 532c. Additionally, the interlacing footprints of interlacing heads 532e and 532d can be the same as or different from the interlacing footprints of interlacing heads 532a, 532b, and 532c.

[0052] 8 illustrates a third entanglement station 522, which includes the same components as the second entanglement stations 518 and 522. Two entanglement heads 532f and 532g are shown for the third entanglement station 522. In an exemplary embodiment, the entanglement heads 532f and 532g can be positioned out of alignment with the entanglement heads 532a, 532b, 532c, 532d, and 532e in the material flow direction 516. Thus, the entanglement heads 532f and 532g are adapted to form a separate and distinct set of nonlinear entangled seams that are distinct from the nonlinear entangled seams formed by the entanglement heads 532a, 532b, 532c, 532d, and 532e. In other words, In this example, the entanglement heads 532f and 532g may be offset from the first edge 660 of the surface 514 of the transport system 512 by a distance different from the offset distance relative to the entanglement heads 532a, 532b, 532c, 532d, and 532e. The entanglement station 522 may include a different number of entanglement heads 532 than shown. The entanglement heads 532f and 532d may also be spaced apart differently than shown. The dimensions of the entanglement heads 532f and 532d may be the same or different from the dimensions of the entanglement heads 532a, 532b, 532c, 532d, and 532e. Furthermore, the entanglement footprints of the entanglement heads 532f and 532g may be the same or different from the entanglement footprints of the entanglement heads 532a, 532b, 532c, 532d, and 532e.

[0053] Although entangling system 500 is shown as including multiple entangling stations positioned sequentially along conveying system 512 in material flow direction 516, it is contemplated herein that entangling system 500 may include a single entangling station, such as entangling station 518. In this embodiment, a layered construct of first nonwoven layer 110, second layer 114, and filler material 116 is combined to form the resulting composite nonwoven fabric 100. The laminations may be passed through the entangling station 518 multiple times. In this manner, the positioning of the entangling heads 532a, 532b, and 532c may be adjusted between each pass so that different areas of the laminated construct are engaged by the entangling heads 532a, 532b, and 532c during each pass. Similarly, different entangling heads may be added, existing entangling heads may be removed, etc. The carriage 524 may carry the entangling heads 532a, 532b, and 532c. 2a, 532b, and 532c can also be adjusted during each pass to engage different portions of the laminated structure.

[0054] The illustrative entanglement system 500 shown in FIG. 5 and further described with respect to FIGS. 6A-8 can create a complex visual array of non-linear entangled seams extending in the material flow direction 516. The components and movements of the entanglement system 500 can be adjusted to create non-linear entangled seams that are closely spaced apart or that are further apart. Additionally, the system 500 can create non-linear entangled seams that cross over or intersect each other one or more times along the material flow direction of a particular entangled seam. As further described with respect to FIGS. 14-16, this creates different thicknesses of the resulting composite nonwoven fabric in first and second directions 610 and 611 that are non-parallel or perpendicular to the material flow direction 516 (i.e., along the cross-section of the resulting composite nonwoven fabric).

[0055] 9A and 9B depict bottom views, looking up from the bottom, of two exemplary entangling heads 920 and 922, respectively. The entangling heads 920 and 922 can be any of the entangling heads described in connection with the entangling system 500 or the entangling station 612. With respect to the entangling head 920, the entangling head includes a structured array of entangling needles 924, or alternatively, orifices 924 adapted to emit fluid jets. The entangling head 920 has an exemplary circular shape in which the entangling needles 924 are adapted to form a circular entangling footprint on the composite nonwoven fabric. The entangling head 920 has a dimension 910 in the material flow direction and dimensions 912 in first and second directions 610 and 611 that are non-parallel or perpendicular to the material flow direction 516. Because the entangling head 920 has a circular shape, the dimensions 910 and 912 are equivalent to the diameter of the entangling head 920 and are equal to each other.

[0056] The entangling head 922 includes a structured array of entangling needles 926, or alternatively, orifices 926 adapted to emit fluid jets. The entangling head 922 has an exemplary rectangular shape, with the entangling needles 926 or orifices 926 adapted to form a rectangular entangling footprint in the composite nonwoven fabric. The entangling head 922 has a dimension 914 in the material flow direction 516, and dimensions 916 in first and second directions 610 and 611 that are non-parallel or perpendicular to the material flow direction 516.

[0057] In an exemplary embodiment, the advancement distance of the transport system 512 in the material flow direction 516 during the movement phase of the entangling system 500 can be less than or equal to the dimensions 910 and 914 of the entangling heads 920 and 922. This ensures that the entangled areas created by the entanglement heads 920 and 922 are directly adjacent and / or overlapping to form an apparently continuous nonlinear entangled seam. Furthermore, the movement of the carriage 524 and / or the transport system 5120 in the first direction 610 and second direction 611 non-parallel or perpendicular to the material flow direction 516 can be less than or equal to the dimensions of the corresponding entanglement heads 920 and 922. This ensures that the entangled areas created by the entanglement heads 920 and 922 are directly adjacent and / or overlapping to form an apparently continuous nonlinear entangled seam. The depiction of the shapes of the interlacing heads 920 and 922 is illustrative, and it is contemplated herein that the interlacing heads may have other shapes, such as oval, square, triangular, etc.

[0058] 10A and 10B each schematically depict a process for producing a composite nonwoven fabric having a nonlinear entangled seam, such as composite nonwoven fabric 100. FIG. 10A depicts the process using entanglement needles and may be performed at any of entanglement stations 518, 520, and 522. FIG. 10B depicts the process using hydroentanglement and may be performed at entanglement station 612. Both B and C present a coordinate system showing the x, y and z directions.

[0059] Referring to FIG. 10A, in step 1010, a first nonwoven layer 110, a second layer 111, and a 14, and filler material 116 on a surface 514 of the conveying system 512, such that the second layer is positioned against the surface 514 and the first nonwoven layer 110 is spaced from the surface 514 by the filler material 116. The conveying system 512 and the laminated construction are in a first stationary phase or position, where the conveying system 512 is not advancing in the material flow direction 516 (i.e., the positive x-direction). During the first stationary phase, the actuator 528 moves the surface 514 toward the first nonwoven layer 110. 14 in a direction 530 perpendicular to the conveying plane of the first nonwoven layer 110, the second layer 114, thereby lowering the entanglement head 532 and moving the entanglement needles 534, and indirectly the entanglement head 532, between the first nonwoven layer 110 and the second layer 114. , and engages the laminated formation of the filler material 116. Alternatively, the actuator 528 actuates the entanglement head 532 and / or the entanglement needles 534, causing the entanglement needles 534 to move downward and engage the laminated formation. This engagement drives fibers from the first nonwoven layer, through the filler material 116, and into (or through) the second layer 114, creating a first entangled area 1012, as shown in step 1014. The first entangled area 1012 can have an entanglement footprint that corresponds to the shape of the structured arrangement of the entanglement needles 534 in the entanglement head 532.

[0060] In step 1016, the interlacing needles 534 interlace the first nonwoven layer 110, the second layer 114, and disengages from the laminated lay-up of filler material 116, and the transport system 512 advances the laminated lay-up a distance 1018 in the material flow direction 516. In an exemplary embodiment, the distance 1018 can be equal to or less than a dimension of the entangling head 532 in the material flow direction 516. In step 1016, the carriage 524 moves a first distance in a first direction 610 non-parallel to the material flow direction 516, which can be equal to or less than a dimension of the entangling head 532 in the first direction 610 non-parallel to the material flow direction 516. The movement of the carriage 524 can occur simultaneously with the movement of the transport system 512 in the material flow direction 516 or can occur after the movement of the transport system 512 in the material flow direction 516 (i.e., when the transport system 512 is in the second stationary phase). Alternatively or additionally, the transport system 512 may move a first distance in a first direction 610 that is non-parallel to the material flow direction 516 .

[0061] In step 1022, the conveying system 512 and the laminated construct are in a second stationary phase or position whereby the conveying system 512 is not advancing in the material flow direction 516. The second stationary phase or position is from the first stationary phase or position whereby the conveying system 512 is advancing in the material flow direction 516. During the second stationary phase, the actuator 528 again moves in a direction 530 perpendicular to the conveying plane of the surface 514, whereby the entanglement head 532 lowers and engages the entanglement needles 534 with the laminated construct of the first nonwoven layer 110, the second layer 114, and the filler material 116. Due to movement of the carriage 524 and / or the transport system 512, the engagement of the entangling head 534 with the laminated formation is in a first direction 610 that is non-parallel to the material flow direction 516. The second interlacing occurs at a location offset from the entangled area 1012. This second interlacing again drives the fibers from the first nonwoven layer 110, through the filler material 116, and into (or through) the second layer 114, creating a second entangled area 1026, as shown in step 1024. The second entangled area 1026 can have an entanglement footprint corresponding to the shape of the structured array of entanglement needles 534 in the entanglement head 532. As shown in step 1024, the second entangled area 1026 partially overlaps the first entangled area 1012. This is for illustrative purposes, and it is contemplated herein that the second entangled area 1026 may not partially overlap the first entangled area 1012.

[0062] The process depicted in FIG. 10A advances relative to one another in the material flow direction, with the interlacing needles 534 engaging the laminated arrangement of the first nonwoven layer 110, the second layer 114, and the filler material 116 during this advancement. 10A can include multiple stationary phases in which the conveying system 512 advances the laminated construct in the material flow direction 516 a distance less than or equal to a dimension of the entangling head 532 in the material flow direction 516, resulting in entangled areas that overlap or directly extend one another. Furthermore, the carriage 524 and / or the conveying system 512 can perform multiple movements in a first direction 610 non-parallel to the material flow direction 516 and a second direction 611 opposite thereto (i.e., the positive y-direction). The distance traveled by the carriage 524 and / or transport system 512 in the first direction 610 and the opposite second direction 611 can be less than or equal to the dimensions of the interlacing head 532 in the first direction 610 and the opposite second direction 611, such that the resulting interlacing areas partially overlap or extend directly from one another.

[0063] 10B is similar to that shown in the process depicted in FIG. 10A, but utilizes hydroentangling to create a non-linear entangled seam. In step 1050, the laminated construction of the first nonwoven layer 110, the second layer 114, and the filler material 116 is transferred to a conveying system 51. 2 on the surface 514 of the conveying system 512, whereby the second layer is positioned against the surface 514 and the first nonwoven layer 110 is spaced from the surface 514 by the filler material 116. In one exemplary embodiment, the conveying system 512 and laminate construct are in a first stationary phase or position, where the conveying system 512 is not advancing in the material flow direction 516. During the first stationary phase, the actuator 618 actuates the entangling head 620 to emit one or more pressurized fluid jets 1052 toward the surface 514 of the conveying system 512 to form a first entangled area 1054, as shown in step 1056. In the exemplary embodiment, the actuator 618 does not move perpendicular to the conveying plane of the surface 514 during the first stationary phase, although it is contemplated herein that the actuator 618 may move perpendicular to the conveying plane of the surface 514 to position the fluid jets 1052 closer to the first nonwoven layer 110. In another exemplary embodiment, the conveying system 512 continuously advances in the material flow direction 516 while the actuator 618 continuously actuates the entangling head 620 to continuously emit one or more pressurized fluid jets 1052. The fluid jets 1052 drive fibers from the first nonwoven layer 110, through the filler material 116, and into (or through) the second layer 114 to create a first entangled area 1054. The first entangled area 1054 can have an entanglement footprint that corresponds to the shape of the structured array of orifices in the entanglement head 620.

[0064] In step 1058, the transport system 512 advances the laminated construct a distance 1060 in the material flow direction 516. In an exemplary embodiment, the distance 1060 can be equal to or less than a dimension of the entangling head 620 in the material flow direction 516. In step 1058, the carriage 616 moves a first distance in a first direction 622 non-parallel to the material flow direction 516, which can be equal to or less than a dimension of the entangling head 620 in the direction non-parallel to the material flow direction 516. The movement of the carriage 616 and / or the transport system 512 can occur simultaneously with the movement of the transport system 512 in the material flow direction 516 or can occur after the movement of the transport system 512 in the material flow direction 516 (i.e., after the transport system 512 has reached a first stationary phase or position). This may occur during a second stationary phase or position where the material is advancing in the material flow direction from the stationary position.

[0065] In step 1022, the transport system 512 and the laminated construction are in a second stationary phase or position, and the actuator 618 actuates the entangling head 620 to emit a fluid jet 1052, which then intertwines the first nonwoven layer 110, the second layer 114, and engages (sprays) with the laminated structure of the filler material 116. As a result, engagement of the fluid jet 1052 with the laminated formation occurs at a location offset from the first interlaced area 1054 in a first direction 622 that is non-parallel to the material flow direction 516. The second engagement again drives the fibers from the first nonwoven layer 110, through the filler material 116, and into (or through) the second layer 114, creating a second entangled area 1068, as shown in step 1066, resulting in an apparently continuous, nonlinear entangled seam 1070 in the composite nonwoven fabric 100 extending in the material flow direction 516. As shown in step 1066, the second entangled area 1068 partially overlaps the first entangled area 1054. This is for illustrative purposes, and it is contemplated herein that the second entangled area 1026 may not partially overlap the first entangled area 1054.

[0066] The process depicted in FIG. 10B is performed by a fluid jet 1052 passing through the first nonwoven layer 110, the second layer 111, and the 10B can include multiple stationary phases over the laminated construct of the entanglement head 620 and the filler material 116 to form entangled areas that extend from one another. Similarly, the process depicted in FIG. 10B can include multiple movement phases in which the transport system 512 advances the laminated construct in the material flow direction 516 a distance less than or equal to the dimension of the entanglement head 620 in the material flow direction 516, resulting in entangled areas that overlap or extend directly from one another. Furthermore, the carriage 616 and / or transport system 512 can perform multiple movements in a first direction 622 non-parallel to the material flow direction 516 and an opposite second direction 623. The movement distance of the carriage 616 and / or transport system 512 in the first direction 610 and the opposite second direction 623 can be less than or equal to the dimension of the entanglement head 620 in the first direction 610 or the opposite second direction 623, resulting in entangled areas that partially overlap or extend directly from one another.

[0067] As previously explained, the interlacing systems described herein, such as interlacing system 500, can create composite nonwoven fabrics, such as composite nonwoven fabric 100, that include long repeating visual sequences of interlace seams, or even no repeating visual sequences. The resulting composite nonwoven fabric can be used to create garment arrays that have a common finish configuration but vary in aesthetics due to the different visual sequences of the nonlinear interlace seams in the resulting garments. The garment arrays share common features, such as a common finish configuration, color, etc., so that a consumer will easily recognize the garment array as being from a common source (e.g., a common manufacturer). However, from the garment array, a consumer will be able to select a garment with a desired interlace seam visual sequence. Furthermore, having long repeating visual sequences of interlace seams, or even no repeating visual sequences, can reduce material waste when forming the garment arrays, i.e., because pattern pieces do not need to be positioned to ensure that each garment includes the same visual sequence of interlace seams in the same location on the garment.

[0068] 11 schematically illustrates a method for manufacturing an array of garments having a common finish configuration but different visual arrangements of nonlinear interlaced seams. In step 1110, a composite nonwoven fabric 100 is provided or obtained. In this example, the composite nonwoven fabric 100 includes a first nonlinear interlaced seam 1112 and a second nonlinear interlaced seam 1114, both of which extend in the material flow direction 516 of the composite nonwoven fabric 100. In an exemplary embodiment, the distance between the first nonlinear interlaced seam 1112 and the second nonlinear interlaced seam 1114 varies along the material flow direction 516. For example, the first nonlinear interlaced seam 1112 can be separated from the second nonlinear interlaced seam by a first distance 1111 at a first location 1113 in the composite nonwoven fabric 100. At a second location 1113 in the composite nonwoven fabric 100, the first nonlinear interlaced seam 1112 is spaced apart by a second distance 1117 that is greater than the first distance 1111. It is possible that the shape may be spaced apart from the interlacing seam 1114.

[0069] In step 1110, a first instance of the pattern 1116 is applied to the composite nonwoven fabric 10. 10, is removed, cut, and / or cut from composite nonwoven fabric 100, where pattern 1116 corresponds to a left sleeve for an upper body garment. In other words, in step 1110, a first portion 1120 is removed from composite nonwoven fabric 100, where first portion 1120 has a shape corresponding to pattern 1116. Pattern 1116 is merely illustrative, and it is contemplated herein that pattern 1116 may correspond to any portion of an upper body garment, a lower body garment, a shoe upper, an article of footwear, etc.

[0070] In step 1118, a first portion 1120 having pattern 1116 is illustrated after being removed from the composite nonwoven fabric 100. As illustrated, the first portion 1120 includes a first nonlinear interlaced seam 1112 and a second nonlinear interlaced seam 1114, which are located at a first location on the first portion 1120 and / or pattern 1116, as generally indicated by reference numeral 1119. In step 1122, the first portion 1120 is incorporated into a first garment 1124. As shown in FIG. 11 , the first nonlinear interlaced seam 1112 and the second nonlinear interlaced seam 1114 present a first visual arrangement of the nonlinear interlaced seams on the first garment 1124, as generally referenced by reference numeral 1126.

[0071] In step 1128, a second instance of pattern 1116 is removed, excised, and / or cut from the composite nonwoven fabric 100. The second instance of pattern 1116 includes a first nonlinear interlaced seam 1112 and a second nonlinear interlaced seam 1114. In other words, in step 1128, a second portion 1132 is removed from the composite nonwoven fabric 100, the second portion 1132 having a shape corresponding to the pattern 1116. Step 1130 illustrates the second portion 1132 having the pattern 1116 after it has been removed from the composite nonwoven fabric 100. As shown, the first portion 1132 includes the first nonlinear interlaced seam 1112 and the second nonlinear interlaced seam 1114, and the first nonlinear interlaced seam 1112 and the second nonlinear interlaced seam 1114 are located at a second location on the second portion and / or pattern 1116, as generally indicated by reference numeral 1131. In step 1134, the second portion 1134 is incorporated into a second garment 1138. As shown in FIG. 11 , the first nonlinear interlaced seam 1112 and the second nonlinear interlaced seam 1114 present a second visual arrangement of nonlinear interlaced seams, generally referenced by the numeral 1136, on the second garment 1138, where the second visual arrangement of nonlinear interlaced seams 1136 is different from the first visual arrangement of nonlinear interlaced seams 1126.

[0072] The process depicted in Figure 11 may be repeated any number of times along the material flow direction 516 of the composite nonwoven fabric 100 to form an array of garments having first and second nonlinear interlaced seams 1112, 1114 located at different points in the pattern 1116 and exhibiting different visual arrangements of the first and second nonlinear interlaced seams 1112, 1114. While Figure 11 depicts only the pattern 1116 applied to the composite nonwoven fabric 100, it is contemplated herein that additional pattern pieces may be applied to the composite nonwoven fabric 100, such that the resulting garment may be formed from the additional pattern pieces applied to the composite nonwoven fabric 100. In this manner, the visual arrangement of the interlaced seams in different regions of the garment may differ from one another to create varied overall aesthetics. A process similar to that depicted in Figure 11 may be used to form, for example, an array of lower body garments having a common finish but different visual arrangements of the nonlinear interlaced seams.

[0073] In an exemplary embodiment, the scrap resulting from the process depicted in FIG. 11 is shredded and then recycled, for example, to one or more of the first nonwoven layer 110, the second layer 114, or the filler material 11. 6. This is because the materials forming the composite nonwoven fabric 100 are the same polymer grade (e.g., recycled polyester) in exemplary embodiments. Furthermore, because the composite nonwoven fabric 100 is formed without the use of separate materials such as threads, adhesives, etc., there is no need to remove portions of scrap material prior to shredding.

[0074] 12 and 13 further illustrate garments produced from the process shown in FIG. 11. FIG. 12 illustrates a front view of an array of upper body garments in a sleeveless top configuration, including a first upper body garment 1210 and a second upper body garment 1212 having a common finished configuration. While shown as a sleeveless top configuration, it is contemplated herein that other configurations may be included, such as vests, pullovers, hooded sweatshirts, jackets, etc. The first upper body garment 1210 includes a neck opening 1214, a waist opening 1216, a first sleeve opening 1218, and a second sleeve opening 1220. Similarly, the second upper body garment 1212 includes a neck opening 1214, a waist opening 1216, a first sleeve opening 1218, and a second sleeve opening 1220. The openings 1222, 1224, 1226, and 1227 are arranged around the neck, waist, and sleeves, respectively. 28. Additionally, although the nonlinear interlaced seams are shown as extending in a horizontal orientation (i.e., extending from the first sleeve opening 1218 / 1226 to the second sleeve opening 1220 / 1228), it is contemplated herein that the nonlinear interlaced seams may extend in a vertical direction (e.g., from the neck opening 1214 / 1222 to the waist opening 1216 / 1224).

[0075] As depicted in the figures, the front panel (body) 1230 of the first upper body garment 1210 and the front panel 1232 of the second upper body garment 1212 can be formed from the same pattern piece applied to the composite nonwoven fabric 100. The front panel 1230 of the first upper body garment 1210 includes a first nonlinear interlaced seam 1234 and a second nonlinear interlaced seam 1236 located at a first location 1238 on the first upper body garment 1210. In the exemplary embodiment, the first location 1238 corresponds to a first distance 1237, measured from a straight vertical line on the front of the first upper body garment 1210 relative to the waist opening 1216 of the first upper body garment 1210, for each of the first nonlinear interlaced seam 1234 and the second nonlinear interlaced seam 1236. The first non-linear interlaced seam 1234 and the second non-linear interlaced seam 1236 present a first visual arrangement of interlaced seams in the first upper body garment 1210.

[0076] The front panel 1232 of the second upper body garment 1212 further includes a first nonlinear interlaced seam 1234 and a second nonlinear interlaced seam 1236 located at a second location 1244 different from the first location 1238 on the second upper body garment 1212. For example, the second location 1244 corresponds to a second distance 1245, for each of the first nonlinear interlaced seam 1234 and the second nonlinear interlaced seam 1236, measured from a straight vertical line on the front of the second upper body garment 1212 relative to the waist opening 1224 of the second upper body garment 1212. The first nonlinear interlaced seam 1234 and the second nonlinear interlaced seam 1236 form a second visual arrangement of interlaced seams on the second upper body garment 1212.

[0077] Although not shown, the array may include additional upper body garments that share a common finish with the first upper body garment 1210 and the second upper body garment 1212. The additional upper body garments in the array exhibit different visual arrangements of the first nonlinear interlaced seam 1234 and the second nonlinear interlaced seam 1236. In other words, the first nonlinear interlaced seam 1234 and the second nonlinear interlaced seam 1236 may be located at different locations in the additional upper body garments relative to the pattern pieces described above used to form the front panels of the additional upper body garments.

[0078] 13 illustrates a front view of an array of lower body garments in the form of shorts, including a first lower body garment 1310 and a second lower body garment 1312 having a common finishing configuration. While shown as shorts, this specification contemplates that other configurations may be included, such as trousers, capri pants, etc. The first lower body garment 1310 has a waist opening 1314. 14, includes a first leg opening 1316a, and a second leg opening 1316b. Similarly, a second lower body garment 1312 includes a waist opening 1322, a first leg opening 1324a, and a second leg opening 1316b. Additionally, although the nonlinear interlaced seam is shown as extending in a horizontal orientation, it is contemplated herein that the nonlinear interlaced seam may extend vertically.

[0079] As depicted in the figures, the front panel 1330 of the first lower body garment 1310 and the front panel 1332 of the second lower body garment 1312 can be formed from the same pattern piece applied to the composite nonwoven fabric 100. The front panel 1330 of the first lower body garment 1310 includes a first nonlinear interlaced seam 1334 and a second nonlinear interlaced seam 1336 located at a first location 1338 in the first lower body garment 1310. In the exemplary embodiment, the first location 1338 corresponds to a first distance 1337, measured from a straight vertical line on the front of the first lower body garment 1310 relative to the waist opening 1314 of the first lower body garment 1310, for each of the first nonlinear interlaced seam 1334 and the second nonlinear interlaced seam 1336. The first non-linear interlaced seam 1334 and the second non-linear interlaced seam 1336 present a first visual arrangement of interlaced seams in the first lower body garment 1310 .

[0080] The front panel 1332 of the second lower body garment 1312 further includes a first nonlinear interlaced seam 1334 and a second nonlinear interlaced seam 1336 located at a second location 1344 different from the first location 1338 on the second lower body garment 1312. For example, the second location 1344 corresponds to a second distance 1345, for each of the first nonlinear interlaced seam 1334 and the second nonlinear interlaced seam 1336, measured from a straight vertical line on the front of the second lower body garment 1312 relative to the waist opening 1324 of the second lower body garment 1312. The first nonlinear interlaced seam 1334 and the second nonlinear interlaced seam 1336 form a second visual arrangement of interlaced seams on the second lower body garment 1312.

[0081] Although not shown, the array may include additional upper body garments having a common finish configuration with the first lower body garment 1310 and the second lower body garment 1312. The additional lower body garments in the array exhibit different visual arrangements of the first nonlinear interlaced seam 1334 and the second nonlinear interlaced seam 1336. In other words, the first nonlinear interlaced seam 1334 and the second nonlinear interlaced seam 1336 may be located at different locations in the additional lower body garments relative to the pattern pieces described above used to form the front panels of the additional lower body garments.

[0082] 12 and 13 include interlaced seams in different visual orientations, it is contemplated herein that garments in a garment array produced with the systems and methods described herein may include interlaced seams in the same visual orientation. For example, the interlacing system 500 may be configured to produce short repeats of the interlaced seam visual orientation, such that the composite nonwoven fabric may include multiple repeats of the interlaced seam visual orientation along the material flow direction 516. In this manner, pattern pieces may be applied to the composite nonwoven fabric to form garments having interlaced seams in the same visual orientation.

[0083] FIG. 14 shows, for example, a nonwoven fabric formed from a first nonwoven layer 110, a second layer 114, and a filler material 116. 1 depicts a second exemplary composite nonwoven fabric 1400. Composite nonwoven fabric 1400 can be formed according to the methods and systems described herein, including entangling system 500. Composite nonwoven fabric 1400 includes nonlinear interlaced seams 1410a, 1410b, 1410c, and 1410d that extend in a material flow direction 516. As shown, nonlinear interlaced seams 1410a and 1410b intersect or cross over at intersection point 1412, and nonlinear interlaced seams 1410c and 1410d intersect or cross over at intersection points 1414 and 1416. Intersection points 1412, 1414, and 1416 represent areas where the entanglement head engages the composite nonwoven fabric 1400 at least twice. As such, intersection points 1412, 1414, and 1416 have a higher stitch density than the rest of the nonlinear entangled seams 1410a, 1410b, 1410c, and 1410d. This higher stitch density at crossing points 1412, 1414, and 1416 in nonlinear interlaced seams 1410a, 1410b, 1410c, and 1410d causes the nonlinear interlaced seams 1410a, 1410b, 1410c, and 1410d to be of reduced thickness compared to the remainder of the nonlinear interlaced seams 1410a, 1410b, 1410c, and 1410d and compared to regions 1418 between the nonlinear interlaced seams 1410a, 1410b, 1410c, and 1410d.

[0084] This is shown in FIG. 15, which is a cross section of the composite nonwoven fabric 1400 at cut line 15-15. 14. Region 1418 has a thickness 1514 measured from a first surface 1513 formed by the first nonwoven layer 110 to an opposite second surface 1516 formed by the second layer 114. Intersection point 1412 has a thickness 1510 measured from the first surface 1513 to the opposite second surface 1516, and nonlinear interlaced seams 1410c and 1410d have a thickness 1512 measured from the first surface 1513 to the opposite second surface 1516. In exemplary embodiments, thickness 1514 is greater than thickness 1512, which is greater than thickness 1510. The ability of composite nonwoven fabric 1400 to create varying thickness in a direction non-parallel to the material flow direction 516 can be used to engineer high and low insulation zones required in a garment incorporating composite nonwoven fabric 1400. The insulating zone has increased thickness (bulkiness) and may correspond to region 1418. The less insulating zone may correspond to an area that includes multiple crossing points, such as crossing points 1412, 1414, and 1416.

[0085] 16 depicts a back view of an exemplary upper body garment 1600 having a torso portion 1610, the torso portion 1610 including a neck opening 1612 and a waist opening 1614. The upper body garment 1600 further includes an optional first sleeve 1616 and an optional second sleeve 1618. Although shown as a top with long sleeves, it is contemplated herein that the upper body garment 1600 may take the form of a vest, pullover, hooded sweatshirt, jacket, etc.

[0086] The upper body garment includes a low insulation zone 1620 located in a mid-back region of the torso portion 1610 and high insulation zones 1622 located on either side of the low insulation zone 1620. The locations of the low insulation zone 1620 and the high insulation zone 1622 can be based, for example, on heat maps of the human body. By way of example, these heat maps can indicate that the mid-back torso of the human body generates a high amount of heat and thus may require less insulation than other areas of the torso. The low insulation zone 1620 includes multiple nonlinear interlacing seams 1624a, 1624b, 1624c, and 1624d that extend in the material flow direction 516. As depicted in the figure, non-linear interlaced seams 1624a, 1624b, 1624c, and 1624d extend from neck opening 1612 to waist opening 1614 of upper body garment 1600, are generally closely spaced, and include multiple crossover points. This results in an overall increased stitch density and an overall decreased thickness in low insulation zone 1620 compared to other portions of upper body garment 1600. In contrast, high insulation zone 1622 includes non-linear interlaced seams 1626a, 1626b, 1626c, and 1626d. Nonlinear interlaced seams 1626a, 1626b, 1626c, and 1626d are generally spaced farther apart than nonlinear interlaced seams 1624a, 1624b, 1624c, and 1624d, and nonlinear interlaced seams 1626a, 1626b, 1626c, and 1626d do not cross one another. In this manner, high insulation zone 1622 has an overall decreased stitch density and an overall increased thickness than low insulation zone 1620. In other words, high insulation zone 1622 has a greater thickness than first nonwoven layer 110, second layer 114, and and regions 1628a, 1628b, 1628c where the filler material 116 is substantially unentangled; and 1628d. The greater thickness and bulk of regions 1628a, 1628b, 1628c, and 1628d helps to trap and store heat.

[0087] The visual arrangement of the nonlinear interlaced seams in Figure 16 is illustrative only, and it is contemplated herein that other visual arrangements may be formed by the nonlinear interlaced seams. Furthermore, although the interlaced seams are shown extending vertically (e.g., from the neck opening to the waist opening), the interlaced seams may be oriented horizontally on the garment. Additionally, upper body garment 1600 may include nonlinear interlaced seams at locations on the upper body garment other than those shown. The depiction of upper body garment 1600 in Figure 16 is meant to convey the concept that parameters associated with the nonlinear interlaced seams may be adjusted to achieve desired properties, including thermal insulation properties. Parameters may include, for example, the spacing between adjacent nonlinear interlaced seams (e.g., larger spacing results in regions 1628a, 1628b, 1628c, and 1628d occupying a larger overall surface area in upper body garment 1600), the number of intersection points between nonlinear interlaced seams (e.g., more intersection points results in increased stitch density and reduced thickness), the width of individual nonlinear interlaced seams (e.g., larger widths result in reduced thickness compared to nonlinear interlaced seams having smaller widths), etc.

[0088] FIG. 17 shows an exemplary nonwoven fabric formed from a first nonwoven layer 110, a second layer 114, and a filler material 116. 17 depicts composite nonwoven fabric 1700. In the exemplary embodiment, composite nonwoven fabric 1700 includes nonlinear interlaced seams 1710a, 1710b, 1710c, and 1710d. Nonlinear interlaced seam 1710a is similar to the other nonlinear interlaced seams described herein for composite nonwoven fabric 100 and composite nonwoven fabric 1400, by way of example. Nonlinear interlaced seams 1710b and 1710c include discontinuous nonlinear interlaced seams. For example, nonlinear interlaced seam 1710b includes discontinuous segment 1712, where no interlaced seam is formed. Nonlinear interlaced seam 1710c includes multiple discontinuous segments, such as discontinuous segment 1714 and discontinuous segment 1716. Additionally, non-linear interlaced seam 1710c includes an interlaced seam portion 1718 in the form of a very short segment, or even an interlaced point, spaced apart from the remainder of non-linear interlaced seam 1710c by non-continuous segment 1720 and non-continuous segment 1722.

[0089] The non-continuous segments 1712, 1714, 1716, 1720, and 1722 can be formed using the entangling system 500 and methods described herein. For example, the non-continuous segment 1712 can be formed by not activating the entangling head 532 that forms the non-linear entangled seam 1710b during one or more stationary phases, thereby preventing the entangling needle(s) 534 and / or orifice(s) associated with the entangling head 532 from contacting the composite nonwoven fabric 1700. The lengths of the non-continuous segments 1712, 1714, 1716, 1720, and 1722 can be adjusted as desired by varying the number of stationary phases during which the entangling head 532 is not activated.

[0090] In an exemplary embodiment, when the entanglement heads 532 are sequentially actuated, and as shown with respect to nonlinear entangled seam 1710b, the carriages 524 and / or transport systems 512 may be positioned in the material flow direction 516 to align with the immediately preceding entangled area 1711 formed before creating the non-continuous segment 1712, such that the next entangled area 1713 is aligned with the immediately preceding entangled area 1711 in the material flow direction 516. Alternatively, and as shown with respect to the non-continuous segment 1714 of nonlinear entangled seam 1710, when the entanglement heads 532 are actuated after the non-continuous segment 1714 is formed, the carriages 524 and / or transport systems 512 may be positioned in the material flow direction 516 to align with the immediately preceding entangled area 1711 formed before creating the non-continuous segment 1714. 17, the next entangled area 1717 can be positioned to be offset in the first direction 610 from the immediately preceding entangled area 1715 formed therein, such that the next entangled area 1717 is offset in the first direction 610 from the immediately preceding entangled area 1715. It is also contemplated herein that the carriage 524 and / or transport system 512 can be positioned to be offset in the second direction 611, such that the subsequent entangled area is offset in the second direction 611 from the preceding entangled area, as shown with respect to the non-contiguous segment 1716.

[0091] With respect to the interlaced seam portion 1718, in an exemplary embodiment, the interlaced seam portion 1718 can be formed by actuating the interlacing head 532 at least once after generating the non-continuous segment 1720 and before generating the non-continuous segment 1722. The length of the interlaced seam portion 1718 can be adjusted based on the number of times the interlacing head 532 is actuated after generating the non-continuous segment 1720 and before generating the non-continuous segment 1722. For example, one or two acts of the interlacing head 532 can create an interlaced point, while actuating the interlacing head 532 between three and ten times can create a short interlaced segment.

[0092] Any combination of continuous and discontinuous interlaced seams is contemplated herein. In exemplary embodiments, discontinuous segments can be created when it is desired to increase the loft and thickness of the composite nonwoven fabric 1700. For example, when the composite nonwoven fabric 1700 is incorporated into a garment, discontinuous nonlinear interlaced seams can be positioned in areas of the garment where a higher amount of insulation is desired. Furthermore, the length of the discontinuous segments can be adjusted according to the insulation requirements (e.g., longer discontinuous segments equate to more loft and higher insulation, while shorter discontinuous segments equate to less loft and lower insulation).

[0093] The embodiments described herein contemplate that, instead of having a laminated construction with separate layers or materials that are joined or secured together at the seam area using an entanglement process, an interlaced seam may be used with a single layer of material that includes nonwoven fibers. The term "single layer" refers to conveying a congruent structure in contrast to separate layers that are not joined together prior to creating the interlaced seam described herein. For example, Figure 18 depicts an exemplary nonwoven fabric 1800 having interlaced seams 1810 and 1812, and Figure 19 depicts a cross-section of nonwoven fabric 1800. The nonwoven fabric 1800 can be a single fiber layer of entangled fibers, or two or more layers having the same or different properties (e.g., different staple length fibers, different denier fibers, different color fibers, different fiber types, different fiber coatings, etc.) and joined together by an entanglement process (e.g., needle punching or hydroentanglement) or other processes such as bonding, adhesives, stitching, etc.), or one or more fiber layers having the same or different properties and joined together by an entanglement process or other processes such as bonding, adhesives, stitching, etc. for thin films or structured fabrics (e.g., knitted, woven, or braided fabrics).

[0094] The non-linear interlaced seams 1810 and 1812 can be formed by the interlacing process described above, and the seams 1810 and 1812 can be used to create areas of reduced thickness and / or to create a visual alignment of the interlaced seams. In an exemplary embodiment, the nonwoven fabric 1800 can be combined with an additional single layer of material. For example, the nonwoven fabric 1800 can be positioned adjacent to a structured textile and joined thereto by interlacing or bonding, adhesives, stitching, etc. One or more additional materials, such as a filler material, can be positioned between the nonwoven fabric 1800 and the structured textile. In another example, the nonwoven fabric 1800 can be positioned adjacent to another single layer of nonwoven fabric having an interlaced seam and joined thereto by interlacing or bonding, adhesives, stitching, etc. One or more additional materials, such as a filler material, can be positioned between the nonwoven fabric 1800 and the structured textile. 0 and an additional single layer of nonwoven fabric. Any and all embodiments, and any variations thereof, are contemplated as being within the scope of the present invention. Nonwoven fabric 1800 can be formed into different apparel articles described herein, such as upper body garments, lower body garments, footwear (e.g., upper) articles, etc. Apparel articles of the same type can have different visual arrangements of the interlacing seams described herein.

[0095] The following clauses represent exemplary embodiments of the concepts contemplated herein. Any one of the following clauses may be combined in a multiple-dependent manner so as to be dependent on one or more other clauses. Furthermore, any combination of dependent claims (clauses that are explicitly dependent on a preceding clause) may be described and combined to be within the scope of the embodiments contemplated herein.

[0096] [Section 1] 1. A method for manufacturing a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material positioned between the first and second nonwoven layers, the method comprising: engaging an entangling head with the composite nonwoven fabric while the composite nonwoven fabric is in a first position on an entangling machine to form a first entangled area in the composite nonwoven fabric; advancing the composite nonwoven fabric with the entangling machine in a material flow direction; moving one or both of the entangling head and the composite nonwoven fabric in a first direction non-parallel to the material flow direction; and engaging the entangling head with the composite nonwoven fabric while the composite nonwoven fabric is in a second position advanced from the first position in the material flow direction to form a second entangled area in the composite nonwoven fabric, the second entangled area extending from the first entangled area to form a nonlinear entangled seam.

[0097] [Section 2] 2. The method for producing the composite nonwoven fabric described in paragraph 1, wherein in each of the first entangled area and the second entangled area, fibers extend from the first nonwoven layer through the filler material and into the second layer.

[0098] [Section 3] 3. The method for producing the composite nonwoven fabric of paragraph 1 or 2, wherein the first entangled area partially overlaps the second entangled area.

[0099] [Section 4] 4. The method for producing the composite nonwoven fabric according to any one of claims 1 to 3, wherein the stitch density in the overlap area between the first entangled area and the second entangled area is higher than the stitch density in the remaining portion between the first entangled area and the second entangled area.

[0100] [Section 5] A method for producing the composite nonwoven fabric described in any one of items 1 to 4, wherein when the composite nonwoven fabric is in the first position, the entanglement head moves in a direction perpendicular to a plane on the surface of the composite nonwoven fabric.

[0101] [Section 6] The method for producing the composite nonwoven fabric according to any one of claims 1 to 5, further comprising the steps of advancing the composite nonwoven fabric in the material flow direction, moving one or both of the entangling head and the composite nonwoven fabric in a second direction non-parallel to the material flow direction, and advancing the composite nonwoven fabric in the material flow direction after the step of forming the second entangled area. and while the woven fabric is at a third position advanced from the second position in the material flow direction, engaging the entangling head with the composite nonwoven fabric to form a third entangled area in the composite nonwoven fabric, the third entangled area extending from the second entangled area to form the nonlinear entangled seam.

[0102] [Section 7] 7. The method for making the composite nonwoven fabric of claim 6, wherein the third entangled area partially overlaps the second entangled area.

[0103] [Section 8] 7. The method for producing the composite nonwoven fabric of claim 6, wherein the third entangled area is positioned adjacent to the second entangled area.

[0104] [Section 9] 9. The method for producing the composite nonwoven fabric according to any one of claims 6 to 8, wherein the second direction is opposite to the first direction.

[0105] [Section 10] 1. A garment comprising: a first nonwoven layer having a material flow direction; a second layer; a filler material positioned between the first nonwoven layer and the second layer; at least one region of the garment where the first nonwoven layer, the second layer, and the filler material are substantially unentangled; and at least one nonlinear interlaced seam extending along the material flow direction, the at least one nonlinear interlaced seam including one or more interlaced areas that extend into each other to form the at least one nonlinear interlaced seam, the one or more interlaced areas including fibers from the first nonwoven layer that extend through the filler material and into the second layer.

[0106] [Section 11] 11. The garment of claim 10, wherein the second layer is a nonwoven material.

[0107] [Section 12] 12. The garment of claim 10 or 11, wherein the one or more interlaced areas include discrete interlaced areas.

[0108] [Section 13] The garment described in any one of items 10 to 12, wherein the thickness of the at least one region in the garment where the first nonwoven layer, the second layer, and the filling material are substantially unentangled is approximately 7 mm to approximately 15 mm.

[0109] [Section 14] 14. The garment of any one of paragraphs 10 to 13, wherein the thickness of the at least one nonlinear interlaced seam is about 5% to about 30% of the thickness of the at least one area in the garment where the first nonwoven layer, the second layer, and the filling material are substantially unentangled.

[0110] [Section 15] 15. The garment according to any one of paragraphs 10 to 14, wherein the filling material is one or more of a synthetic fiber sheet, loose synthetic fibers, and down.

[0111] [Section 16] The garment of any one of paragraphs 10 and 12-15, wherein the second layer is a woven material.

[0112] [Section 17] The garment according to any one of paragraphs 10-11 and 13-15, wherein the one or more entangled areas partially overlap each other.

[0113] [Section 18] 18. The garment of any one of paragraphs 10 to 17, further comprising a plurality of additional non-linear interlace seams forming a visual arrangement with no repeating interlace seams.

[0114] [Section 19] 1. A composite nonwoven fabric comprising: a first nonwoven layer having a material flow direction; a second layer; a filler material positioned between the first nonwoven layer and the second layer; at least one region of the composite nonwoven fabric where the first nonwoven layer, the second layer, and the filler material are substantially unentangled; and at least one nonlinear interwoven seam extending along the material flow direction, the at least one nonlinear interwoven seam including one or more interwoven areas that extend together to form the at least one nonlinear interwoven seam, the one or more interwoven areas including fibers from the first nonwoven layer that extend through the filler material and into the second layer.

[0115] [Section 20] 20. The composite nonwoven fabric of claim 19, wherein the second layer is a nonwoven material.

[0116] [Section 21] 21. The composite nonwoven fabric of paragraph 19 or 20, wherein the one or more entangled areas comprise discrete entangled areas.

[0117] [Section 22] 22. The composite nonwoven fabric according to any one of claims 19 to 21, wherein the first nonwoven layer, The second layer and the filler material are substantially unentangled in the composite nonwoven fabric. A composite nonwoven fabric, wherein at least one region has a thickness of about 7 mm to about 15 mm.

[0118] [Section 23] 23. The composite nonwoven fabric of any one of items 19 to 22, wherein the thickness of the at least one nonlinear interlaced seam is about 5% to about 30% of the thickness of the at least one region in the composite nonwoven fabric where the first nonwoven layer, the second layer, and the filler material are substantially unentangled.

[0119] [Section 24] 24. The composite nonwoven fabric of any one of claims 19 to 23, wherein the filler material is one or more of a synthetic fiber sheet, loose synthetic fiber, and down.

[0120] [Section 25] 25. The composite nonwoven fabric of any one of paragraphs 19 and 21-24, wherein the second layer is a woven material.

[0121] [Section 26] 26. The composite nonwoven fabric of any one of paragraphs 19-20 and 22-25, wherein the one or more entangled areas partially overlap each other.

[0122] [Section 27] 27. The composite nonwoven fabric of any one of paragraphs 19 to 26, further comprising a plurality of additional nonlinear interlaced seams forming a visual array with no repeating interlaced seams.

[0123] [Section 28] An entangling system for forming at least one non-linear entangled seam in a composite nonwoven fabric, the entangling system comprising: a first entangling station, the first entangling station comprising: a conveying system having a surface adapted to intermittently advance the composite nonwoven fabric in a material flow direction; a first actuator; a first entangling head coupled to the first actuator, the first actuator adapted to actuate the first entangling head to move in a direction perpendicular to a conveying plane of the conveying system; and a first carriage coupled to the first entangling head, the first carriage adapted to move in a first direction non-parallel to the material flow direction.

[0124] [Section 29] 30. The interlacing system of claim 28, wherein the first direction is perpendicular to the material flow direction.

[0125] [Section 30] 29. The interlacing system according to claim 28, wherein the first carriage further comprises: An entangling system adapted to move in a second direction non-parallel to the material flow direction and opposite to the first direction.

[0126] [Section 31] 31. The interlacing system of claim 30, wherein the second direction is perpendicular to the material flow direction.

[0127] [Section 32] In the interlacing system according to any one of items 28 to 31, the first interlacing head The intertwining system has a first dimension in the material flow direction.

[0128] [Section 33] 33. The interlacing system according to any one of claims 28 to 32, wherein the advancement distance of the conveying system is less than or equal to the first dimension of the first interlacing head.

[0129] [Section 34] 34. The interlacing system according to any one of claims 28 to 33, wherein the first actuator is adapted to move in a direction perpendicular to the conveying plane when the conveying system is stationary.

[0130] [Section 35] In the interlacing system according to any one of items 28 to 34, the first carrier an interlacing system, wherein the interlacing head is indirectly coupled to the first interlacing head by the first actuator.

[0131] [Section 36] Item 36. The entangling system according to any one of items 28 to 35, further comprising a second entangling station, the second entangling station including: the conveying system having a surface adapted to intermittently advance the composite nonwoven fabric in a material flow direction; a second actuator; a second entangling head coupled to the second actuator, the second actuator adapted to actuate the second entangling head to move in a direction perpendicular to a conveying plane of the conveying system; and a second carriage coupled to the second entangling head, the second carriage adapted to move in the first direction non-parallel to the material flow direction.

[0132] [Section 37] 37. The interlacing system according to claim 36, wherein the first interlacing head is positioned at a first distance inward from a first edge of the surface of the conveying system, and the second interlacing head is positioned at a second distance inward from the first edge of the surface of the conveying system, the second distance being different from the first distance. Interlacing system positioned at a distance.

[0133] [Section 38] 38. The interlacing system according to claim 36 or 37, wherein the second interlacing station is positioned subsequent to the first interlacing station in the material flow direction. system.

[0134] [Section 39] Item 39. The interlacing system according to any one of Items 28 to 38, wherein the first interlacing head includes a plurality of interlacing needles.

[0135] [Section 40] 1. A method of manufacturing an array of garments having a common finish configuration, comprising the steps of: procuring a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material positioned between the first and second nonwoven layers, the composite nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, the first and second nonlinear interlaced seams each including an interlaced area that extends from one another to form an apparently continuous nonlinear interlaced seam, the interlaced area including fibers extending from the first nonwoven layer through the filler material to the second layer; and using the first instance of the pattern piece to form a first garment, wherein the first and second nonlinear interlaced seams are located at a first location on the pattern piece; removing a second instance of a pattern piece from the composite nonwoven fabric, the pattern piece having the first and second nonlinear interlaced seams; and using the second instance of the pattern piece to form a second garment, wherein the first and second nonlinear interlaced seams are located at a second location on the pattern piece, different from the first location.

[0136] [Section 41] 41. The method of manufacturing the garment array of claim 40, wherein each of the first nonlinear interlaced seam and the second nonlinear interlaced seam extends in a material flow direction.

[0137] [Section 42] 42. The method of manufacturing the garment array of claim 40 or 41, wherein the interlacing areas partially overlap one another.

[0138] [Section 43] 43. A method of manufacturing the garment array of any one of paragraphs 40 to 42, further comprising the steps of: removing a third instance of a pattern piece from the composite nonwoven fabric, the pattern piece having the first nonlinear interlaced seam and the second nonlinear interlaced seam; and using the third instance of the pattern piece to form a third garment, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a third location on the pattern piece that is different from one or both of the first and second locations.

[0139] [Section 44] 44. The method for manufacturing the garment array of any one of paragraphs 41 to 43, wherein the garment array includes upper body garments.

[0140] [Section 45] 44. The method for manufacturing the garment array according to any one of paragraphs 41 to 43, wherein the garment array includes lower body garments.

[0141] [Section 46] A composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material positioned between the first and second nonwoven layers, the composite nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, the first nonlinear interlaced seam and the second nonlinear interlaced seam each including an interlaced area extending from one another to form the first nonlinear interlaced seam and the second nonlinear interlaced seam, respectively, the interlaced area including fibers from the first nonwoven layer extending through the filler material and into the second layer. and a second garment formed from second instances of pattern pieces taken from the composite nonwoven fabric, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a second location on the pattern pieces of the second garment, the second location being different from the first location. and the second garment positioned on the first garment.

[0142] [Section 47] 47. The garment array of paragraph 46, wherein each of the first interlacing seam and the second interlacing seam extends in a material flow direction.

[0143] [Section 48] 48. The garment array of paragraph 46 or 47, wherein the interlacing areas partially overlap each other.

[0144] [Section 49] 49. The garment array of any one of paragraphs 46 to 48, further comprising a third garment formed from a third instance of a pattern piece removed from the composite nonwoven fabric, wherein the first nonlinear interlaced seam and the second nonlinear interlaced seam are different from one or both of the first location and the second location for the pattern piece in the third garment. a garment array comprising the third garment located at a third location, the third garment being

[0145] [Section 50] 50. The clothing array according to any one of paragraphs 46 to 49, wherein the clothing array includes upper body garments.

[0146] [Section 51] 50. The clothing array according to any one of paragraphs 46 to 49, wherein the clothing array includes lower body garments.

[0147] [Section 52] 1. A method for manufacturing an array of garments having a common finish configuration, comprising the steps of: providing a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material positioned between the first and second nonwoven layers, the composite nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, the first and second nonlinear interlaced seams each including an interlaced area that extends from one another to form an apparently continuous nonlinear interlaced seam, the interlaced area including fibers extending from the first nonwoven layer through the filler material to the second layer; and removing a first portion from the composite nonwoven fabric having a first pattern, the first portion including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, the first and second nonlinear interlaced seams each ... interlaced area that extends from the first nonwoven layer through the filler material to the second layer, the interlaced area including fibers extending from the first nonwoven layer through the filler material to the second layer. removing a first portion from the composite nonwoven fabric, the first portion having a nonlinear interlaced seam and a second nonlinear interlaced seam; using the first portion to form a first garment, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a first location on the first portion; removing a second portion from the composite nonwoven fabric, the second portion having the first pattern, the second portion having the first nonlinear interlaced seam and the second nonlinear interlaced seam; and using the second portion to form a second garment, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a second location on the second portion that is different from the first location.

[0148] [Section 53] 53. The method of manufacturing an array of garments of paragraph 52, wherein each of the first interlacing seams and the second interlacing seams extends in a material flow direction.

[0149] [Section 54] Item 54. The method for manufacturing an array of garments of item 53, wherein the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam varies along the material flow direction, and the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam is measured in a direction non-parallel to the material flow direction.

[0150] [Section 55] 55. A method for manufacturing an array of garments according to any one of paragraphs 52 to 54, wherein the first non-linear interlaced seam and the second non-linear interlaced seam comprise different visual arrangements of interlaced seams.

[0151] [Section 56] 56. A method for manufacturing an array of garments according to any one of paragraphs 52 to 55, wherein the intertwined areas partially overlap each other.

[0152] [Section 57] 57. A method for manufacturing an array of garments according to any one of paragraphs 52 to 56, wherein the array of garments includes upper body garments.

[0153] [Section 57] 57. A method for manufacturing an array of garments according to any one of paragraphs 52 to 56, wherein the array of garments includes lower body garments.

[0154] [Section 59] a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material positioned between the first and second nonwoven layers, the composite nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, the first nonlinear interlaced seam and the second nonlinear interlaced seam each including an interlaced area extending from one another to form the first nonlinear interlaced seam and the second nonlinear interlaced seam, respectively, the interlaced area including fibers from the first nonwoven layer extending through the filler material and into the second layer; and a second garment formed from a second portion of the composite nonwoven fabric having the first pattern, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a second location on the second garment, the second location being different from the first location on the second garment.

[0155] [Section 60] 60. The garment array of paragraph 59, wherein each of the first interlacing seam and the second interlacing seam extends in a material flow direction.

[0156] [Section 61] 61. The method for manufacturing an array of garments of claim 60, wherein the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam varies along the material flow direction, and the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam is measured in a direction non-parallel to the material flow direction.

[0157] [Section 62] 62. A method for manufacturing an array of garments according to any one of paragraphs 59 to 61, wherein the first non-linear interlaced seam and the second non-linear interlaced seam comprise different visual arrangements of interlaced seams.

[0158] [Section 63] 63. A method for manufacturing an array of garments according to any one of paragraphs 59 to 62, wherein the intertwined areas partially overlap each other.

[0159] [Section 64] 64. A method for manufacturing an array of garments according to any one of paragraphs 59 to 63, wherein the array of garments includes upper body garments.

[0160] [Section 65] 64. A method for manufacturing an array of garments according to any one of paragraphs 59 to 63, wherein the array of garments includes lower body garments.

[0161] [Section 66] 1. An entangling system for forming at least one nonlinear entangling seam in a composite nonwoven fabric, the system comprising: a first entangling station, the first entangling station entangling the composite nonwoven fabric to a material frame; an entangling system comprising: a conveying system having a surface adapted to advance a material in a row direction; a first actuator adapted to actuate a first entangling head coupled to the first actuator; and a first carriage coupled to the first entangling head, the first carriage adapted to move in a first direction non-parallel to the material flow direction.

[0162] [Section 67] 67. The entangling system of paragraph 66, wherein the first actuator is adapted to actuate the first entangling head to emit one or more fluid jets.

[0163] [Section 68] 67. The interlacing system of claim 66, wherein the interlacing head includes interlacing needles, and the first actuator is adapted to move one or both of the interlacing head and interlacing needles in a direction perpendicular to the conveying plane of the surface.

[0164] [Section 69] Item 66. An interlacing system according to any one of items 66 to 68, wherein the first carriage is further adapted to move in a second direction opposite to the first direction and non-parallel to the material flow direction.

[0165] [Section 70] 70. The interlacing system of paragraph 69, wherein the second direction is perpendicular to the material flow direction.

[0166] [Section 71] 71. The entangling system of any one of paragraphs 66 to 70, wherein the first entangling head has a first dimension in the material flow direction.

[0167] [Section 72] Item 72. The entangling system of item 71, wherein the conveying system is adapted to advance the composite nonwoven fabric in the material flow direction, and the advancement distance of the conveying system is less than the first dimension of the first entangling head.

[0168] [Section 73] 73. The interlacing system according to any one of items 66 to 72, wherein the first carriage is indirectly coupled to the first interlacing head by the first actuator.

[0169] [Section 74] Item 74. The interlacing system according to any one of items 66 to 73, wherein the first interlacing station further comprises a plurality of additional interlacing heads coupled to the first actuator.

[0170] [Section 75] 75. The interlacing system of claim 74, wherein the plurality of additional interlacing heads coupled to the first actuator are unevenly spaced apart from one another.

[0171] [Section 76] The confounding system according to any one of items 66 to 75, further comprising a second confounding element. a second entangling station including the conveying system having a surface adapted to advance the composite nonwoven fabric in a material flow direction, the second entangling station including: a second actuator adapted to actuate a second entangling head coupled to the second actuator; and a second carriage coupled to the second entangling head, the second carriage adapted to move in the first direction non-parallel to the material flow direction.

[0172] [Section 77] Item 76. The interlacing system of claim 76, wherein the first interlacing head is positioned at a first distance inward from a first edge of the surface of the conveying system, and the second interlacing head is positioned at a second distance inward from the first edge of the surface of the conveying system, the second distance being different from the first distance.

[0173] [Section 78] 78. The interlacing system according to paragraph 76 or 77, wherein the second interlacing station is positioned subsequent to the first interlacing station in the material flow direction.

[0174] [Section 79] Item 79. The interlacing system according to any one of items 76 to 78, wherein the second interlacing station further comprises a plurality of additional interlacing heads coupled to the second actuator.

[0175] [Section 80] 80. The interlacing system of claim 79, wherein the spacing arrangement between the plurality of additional interlacing heads coupled to the second actuator is different from the spacing arrangement between the plurality of additional interlacing heads coupled to the first actuator.

[0176] [Section 81] 81. The interlacing system according to any one of claims 79 to 80, wherein the number of the plurality of additional interlacing heads coupled to the second actuator is different from the number of the plurality of additional interlacing heads coupled to the first actuator.

[0177] [Section 82] 82. The interlacing system according to any one of paragraphs 76 to 81, wherein the dimensions of the second interlacing head are different from the dimensions of the first interlacing head.

[0178] [Section 83] 83. The entanglement system according to any one of items 76 to 82, wherein the entanglement footprint produced by the second entanglement head is different from the entanglement pattern produced by the first entanglement head.

[0179] [Section 84] 1. A method of manufacturing a nonwoven fabric, comprising the steps of: engaging an entangling head with a nonwoven fabric while the nonwoven fabric is in a first position on an entangling machine to form a first entangled area in the nonwoven fabric; advancing the nonwoven fabric in a material flow direction through the entangling machine; moving one or both of the entangling head and the nonwoven fabric in a first direction non-parallel to the material flow direction; and engaging the entangling head with the nonwoven fabric while the nonwoven fabric is in a second position advanced from the first position in the material flow direction to form a second entangled area in the nonwoven fabric, the second entangled area being and forming a second interlaced area extending from the first interlaced area to form a non-linear interlaced seam.

[0180] [Section 85] 85. The method for producing the nonwoven fabric of claim 84, wherein in each of the first entanglement area and the second entanglement area, the fibers forming the nonwoven fabric are moved from a generally horizontal orientation to a generally vertical orientation.

[0181] [Section 86] 86. The method for making the nonwoven fabric of paragraph 84 or 85, wherein the first entangled area partially overlaps the second entangled area.

[0182] [Section 87] Item 86. The method for producing the nonwoven fabric of item 86, wherein the stitch density in the overlap area between the first entangled area and the second entangled area is higher than the stitch density in the remaining portion between the first entangled area and the second entangled area.

[0183] [Section 88] 88. A method for producing the nonwoven fabric described in any one of items 84 to 87, wherein when the nonwoven fabric is in the first position, the entanglement head moves in a direction perpendicular to a plane on the surface of the nonwoven fabric.

[0184] [Section 89] Item 84. A method for producing the nonwoven fabric of any one of items 84 to 88, further comprising, following the step of forming the second entangled area, advancing the nonwoven fabric in the material flow direction; moving one or both of the entanglement head and the nonwoven fabric in a second direction opposite to the first direction and non-parallel to the material flow direction; and, while the nonwoven fabric is at a third position advanced from the second position in the material flow direction, engaging the entanglement head with the nonwoven fabric to form a third entangled area in the nonwoven fabric, the third entangled area extending from the second entangled area to form the nonlinear entangled seam.

[0185] [Section 90] 90. The method for making the nonwoven fabric of paragraph 89, wherein the third entangled area partially overlaps the second entangled area.

[0186] [Section 91] 1. A garment comprising: a nonwoven fabric having a material flow direction; and at least one nonlinear interlaced seam extending along the material flow direction, the at least one nonlinear interlaced seam including one or more interlaced areas that extend into each other to form the at least one nonlinear interlaced seam, wherein in each of the one or more interlaced areas, the fibers forming the nonwoven fabric have a substantially vertical orientation.

[0187] [Section 92] 92. The garment of claim 91, wherein the one or more intertwined areas include discrete areas.

[0188] [Section 93] 92. The garment of claim 91, wherein the one or more intertwined areas are partially intertwined with one another. Overlapping, clothing.

[0189] [Section 94] 94. The garment of any one of claims 91 to 93, further comprising a plurality of additional non-linear interlacing seams, the plurality of additional non-linear interlacing seams forming a non-repeating visual arrangement of interlacing seams.

[0190] [Section 95] Item 91-94: The garment of any one of items 91-94, further comprising one or more additional layers secured to the nonwoven fabric by one or more of interlacing, stitching, bonding, and adhesives.

[0191] [Section 96] Item 95. The garment of item 95, wherein the one or more additional layers include one or more of a structured fabric, a nonwoven layer, a film, and a filler material.

[0192] [Section 97] 1. A nonwoven fabric having a material flow direction, the nonwoven fabric comprising at least one nonlinear interlaced seam extending along the material flow direction, the nonwoven fabric including one or more interlaced areas extending together to form the at least one nonlinear interlaced seam, wherein in each of the one or more interlaced areas, the fibers forming the nonwoven fabric have a substantially perpendicular orientation.

[0193] [Section 98] 98. The nonwoven fabric of paragraph 97, wherein the one or more entangled areas comprise discrete entangled areas.

[0194] [Section 99] 98. The nonwoven fabric of paragraph 97, wherein the one or more entangled areas partially overlap one another.

[0195] [Section 100] Item 97. The nonwoven fabric of any one of items 97 to 99, further comprising a plurality of additional nonlinear interlaced seams, wherein the plurality of additional nonlinear interlaced seams form a non-repeating visual array of interlaced seams.

[0196] [Section 101] 1. An array of garments having a common finish configuration, the garment array comprising: a first garment formed from a nonwoven textile including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, each of the first nonlinear interlaced seam and the second nonlinear interlaced seam including an interlaced area that extends toward each other to form the first nonlinear interlaced seam and the second nonlinear interlaced seam, respectively, the interlaced area including fibers from a nonwoven layer having a substantially perpendicular orientation; and a second garment formed from a second instance of a pattern piece removed from the nonwoven textile, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a second location relative to the pattern piece, the second location being different from the first location.

[0197] [Section 102] Item 101. The garment array of item 101, wherein each of the first nonlinear interlaced seam and the second nonlinear interlaced seam extends in a material flow direction.

[0198] [Section 103] 103. The garment array of claim 101 or 102, wherein the interlacing areas partially overlap each other.

[0199] [Section 104] 104. The garment array of any one of paragraphs 101 to 103, further comprising a third garment formed from a third instance of a pattern piece removed from the nonwoven fabric, wherein the first nonlinear interlaced seam and the second nonlinear interlaced seam are located at a third location on the third garment that is different from one or both of the first location and the second location relative to the pattern piece.

[0200] [Section 105] 105. The clothing array of any one of paragraphs 101 to 104, wherein the array of garments includes upper body garments.

[0201] [Section 106] 105. The clothing array according to any one of paragraphs 101 to 104, wherein the array of clothing includes lower body clothing.

[0202] [Section 107] A method for manufacturing an array of garments having a common finish configuration includes the steps of: obtaining a nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, each of the first nonlinear interlaced seam and the second nonlinear interlaced seam including an interlaced area that extends from one another to form an apparently continuous nonlinear interlaced seam, the interlaced area including fibers having a substantially perpendicular orientation; and removing a first portion from the nonwoven fabric having a first pattern, the first portion including the first nonlinear interlaced seam and the second nonlinear interlaced seam. using the first portion to form a first garment, the first portion having the first pattern, the first portion having the first nonlinear interlaced seam and the second nonlinear interlaced seam located at a first location on the first portion; removing a second portion from the nonwoven fabric having the first pattern, the second portion having the first nonlinear interlaced seam and the second nonlinear interlaced seam; and using the second portion to form a second garment, the first nonlinear interlaced seam and the second nonlinear interlaced seam located at a second location on the second portion that is different from the first locations.

[0203] [Section 108] 108. The method of manufacturing the garment array of claim 107, wherein each of the first interlacing seams and the second interlacing seams extends in a material flow direction.

[0204] [Section 109] Item 108. The method for manufacturing the garment array of item 108, wherein the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam varies along the material flow direction, and the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam is measured in a direction non-parallel to the material flow direction.

[0205] [Section 110] 109. The method for manufacturing the garment array of any one of claims 107 to 109, wherein the first nonlinear interlacing seam and the second nonlinear interlacing seam comprise different visual arrangements of interlacing seams.

[0206] [Section 111] 111. The method for manufacturing the garment array of any one of paragraphs 107 to 110, wherein the intertwining areas partially overlap each other.

[0207] [Section 112] 12. The method of manufacturing the garment array of any one of claims 107 to 111, wherein the garment array includes upper body garments.

[0208] [Section 113] 12. The method for manufacturing the garment array of any one of claims 107 to 111, wherein the garment array includes lower body garments.

[0209] [Section 114] An array of garments having a common finish configuration, the array of garments being formed from a nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, each of the first nonlinear interlaced seam and the second nonlinear interlaced seam including an interlaced area extending from one another to form the first nonlinear interlaced seam and the second nonlinear interlaced seam, respectively, wherein the fibers forming the nonwoven fabric have a substantially perpendicular orientation in the interlaced area. The array of garments includes a first garment formed from a first portion of the nonwoven fabric having a first pattern. and a second garment formed from a second portion of the nonwoven fabric having the first pattern, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a second location on the second portion of the second garment, the second location being different from the first locations.

[0210] [Section 115] Item 114. The garment array of item 114, wherein each of the first nonlinear interlaced seam and the second nonlinear interlaced seam extends in a material flow direction.

[0211] [Section 116] Item 115. The garment array of item 115, wherein the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam varies along the material flow direction, and the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam is measured in a direction non-parallel to the material flow direction.

[0212] [Section 117] Item 117. The clothing array of any one of items 114 to 116, wherein the first non-linear interlacing seam and the second non-linear interlacing seam comprise different visual arrangements of interlacing seams.

[0213] [Section 118] Item 118. The garment array of any one of items 114 to 117, wherein the intertwining areas partially overlap each other.

[0214] [Section 119] In the clothing array according to any one of items 114 to 118, I is a clothing array including upper body clothing.

[0215] [Section 120] Item 114. The clothing array of any one of items 114 to 118, wherein the array of clothing includes lower body garments.

[0216] Aspects of the present disclosure have been described above with intent to be illustrative and not restrictive. Alternative aspects will be apparent to those skilled in the art that do not depart from the scope of the present disclosure. Those skilled in the art may develop alternative means of implementing the improvements described above without departing from the scope of the present disclosure.

[0217] It is contemplated that certain features and subcombinations are of utility and may be employed without reciting other features and subcombinations and still be within the scope of the claims. Not all steps listed in the various figures need be performed in the particular order described.

Claims

1. 1. A method of manufacturing an array of garments having a common finish configuration, comprising the steps of: procuring a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material positioned between the first and second nonwoven layers, the composite nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, the first and second nonlinear interlaced seams each including an interlaced area that extends from one another to form an apparently continuous nonlinear interlaced seam, the interlaced area including fibers extending from the first nonwoven layer through the filler material to the second layer; and using the first instance of the pattern piece to form a first garment, wherein the first and second nonlinear interlaced seams are located at a first location on the pattern piece; removing a second instance of a pattern piece from the composite nonwoven fabric, the pattern piece having the first and second nonlinear interlaced seams; and using the second instance of the pattern piece to form a second garment, wherein the first and second nonlinear interlaced seams are located at a second location on the pattern piece, different from the first location.

2. 10. The method of manufacturing the array of garments of claim 1, wherein each of the first nonlinear interlaced seam and the second nonlinear interlaced seam extends in a material flow direction.

3. 10. The method of manufacturing the array of garments of claim 1, wherein the interlaced areas partially overlap one another.

4. 10. The method of manufacturing the array of garments of claim 1, wherein the array of garments includes upper body garments.

5. 10. The method of manufacturing the array of garments of claim 1, wherein the array of garments comprises lower body garments.

6. A garment having a common finish formed from a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material positioned between the first and second nonwoven layers, the composite nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, the first and second nonlinear interlaced seams each including an interlaced area extending from one another to form the first and second nonlinear interlaced seams, respectively, the interlaced areas including fibers from the first nonwoven layer that extend through the filler material and into the second layer. a first garment formed from first instances of pattern pieces taken from the composite nonwoven fabric, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a first location on the first garment; and a second garment formed from second instances of pattern pieces taken from the composite nonwoven fabric, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a second location on the second garment, different from the first locations relative to the pattern pieces.

7. 7. The array of garments of claim 6, wherein each of the first nonlinear interlaced seam and the second nonlinear interlaced seam extends in a material flow direction.

8. 7. The array of garments of claim 6, wherein the interlaced areas partially overlap one another.

9. 7. The array of garments of claim 6, wherein the array of garments includes upper body garments.

10. 7. The array of garments of claim 6, wherein the array of garments includes lower body garments.

11. A composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler material positioned between the first and second nonwoven layers, the composite nonwoven fabric including at least a first nonlinear interlaced seam and a second nonlinear interlaced seam, the first and second nonlinear interlaced seams each including an interlaced area extending from one another to form the first and second nonlinear interlaced seams, respectively, the interlaced areas including fibers from the first nonwoven layer extending through the filler material and into the second layer. An array of garments having a common finish configuration, the array comprising: a first garment formed from a first portion of the composite nonwoven fabric having a first pattern, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a first location on the first portion of the first garment; and a second garment formed from a second portion of the composite nonwoven fabric having the first pattern, the first nonlinear interlaced seam and the second nonlinear interlaced seam being located at a second location on the second garment that is different from the first locations.

12. 12. The array of garments of claim 11, wherein each of the first nonlinear interlaced seam and the second nonlinear interlaced seam extends in a material flow direction.

13. 13. The array of garments of claim 12, wherein a distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam varies along the material flow direction, and wherein the distance between the first nonlinear interlaced seam and the second nonlinear interlaced seam is measured in a direction non-parallel to the material flow direction.

14. 12. The array of garments of claim 11, wherein the first non-linear interlacing seam and the second non-linear interlacing seam comprise different visual arrangements of interlacing seams.

15. 12. The array of garments of claim 11, wherein the interlaced areas partially overlap one another.

16. 12. The array of garments of claim 11, wherein the array of garments includes upper body garments.

17. 12. The array of garments of claim 11, wherein the array of garments includes lower body garments.

Images