Debossing and fleecing method for composite nonwoven fabric suitable for clothing, and manufacturing method thereof

Abstract

The present invention relates to a composite nonwoven fabric having at least a first entangled fiber web, a second entangled fiber web, and an elastic layer located between the first entangled fiber web and the second entangled fiber web. The composite nonwoven fabric includes different features including one or more debossed portions and one or more pleated structures.

Description

[Technical Field]

[0001] Aspects of the present application relate to methods for debossing and fleecing composite nonwoven fabrics suitable for garments and other articles, and methods for making the same. [Background technology]

[0002] Conventional nonwoven fabrics generally have characteristics that make them unsuitable for apparel. Due to these characteristics and their end use in, for example, the cleaning and personal hygiene industries, conventional nonwoven fabric products may be incompatible with finishing processes and techniques typically used for knitted and / or woven fabric products. As a result, conventional nonwoven fabrics generally lack the aesthetic and / or functional characteristics desirable for apparel. [Brief explanation of the drawings]

[0003] Examples of each aspect of the present application will be described in detail below with reference to the drawings. [Figure 1] FIG. 1 illustrates an exemplary life cycle of an exemplary printed composite nonwoven fabric, according to aspects of the present application. [Figure 2] FIG. 2 illustrates a first fibrous web for the exemplary composite nonwoven fabric of FIG. 1, according to embodiments of the present application. [Figure 3] FIG. 2 illustrates a printing layer for the exemplary composite nonwoven fabric of FIG. 1, according to embodiments of the present application. [Figure 4] FIG. 2 illustrates a second fibrous web for the exemplary composite nonwoven fabric of FIG. 1, according to embodiments of the present application. [Figure 5] FIG. 2 illustrates an optional third fibrous web for the exemplary composite nonwoven fabric of FIG. 1, according to embodiments of the present application. [Figure 6] FIG. 2 illustrates an elastic layer for the exemplary composite nonwoven fabric of FIG. 1, according to embodiments of the present application. [Figure 7] 2A and 2B illustrate an exemplary method for manufacturing the exemplary printed composite nonwoven fabric of FIG. 1 and a garment made from the exemplary printed composite nonwoven fabric of FIG. 1, according to various embodiments of the present application. [Figure 8]8A and 8B illustrate an exemplary printing layer including an internal fiber web and a printing element manufactured using the manufacturing process of FIG. 7 according to various embodiments of the present application. [Figure 9] 9A-9C show cross-sectional views taken along section line 9-9 of FIG. 8 according to various embodiments of the present application. [Figure 10] 9 shows a cross-sectional view of an alternative printing part to the exemplary printing layer of FIG. 8, according to embodiments of the present application. [Figure 11] 9A and 9B show an exemplary printed composite nonwoven fabric having the printed layer of FIG. 8 produced using the manufacturing process of FIG. 7 according to embodiments of the present application. [Figure 12] 12-12 in accordance with various embodiments of the present application. [Figure 13] 13 shows an enlarged view cut away at area 13 of FIG. 12, according to embodiments of the present application. [Figure 14] 13 shows an enlarged view cut away at area 14 of FIG. 12, according to embodiments of the present application. [Figure 15] 8A and 8B illustrate an exemplary printing layer including a spunlace layer and a printing part manufactured using the manufacturing process of FIG. 7 according to embodiments of the present application. [Figure 16] 16A-16B show cross-sectional views taken along section line 16-16 in FIG. 15 according to various embodiments of the present application. [Figure 17] 16 shows a cross-sectional view of an alternative printing part to the exemplary printing layer of FIG. 15, according to embodiments of the present application. [Figure 18] 16A and 16B show an exemplary printed composite nonwoven fabric having the printed layer of FIG. 15 produced using the manufacturing process of FIG. 7 according to embodiments of the present application. [Figure 19] 19 shows a cross-sectional view taken along section line 19-19 of FIG. 18 according to various embodiments of the present application. [Figure 20] 20 shows an enlarged view cut away at area 20 of FIG. 19, according to embodiments of the present application. [Figure 21] 20 shows an enlarged view of area 21 of FIG. 19, according to embodiments of the present application. [Figure 22] 1A-1C illustrate exemplary upper body apparel according to aspects of the present application. [Figure 23] 1A-1C illustrate exemplary lower-body apparel articles according to aspects of the present application. [Figure 24] 24 shows a cross-sectional view taken along section line 24-24 of FIG. 22 according to various embodiments of the present application. [Figure 25] 25A-25C show cross-sectional views taken along section line 25-25 of FIG. 23 according to various embodiments of the present application. [Figure 26] FIG. 1 illustrates an exploded view of an exemplary composite nonwoven fabric for use in fabrication processes and techniques according to aspects of the present application. [Figure 27A] FIG. 1 illustrates a first outward-facing side of an exemplary composite nonwoven fabric having debossed portions, according to various embodiments of the present application. [Figure 27B] FIG. 27B illustrates the second side of the exemplary composite nonwoven fabric of FIG. 27A, according to embodiments of the present application. [Figure 28] FIG. 27B illustrates a cross-sectional view of the exemplary composite nonwoven fabric of FIG. 27A, according to embodiments of the present application. [Figure 29] 27B illustrates an exemplary manufacturing process for use in forming the debossed portion of the exemplary composite nonwoven fabric of FIG. 27A and for use in manufacturing apparel using the exemplary composite nonwoven fabric of FIG. 27A, according to various embodiments of the present application. [Figure 30A] 1 illustrates an exterior view of an exemplary upper body garment according to aspects of the present application. [Figure 30B] 30B illustrates an inner surface of the exemplary upper body apparel of FIG. 30A according to various embodiments of the present application. [Figure 31A] 1A-1C illustrate exemplary lower-body apparel articles according to aspects of the present application. [Figure 31B] 1A-1C illustrate the exterior surfaces of an exemplary lower body garment according to aspects of the present application. [Figure 32A] 1 illustrates a first outward-facing side of an exemplary pleated structure according to various aspects of the present application; [Figure 32B] 32B illustrates a second outward-facing side of the exemplary pleat structure of FIG. 32A, according to various embodiments of the present application. [Figure 33] FIG. 32B illustrates an exploded view of the exemplary pleat structure of FIG. 32A, according to embodiments of the present application. [Figure 34] 32B illustrates an exemplary manufacturing process for forming the pleated structure of FIG. 32A and for manufacturing an article of clothing further using the pleated structure of FIG. 32A, according to various embodiments of the present application; [Figure 35] 1A-1C illustrate exemplary upper body apparel according to aspects of the present application. [Figure 36] 1A-1C illustrate exemplary lower-body apparel articles according to aspects of the present application. [Figure 37] 36 illustrates a cross-sectional view of the exemplary upper body apparel of FIG. 35 according to various embodiments of the present application. DETAILED DESCRIPTION OF THE INVENTION

[0004] The subject matter of the present invention is described in detail herein to satisfy legal requirements. However, the description itself is not intended to limit the scope of the disclosure. Rather, the inventors contemplate that the claimed or disclosed subject matter may be implemented in conjunction with other current or future technologies, including different steps or combinations of steps similar to those described herein. Additionally, the terms "step" and / or "block" may be used herein to indicate different elements of a method used, but should not be construed as implying any particular order between the steps disclosed herein, unless the order of individual steps is explicitly stated.

[0005] Conventional nonwoven fabrics generally have characteristics that make them unsuitable for apparel. These characteristics can include lack of stretch and recovery, high weight, lack of drape, rough feel, symmetrical faces or surfaces, and lack of thermal insulation where thermal insulation is desired. Due to these characteristics and their end use in, for example, the laundry and personal hygiene manufacturing industries, conventional nonwoven fabrics can be difficult to print and can lack aesthetic appeal. Furthermore, when nonwoven fabrics are printed, the aesthetic quality of the print is applied to the outermost surface, which is of poor quality and fades over time due to wear and tear. Such aesthetic quality is undesirable for nonwoven fabrics suitable for apparel.

[0006] Aspects of the present application relate to printed composite nonwoven fabrics suitable for apparel and other articles, and methods for making the same. At a high level, the printed composite nonwoven fabric includes one or more entangled fiber webs and a printed layer (e.g., an inner layer including a printed component). In an exemplary embodiment, the printed composite nonwoven fabric includes a first entangled fiber web and an inner layer. The first entangled fiber web includes a first surface and an opposing second surface. The first surface of the first entangled web at least partially forms the first decorative surface of the printed composite nonwoven fabric. The inner layer has a first surface disposed adjacent to the second surface of the first entangled fiber web. The first surface of the inner layer includes a printed component having a first portion that is incorporated into the first entangled fiber web to a greater extent than a second portion of the printed component.

[0007] In other exemplary embodiments, the printed composite nonwoven fabric can include one or more additional layers (e.g., a second fiber-entangled web, a third fiber-entangled web, and / or an elastic layer) laminated together and / or entangled with the first entangled web and / or the inner layer. In one embodiment, the printed composite nonwoven fabric includes a second fiber-entangled web having a first surface and a second surface opposite the first surface that at least partially forms the second decorative surface side of the printed composite nonwoven fabric. Thus, the inner layer is positioned between the first fiber-entangled web and the second fiber-entangled web such that the first surface of the inner layer is adjacent to the second surface of the first fiber-entangled web and the second surface of the inner layer is adjacent to the first surface of the second fiber-entangled web.

[0008] In addition, according to various embodiments of the present application, the printed composite nonwoven fabric may have an asymmetrical face (e.g., a printed asymmetrical face composite nonwoven fabric) due to the characteristics of the first and second entangled fiber webs and the characteristics of the inner layer and / or any additional layers. In another exemplary embodiment, these characteristics may be configured to allow the printed composite nonwoven fabric to fit into a garment. When the printed composite nonwoven fabric is incorporated into a garment, the first decorative face side forms the outer surface of the garment, and the second decorative face side forms the inner surface of the article. Therefore, the first entangled web may have characteristics suitable for exposing the first entangled fiber web to the external environment when the printed asymmetrical face composite nonwoven fabric is incorporated into a garment. For example, the denier of the fibers forming the first entangled web may be approximately twice as large as the denier of the fibers forming the second entangled web, allowing the first entangled web to withstand abrasive forces without fiber breakage, thereby improving the durability of the printed part.

[0009] Due to its characteristics, the second entangled fiber web is suitable for forming the skin-facing surface when the printed asymmetric surface composite nonwoven fabric is formed into a garment. For example, the denier of the fibers forming the second entangled web can be about half the denier of the fibers forming the first entangled web, since the second decorative surface side is less exposed to abrasive forces. Furthermore, a smaller denier can create a soft texture that is comfortable for skin or near-skin contact. The second entangled web may also contain silicone resin-coated fibers that impart a soft texture and improve the drapeability of the fabric (i.e., prevent the fabric from becoming stiff).

[0010] Other asymmetrical features of the printed composite nonwoven fabric contemplated herein include different color characteristics associated with the printed element and / or the first and second decorative side. In one embodiment, the printed element is more visible on the first decorative side than on the second decorative side. In another embodiment, the printed element is visible on the first decorative side but not on the second decorative side. In another embodiment, the color characteristic may be in the form of a heather effect that is more pronounced on the first decorative side compared to the second decorative side. The printed element and different color characteristics can impart a desired aesthetic to a clothing article formed from the nonwoven fabric and can also provide a visual cue to the wearer as to which side of the clothing article faces outward and which side faces inward. The different color characteristics can also make the clothing article suitable for reversible wear ("inside out" clothing). For example, different color characteristics can be imparted to the sides by having fibers forming different layers of the fabric be of particular colors and / or by selecting entanglement parameters such that the colored fibers preferentially migrate more toward the first side compared to the second side.

[0011] The one or more additional layers of the printed composite nonwoven fabric may further include an elastic layer between the first entangled fiber web and the second entangled fiber web. The elastic layer imparts stretchability and recovery to the printed composite nonwoven fabric, making it suitable for use in clothing such as upper and lower body garments. The elastic layer itself may lack sufficient tensile strength to withstand normal wear. Therefore, the elastic layer is incorporated into the printed composite nonwoven fabric by using an entanglement process to extend fibers from different webs to create a cohesive structure.

[0012] In some exemplary embodiments, one or more additional layers of the printed composite nonwoven fabric include an additional entangled web (e.g., a third fiber entangled web) laminated with the elastic layer. The weight of the pre-entangled web can be selected to obtain a lightweight composite nonwoven fabric with minimal thickness after entanglement. The number of entangled webs, fiber denier, fiber type, fiber length, etc. can also be selected to form a final printed composite nonwoven fabric that provides enhanced thermal insulation by trapping air between the fibers that form the fabric. Additionally, the properties of the different webs and / or the number of webs used to form the printed composite nonwoven fabric can be adjusted to achieve different desired final properties of the printed nonwoven fabric, including different desired final properties of each side of the printed composite nonwoven fabric. The result is a lightweight printed asymmetrical surface composite nonwoven fabric with stretchability and recovery, excellent drape, interesting visual aesthetics, excellent abrasion resistance, and a soft handle, making the printed composite nonwoven fabric suitable for forming apparel suitable for sportswear.

[0013] The composite nonwoven fabrics contemplated herein can be finished in a variety of ways. For example, the textile can be printed with one or more patterns, graphics, logos, etc. using selected printing techniques. In one exemplary embodiment, one or more fiber webs can be printed prior to entanglement, with the printed components incorporated into the nonwoven fabric during entanglement. When the nonwoven fabric is formed into a garment, the edges of the textile can be sewn together using different techniques. For example, the edges of the fabric can be overlapped, and an entanglement process can be used to entangle fibers from the edges of the fabric to form a seam.

[0014] In various embodiments of the present application, it is also contemplated that the printed composite nonwoven fabric is recyclable, and in some embodiments, the fabric may be fully recyclable. Thus, in various embodiments, the fibers selected to form the intertwined web may include recycled materials, including recycled polyethylene terephthalate (PET) fibers, commonly referred to as polyester fibers. Additionally, the materials selected to form the elastic layer may be fully recyclable. The use of recycled fibers and materials reduces the carbon footprint of the printed composite nonwoven fabric.

[0015] A printed composite nonwoven fabric is formed by placing a printed layer (e.g., an inner layer including a printed component) between a first fibrous web and one or more additional layers to form a composite structure. The printed layer can be formed by forming the printed component on the inner layer using a printing technique before forming the composite structure. The selection of the properties of the first fibrous web, inner layer, and one or more additional layers, such as the number of webs, fiber denier, weight of each web, fiber length, fiber color, and fiber coverage, is based on the desired final properties of the printed composite nonwoven fabric. After forming the printed layer, a mechanical entanglement process is carried out after combining the first fibrous web and one or more additional layers to form a composite structure. In one exemplary embodiment, the mechanical entanglement process is needlepunching. Parameters related to the needlepunching process, such as needle selection, stitch density, penetration depth, penetration direction, and number of needle passes, are selected based on the desired final properties of the asymmetric surface-printed composite nonwoven fabric. For example, parameters may be selected to produce a nonwoven fabric having a desired thickness, a desired degree of stretch and recovery, a desired weight, a desired drape or stiffness, and the like.

[0016] Another aspect of the present application relates to a method for producing a printed composite nonwoven fabric, which generally includes one or more steps related to forming a printed layer, combining the printed layer with a first fiber web and / or one or more additional layers to form a composite structure, and subjecting the composite structure to an entanglement process. In an exemplary embodiment, the method for producing a printed composite nonwoven fabric includes placing a first surface of the printed layer adjacent to a second surface of a first fiber web to form a composite structure. The printed layer includes a printed element that can be at least partially formed from a colorant previously applied to an inner layer. The method further includes subjecting the composite structure to a needle entanglement process and bonding at least a portion of the printed element to the first fiber web after the needle entanglement process.

[0017] In some exemplary embodiments, a method for producing a printed asymmetric composite nonwoven fabric includes forming a printed element on an inner layer using a printing technique to form a printed layer, and positioning a first surface of the printed layer adjacent to a second surface of a first fibrous web to form a composite structure. The method further includes subjecting the composite structure to a variable entanglement process, in which at least a portion of the printed element and the first surface of the first fibrous web at least partially form a first decorative surface side of the asymmetric composite nonwoven fabric.

[0018] In further exemplary embodiments, a printed part can be formed on the inner layer using a printing technique (e.g., applying a colorant by digital printing, applying a sublimation dye by sublimation printing, etc.). In these embodiments, it is contemplated that the printed part can be formed pre-entangled on the inner layer (i.e., before the fibers of one or more entangled fiber webs included in the printed composite nonwoven fabric are entangled). These embodiments contemplate that the inner layer includes a fibrous web (e.g., a pre-entangled fiber web), and further contemplate that the inner layer may be a spunlace layer and / or include spunlace fibers.

[0019] As used herein, the term "apparel" is intended to encompass products worn by a wearer. These may include upper-body garments (e.g., outerwear, t-shirts, pullovers, hoodies, jackets, coats, etc.) and lower-body garments (e.g., trousers, pants, tights, shorts, unitards, etc.). Apparel may also include hats, gloves, sleeves (e.g., arm covers, calf sleeves), footwear (e.g., shoe uppers), etc. When referring to apparel, the term "inner-facing surface" refers to the surface configured to face the wearer's body surface, and the term "outer-facing surface" refers to the surface configured to face the external environment, away from the wearer's body surface. The term "innermost surface" refers to the surface closest to the wearer's body surface relative to other layers of the apparel, and the term "outermost surface" refers to the surface farthest from the wearer's body surface relative to other layers of the apparel.

[0020] As used herein, the term "nonwoven fabric" refers to fibers that are not in the form of a knit, braided, plaited, or other structured structure, but are held together by mechanical and / or chemical interactions. In certain embodiments, nonwoven fabrics include a collection of fibers that are mechanically manipulated to form a mat material. In other words, nonwoven fabrics are produced directly from fibers. Nonwoven fabrics can include different fiber webs that form a cohesive structure, and the different fiber webs can have different or similar fiber compositions and / or different properties. The term "fiber web" refers to a fiber web prior to mechanical entanglement with one or more other fiber webs. Fiber webs include fibers that have undergone carding and wrapping processes to align the fibers in one or more common directions extending along the X and Y planes to achieve a desired basis weight. Fiber webs may also be subjected to a light needlepunching process or mechanical entanglement process that entangles the fibers of the web to some extent so that the fiber web forms a cohesive structure that can be manipulated (e.g., entanglement onto rollers, unwinding from rollers, lamination, etc.). The fibrous web may undergo one or more additional processing steps, such as printing, before being entangled with other fibrous webs to form a composite nonwoven fabric. When referring to a composite nonwoven fabric, the term "entangled fibrous web" refers to a fibrous web after being mechanically entangled with one or more other fibrous webs. Thus, the entangled fibrous web may contain fibers originally present in the fibrous web that forms the layer, as well as fibers present in other fibrous webs that have been transferred to the entangled fibrous web through the entanglement process. The term "inner layer" as used herein refers to a nonwoven fabric layer located between at least two other layers of nonwoven fabric. The term "printed layer" as used herein refers to a nonwoven fabric layer containing a printed component.

[0021] In exemplary embodiments, the printing layer is positioned inside the outermost fiber web (e.g., the first fiber web) or layer of the printed composite nonwoven fabric. These embodiments assume that the printing layer and the printing components are less or not exposed to the external environment. This reduces the risk of wear and tear on the printing layer and the printing components. In another exemplary embodiment, the placement of the printing layer in an inner layer is also advantageous for fixing the printing layer in the appropriate position within the printed composite nonwoven fabric. Furthermore, the characteristics of the printing layer can result in less entanglement than other fiber webs and / or layers of the printed composite nonwoven fabric. Therefore, when the printing layer is positioned between two fiber webs and / or layers as an inner layer of the printed composite nonwoven fabric, it can provide more entanglement to the printing layer than when it is positioned as the outer or outermost layer of the printed composite nonwoven fabric.

[0022] Mechanical entanglement processes contemplated herein can include needle entanglement (commonly referred to as needlepunching) using barbed or structured needles (e.g., bifurcated needles) or fluid entanglement. In embodiments contemplated herein, needlepunching can be used due to the small denier of the fibers used and the ability to fine-tune various parameters associated with the needlepunching process. Needlepunching generally uses barbed or spiked needles 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). Generally, referring to the needlepunching process, a web that has undergone carding, wrapping, or pre-needlepunching can be stacked with other webs that have undergone carding, wrapping, or pre-needlepunching and passed between a bed plate and a stripper plate located on opposite sides of the stacked web structure. Barbed needles fixed to the needle plate enter and exit the stacked web structure, and a stripper plate strips the fibers from the needles after the needles enter and exit the stacked web structure. Web compression during needlepunching can be controlled by adjusting the distance between the stripper plate and the bed plate. As the laminate web structure moves longitudinally along the conveying system, the needle plate repeatedly engages and disengages the laminate web structure to needlepunch the length of the laminate web structure. Embodiments of the present application contemplate the use of multiple needle plates sequentially positioned at different points along the conveying system, with different needle plates engaging the laminate web structure from different sides (e.g., top and bottom) of the laminate web structure as it moves longitudinally. Each interface between the needle board and the laminate web structure is known herein as a "pass." Parameters associated with a particular needle plate can be adjusted to obtain desired properties (e.g., basis weight, caliper, etc.) of the resulting needlepunched nonwoven fabric. Different parameters affect the cm used during the interlacing pass. 2 (n / cm 2The needle punching process parameters may include needle density (SD), which is the number of needles per inch, and penetration depth (PD), which is the distance the needles penetrate the stacked web structure before being pulled out of the stacked web structure. Parameters related to the needle punching process, such as the spacing between the bed plate and the stripper plate, and the conveying speed of the layered web structure, also generally can be adjusted.

[0023] While other types of needles are contemplated, the present embodiments contemplate the use of barbed needles (needles with barbs arranged along the needle's length). The barbs on the needles "capture" fibers as they move from a first side of the layered web structure to the opposite second side. The movement of the needles through the layered web structure effectively displaces or pushes the fibers captured by the barbs from a position closer to the first decorative surface side to a position closer to the second decorative surface side, further causing physical interactions with other fibers and helping to "lock" the displaced fibers in place through friction or the like. The present application also contemplates these needles passing through the layered web structure from the second decorative surface side to the first decorative surface side. In exemplary embodiments, the number of barbs on a needle that interact with fibers may be based on the needle's penetration depth. For example, if the penetration depth is a first amount, all barbs can interact with fibers, and as the penetration depth decreases, fewer barbs can interact with fibers. In further exemplary embodiments, the size of the barbs can be adjusted based on the denier of the fibers used in the web. For example, the barb dimensions can be selected to interface with small denier (e.g., finer) fibers instead of large denier fibers, thereby causing preferential movement of the small denier fibers rather than the large denier. In another example, the barb size is selected to engage both small denier and large denier fibers, thereby allowing the two types of fibers to move through the web.

[0024] After entanglement, the nonwoven fabric can include a first decorative side and an opposing second decorative side, with the two decorative sides facing outward relative to the interior of the nonwoven fabric and comprising the outermost surfaces of the nonwoven fabric. This allows both the first decorative side and the second decorative side to be fully visible when the nonwoven fabric is viewed. Both the first decorative side and the second decorative side may extend along x,y planes that are generally parallel to but offset from each other.

[0025] The term "elastic layer" as used herein refers to a layer that has stretch and recovery properties along at least one orientation axis (i.e., elastic recovery properties), including layers that have stretch and recovery properties along a single orientation axis and layers that have stretch and recovery properties along multiple orientation axes. Examples of orientation axes include the length direction, width direction, x-direction, y-direction, and any direction angularly offset from the length direction, width direction, x-direction, and y-direction. The elastic layer can be formed of a thermoplastic elastomer, such as a thermoplastic polyurethane (TPU), a thermoplastic polyetherester elastomer (TPEE), or a combination of TPU and TPEE. The elastic layer can include a spunbond layer, a film, a web, or the like. In an exemplary embodiment, the elastic layer can include a spunbond TPEE or a meltblown TPU. Nonwoven elastomeric materials (e.g., a spunbond TPEE or a meltblown TPU) allow for a lower basis weight than elastomeric films. Similarly, webs are typically more breathable and permeable, and typically more flexible (i.e., less stiff) than films, due to the nature of fibers versus films. These factors (low basis weight, breathability and permeability, and flexibility) make the exemplary composite nonwoven fabrics described herein ideal for use in apparel environments where these are desirable characteristics.

[0026] For fibers, the term denier or denier per fiber is a measure of the linear mass density of the fiber, more specifically, the mass in grams per 9000 meters of fiber. In one exemplary embodiment, fiber denier can be measured using ASTM D1577-07. Fiber diameter can be calculated based on the fiber denier and fiber density. Fibers contemplated herein can be formed from many different materials (e.g., cotton, nylon, etc.), including polyethylene terephthalate (PET), commonly referred to as polyester. PET fibers can include original PET fibers (non-recycled fibers) and recycled PET fibers. Recycled PET fibers include shredded PET fibers derived from shredders and re-extruded PET fibers (re-extruded fibers using recycled PET chips). In yet another embodiment, fibers contemplated herein can be configured to impart hydrophobic properties to nonwoven fabrics.

[0027] As used herein, the term "silicone-coated fiber" can refer to a fiber having a continuous silicone coating, such that the silicone coating completely covers the fiber along its length. In one example, the fiber can form a core, and the silicone can form a sheath surrounding the core. In another exemplary embodiment, the term "silicone-coated fiber" can refer to a fiber having an intermittent silicone coating in at least some areas along the fiber length. For example, the silicone coating can be applied onto the fiber. In this embodiment, if a particular fiber web contains 100% by weight of silicone-coated fibers, this specification contemplates that the fibers forming the web can have areas that do not contain the silicone coating. This specification contemplates incorporating the silicone-coated fibers into a web of fibers that forms a composite nonwoven fabric. In other words, the silicone coating is not applied to the fibers after the composite nonwoven fabric is formed, for example, using a silicone spray finish.

[0028] As used herein, when referring to nonwoven fabrics, the term "color" or "color property" generally refers to the observable color of the fibers forming the fabric. In these embodiments, it is contemplated that the color may be any color that can be imparted to the fibers using dyes, pigments, and / or colorants known in the art. Thus, the fibers can be configured to have colors including, but not limited to, red, orange, yellow, green, blue, indigo, purple, white, black, and chromaticities thereof. In one exemplary embodiment, color can be imparted to the fibers during their formation (commonly referred to as solution dyeing). In solution dyeing, color is added to the fibers as they are extruded and becomes integrated with the fibers, rather than being added to the fibers in a post-forming step (e.g., a piece-dyeing step).

[0029] Color-related aspects further consider determining whether a color is different from another color and whether a color is substantially the same as another color. In these aspects, color may include a color number that can be determined by using an instrument that objectively measures and / or calculates the color value of an object's color by standardizing and / or quantifying factors that may affect color perception. Such instruments include, but are not limited to, a colorimeter, a spectroradiometer, a spectrophotometer, and the like. Accordingly, aspects of the present application contemplate that the "color" of a textile provided by a fiber may include a color number measured and / or calculated using a colorimeter, a spectroradiometer, and / or a spectrophotometer. Furthermore, a numeric color value can be associated with a color space or color model, which is a specific configuration of a particular color that provides a color representation of the numeric color value. In this manner, each numeric color value corresponds to a single color represented in the color space or color model.

[0030] Such a determination can be made, for example, by using a colorimeter, spectroradiometer, or spectrophotometer to measure and / or calculate the numeric color value of a first textile having a first color, and using the same instrument to measure and / or calculate the numeric color value of a second textile having a second color (i.e., if a spectrophotometer measures the numeric color value of the first color, a spectrophotometer is used to measure the numeric color value of the second color), and then comparing the numeric color value of the first color to the numeric color value of the second color. In another example, this determination can be made by using a colorimeter, spectroradiometer, or spectrophotometer to measure and / or calculate the numeric color value of a first region of the textile, and using the same instrument to measure and / or calculate the numeric color value of a second region of the textile having the second color, and then comparing the numeric color value of the first color to the numeric color value of the second color. If the numeric color values ​​are not equal, then the first color or first color characteristic is different from the second color or second color characteristic, and vice versa.

[0031] Furthermore, the visual difference between two colors can be correlated with the percentage difference between the numerical color values ​​of the first and second colors, with the visual difference considered to be greater as the percentage difference between the color values ​​increases. Furthermore, the visual difference can be based on a comparison between the color representations of the color values ​​in a color space or model. For example, if a first color has a numerical color value corresponding to a representation of black or navy blue, and a second color has a numerical color value corresponding to a representation of red or yellow, the visual distinction between the first and second colors is greater than the visual distinction between a first color represented as red and a second color represented as yellow.

[0032] The term "semitransparent" refers to the transmission of light, and refers to the physical properties of an object when light is shone onto its surface, where some of the light passes through or is transmitted by the object, and some of the light is diffused, reflected, and / or absorbed. Thus, when describing one or more additional layers of a fiber web and / or nonwoven fabric, the term "semitransparent" refers to a fiber web or layer through which light partially passes. Also, when a fiber web or layer is described herein as "at least partially" translucent, it should be understood that "at least partially" refers to a portion, area, region, or location of the fiber web or layer, where the fiber web or layer is translucent, and not its transmittance. For example, a fiber web or layer of an at least partially translucent printed composite nonwoven fabric means that light partially passes through a portion, area, region, or location of the layer. In another example, a fiber web or layer at least partially translucent means that light partially passes through one or more portions of the fiber web or layer, while light may or may not pass through other different portions of the fiber web or layer.

[0033] The term "textile printing technology" as used herein generally refers to a process for applying a colorant to a substrate (e.g., the inner layer of a printed nonwoven composite fabric) and includes any textile printing process, technique, or method known to those skilled in the art. Generally, the colorant may be a colorant, a sublimable dye, or both, and the colorant and sublimable dye may be configured to have a color, including, but not limited to, red, orange, yellow, green, blue, indigo, purple, white, black, and shades thereof. Thus, in exemplary embodiments, the textile printing technology contemplated herein includes direct textile printing techniques that transfer one or more colorants to a substrate. Examples of direct textile printing techniques include screen printing, rotary printing, digital printing, and the like. The term "colorant" as used herein generally refers to an ink, pigment, dye, or any other substance that colors something, and can include a wide range of inks, pigments, or dyes that are compatible with at least one of the direct textile printing techniques discussed herein. In exemplary embodiments, the colorant can include commercially available inks known to those skilled in the art or proprietary inks used in conjunction with digital textile printing techniques. The inks can be water-based or oil-based and can include, but are not limited to, cracking inks, discharge inks, glitter or shimmer inks, gloss inks, metallic inks, specular silver inks, plastisol inks, polyvinyl chloride inks (PVC inks), non-PVC inks, phthalate inks, non-phthalate inks, acrylic inks, suede inks, oil-based acrylic inks, polyurethane inks, high-density inks, solvent inks, ultraviolet inks, and combinations thereof. It is also contemplated that the inks may include specialty inks that may have one or more properties not typically found in commercially available inks. Such properties can include visual properties that can give the specialty ink a metallic, pearlescent, color-changing, or reflective appearance. Any of these inks can also include additives that affect certain properties or components of the ink or impart additional properties or components to the ink. For example, additives can improve the compatibility of the ink with certain inks and materials, and therefore can be used to promote compatibility of the ink with the surface of the printed composite nonwoven fabric layer.

[0034] In another exemplary embodiment, the textile printing technique contemplated herein includes sublimation printing. As used herein, the term "sublimation printing process" refers to a textile printing technique that uses heat and pressure to apply a dye to a substrate. Generally, a sublimation printing process applies one or more sublimable dyes that can have an affinity for a substrate (e.g., the inner layer of a nonwoven fabric) and are applied to the substrate by sublimation printing. The sublimable dyes can include plant- or synthetic-derived colorants, which may be finely ground and contained in a dispersion, and the sublimable dyes can be infused into the substrate at a molecular level, impregnating the material with color. As those skilled in the art will appreciate, sublimation printing utilizes sublimation science, in which heat is applied to a solid to convert it into a gas through an endothermic reaction without passing through a liquid phase.

[0035] Sublimation printing can involve solid heat-sensitive dyes that are dissolved in a liquid, become gaseous under heat and pressure, bond with a compatible substrate, and then revert to a solid state. This allows the sublimation dye to be infused into the substrate at a molecular level. The sublimation printing process contemplated herein can utilize a variety of ingredients and techniques to apply the sublimation dye to a substrate (e.g., the inner layer of a nonwoven fabric), and different sublimation printing processes can include similar and / or different aspects. For example, one process can apply the sublimation dye directly to the substrate, while another process can use a transfer sheet. Some sublimation printing techniques can also include a sublimation printer and / or use heat or energy to attach the sublimation dye to the substrate. In one non-limiting example, one or more sublimation dyes can be transferred to the inner layer using a heat press, where the inner layer and the one or more sublimation dyes applied thereto are exposed to a temperature of approximately 195°C for approximately 1 second. This allows the one or more sublimation dyes to be transferred to the inner layer and absorbed into at least a portion of the inner layer. In other embodiments, the sublimable dye(s) may be transferred to the inner layer using a heat press, whereby the inner layer and the sublimable dye(s) applied thereto are exposed to about 225°C to about 165°C, about 220°C to about 170°C, about 215°C to about 175°C, about 210°C to about 180°C, about 205°C to about 185°C, about 200°C to about 190°C, or about 195°C for about 30 seconds, about 25 seconds, about 20 seconds, about 15 seconds, about 10 seconds, or about 5 seconds. As used herein, the term "about" generally means within ±10% of the indicated value.

[0036] The term "printed part" as used herein refers to an image, graphic, design, or visual mark formed on a layer by one or more colorants or sublimable dyes applied to the layer by a printing technique according to any aspect of the present application. The printed part may also include shapes, such as logos, images, geometric shapes, organic shapes, patterns, letters, numbers, and other brand-related shapes. The printed part may also be formed, at least in part, with one or more colors provided by one or more colorants or sublimable dyes, which may be configured to any color, including, but not limited to, red, orange, yellow, green, blue, indigo, purple, and shades thereof.

[0037] Further aspects of the present application are directed to debossed and pleated composite nonwoven fabrics suitable for apparel and other articles, and methods for making the same. At a high level, the composite nonwoven fabric may include a first region including a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first and second entangled fiber webs. The composite nonwoven fabric may also include a second region including a debossed portion including a plurality of fibers from the first entangled fiber web integrated within the elastic layer, and the second entangled fiber web.

[0038] Continuing at a high level, the pleated structure may include a composite nonwoven fabric including a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first entangled fiber web and the second entangled fiber web. The pleated structure may further include an elastically recoverable structured fabric positioned adjacent to an outermost surface of the second entangled fiber web, and may further include a plurality of pleats formed from the composite nonwoven fabric and the elastically recoverable structured fabric.

[0039] This application provides various measurements related to the pre-entangled web and the resulting composite nonwoven fabric. The thickness of the resulting composite nonwoven fabric can be measured using a precision thickness gauge. To measure thickness, for example, a fabric can be placed on a flat anvil and a presser foot can be pressed against the fabric from above with a standard fixed load. The dial indicator on the precision thickness gauge indicates thickness in mm. Basis weight is measured in grams per square meter (gsm) using the ISO 3801 test standard. Fabric stiffness generally corresponds to drapeability and is measured using the ASTM D 4032 (2008) test standard in kilogram-force (Kgf). Fabric elongation and recovery are measured using the ASTM 2594 test standard and expressed as a percentage. As used herein, the term "stretch" refers to a fabric property measured as the increase in a specified distance at a specified tension, typically expressed as a percentage of the original reference distance (i.e., resting length or width). The term "stretch" as used herein refers to the increase in distance of a particular reference (i.e., resting length or width) after stretching to a specified tension during a time interval during which the tension is released, generally expressed as a percentage of the original reference distance. "Recovery" as used herein refers to the ability of a woven fabric to return to its original reference distance (i.e., its resting length or width), generally expressed as a percentage of the original reference distance. Thermal resistance is typically measured using the ISO 11092 test standard as RCT (Mean). 2 *Equivalent to the thermal insulation characteristics measured in K / W.

[0040] Unless otherwise specified, all measurements described in this application are taken with the nonwoven fabric in a rest (unstretched) state at standard ambient temperature and pressure (25°C or 298.15K, 1 bar).

[0041] FIG. 1 illustrates an exemplary life cycle of a composite nonwoven fabric contemplated herein. Reference numeral 100 designates a first fibrous web 110, an inner layer 120 having a printing element 130 (e.g., a printing layer), and one or more additional layers 140 (e.g., a second fibrous web, a third fibrous web, and / or an elastic layer) prior to entanglement. It is contemplated herein that, in some exemplary embodiments, any of the one or more additional layers 140 may be optional. In exemplary embodiments, the fibers used to form the first fibrous web 110, the inner layer 120, and the one or more additional layers 140 may include recycled fibers, particularly recycled PET fibers. Additionally, if the one or more additional layers 140 include an elastic layer, it is contemplated in exemplary embodiments herein that the elastic layer may be formed from a recyclable material. Arrow 102 generally indicates an entanglement step in which fibers in the first fibrous web 110, the inner layer 120, and / or the one or more additional layers 140 are entangled with one another, with one or more fibers extending into other layers to form the cohesively printed composite nonwoven fabric 150. Arrow 104 generally indicates a processing step in which the printed composite nonwoven fabric 150 is formed into an apparel item 160 that includes the printed component 130. While the apparel item 160 is shown as an outerwear garment, it is contemplated herein that the apparel item 160 may take other forms, such as an outerwear garment, a shoe upper, a hat, a glove, a sleeve, etc. At the end of the life of the garment 160, it is envisioned that the wearer may return the garment 160, for example, to a manufacturer / retailer, where it may be fully recycled, as indicated by arrow 106, to form chopped and / or re-extruded fibers that are used to form fibrous webs such as the first fibrous web 110, the inner layer 120, and / or one or more additional layers 140, forming self-retaining loops that reduce the carbon impact commonly associated with the production of textile garments (including knit, woven, and nonwoven textile garments).

[0042] FIG. 2 shows the first fibrous web 110 before it is entangled with other webs and / or laminated with other layers. In exemplary embodiments, properties associated with the first fibrous web 110 can be selected to achieve desired final properties of the printed composite nonwoven fabric 150. As described above, the first fibrous web 110 is envisioned to form the first decorative side of the printed composite nonwoven fabric 150 when entangled with other webs and / or laminated with other layers. When the printed composite nonwoven fabric 150 is formed into an article of clothing, the first decorative side forms the outer-facing surface, and in some embodiments, the outermost surface of the article of clothing. Therefore, desired performance properties associated with the first fibrous web 110 include, for example, durability, abrasion resistance, and concealment. In exemplary embodiments, the first fibrous web 110 has a basis weight of about 20 grams per square meter (gsm) to about 150 gsm, about 35 gsm to about 65 gsm, about 40 gsm to about 60 gsm, about 45 gsm to about 55 gsm, or about 50 gsm. Setting the basis weight of the first fibrous web 110 within this range can result in a nonwoven fabric having a basis weight within the desired range after combining the first fibrous web 110 with other webs and / or elastic layers.

[0043] The first fibrous web 110 is formed of fibers, such as fibers 210 (shown diagrammatically), which may be oriented in a substantially common direction by carding and wrapping processes. In an exemplary embodiment, fibers 210 may include PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also contemplated herein. In one exemplary embodiment, fibers 210 may include 100% recycled fibers by weight, such as 100% recycled PET fibers by weight. However, in other embodiments, fibers 210 may include 100% virgin fibers by weight or other combinations of virgin and recycled fibers, as desired. The short fiber length of fibers 210 may be within a range of about 40 mm to about 60 mm, about 45 mm to about 55 mm, or about 51 mm. Using this fiber length results in optimal entanglement. For example, below 40 mm, the fibers may not have sufficient length to intertwine, and above 60 mm, the fibers may not be substantially intertwined when the needles are withdrawn from the nonwoven during intertwine. In exemplary embodiments, the fibers 210 may comprise a uniform length, for example, when formed from original extruded or re-extruded PET and cut to a specified length. In other embodiments, the fibers 210 may comprise a variation in staple length, for example, when the fibers 210 are from a chopped fiber source. Any and all embodiments, and variations thereof, are contemplated as being included within each embodiment of the present application.

[0044] The fibers 210 can have a denier of about 1.2D or greater, or about 1.2D to about 3.5D, about 1.2D to about 1.7D, about 1.3D to about 1.6D, or about 1.5D. Using a denier in this range reduces the resistance of the fibers 210 to breakage and improves the durability and abrasion resistance of the first decorative side of the printed composite nonwoven fabric 150. Selecting a denier within this range while maintaining the basis weight of the first fibrous web 110 also provides good, uniform coverage of the first decorative side, which contributes to improving the durability properties of the first decorative side. Selecting a denier greater than 3.5D, for example, while maintaining the basis weight of the first fibrous web 110, can provide less coverage of the first decorative side in some cases, such as when it is desired to expose, or at least partially expose, the printed components.

[0045] In an exemplary embodiment, the fibers 210 used to form the first fiber web 110 can include a first color characteristic. For example, if the fibers 210 are solution-dyed, the first color characteristic can be imparted to the fibers 210 during the extrusion process. In an exemplary embodiment, the color characteristic can be white, although other colors are contemplated herein. Using solution-dyed fibers to form the printed composite nonwoven fabric 150 eliminates the need for a post-formation dyeing process, further contributing to a reduced carbon footprint of the printed composite nonwoven fabric 150. In another exemplary embodiment, the fibers 210 can be configured to make the first fiber web 110 at least partially translucent. That is, the pre-entangled or post-entangled first fiber web 110 allows the printed components 130 of the inner layer 120 of the printed composite nonwoven fabric 150 to be at least partially visible through the first fiber web 110 on the first decorative surface side.

[0046] FIG. 3 shows the inner layer 120 having the printed element 130 before entanglement and / or lamination with other webs and / or layers. In exemplary embodiments, properties associated with the inner layer 120 can be selected to achieve desired final properties of the printed element 130 and / or the printed composite nonwoven fabric 150. Generally, the inner layer 120 may be configured to include a printed element 130 that is compatible with at least one printing technology contemplated herein and has desired aesthetic properties. In one example, the inner layer 120 has a first color characteristic (white) and at least one surface adapted to receive one or more coloring substances, which together form the printed element 130. In exemplary embodiments, the inner layer 120 may be a fibrous web formed of any selected fibers having characteristics associated with the fibers contemplated herein. In other exemplary embodiments, the inner layer 120 is a spunlace layer having characteristics configured to provide the printed element 130 with desired aesthetic properties. Other aspects related to the inner layer 120 are described in more detail below.

[0047] 4-6 each illustrate an exemplary fibrous web or layer that may be included in one or more additional layers 140 of the printed composite nonwoven fabric 150. FIG. 4 illustrates the second fibrous web 112 before it is entangled with other webs and / or laminated with other layers. In exemplary embodiments, properties associated with the second fibrous web 112 can be selected to achieve desired final properties of the printed composite nonwoven fabric 150. As described above, the present application contemplates that the second fibrous web 112, when entangled with other webs, forms the opposite, second decorative side of the printed composite nonwoven fabric 150. When the printed composite nonwoven fabric 150 forms an article of clothing, the present application contemplates that the second decorative side forms the inner-facing surface of the article of clothing, and in some embodiments, the innermost surface. Accordingly, properties associated with the second fibrous web 112 include, for example, a soft feel or hand. In exemplary embodiments, the second fibrous web 112 has a basis weight of about 20 gsm to about 150 gsm, about 35 grams per square meter (gsm) to about 65 gsm, about 40 gsm to about 60 gsm, about 45 gsm to about 55 gsm, or about 50 gsm. In exemplary embodiments, the second fibrous web 112 has substantially the same basis weight as the first fibrous web 110. Setting the basis weight of the second fibrous web 112 within this range allows for a nonwoven fabric having a desired basis weight range to be obtained after the second fibrous web 112 is combined with other webs and / or laminated with other layers.

[0048] The second fibrous web 112 can be formed of two types of fibers, such as fibers 310 (shown schematically) and fibers 312 (shown schematically), which can be oriented in a substantially common direction for carding and cross-lapping processes. In an exemplary embodiment, fibers 310 can include PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are contemplated herein. In one exemplary embodiment, fibers 310 can include 100% recycled fibers by weight, such as 100% recycled PET fibers by weight. However, in other embodiments, fibers 410 can include 100% virgin fibers by weight or other combinations of virgin and recycled fibers, as desired.

[0049] The fibers 312 are shown with dotted lines to indicate that they have different characteristics than the fibers 310. The fibers 312 may include, for example, silicone resin-coated fibers. The fibers 312 may be coated with a silicone resin before being incorporated into the second fibrous web 112. In exemplary embodiments, the second fibrous web 112 may include about 10% to about 100% by weight of the fibers 312, about 40% by weight of the fibers 310 and about 60% by weight of the fibers 312, about 45% by weight of the fibers 310 and about 55% by weight of the fibers 312, about 55% by weight of the fibers 310 and about 45% by weight of the fibers 312, or about 60% by weight of the fibers 310 and about 40% by weight of the fibers 312. While the second fibrous web 112 is shown to include about 100% by weight of the fibers 312, it is contemplated herein that the fibers 312 are intermittently coated with the silicone resin along their length. Using fibers 310 and 312 within the above ranges can impart a good texture to the second surface formed by the second fiber web 112. It also imparts good drape to the printed composite nonwoven fabric 150. In other words, the printed composite nonwoven fabric 150 is not as stiff as nonwoven fabrics used in conventional clean spaces and personal sanitary spaces. Furthermore, since silicone-coated fibers can move more easily during entanglement, using fibers 310 and 312 within the above ranges can reduce the amount of needle force required to entangle the fiber web described herein. Incorporating silicone resin-coated fibers below the above ranges can cause dryness and discomfort on the second decorative surface side during wear. On the other hand, incorporating silicone resin-coated fibers above the above ranges can cause the second decorative surface side to feel smooth, which can also cause discomfort to the wearer. Furthermore, using silicone resin-coated fibers above the above ranges can make the carding process difficult because the carding wire cannot frictionally engage with the fibers to obtain a uniform carded web. Furthermore, if silicone resin-coated fibers are used in excess of the above range, the silicone resin will reduce the frictional force, affecting the structural integrity of the printed composite nonwoven fabric 150, and may result in insufficient entanglement between the fibers.

[0050] The use of silicone resin-coated fibers eliminates the need to add a silicone resin finish to the printed composite nonwoven fabric 150 in the post-processing process. As is well known, in the textile field, it is common to add a silicone fabric softener to knitted or woven fabrics in the post-processing process. By eliminating this process, the carbon footprint of the printed composite nonwoven fabric 150 can be further reduced.

[0051] The staple length of each of fibers 310 and 312 may be within a range of about 40 mm to about 60 mm, about 45 mm to about 55 mm, or about 51 mm. As with fiber 210, this length can provide optimal entanglement. In exemplary embodiments, fibers 310 and / or 312 can have a uniform length, such as when the fibers are formed from virgin extruded or re-extruded PET and cut to length. In other embodiments, fibers 310 and / or 312 can include variations in staple length, for example, when fibers 310 and / or 312 are from chopped fibers. Any and all embodiments, and variations thereof, are contemplated as encompassed by the present application.

[0052] Each of the fibers 310 and 312 can have a denier of about 1D or less. The denier can be, for example, about 0.1D, about 0.2D, about 0.3D, about 0.4D, about 0.5D, about 0.6D, about 0.7D, about 0.8D, or about 0.9D. In an exemplary embodiment, the denier of the fibers 310 and 312 can be about 0.6D to about 1D, about 0.7D to about 0.9D, or about 0.8D. Using a denier in this range contributes to imparting a soft feel or touch to the second decorative surface side formed by the second fibrous web 112. Additionally, selecting a denier within this range while maintaining the basis weight of the second fibrous web 112 provides good coverage of the second decorative surface side.

[0053] In exemplary embodiments, each of the fibers 310 and 312 used to form the second fibrous web 112 may have the same color characteristics or different color characteristics. In exemplary embodiments, both fibers 310 and 312 include the first color characteristic of fiber 210. Like fiber 210, each of fibers 310 and 312 may be dope-dyed, further reducing the need for post-processing dyeing steps in the resulting composite nonwoven fabric.

[0054] 5 shows the optional third fibrous web 114 before it is entangled with other webs and / or laminated with other layers. It is envisioned herein that the third fibrous web 114, when incorporated into the printed composite nonwoven fabric 150 as part of one or more additional layers 140, is located between the first fibrous web 110 and the second fibrous web 112. In an exemplary embodiment, properties associated with the third fibrous web 114 can be selected to achieve desired final properties of the printed composite nonwoven fabric 150. In an exemplary embodiment, the third fibrous web 114 can be incorporated into the printed composite nonwoven fabric 150 to achieve a desired basis weight of the printed composite nonwoven fabric 150, a desired thickness of the printed composite nonwoven fabric 150, a desired thermal insulation property of the printed composite nonwoven fabric 150, a desired pile of the printed composite nonwoven fabric 150, etc. As will be explained further below, to impart visual aesthetics to the printed composite nonwoven fabric 150, the fibers forming the third fibrous web 114 can have different color characteristics than the fibers used to form the first fibrous web 110 and the second fibrous web 112. The third fibrous web 114, like the first fibrous web 110 and the second fibrous web 112, has a basis weight of 20 gsm to about 150 gsm, about 35 grams per square meter (gsm) to about 65 gsm, about 40 gsm to about 60 gsm, about 45 gsm to about 55 gsm, or about 50 gsm. Setting the basis weight of the third fibrous web 110 within this range results in a nonwoven fabric having a basis weight within the desired range after the third fibrous web 114 is combined with other fibrous webs and / or elastic layers.

[0055] The third fibrous web 114 is formed of fibers, such as fibers 410 (schematically shown), which can be oriented in a substantially common direction by carding and cross-lapping processes. In an exemplary embodiment, fibers 410 can include PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are contemplated herein. In one exemplary embodiment, fibers 410 can include 100% recycled fibers by weight, such as 100% recycled PET fibers by weight. However, in other embodiments, fibers 410 can include 100% virgin fibers by weight or other combinations of virgin and recycled fibers, as desired. Similar to fibers 210, 310, and 312, the staple length of fibers 410 can range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. In exemplary embodiments, the fibers 410 can have a uniform length, such as when the fibers are formed from virgin extruded or re-extruded PET and cut to a defined length. In other embodiments, the fibers 410 can include a variation in staple length, for example, when the fibers 410 are from a chopped fiber source. Any and all embodiments, and variations thereof, are contemplated as being included within each embodiment of the present application.

[0056] The fibers 410 may have a denier of about 1.2 or greater, about 1.2D to about 3.5D, about 1.3D to about 1.6D, or about 1.5D. Using a denier in this range makes the fibers 410 less susceptible to breakage and improves the durability and abrasion resistance of the printed composite nonwoven fabric 150. Because the third fibrous web 114 is positioned between the first fibrous web 110 and the second fibrous web 112 during use, a soft feel is less important than, for example, the second fibrous web 112. Selecting a denier in this range while maintaining the basis weight of the third fibrous web 114 improves the overall coverage and / or opacity of the printed composite nonwoven fabric 150.

[0057] In some embodiments, the fibers 410 used to form the third fibrous web 114 can include a second color characteristic different from the first color characteristic. This is depicted using diagonal shading lines in FIG. 4 . It is envisioned herein that the fibers 410 are solution dyed, further reducing the carbon footprint of the printed composite nonwoven fabric 150. As described in more detail below, during entanglement of the first fibrous web 110, the second fibrous web 112, and the third fibrous web 114, the fibers 410 may migrate more toward one decorative side than toward the other decorative side, thereby making the second color characteristic more visually distinguishable or distinct on one decorative side than the other decorative side. It is envisioned herein that the fibers 210 of the first fibrous web 110, the fibers 310 of the second fibrous web 112, and the fibers 410 of the third fibrous web 114 are not coated with a silicone resin.

[0058] FIG. 6 illustrates an elastic layer 116 that can be included as part of the one or more additional layers 140. In exemplary embodiments, the basis weight of the elastic layer 116 can be about 20 gsm to about 150 gsm, about 50 gsm to about 70 gsm, about 55 gsm to about 65 gsm, or about 60 gsm. The basis weight of the elastic layer 116 can be selected to achieve the desired basis weight of the resulting printed composite nonwoven fabric. Embodiments of the present application contemplate forming the elastic layer 116 from a thermoplastic elastomer, such as a thermoplastic polyurethane (TPU), a thermoplastic polyetherester elastomer (TPEEE), or a combination of a TPU and a TPEEE. The elastic layer can include a spunbond layer, a film, a web, or the like. In certain exemplary embodiments, the elastic layer 116 can include a TPEE spunbond layer. In some exemplary embodiments, spunbond layers have been found to be superior to, for example, films in needlepunching processes while maintaining stretch and recovery. Generally, the elastic layer 116 is selected to impart the desired stretch and recovery properties to the printed composite nonwoven fabric 150 while substantially maintaining its structural integrity during the entanglement process. The present application contemplates that the elastic layer 116 has a color characteristic. In an exemplary embodiment, the color characteristic can be a first color characteristic associated with the fibers 210, 310, and 312, although other color characteristics are contemplated herein.

[0059] 7 illustrates an exemplary manufacturing process for producing an exemplary printed composite nonwoven fabric 150 and incorporating it into an article of clothing 160, which process is designated generally as 700. The description of the manufacturing components in FIG. 7 is merely exemplary and is intended to convey the general characteristics of the various steps of manufacturing process 700. Additionally, although the steps are shown as being performed in sequence, it is contemplated that in embodiments herein, manufacturing process 700 may include any combination of one or more steps, where any step may be repeated or performed in a different order than that shown. At a high level, FIG. 7 shows several individual steps of a manufacturing process 700, including using a printing technique to form a printed component 130 on the inner layer 120 to form a printed layer 170, placing a first surface of the printed layer 170 adjacent to a second surface of the first fiber web 110 to form a composite structure 180, subjecting the composite structure 180 to an entanglement process to form a printed composite nonwoven fabric 150, and incorporating the printed composite nonwoven fabric 150 into a garment 160.

[0060] From step 702, the inner layer 120 is obtained and / or provided. In step 704, a printing part 130 is formed using a printing technique, which is generally described as applying a coloring substance 132 to a first surface of the inner layer 120. Step 706 describes optional and / or additional steps related to the printing technique used, which in this example generally describes a curing process in which the applied coloring substance 132 and inner layer 120 are subjected to heat generated by a heat source 707. In step 708, a first surface of the printing layer 170 is positioned adjacent to a second surface of the first fibrous web 110, and in an optional substep, the opposing second surface of the printing layer 170 is placed adjacent to a first surface of one or more additional layers 140. The first fibrous web 110 and the printing layer 170 form a composite structure 180, which may optionally include one or more additional layers 140. Step 710 generally describes subjecting the composite structure 180 to an entanglement process that includes first conditions 711 and second conditions 712. In an exemplary embodiment, the first conditions 711 are a first pass of needle punching associated with a first set of parameters, and the second conditions 712 are a second pass of needle punching associated with a second set of parameters. The first conditions 711 and the second conditions 712 are merely exemplary, and it is contemplated herein that more or fewer needle passes can be used to achieve the desired printed composite nonwoven fabric. As shown in step 714, after completion of the entanglement process, the composite structure 180 becomes the printed composite nonwoven fabric 150. In step 716, the printed composite nonwoven fabric 150 is then incorporated into the garment 160. Additional aspects related to the steps of the manufacturing process 700 are described in more detail below in connection with example configurations of the printed layer 170 and the printed composite nonwoven fabric 150.

[0061] 8 shows an exemplary printing layer 870 before being combined with the first fiber web 110 and / or one or more additional layers 140. As shown, the printing layer 870 has a first surface 871 and includes an internal fiber web 820 and a printing component 130. In various embodiments, the internal fiber web 820 has one or more characteristics similar to the third fiber web 114, and therefore the fibers 412 forming the internal fiber web 820 may also include one or more characteristics similar to the fibers 410. However, in this example, the fibers 412 are described as having different color characteristics than the fibers 410, and it is contemplated that the color characteristics of the fibers 412 may be configured such that the printing component 130 can be visually distinguished or differentiated from the internal fiber web of the fibers 820. In one exemplary embodiment, the color characteristic of the fibers 412 can be white, while in other exemplary embodiments, the color characteristic can be gray or lighter shades of red, orange, yellow, green, blue, indigo, or purple. The fibers 412 can be solution dyed, and during entanglement with other fiber webs, the fibers 412 can migrate toward one decorative side more than the other decorative side, such that the color characteristic is more visually distinguishable or distinct on one decorative side than the other decorative side. It is also contemplated herein that the fibers 412 are not coated with a silicone resin.

[0062] In other exemplary embodiments, it is contemplated that, similar to the third fibrous web 114, properties associated with the internal fibrous web 820 may be selected to achieve desired final properties of the printed composite nonwoven fabric 150. In exemplary embodiments, the internal fibrous web 820 can be incorporated into the printed composite nonwoven fabric 150 to achieve a desired basis weight, a desired thickness, a desired thermal insulation, a desired pile, etc. Similar to the third fibrous web 114, the basis weight of the internal fibrous web 820 is from about 20 gsm to about 150 gsm, from about 35 grams per square meter (gsm) to about 65 gsm, from about 40 gsm to about 60 gsm, from about 45 gsm to about 55 gsm, or about 50 gsm. The basis weight of the internal fibrous web 820 is set within this range so that, after the internal fibrous web 820 is incorporated with other webs and / or layers, the printed composite nonwoven fabric 150 will have a basis weight within the desired range.

[0063] As described above, the internal fibrous web 820 can be formed of fibers, such as fibers 412 (shown diagrammatically), oriented in a substantially common direction by carding and cross-lapping processes. In an exemplary embodiment, fibers 412 can include PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also contemplated herein. In one exemplary embodiment, fibers 412 can include 100% recycled fibers by weight, such as 100% recycled PET fibers by weight. However, in other embodiments, fibers 412 can include 100% virgin fibers by weight or other combinations of virgin and recycled fibers, as desired. Similar to fibers 410, the staple length of fibers 412 can range from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. In an exemplary embodiment, fibers 412 can include a uniform length, for example, when the fibers are formed from virgin extruded PET or re-extruded PET and cut to a specified length. In other embodiments, the fibers 412 may include variations in staple length, for example, if the fibers 412 are from a chopped fiber origin. Any and all embodiments, and variations thereof, are contemplated as being included within each embodiment of the present application.

[0064] The fibers 412 can have a denier of about 1.2D or greater, about 1.2D to about 3.5D, about 1.3D to about 1.6D, or about 1.5D. Using a denier in this range makes the fibers 412 less likely to break and improves the durability and abrasion resistance of the printed composite nonwoven fabric 150. Because the internal fibrous web 820 is located between the first fibrous web 110 and the second fibrous web 112 during use, a soft feel is less important than, for example, the second fibrous web 112. Selecting a denier in this range while maintaining the basis weight of the internal fibrous web 820 improves the overall coverage and / or opacity of the printed composite nonwoven fabric 150.

[0065] 8 , the printing component 130 is formed with a colorant 134 applied to the first surface 871 by a digital printing method. As described above, the colorant 134 can impart one or more color characteristics to the printing component 130, such as, for example, red, orange, yellow, green, blue, indigo, purple, and / or shades thereof. The printing component 130 is disposed in one or more regions (not shown) of the internal fiber web 820. Although the printing component 130 is depicted as a rectangle, in this exemplary embodiment, the printing component 130 can include one or more shapes, including brand-related shapes such as images, graphics, designs, visual marks, logos, geometric shapes, organic shapes, patterns, letters, numbers, and the like.

[0066] FIG. 9 shows a cross-section of the printing layer 870 of FIG. 8 . As shown, the colorant 134 forming the printing element 130 is located on the first surface 871 of the printing layer 870 and extends partially through the internal fibrous web 820 toward the opposing second surface 872 of the printing layer 870. While the colorant 134 is clearly depicted and displayed on the first surface 871 and the internal fibrous web 820, it should be understood that such depiction of the colorant 134 is exemplary. Accordingly, various embodiments of the present application contemplate that the colorant 134 may be included in the printing layer 870 in a less depicted and / or irregular manner. It is also contemplated that the colorant 134 may include portions that are attached to and / or at least partially absorbed by the fibers 412 of the internal fibrous web 820, as well as other portions that are not attached to the fibers 412.

[0067] 10 shows an alternative cross-section of a printing layer 870 in which the printing components are formed by sublimable dyes 136 instead of colorants. Thus, the sublimable dyes 136 can be applied to the first surface 871 by a sublimation printing process. Due to differences between sublimation and digital printing processes, and differences between the sublimable dyes 136 and the colorants 134, the sublimable dyes 136 are incorporated into the printing layer 870 in a different manner than the colorants 134. As shown, the sublimable dyes 136 are more absorbed into the printing layer 870. That is, the sublimable dyes 136 do not extend above the first surface 871, but extend partially through the interior of the internal fiber web 820 to a greater extent than the colorants 134. 9, the representation of the sublimable dye 136 clearly depicted on the first surface 871 and penetrating the internal fibrous web 820 is exemplary, and it is contemplated that in various embodiments of the present application the sublimable dye 136 may be included in the printing layer 870 in a less depicted and / or irregular manner. It is also contemplated that the sublimable dye 136 may include portions that are bonded to, adhere to, and / or at least partially absorbed by the fibers 412 of the internal fibrous web 820, as well as other portions that are not connected to and / or separate from the fibers 412.

[0068] 11-14 illustrate various embodiments of an exemplary printed composite nonwoven fabric 850 formed by subjecting a first fibrous web 110, a printed layer 870 (e.g., an internal fibrous web 820 including a printed component 130), a second fibrous web 112, and an elastic layer 116 to an entanglement process. FIG. 11 illustrates a first decorative side 851 of the printed composite nonwoven fabric 850 formed at least in part from the first entangled fiber web 810. As best shown in FIG. 12 (showing a cross-section of the printed composite nonwoven fabric 850), the first entangled fiber web 810 includes fiber 210 from the first fibrous web 110, fibers 310 and 312 from the second fibrous web 112, and fiber 412 from the internal fibrous web 820. The second decorative surface side 852 of the printed composite nonwoven fabric 850 is at least partially formed by a second fiber-entangled web 812 mainly including fibers 310 and 312. An internal fiber-entangled web 814 mainly including fibers 412 is located between the first fiber-entangled web 810 and the second fiber-entangled web 812. The internal fiber-entangled web 814 further includes a first-surface printed component 130 disposed adjacent to the second surface of the first fiber-entangled web 810. The elastic layer 116 is also located between the first fiber-entangled web 810 and the second fiber-entangled web 812 and adjacent to the internal fiber-entangled web 814.

[0069] In exemplary embodiments, the printed component 130 is at least partially visible through the first fiber entangled web 810, such that the printed component 130 is visible on the first decorative surface side 851 of the printed composite nonwoven fabric 850 due to entanglement parameters, characteristics of the fibers 412, and / or characteristics of the colorant 134. Additionally, for the same reasons, different regions of the internal fiber entangled web 814 and different portions of the printed component 130 are incorporated differently into the first fiber entangled web 810. In exemplary embodiments, the first fiber entangled web 810 may be at least partially translucent. In other exemplary embodiments, the parameters of the entanglement process may be configured to migrate discrete particles of colorant and / or sublimable dye and fibers containing the colorant and / or sublimable dye that form the printed component 130 to the first fiber entangled web 810 and / or the first decorative surface side 851.

[0070] Figure 13 shows an enlarged cross-section of the printed composite nonwoven fabric 850 of Figure 12. Figure 13 shows a first region 821 of the internally entangled fiber web 814, including an example configuration of the fibers 210, 310, 312, and 412 and the printing component 130. The first region 821 includes a first portion 831 of the printing component 130, and in the first region 821, at least some of the colorant 134 is attached to the fiber 412 to form the fiber 414. The fibers 412 and 414 and the fibers 310 and 312 are incorporated into the first entangled fiber web 810. The fibers 414 are incorporated such that at least one fiber 414 extends to the first decorative surface side 851 of the printed composite nonwoven fabric 850. Also, the first portion 831 of the printing element 130 comprises at least some discrete particles of the colorant 134 that are not attached to the fibers 412. Thus, in the first region 821, the first decorative surface side 851 is formed, at least in part, by the colorant 134 and the fibers 414 in the first portion of the printing element 130.

[0071] FIG. 14 shows an enlarged cross-section of the printed composite nonwoven fabric 850 of FIG. 12. FIG. 14 illustrates a second region 822 of the internally entangled fiber web 814, showing an example configuration of fibers 210, 310, 312, and 412 and the printing component 130. The second region 822 includes a second portion 832 of the printing component 130. Similar to the first region 821, in the second region 822, the colorant 134 adheres to fibers 412 to form fibers 414, and is also present as discrete particles not adhered to fibers 412. However, unlike the first region 821, in the second region 822, the fibers 412 and 414 are excluded from the first entangled fiber web 810. The fibers 210, 310, and 312 have similar configurations in the first region 821 and the second region 822. Specifically, at least a portion of the fibers 210 extend into the internal fiber-entangled web 814, and the remaining fibers 210 extend through the internal fiber-entangled web 814 and the elastic layer 116 and further into the second fiber-entangled web 812. Also, at least a portion of the fibers 310 and 312 extend through the elastic layer 116 and the internal fiber-entangled web 814 into the first fiber-entangled web 810.

[0072] FIG. 15 illustrates an exemplary printing layer 970 prior to being combined with the first fibrous web 110 and / or one or more additional layers 140. As illustrated, the printing layer 970 has a first surface 971 and includes a spunlace layer 920 and a printing component 130. In various embodiments, the spunlace layer 920 is configured to provide a desired aesthetic to the printing component 130; thus, the spunlace layer 920 may include one or more features suitable for printing and supporting the printing component 130. In exemplary embodiments, the spunlace layer 920 may be configured such that the printing component 130 is visually distinguishable or distinct from the spunlace layer 920. In one exemplary embodiment, the color characteristic of the spunlace layer 920 may be white; in other exemplary embodiments, the color characteristic may be gray or a lighter shade of red, orange, yellow, green, blue, indigo, or purple. In other exemplary embodiments, the spunlace layer 920 can include spunlace fibers, which may be in the form of a web. In other example embodiments, the basis weight of the spunlace layer 920 can be from about 20 gsm to about 150 gsm, from about 30 gsm to about 50 gsm, from about 35 gsm to about 45 gsm, or about 40 gsm.

[0073] In further exemplary embodiments, the spunlace layer 920 is expected to be formed of PET. These embodiments also contemplate that the spunlace layer 920 includes PET fibers (recycled or virgin), although other virgin and recycled fiber types (e.g., polyamide, cotton, etc.) are also contemplated. In one exemplary embodiment, the fibers of the spunlace layer 920 can include 100% recycled fibers by weight, such as 100% recycled PET fibers by weight. However, in other embodiments, the fibers of the spunlace layer 920 can include 100% virgin fibers by weight or other combinations of virgin and recycled fibers, as desired. In yet other embodiments, the staple length of the fibers of the spunlace layer 920 can be longer than the staple length of the fibers included in the other fibrous webs of the printed composite nonwoven fabric 950. In one exemplary embodiment, the fibers of the spunlace layer 920 can include variations in staple length, while in other exemplary embodiments, the fibers of the spunlace layer 920 can be continuous throughout the spunlace layer 920. In yet another embodiment, it is contemplated that the fibers of the spunlace layer 920 can include a denier configured to provide properties of the spunlace layer 920 that provide the desired aesthetics for the printed component 130. In another exemplary embodiment, the fibers of the spunlace layer 920 can be configured to impart hydrophobic properties to the spunlace layer 920 and, in turn, to impart hydrophobic properties to the printed composite nonwoven fabric 950. Any and all embodiments, and variations thereof, are contemplated as being included within each embodiment of the present application.

[0074] Returning to the example of FIG. 15 , the printing component 130 is formed by a sublimation dye 136 applied to the first surface 971 by a dye sublimation process. As described above, the sublimation dye 136 can provide the printing component 130 with one or more color characteristics, such as red, orange, yellow, green, blue, indigo, purple, and / or shades thereof. Additionally, the printing component 130 is located in one or more regions (not shown) of the spunlace layer 920. Even though the printing component 130 is depicted as a rectangle, in this exemplary embodiment, it is envisioned that the printing component 130 can include one or more shapes, including brand-related shapes such as images, graphics, designs, visual marks, logos, geometric shapes, organic shapes, patterns, letters, numbers, and the like.

[0075] Figure 16 shows a cross-sectional view of the printing layer 970 of Figure 15. As shown, the sublimable dye 136 is applied to a first side 971 and is at least partially absorbed into the spunlace layer 920 toward the opposing second side 972 of the printing layer 970. While the sublimable dye 136 is clearly depicted on the first side 971 and appears throughout the printing layer 970, it should be understood that this depiction of the sublimable dye 136 is for illustrative purposes only. Accordingly, embodiments of the present application contemplate the sublimable dye 136 being included in the printing layer 970 in a less depicted and / or irregular manner. It is envisioned that the sublimable dye 136 includes portions that are bonded to, adhere to, and / or at least partially absorbed into the spunlace layer 920 and its fibers, and further includes other portions that are not connected to and / or separate from the spunlace layer 920 and its fibers.

[0076] FIG. 17 illustrates an alternative cross-section of a printing layer 970 in which the printing element 130 is formed with a colorant 134 instead of a sublimable dye 136. Thus, the colorant 134 can be applied to the first surface 971 by a digital printing process. Due to differences between digital and sublimation printing processes, and between the colorant 134 and the sublimable dye 136, the colorant 134 is incorporated into the printing layer 970 in a different manner than the sublimable dye 136. As illustrated, the colorant 134 extends partially onto the first surface 971 of the printing layer 970 and partially through the spunlace layer 920 toward the opposing second surface 972 of the printing layer 970. While the colorant 134 is clearly depicted and displayed on the first surface 971 and the spunlace layer 920, it should be understood that such display of the colorant 134 is illustrative. Accordingly, embodiments of the present application contemplate that the colorant 134 may be included in the printing layer 970 in a less patterned and / or irregular manner. It is also contemplated that the colorant 134 may include portions that are at least partially attached to and / or absorbed by the spunlace layer 920 and its fibers, and may further include other portions that are not connected to the spunlace layer 920 and its fibers.

[0077] 18-21 illustrate various embodiments of an exemplary printed composite nonwoven fabric 950 formed by subjecting a first fibrous web 110, a printed layer 970 (e.g., a spunlace layer 920 including a printed component 130), a second fibrous web 112, a third fibrous web 114, and an elastic layer 116 to an entanglement process. FIG. 18 illustrates a first decorative side 951 of the printed composite nonwoven fabric 950 formed at least in part from the first entangled fiber web 910. As best shown in FIG. 19 (showing a cross-section of the printed composite nonwoven fabric 950), the first entangled fiber web 910 includes fibers 210 from the first fibrous web 110, fibers 310 and 312 from the second fibrous web 112, and fibers 410 from the third fibrous web 114. The second decorative surface side 952 of the printed composite nonwoven fabric 950 is at least partially formed by a second entangled fiber web 912 primarily comprising fibers 310 and 312. A third entangled fiber web 914 primarily comprising fiber 410 is located between the first entangled fiber web 910 and the second entangled fiber web 912. The spunlace layer 920 is located between the first entangled fiber web 910 and the third entangled fiber web 914, and further includes a first-surface printed component 130 disposed adjacent to the second surface of the first entangled fiber web 910. The elastic layer 116 is located between the second entangled fiber web 912 and the third entangled fiber web 914.

[0078] In an exemplary embodiment, the printed component 130 is at least partially visible through the first fiber-entangled web 910 such that the printed component 130 is visible on the first decorative side 951 of the printed composite nonwoven fabric 950 due to entanglement parameters, characteristics of the fibers 110, the spunlace layer 920, and / or characteristics of the sublimable dyes 136. Additionally, for the same reasons, different regions of the spunlace layer 920 and different portions of the printed component 130 are incorporated into the first fiber-entangled web 910 in different ways.

[0079] FIG. 20 shows an enlarged cross-section of the printed composite nonwoven fabric 950 of FIG. 19. FIG. 20 illustrates a first region 921 of the spunlace layer 920, including fibers 210, 310, 312, and 410, fiber 416 of the spunlace layer 920, and an example configuration of the printing component 130. The first region 921 includes a first portion 931 of the printing component 130, and in the first region 921, at least some sublimable dyes 136 are attached to the fibers 416 to form fibers 418. Additionally, fibers 416 and 418 and fibers 310, 312, and 410 are incorporated into a first entangled fiber web 910. The fibers 418 are incorporated such that at least one fiber 418 extends to a first decorative surface 951 of the printed composite nonwoven fabric 950. Also, the first portion 931 of the printing element 130 includes at least some discrete particles of the sublimable dye 136 that are not attached to the fibers 416. Thus, in the first region 921, the first decorative surface side 951 is at least partially formed by the sublimable dye 136 and the fibers 418 in the first portion 931 of the printing element 130.

[0080] FIG. 21 shows an enlarged cross-section of the printed composite nonwoven fabric 950 of FIG. 19. FIG. 21 illustrates a second region 922 of the spunlace layer 920, showing an example configuration of the fibers 210, 310, 312, 410, 416, and 418 and the printing component 130. The second region 922 includes a second portion 932 of the printing component 130. Like the first region 921, in the second region 922, the sublimable dye 136 is attached and / or bonded to the fiber 416 to form the fiber 418, and is also included as discrete particles not attached to the fiber 416. However, unlike the first region 921, in the second region 922, the fibers 416 and 418 are excluded from the first entangled fiber web 910. The fibers 210, 310, 312, and 410 have similar configurations in the first region 921 and the second region 922. Specifically, at least a portion of fibers 210 extend through spunlace layer 920 into the third entangled fiber web 914, with the remaining fibers 210 extending further through elastic layer 116 into the second entangled fiber web 912. Additionally, at least a portion of fibers 310 and 312 extend through elastic layer 116, third entangled fiber web 914, and spunlace layer 920 into the first entangled fiber web 910. Additionally, at least a portion of fibers 410 extend through spunlace layer 920 into the first entangled fiber web 910, with the remaining fibers 410 extending through elastic layer 116 into the second entangled fiber web 912.

[0081] 22 illustrates an exemplary lower-body apparel item 1000 in the form of an outer garment having short sleeves, although other configurations are contemplated, such as a jacket, hoodie, long-sleeved shirt, sleeveless shirt, vest, etc. As shown, the lower-body apparel item 1000 is formed from a first composite nonwoven fabric 1010 and a second composite nonwoven fabric 1020. Aspects of the present application contemplate that the first composite nonwoven fabric 1010 and / or the second composite nonwoven fabric 1020 may have the same or similar characteristics as any of the printed composite nonwoven fabrics 150, 850, 950. Although not shown, in each embodiment of the present application, the first composite nonwoven fabric 1010 and / or the second composite nonwoven fabric 1020 may include any of the printed layers 170, 870, 970, and further, in each embodiment of the present application, it is also contemplated that the lower body apparel item 1000 may include the printed component 130.

[0082] The lower body apparel 1000 includes several seam locations, where the first composite nonwoven fabric 1010 and / or the second composite nonwoven fabric 1020 are joined to each other or to other portions of the lower body apparel 1000 (e.g., sleeve portions, collar portions, etc.). A first seam location 1002 is located near a side portion of the lower body apparel 1000 (e.g., a side seam), a second seam location 1004 is located near an upper portion of the lower body apparel 1000 (e.g., a seam extending between the collar and sleeve), a third seam location 1006 is located near the collar portion of the lower body apparel 1000, and a fourth seam location 1008 is located near a sleeve portion of the lower body apparel 1000.

[0083] 23 shows an exemplary lower-body apparel item 1100 in the form of a lower-body garment. While the lower-body apparel item 1100 is shown as pants in this application, it is contemplated that it may be in the form of pants, three-quarter length pants, tights, etc. As shown in the figure, the lower-body apparel item 1100 is formed from a first composite nonwoven fabric 1110 and a second composite nonwoven fabric 1120. In each embodiment of the present application, it is contemplated that the first composite nonwoven fabric 1110 and / or the second composite nonwoven fabric 1120 may have the same or similar characteristics as any of the printed composite nonwoven fabrics 150, 850, and 950. Although not shown, in each embodiment of the present application, the first composite nonwoven fabric 1110 and / or the second composite nonwoven fabric 1120 may include any of the printed layers 170, 870, 970, and further, in each embodiment of the present application, it is also contemplated that the lower body apparel item 1100 may include the printed component 130.

[0084] The lower body apparel 1100 includes several seam locations where the first composite nonwoven fabric 1110 and / or the second composite nonwoven fabric 1120 are joined to each other or to other portions of the lower body apparel 1100 (e.g., waist, pocket, etc.). A first seam location 1102 is located near an outer portion (e.g., a side seam) of the lower body apparel 11000, a second seam location 1104 is located near an inner portion (e.g., an inner seam) of the lower body apparel 11000, a third seam location 1106 is located near a waist portion (e.g., a belt) of the lower body apparel 1100, and a fourth seam location 1108 is located near a pocket of the lower body apparel 1100.

[0085] Figure 24 shows a cross-sectional view of the upper body apparel item of Figure 22, illustrating an example of a first seam 1001. Generally, the first seam 1001 is formed by entanglement of fibers 1030 of the first composite nonwoven fabric 1010 with fibers 1040 of the second composite nonwoven fabric 1020. The first composite nonwoven fabric 1010 also includes a first entangled fiber web 1031 that at least partially forms a first decorative side 1011 of the first composite nonwoven fabric 1010, a second entangled fiber web 1032 that at least partially forms an opposing second decorative side 1012 of the first composite nonwoven fabric 1010, and a third entangled fiber web 1033 located between the first entangled fiber web 1031 and the second entangled fiber web 1032. Similarly, the second composite nonwoven fabric 1020 further includes a first entangled fiber web 1041 at least partially forming a first decorative surface side 1021 of the second composite nonwoven fabric 1020, a second entangled fiber web 1042 at least partially forming an opposing second decorative surface side 1022 of the second composite nonwoven fabric 1020, and a third entangled fiber web 1043 located between the first entangled fiber web 1041 and the second entangled fiber web 1042. In an exemplary embodiment, forming the first seam 1001 may include positioning a first edge 1014 of the first composite nonwoven fabric 1010 adjacent to a second edge 1024 of the second composite nonwoven fabric 1020 such that the first decorative surface side 1111 of the first composite nonwoven fabric 1010 is adjacent to or in contact with the first decorative surface side 1021 of the second composite nonwoven fabric 1020. Then, while the first composite nonwoven fabric 1010 and the second composite nonwoven fabric 1020 are held in position, an entanglement process is applied to the first edge 1014 and the second edge 1024 so that fibers 1030 obtained from either the first entangled fiber web 1031, the second entangled fiber web 1032, or the third entangled fiber web 1033 are entangled with fibers 1040 obtained from either the first entangled fiber web 1041, the second entangled fiber web 1042, or the third entangled fiber web 1043.

[0086] Figure 25 shows a cross-sectional view of the lower-body apparel item 1100 of Figure 23, illustrating an example of a second seam 1101. Generally, the second seam 1101 is formed by entanglement of fibers 1130 of the first composite nonwoven fabric 1110 with fibers 1140 of the second composite nonwoven fabric 1120. The first composite nonwoven fabric 1110 also includes a first entangled fiber web 1131 that at least partially forms a first decorative side 1111 of the first composite nonwoven fabric 1110, a second entangled fiber web 1132 that at least partially forms an opposing second decorative side 1112 of the first composite nonwoven fabric 1110, and a third entangled fiber web 1133 located between the first entangled fiber web 1131 and the second entangled fiber web 1132. Similarly, the second composite nonwoven fabric 1120 includes a first entangled fiber web 1141 at least partially forming a first decorative facing side 1121 of the second composite nonwoven fabric 1120, a second entangled fiber web 1142 at least partially forming an opposing second decorative facing side 1122 of the second composite nonwoven fabric 1120, and a third entangled fiber web 1143 located between the first entangled fiber web 1141 and the second entangled fiber web 1142. In an exemplary embodiment, forming the second seam 1101 can include positioning a first edge 1114 of the first composite nonwoven fabric 1110 adjacent to a second edge 1124 of the second composite nonwoven fabric 1120 such that the second decorative facing side 1112 of the first composite nonwoven fabric 1110 is adjacent to or contacts the first decorative facing side 1121 of the second composite nonwoven fabric 1120. Then, while the first composite nonwoven fabric 1110 and the second composite nonwoven fabric 1120 are held in their positions, an entanglement process is applied to the first edge portion 1114 and the second edge portion 1124 so that the fibers 1130 obtained from either the first fiber entangled web 1131, the second fiber entangled web 1132, or the third fiber entangled web 1133 are entangled with the fibers 1140 obtained from either the first fiber entangled web 1141, the second fiber entangled web 1142, or the third fiber entangled web 1143.

[0087] Figure 26 shows an exploded view of an example composite nonwoven fabric 1250 for use in a manufacturing process that provides aesthetic and / or functional properties to the composite nonwoven fabric 1250, which is provided in an article of apparel incorporating the composite nonwoven fabric 1250. According to various embodiments herein, the composite nonwoven fabric 1250 can be formed by performing an entanglement process on the first fibrous web 110, the second fibrous web 112, and the elastic layer 116. Thus, in Figure 26, the composite nonwoven fabric 1250 is depicted after the entanglement process, but before the manufacturing process to form debossed or pleated structures.

[0088] As shown, the composite nonwoven fabric includes a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first and second entangled fiber webs. The first fibrous web 1210 comprises fibers 210 from the first fibrous web 110 and at least partially forms a first outward-facing side 1251 of the composite nonwoven fabric 1250. Similarly, the second fibrous web 1212 comprises fibers 310, 312 from the second fibrous web 112 and at least partially forms an opposing second outward-facing side 1252 of the composite nonwoven fabric 1250 (not shown in FIG. 26). The elastic layer may be formed of a thermoplastic elastomer, such as thermoplastic polyurethane (TPU), thermoplastic polyetherester elastomer (TPEE), or a combination of TPU and TPEE. In certain exemplary embodiments, the elastic layer 1216 may incorporate a TPEE meltblown layer.

[0089] Embodiments herein contemplate that fibers 210, 310, 312 may include any of the respective properties described herein. Such properties of fibers 210, 310, 312 may be tailored and / or selectively included to achieve the final properties desired for composite nonwoven fabric 1250. Similar embodiments herein contemplate that elastic layer 1216 may include any of the properties discussed herein. Furthermore, such properties of elastic layer 1216 may be tailored and / or selectively included to achieve the final properties desired for composite nonwoven fabric 1250. Any and all embodiments, and variations thereof, are contemplated as being included within each embodiment herein.

[0090] Although not described, embodiments herein contemplate that the composite nonwoven fabric 1250 may include one or more additional entangled webs of fibers and / or layers, which may be any of the entangled webs of fibers and / or layers discussed herein. In more specific embodiments, any of the one or more additional entangled webs and / or layers of the composite nonwoven fabric 1250 may be the first entangled fiber web 810, 910, 1210, the second entangled fiber web 812, 912, 1212, the inner entangled fiber web 814, the third entangled fiber web 914, the elastic layer 116, 1216, the inner layer 120, the printing layer 170, 870, 970, or the spunlace layer 920. Additional embodiments contemplate that the properties of the entangled web may be tailored and / or selectively include one or more additional fibers and / or layers to achieve desired final properties of the composite nonwoven fabric 1250. In further embodiments, it is contemplated that the arrangement of one or more additional fiber-entangled webs and / or layers, first fiber-entangled web 1210, second fiber-entangled web 1212, and elastic layer 1216 may be adjusted and / or configured to achieve desired final properties of composite nonwoven fabric 1250.

[0091] In embodiments of the present invention, it is contemplated that one or more properties of the first entangled fiber web 1210, the second entangled fiber web 1212, and / or the elastic layer 1216 may be configured such that the composite nonwoven fabric 1250 is suitable for a manufacturing process that forms debossed features on the composite nonwoven fabric 1250. Examples of properties of the first entangled fiber web 1210, the second entangled fiber web 1212, and / or the elastic layer 1216 include, but are not limited to, melt temperature, thickness, color, basis weight, material composition, hydrophobicity, hydrophilicity, fiber composition, fiber table length, fiber denier, etc.

[0092] In certain exemplary embodiments, the first entangled fiber web 1210, the second entangled fiber web 1212, and the elastic layer 1216 each comprise a material having a melting temperature. While not shown, in the example of Figure 26, the first entangled fiber web 1210 comprises a first material having a first melting temperature, the second entangled fiber web 1212 comprises a second material having a second melting temperature, and the elastic layer 1216 comprises a third material having a third melting temperature that is approximately 40°C lower than the first melting temperature of the first material. Additional embodiments herein contemplate a first melting temperature of the first material of about 210°C to about 190°C, about 205°C to about 195°C, or about 200°C, and further contemplate a second melting temperature of the second material of about 210°C to about 190°C, about 205°C to about 195°C, or about 200°C. These embodiments also contemplate a third melting temperature of the third material of about 170°C to about 150°C, about 165°C to about 155°C, or about 160°C. In certain exemplary embodiments, the first melting temperature of the first material is about 200°C, the second melting temperature of the second material is about 200°C, and the third melting temperature of the third material is about 160°C. As used herein, the term "about" generally means within ±10% of the indicated value. It is further contemplated in embodiments herein that the first, second, and third materials and their respective melting temperatures may be associated with different material layers. For example, the first entangled fiber web 1210 may be formed of a second material or a third material. Similarly, the second entangled fiber web 1212 may be formed of a first material or a third material. Similarly, the elastic layer 1216 may be formed of a first material or a second material. In a further embodiment of the present application, a layer of a material formed of a third material used to form the first entangled fiber web 1210, the second entangled fiber web 1212, or the elastic layer 1216 is contemplated to be positioned between other layers formed of the first and second materials. Furthermore, this embodiment contemplates that the layer formed of a lower melting temperature third material may include a color (referred to herein as a "third color") that may be imparted to the fibers forming the layer during an extrusion process or a post-extrusion process, such as textile printing.

[0093] 27A-28 show various embodiments of a composite nonwoven fabric 1250 after a manufacturing process has been performed to form debossed features 1230 on a first outward-facing side 1251 of the composite nonwoven fabric 1250. In FIGS. 27A and 27B, the composite nonwoven fabric 1250 is shown schematically to represent the color characteristics of the first entangled fiber web 1210, the second entangled fiber web 1212, and the elastic layer 1216. Thus, in FIG. 27A, the diagonal lines represent the first color 1241 of the first entangled web of fibers 1210, and the dots represent the third color 1243 of the elastic layer 1216. In FIG. 27B, the horizontal lines represent the second color 1242 of the second wound web 1212.

[0094] 27A illustrates a first outward-facing side 1251 of a composite nonwoven fabric 1250, and as shown, the debossed portions 1230 are visible on the first outward-facing side 1251. The composite nonwoven fabric 1250 includes a first region 1221 and a second region 1222, which are also visible on the first outward-facing side 1251. In the first region 1221, the first outward-facing side 1251 is at least partially formed by the first entangled fiber web 1210, such that the first color 1241 of the first entangled fiber web 1210 is visible on the first outward-facing side 1251 in the first region 1221. In the second region 1222, the first outward-facing side 1251 is at least partially formed by the debossed portions 1230, such that the debossed portions 1230 are visible on the first outward-facing side 1251 in the second region 1222. Additionally, because at least some of the fibers 210 of the first entangled fiber web 1210 are integrated within the debossed portions 1230 in the second region 1222, the third color 1243 of the elastic layer 1216 is visible on the first outward side 1251 in the second region 1222. The third color 1243 may be added by a sustainable inkless process during the extrusion of the fibers that may form the elastic layer 1016 (e.g., also referred to as coat dyeing), or the third color 143 may be added after the extrusion of the fibers that may form the elastic layer 1016 by, for example, a textile printing process as contemplated herein.

[0095] 27B illustrates the opposing second outward-facing side 1252 of the composite nonwoven fabric 1250, and as shown, the debossed portions 1230 are not visible on the opposing second outward-facing side 1252. The opposing second outward-facing side 1252 is at least partially formed by the second entangled fiber web 1212 in the first region 1221 and the second region 1222, unlike the first outward-facing side 1251. This allows the second color 1242 of the second entangled fiber web 1212 to be visible on the opposing second outward-facing side 1252 in the first region 1221 and the second region 1222.

[0096] It is contemplated here that first color 1241 may be different from third color 1243 and / or different from second color 1242 and third color 1243. In another exemplary embodiment, second color 1242 may be different from third color 1243. In another exemplary embodiment, first color 1241 may be substantially identical to second color 1242, and first color 1241 may be substantially identical to third color 1243. According to the embodiments discussed herein, a color may be determined to be different from another color. A color may also be determined to be “similar” or “substantially identical” to another color based on the difference between the numeric color value of the color and a numeric color value that is a percentage of one of the numeric color values. A first color and a second color are “substantially identical” if the percentage difference between the numeric color value of the first color and the numeric color value of the second color is 5% or less.

[0097] 28 is a cross-sectional view of a composite nonwoven fabric 1250. As shown, the second region 1222 is debossed relative to the first region 1221. In other words, the thickness of the composite nonwoven fabric 1250 in the first region 1221 is greater than the thickness of the composite nonwoven fabric 1250 in the second region 1222. More specifically, the thickness 1262 of the debossed portion 1230 is approximately 50% less than the thickness 1261 of the first entangled fiber web 1210 and the elastic layer 1216 in the first region 1221. Additionally, the thickness 1263 of the second fibrous web 1212 in the composite nonwoven fabric 1250 is within approximately 95% of the thickness of each of the first region 1221 and the second region 1222. In other words, the thickness of the second entangled fiber web 1212 in the composite nonwoven fabric 1250 in the first region 1221 is within about 95% of the thickness of the second entangled fiber web 1212 in the composite nonwoven fabric 1250 in the second region 1222.

[0098] In various embodiments, the debossed portion 1230 may refer to a portion of the second region 1222 that includes the first entangled fiber web 1210 and the elastic layer 1216, but not the second entangled fiber web 1212. In further embodiments, it is contemplated that the relationship and / or configuration of the first entangled web 1210 and the elastic layer 1216 in the debossed portion 1230 may be described differently. In one exemplary embodiment, the debossed portion 1230 may include a film-like elastic layer 1216 that envelops the plurality of fibers 212 from the first entangled fiber web 1210. As used herein, when describing the fibrous structure of the debossed portion, the term "enveloping" means that at least half of the fiber surface area is surrounded by the film form of the elastic layer. In another exemplary embodiment, the debossed portion 1230 may include a matrix structure formed of the plurality of fibers 212 and the film.

[0099] 26A-28 depict the first entangled fiber web 1210, the second entangled fiber web 1212, and the elastic layer 1216 as distinct layers, it is envisioned that the first entangled fiber web 1210 and the second entangled fiber web 1212 are entangled with one another and extend through the elastic layer 1216 to form a cohesive structure. However, in one exemplary embodiment, the first entangled fiber web 1210, the second entangled fiber web 1212, and the elastic layer 1216 each retain the characteristics of a distinct layer in the first region 1221 of the composite nonwoven fabric 1250. Conversely, in the second region 1222 of the composite nonwoven fabric 1250, only the second entangled fiber web 1212 retains the characteristics of its own layer, as the fibers of the first entangled fiber web 1210 are integrated into the elastic layer 1216 at the debossed portions 1230.

[0100] FIG. 29 illustrates an exemplary manufacturing process, generally designated 1300, for forming debossed portion 1230 of composite nonwoven fabric 1250 and incorporating it into apparel 1320. It should be understood that any description of the manufacturing of a part in FIG. 29 is exemplary and intended to convey the general characteristics of the various steps of manufacturing process 1300. Additionally, while the steps of manufacturing process 1300 are described as being performed sequentially, it is contemplated in embodiments herein that manufacturing process 1300 may include any combination of one or more steps, and that any steps may be performed repeatedly in an order different from that described. At a high level, FIG. 29 generally illustrates various steps of manufacturing process 1300, including applying one or more of heat and pressure to second region 1222 of first outward-facing side 1251 of composite nonwoven fabric 1250 to provide graphic 1270.

[0101] From step 1302, a composite nonwoven fabric 1250 is obtained and / or provided. The composite nonwoven fabric 1250 includes a first entangled fiber web 1210 having a first color 1241, a second entangled fiber web 1212 having a second color 1242 (not visible), and an elastic layer 1216 having a third color 1243 positioned between the first entangled fiber web 1210 and the second entangled fiber web 1212. The first color 1241 and the third color 1243 are shown similarly to Figures 27A and 27B.

[0102] In step 1304, one or more of heat and pressure 1314 (illustrated by arrows) are applied to the second region 1222 on the first outward-facing side 1251 of the composite nonwoven fabric 1250 such that the elastic layer 1216 forms a film that envelops the plurality of fibers from the first fiber-entangled web 1210. In the example of FIG. 29 , a debossing tool 1310 is used to apply the one or more of heat and pressure 1314 to the second region 1222 of the composite nonwoven fabric 1250. The debossing tool 1310 is only one example, and other tooling methods are contemplated herein, including, for example, lasers, ultrasonic welders, etc. The debossing tool 1310 includes a tooling piece 1312 and is configured to transfer heat to the tooling piece 1312 and / or portions of the first outward-facing side 1251 that contact or nearly contact a surface (not visible) of the tooling piece 1312 during the application of the one or more of heat and pressure 1314. Additionally, although tooling piece 1312 is depicted as having a circular shape, it is contemplated in embodiments herein that tooling piece 1312 and / or its surface may include designs, visual marks, one or more shapes, and / or one or more linear or curved portions (e.g., signs, geometric shapes, organic shapes, patterns, letters, numbers, etc.) associated with the brand's commercial products.

[0103] To begin the application of one or more of the heat and pressure 1314, the debossing tool 1310 is positioned at the second region 1222 such that the tooling piece 1312 and / or its surface is in contact or near contact with the first outward-facing side 1251. The debossing tool 1310 is then held in place as one or more of the heat and pressure 1314 is applied to the second region 1222 of the first outward-facing side 1251 of the composite nonwoven fabric 1250. To end the application of one or more of the heat and pressure 1314, the debossing tool 1310 is repositioned at the second region 1222 such that the tooling piece 1312 and its surface is spaced away from the first outward-facing side 1251.

[0104] In an exemplary embodiment, the debossing tool 1310 is configured to apply one or more of heat and pressure 1314 at a temperature and duration sufficient to cause the elastic layer 1216 to form a film that envelops the plurality of fibers from the first entangled fiber web 1210. In other exemplary embodiments, the debossing tool 1310 is configured to apply heat to the second region 1222 of the first outward-facing side 1251 at a temperature of about 210°C to about 160°C, about 205°C to about 165°C, about 200°C to about 170°C, about 195°C to about 175°C, about 190°C to about 180°C, about 200°C to about 190°C, or about 195°C for about 80 seconds to about 20 seconds, about 75 seconds to about 25 seconds, about 70 seconds to about 30 seconds, about 65 seconds to about 35 seconds, about 60 seconds to about 40 seconds, about 55 seconds to about 45 seconds, or about 50 seconds. In certain exemplary embodiments, the debossing tool 1310 is configured to apply heat to the second region 1222 of the first outward-facing side 1251 at a temperature of about 190°C to about 170°C for about 32 seconds to about 28 seconds. In another specific exemplary embodiment, the debossing tool 1310 is configured to apply heat to the second region 1222 of the first outward-facing side 1251 at a temperature of about 180° C. for about 30 seconds. As used herein, the term “about” generally means within ±10% of the indicated value. In yet another specific exemplary embodiment, one or more of the heat and pressure 1314 are applied simultaneously.

[0105] Step 1304 further includes positioning the composite nonwoven fabric 1250 on the deformable surface 1318 such that the opposing second outwardly facing side 1252 of the composite nonwoven fabric 1250 is disposed adjacent to the deformable surface 1318 during the application of the one or more of heat and pressure 1314. The deformable surface 1318 is configured to inhibit and / or reduce any residual heat contact with the opposing second outwardly facing side 1252 during the application of the one or more of heat and pressure 1314. Accordingly, the deformable surface 1318 is insulating and formed of a highly insulating material (e.g., rubber foam). Furthermore, the deformable surface 1318 is configured to deform to correspond to the shape of the tooling piece 1312 and / or its surface during the application of the one or more of heat and pressure 1314.

[0106] In step 1306, the application of one or more of heat and pressure 1314 is discontinued, leaving the elastic layer 1216 in the second region 1222 of the composite nonwoven fabric 1250 to form a film 1330 that encapsulates the plurality of fibers from the first entangled fiber web 1210. This causes the first outward-facing side 1251 in the second region 1222 to be colored as the third color 1243, and the first outward-facing side 1251 in the first region 1221 to be colored as the first color 1241. Additionally, the second region 1222 forms a graphic 1270 on the first outward-facing side 1251 of the composite nonwoven fabric 1250. The graphic 1270 has a shape corresponding to the shape of the tooling piece 1312 and / or its surface. 29, even though graphic 1270 is circular, embodiments herein contemplate that graphic 1270 may include a design, visual mark, one or more shapes, and / or one or more linear or curved portions (e.g., signs, geometric shapes, organic shapes, patterns, letters, numbers, etc.) associated with a brand's commercial products. These embodiments also contemplate that a figure having a different shape than figure 1270 may be formed using a debossing tool having a tooling piece having a different shape than tooling piece 1312.

[0107] In one exemplary embodiment, the thickness of the composite nonwoven fabric 1250 in the second region 1222 is about 50% less than the thickness of the composite nonwoven fabric 1250 in the first region 1221. In other exemplary embodiments, the thickness of the composite nonwoven fabric in the second region 1222 is about 70% to about 30%, about 65% to about 35%, about 60% to about 40%, or about 55% to about 45% less than the thickness of the composite nonwoven fabric 1250 in the first region 1221. In further exemplary embodiments, the thickness of the second entangled fiber web 1212 in the composite nonwoven fabric 1250 is within about 95% to about 85%, about 90%, or about 95% of each other in the first region 1221 and the second region 1222. As used herein, the term "about" generally means within ±10% of the indicated value.

[0108] Then, in step 716, the printed composite nonwoven fabric 150 is incorporated into an article of clothing 160. The composite nonwoven fabric 1250 can form at least a portion of an article of clothing 1320, and in an exemplary embodiment, it is envisioned that the composite nonwoven fabric 1250 is a panel of the article of clothing 1320 that is combined with one or more other textiles (e.g., composite nonwoven fabrics, woven fabrics, and / or knit fabrics) to form the article of clothing 1320.

[0109] 30A and 30B illustrate an exemplary upper body article of clothing 1400 including a composite nonwoven fabric 1450. The outer garment of clothing 1400 is in the form of a long-sleeved outer garment as shown in FIG. 30A to illustrate that the outer garment of clothing 1400 may be in the form of a jacket, hoodie, short-sleeved shirt, etc. FIG. 30B illustrates that the sleeveless outer garment of clothing 1400 may be in the form of a sleeveless shirt, vest, etc. Clothing 2800 includes an outward-facing surface 2810 and an inward-facing surface (not visible). As shown, the outward-facing surface 1401 is the outermost surface of upper body clothing 1400, and similarly, the inward-facing surface 1402 is the innermost surface of upper body clothing 1400. Furthermore, the first outward-facing side 1451 of the composite nonwoven fabric 1450 at least partially forms the outward-facing surface 1401 of the upper body apparel 1400, and the opposing second outward-facing side 1452 of the composite nonwoven fabric 1450 at least partially forms the inward-facing surface 1402 of the upper body apparel 1400.

[0110] Composite nonwoven fabric 1450 includes the same features as composite nonwoven fabric 1250, but includes additional regions with additional debossed sections. Thus, composite nonwoven fabric 1450 includes first region 1421, second region 1422, and third region 1423. First region 1421 includes a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first and second entangled fiber webs. In second region 1422, composite nonwoven fabric 1450 includes a first debossed section 1431 and a second entangled fiber web, and third region 1423 includes a second debossed section 1432 and the first entangled fiber web.

[0111] The first debossed portion 1431 has the same characteristics as the debossed portion 1230 and, therefore, is formed on the first outward-facing side 1451 of the composite nonwoven fabric 1450 and includes a plurality of fibers from the first entangled fiber web integrated within the elastic layer. The first debossed portion 1431 also forms a first graphic 1471 that is visible on the outward-facing surface 1401 of the upper body apparel 1400 and is not visible on the inward-facing surface 1402 of the upper body apparel 1400, as shown in FIGS. 30A and 30B .

[0112] The second debossed portion 1432 includes similar features to the debossed portion 1230, but is formed on the opposite, second, outward-facing side 1452 of the composite nonwoven fabric 1450. Thus, unlike the debossed portion 1230, the second debossed portion 1432 includes a plurality of fibers from a second entangled fiber web integrated within the elastic layer. The second debossed portion 1432 forms a second graphic 1472, which, in one exemplary embodiment, has a different appearance than the first graphic 1471. In another exemplary embodiment, the second graphic 1472 may have substantially the same appearance as the first graphic 1471. Also, as shown in FIG. 30 , the second debossed portion 1432 is visible on the inward-facing surface 1402 of the upper body apparel 1400 but is not visible on the outward-facing surface 1401 of the upper body apparel 1400.

[0113] In one exemplary embodiment, second debossed portion 1432 may be formed similarly to debossed portion 1230, except that debossing tool 1310 may be applied to second entangled fiber web 1212 instead of first entangled fiber web 1210. Here, elastic layer 1216 forms a film that encases a plurality of fibers from second entangled fiber web 1212 such that second debossed portion 1432 is a third color 1243 similar to first debossed portion 1431. In one exemplary embodiment, second debossed portion 1432 may include care instructions for garment 1400, which avoids additional manufacturing processes involving, for example, sewing or application of a care label, and facilitates easier recycling of garment 1400.

[0114] 31A and 31B show an example of a lower-body apparel item 1500 including a composite nonwoven fabric 1550. The lower-body apparel item 1500 is in the form of a lower-body garment and is shown as pants, although the lower-body apparel item 1500 could be in the form of shorts, capri pants, tights, etc. The lower-body apparel item 1500 includes an outward-facing surface 1501 and an inward-facing surface 1502. As shown, the outward-facing surface 1501 is the outermost surface of the lower-body apparel item 1500, and similarly, the inward-facing surface 1502 is the innermost surface of the lower-body apparel item 1500. Furthermore, a first outward-facing side 1551 of the composite nonwoven fabric 1550 at least partially forms the outward-facing surface 1501, and an opposing second outward-facing side 1552 of the composite nonwoven fabric 1550 at least partially forms the inward-facing surface 1502.

[0115] Composite nonwoven fabric 1550 includes the same features as composite nonwoven fabric 1250, but includes additional regions with additional debossed portions. Thus, composite nonwoven fabric 1550 includes first region 1521, second region 1522, third region 1523, fourth region 1524, and fifth region 1525. First region 1521 includes a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first and second entangled fiber webs. Second and third regions 1522 and 1523 both include a second entangled fiber web and include first debossed portions 1531 and second debossed portions 1532, respectively. Fourth and fifth regions 1524 and 1525 both include the first entangled fiber web and include third debossed portions 1533 and fourth debossed portions 1534, respectively.

[0116] The first and second debossed portions 1531, 1532 have the same characteristics as the debossed portion 1230 and, therefore, are formed on the first outward-facing side 1551 of the composite nonwoven fabric 1550 and include a plurality of fibers from the first entangled fiber web integrated within the elastic layer. Additionally, the first debossed portion 1531 forms a first graphic 1571, and the second debossed portion 1532 forms a second graphic 1572. As shown in FIGS. 31A and 31B , the first and second debossed portions 1531, 1532 are visible on the outward-facing surface 1501 of the lower-body apparel 1500 and are not visible on the inward-facing surface 1502 of the lower-body apparel 1500.

[0117] The third and fourth debossed portions 1533, 1534 include similar features to the debossed portion 1230, but are formed on the opposite, second outward-facing side 1552 of the composite nonwoven fabric 1550. Thus, unlike the debossed portion 1230, the third and fourth debossed portions 1533, 1534 include a plurality of fibers from the second entangled web of fibers integrated within the elastic layer. The third debossed portion 1533 forms a third graphic 1573, and the fourth debossed portion 1534 forms a fourth graphic 1574. It is contemplated that any of the first, second, third, and fourth graphics 1571, 1572, 1573, and 1574 may have the same or different appearances. As shown in FIGS. 31A and 31B, the third and fourth debossed portions 1533, 1534 are visible on the inner surface 1502 of the lower-body clothing item 1500, but are not visible on the outer surface 1501 of the lower-body clothing item 1500.

[0118] 32A-33 show an example of a pleated structure 1600 including a composite nonwoven fabric 1850, an elastically recoverable structured fabric 1620, and a plurality of pleats 1630. As used herein, the term "structured fabric" refers to a fabric having either a knitted or woven structure, and the term "elastically recoverable" refers to a fabric that substantially recovers to its original length when subjected to tension. FIG. 32A shows a first side 1601 of the pleated structure 1600 formed at least in part by the composite nonwoven fabric 1850, and FIG. 32B shows a second side 1602 of the pleated structure 1600 formed at least in part by the elastically recoverable structured fabric 1620. Furthermore, as described below, the pleated structure 1600 is configured such that the peaks of the plurality of pleats 1630 are formed on the first side 1601 and the valleys of the plurality of pleats 1630 are formed on the second side 1602.

[0119] 33 shows an exploded view of pleated structure 1600, with composite nonwoven fabric 1850 including a first entangled fiber web 1810, a second entangled fiber web 1812, and an elastic layer 1816 positioned between the first entangled fiber web 1810 and the second entangled fiber web 1812. The composite nonwoven fabric 1850 is formed by subjecting the first entangled fiber web 110, the second entangled fiber web 112, and the elastic layer 116 to an entanglement process. Thus, the first entangled web 1810 includes fibers 210 (not identified) from the first web 110 and at least partially forms a first outward-facing side 1851 (shown in FIG. 32A ) of the composite nonwoven fabric 1850. Similarly, the second fibrous web 1812 includes fibers 310, 312 (not identified) from the second fibrous web 112 and at least partially forms the opposing second outwardly facing side 1852 of the composite nonwoven fabric 1850. The elastic layer may be formed of a thermoplastic elastomer, such as a thermoplastic polyurethane (TPU), a thermoplastic polyetherester elastomer (TPEE), or a combination of TPU and TPEE.

[0120] The elastically recoverable structured fabric 1620 is disposed adjacent to the outermost surface 1881 of the second entangled fiber web 1812 and secured thereto via an adhesive layer 1610. In one exemplary embodiment, the adhesive layer 1610 is included in the pleated structure 1600 such that the elastically recoverable structured fabric 1620 is secured to the second entangled fiber web 1812 in intermittent regions of the outermost surface 1881. In the example of FIG. 33 , the adhesive layer 1610 is included on the outermost surface 1881 in one or more first regions 1641 and is absent from the outermost surface 1881 in one or more second regions 1642. As a result of this adhesive layer 1610 configuration, the elastically recoverable structured fabric 1620 is secured to the second entangled fiber web 1812 in one or more first regions 1641 and is not secured to the second entangled fiber web 1812 in one or more second regions 1642.

[0121] Embodiments of the present application contemplate that each of the one or more first regions 1641 has a length and a width, where the length is greater than the width of the one or more first regions 1641. Continuing with these exemplary embodiments, each of the one or more second regions 1642 has a length and a width, where the length is greater than the width of the one or more second regions 1642. In other embodiments, the one or more first regions 1641 are separated from one another by one or more second regions 1642.

[0122] In one exemplary embodiment, adhesive layer 1610 may be a heat-activatable adhesive configured to melt and flow when heated to a predetermined temperature. In one exemplary embodiment, the heat activation temperature of adhesive layer 1610 ranges from about 125°C to about 135°C. In one exemplary embodiment, the heat activation temperature of adhesive layer 1610 is lower than the melting temperature of the materials forming each of first entangled fiber web 1810, second entangled fiber web 1812, and elastic layer 1816 (melting temperatures are described above). In other embodiments, it is contemplated that adhesive layer 1610 may be further configured to chemically bond with composite nonwoven fabric 1850 and / or mechanically bond with elastically recoverable structured textile 1620. Furthermore, adhesive layer 1610 may be a thermoplastic film, and in one exemplary embodiment, it is contemplated that adhesive layer 1610 includes a thermoplastic elastomer. In another exemplary embodiment, adhesive layer 1610 may be a Bemis adhesive tape.

[0123] In other exemplary embodiments, the elastic recovery structured fabric 1620 is configured to have stretch and recovery properties. Thus, when tension is applied, the elastic recovery structured fabric 1620 transitions to a taut state, and when the tension is released, the elastic recovery structured fabric 1620 returns from the taut state to a resting state. In other embodiments of the present application, the elastic recovery structured fabric 1620 is contemplated to include a warp or weft woven mesh structure and a material that has stretch and recovery properties. In one example, the elastic recovery structured fabric 1620 includes a first material that includes elastic yarns and / or a second material that includes polyester.

[0124] Further embodiments of the present application contemplate that the composite nonwoven fabric 1850 can include one or more additional entangled webs of fibers and / or layers, which may be any of the entangled webs of fibers and / or layers discussed herein. In more specific embodiments, any of the one or more additional entangled webs and / or layers of the composite nonwoven fabric 1850 may be the first entangled fiber web 810, 910, 1210, 1810, the second entangled fiber web 812, 912, 1212, 1812, the inner entangled fiber web 814, the third entangled fiber web 914, the elastic layer 116, 1216, 1816, the inner layer 120, the printed layer 170, 870, 970, or the spunlaced layer 920. Additional embodiments contemplate that the properties of the entangled web may be tailored and / or selectively include one or more additional fibers and / or layers to achieve desired final properties of the composite nonwoven fabric 1850. In further embodiments, it is contemplated that the arrangement of one or more additional fiber-entangled webs and / or layers, first fiber-entangled web 1810, second fiber-entangled web 1812, and elastic layer 1816 may be adjusted and / or configured to achieve desired final properties of composite nonwoven fabric 1850.

[0125] In one exemplary embodiment, the first entangled fiber web 1810, the second entangled fiber web 1812, and the elastic layer 1816 may each be configured to provide the composite nonwoven fabric 1850 with a fabric stiffness, stretch, and / or recovery suitable for forming the pleated structure 1600. In one embodiment, the composite nonwoven fabric 1850 may have insufficient fiber stiffness to resist the recovery of the elastically recoverable structured fabric 1620. In another embodiment, the first entangled fiber web 1810, the second entangled fiber web 1812, and the elastic layer 1816 may be configured to have a melt temperature higher than the activation temperature of the adhesive layer 1610. Other embodiments herein contemplate that the properties of the fibers 210, 310, 312 and the elastic layer 1816 may be tailored and / or selectively included to achieve desired final properties of the composite nonwoven fabric 1850. Any and all embodiments, and variations thereof, are contemplated as being included within each embodiment of this application.

[0126] FIG. 34 illustrates an exemplary manufacturing process for forming free-form structure 1600 and incorporating it into apparel 1720, generally designated by the numeral 1700. It should be understood that any description of the components of manufacture in FIG. 34 is exemplary and intended to convey the general nature of the various steps of manufacturing process 1700. Additionally, although the steps of manufacturing process 1700 are described as being performed sequentially, aspects of the present application contemplate that manufacturing process 1700 may include any combination of one or more steps, and that any steps may be repeated or performed in an order different from that described.

[0127] At a high level, FIG. 34 generally depicts various steps of manufacturing process 1700, including tensioning elastically recoverable structured fabric 1620, positioning elastically recoverable structured fabric 1620 while in a tensioned state on a surface of composite nonwoven fabric 1850, selectively securing composite nonwoven fabric 1850 to elastically recoverable structured fabric 1620 in one or more first regions 1641, and releasing the tension applied to elastically recoverable structured fabric 1620 to form a plurality of pleats 1630.

[0128] From step 1702, a composite nonwoven fabric 1850 is obtained and / or provided. The composite nonwoven fabric 1850 includes a first entangled fiber web 1810 (not visible), a second entangled fiber web 1812, and an elastic layer 1816 (not visible) positioned between the first entangled fiber web 1810 and the second entangled fiber web 1812.

[0129] In step 1704, an adhesive layer 1610 is applied to the outermost surface 1881 of the second entangled fiber web 1812. The adhesive layer 1610 is applied so as to be aligned with the one or more first regions 1641. In an exemplary embodiment, each of the one or more first regions 1641 has a length and a width, and the length is greater than the width of the one or more first regions 1641. Continuing with these exemplary embodiments, each of the one or more second regions 1642 has a length and a width, and the length is greater than the width of the one or more second regions 1642. In other embodiments, the one or more first regions 1641 are separated from one another by one or more second regions 1642. In one exemplary embodiment, the longitudinal axes of the one or more first regions 1641 are aligned parallel to the longitudinal axes of the one or more second regions 1642.

[0130] In step 1706, the elastic recovery structured fabric 1620 is stretched. In embodiments, the elastic recovery structured fabric 1620 can be tensioned by stretching the elastic recovery structured fabric 1620 in its warp or weft direction, or in its machine direction (indicated by the arrows). In an exemplary embodiment, the tension applied to the elastic recovery structured fabric 1620 is sufficient to elongate the elastic recovery structured fabric 1620 by about 55%. In other embodiments, the tension applied to the elastic recovery structured fabric 1620 elongates the elastic recovery structured fabric 1620 by about 75% to about 25%, about 70% to about 30%, about 65% to about 35%, about 60% to about 40%, or about 55% to about 45%. In step 1708, the elastically recoverable structured fabric 1620 is placed on the outermost surface 1881 of the second entangled fiber web 1812 of the composite nonwoven fabric 1850. Additionally, the elastically recoverable structured fabric 1620 is positioned while in tension.

[0131] In step 1710, the composite nonwoven textile 1850 is selectively secured to the elastically recoverable structured textile 1620 in one or more first regions 1641. In an exemplary embodiment, the composite nonwoven textile 1850 and the elastically recoverable structured textile 1620 may be selectively secured by heating at a temperature sufficient to activate the adhesive layer 1610. In FIG. 34, a heating element 1716 is shown for applying heat, and in one embodiment, the heating element 1716 is a hot press. In yet another exemplary embodiment, the composite nonwoven textile 1850 and the elastically recoverable structured textile 1620 may be selectively secured by applying a first heating cycle at a temperature of about 150° C. to about 160° C. for about 10 seconds, followed by a second heating cycle at a temperature of about 150° C. to about 160° C. for about 10 seconds. In other embodiments, pressure may be applied during securing of the composite nonwoven textile 1850 and the elastically recoverable structured textile 1620. Embodiments herein also contemplate holding the elastically recoverable structured fabric 1620 under tension for approximately 20 seconds after heating is stopped.

[0132] In step 1712, the tension applied to the elastically recoverable structured fabric 1620 is released to form the plurality of pleats 1630 and further form the pleated structure 1600 (e.g., a composite nonwoven fabric 1850 having the plurality of pleats 1630). Upon release, the one or more first regions 1641 form valleys of the plurality of pleats 1630 on the second side 1602 of the pleated structure 1600, and the one or more second regions 1642 form peaks of the plurality of pleats 1630 on the first side 1601 of the pleated structure 1600. In embodiments herein, it is contemplated that the elastically recoverable structured fabric 1620 is maintained in tension in the one or more first regions 1641 so that the adhesive layer 1610 at least partially impregnates the elastically recoverable structured fabric 1620 and "locks" the knitted or woven structure in these regions. As shown, the longitudinal axes of the plurality of pleats 1630 are aligned parallel to the longitudinal axes of the one or more first regions 1641 and / or the one or more second regions 1642 .

[0133] In step 1714, pleat structure 1600 is incorporated into apparel 1720. Pleat structure 1600 can form at least a portion of apparel 1720, and one exemplary embodiment contemplates pleat structure 1600 forming a cuff of apparel 1720, which may be located, for example, on a sleeve, a waist opening, a collar, a waistband, a distal leg cuff, etc.

[0134] Figure 35 shows upper body apparel 2000 having one or more sections formed by composite nonwoven fabric 1850, where apparel 2000 includes pleat structure 1600 in one or more locations on apparel 2000. Similarly, Figure 36 shows lower body apparel 2100 having one or more sections formed by composite nonwoven fabric 1850, where apparel 2100 includes pleat structure 1600 in one or more locations on apparel 2100. Outer-facing surfaces 2001 of apparel 2000 and apparel 2100 are shown. In apparel 2000, pleat structure 1600 forms cuffs located at the ends of the sleeves, and in apparel 2100, pleat structure 1600 forms cuffs located at the leg openings of apparel 2100. Pleated structure 1600 can also be used to form the waist opening as shown in apparel item 2000 and the belt of apparel item 2100.

[0135] Each of the cuffs can include a composite nonwoven 1850, an elastically recoverable structured textile 1620, and a plurality of first pleats 1631, in association with an adhesive layer 1610 shown in Figure 34. In one exemplary embodiment, the cuffs can be formed by folding the pleated structure 1600 so that the surfaces of the elastically recoverable structured textile 1620 are positioned adjacent to one another (i.e., the surfaces are in a coplanar relationship), and the composite nonwoven 1850 forms the outward-facing surface of the cuff and the inward-facing side of the cuff.

[0136] 37 is a cross-sectional view of a cuff of outerwear of apparel item 2000, and also shows an enlarged view of a portion of that cross-section. As shown, pleated structure 1600 is folded or reconfigured such that the surfaces of elastically recoverable structured textile 1620, which are the outward-facing surfaces of pleated structure 1600, form two surfaces that are adjacent to each other (i.e., these surfaces are in a coplanar relationship). Composite nonwoven fabric 1850 forms the outward-facing surface of the cuff and the inward-facing side of the cuff. This results in a plurality of first pleats 1631 located on the outermost surface 2001 of upper body apparel item 2000, and a plurality of second pleats 1632 located on the innermost surface 2001-2002 of upper body apparel item 2000.

[0137] The first plurality of pleats 1631 are included in a first portion of the pleated structure 1600 and are formed from the first composite nonwoven 2050 (i.e., the portion of the composite nonwoven 1850 that forms the outer surface of the cuff), the first elastically recoverable structured woven fabric 1621, and the first adhesive layer 1611. Similarly, the second plurality of pleats 1632 are included in a second portion of the pleated structure 1600 and are formed from the second composite nonwoven 1950 (i.e., the portion of the composite nonwoven 1850 that forms the inward-facing side of the cuff), the second elastically recoverable structured woven fabric 1622, and the second adhesive layer 1612. Because the first composite nonwoven 2050 and the second composite nonwoven 1950 are both part of the composite nonwoven 1850, they have identical characteristics. Thus, the first composite nonwoven fabric 2050 includes a first fiber-entangled web 2010, a second fiber-entangled web 2012, and a first elastic layer 2016 positioned between the first fiber-entangled web 2010 and the second fiber-entangled web 2012. Similarly, the second composite nonwoven fabric 1950 includes a third fiber-entangled web 1910, a fourth fiber-entangled web 1912, and a second elastic layer 1916 positioned between the third fiber-entangled web 1910 and the fourth fiber-entangled web 1912. In one exemplary embodiment, the first and second composite nonwoven fabrics 2050, 1950 may be derived from different composite nonwoven fabrics and may therefore include one or more different characteristics.

[0138] As shown in the enlarged view of FIG. 37 , the second fiber-entangled web 2012 has a first outermost surface 2081 secured to the third side 1625 of the first elastically recoverable structured fabric 1621 in one or more first regions 1641, and the fourth fiber-entangled web 1912 has a second outermost surface 1981 secured to the fourth side 1626 of the second elastically recoverable structured fabric 1622 in one or more first regions 1641. In one or more second regions 1642, the first and second outermost surfaces 2081, 1981 are not secured to the first and second elastically recoverable structured fabrics 1621, 1622, respectively, which at least partially contributes to forming the peaks and valleys in the first and second composite nonwoven fabrics 2050, 1950. Furthermore, the first elastically recoverable structured fabric 1621 and the second elastically recoverable structured fabric 1622 can be tensioned (i.e., maintained in tension by the adhesive layer 1610) in one or more first regions 1641 and untensioned in one or more second regions 1642 to facilitate the formation of peaks and valleys in the first and second composite nonwoven fabrics 2050, 1950.

[0139] In various embodiments, the first and second elastically recoverable structured fabrics 1621, 1622 maintain adjacent positions throughout the cuff, but may be spaced apart in other ways. In Figure 37, the first surface 1623 of the first elastically recoverable structured fabric 1621 is separated from the second surface 1624 of the second elastically recoverable structured fabric 1622 in one or more second regions 1642, and the first and second surfaces 1623, 1624 are shown in contact with one another in one or more first regions 1641. In other words, the first and second surfaces 1623, 1624 are in a coplanar relationship throughout the cuff.

[0140] 37 is exemplary, and it should be understood that various embodiments herein contemplate that the pleat structure 1600 may have one or more different structures throughout the cuff. In one example, the first and second surfaces 1623, 1624 may be spaced apart in one or more first regions 1641. In another example, the plurality of first pleats 1631 may be offset from the plurality of second pleats 1632.

[0141] The following sections represent exemplary aspects of the concepts contemplated herein. Any of the following sections may be combined in a multiple dependent manner, depending on one or more other sections. Also, any combination of dependent claims (sections that are explicitly dependent on a previous section) may be combined in any manner without departing from the scope of the aspects contemplated herein. The following sections are exemplary only and not limiting.

[0142] Item 1. A method for producing a printed composite nonwoven fabric, comprising: placing a first surface of a printed layer including a printed component adjacent to a second surface of a first fiber web to form a composite structure; and subjecting the composite structure to a needle entanglement process; and incorporating at least a portion of the printed component into the first fiber web after the needle entanglement process.

[0143] Item 2: A method for producing a printed composite nonwoven fabric as described in item 1, wherein the printing layer is an internal fiber web, and the internal fiber web has a first region including a first portion of the printing part and a second region including a second portion of the printing part.

[0144] Item 3: A method for producing a printed composite nonwoven fabric according to Item 2, wherein the first region of the internal fiber web and the first fiber web have greater mechanical entanglement than the second region of the internal fiber web.

[0145] Item 4: A method for producing a printed composite nonwoven fabric according to any one of items 2 and 3, wherein after the composite structure is subjected to the needle entanglement process, at least some of the fibers in the first region of the internal fiber web are mechanically entangled with the first fiber web, and at least some of the fibers in the second region of the internal fiber web are mechanically independent from the first fiber web.

[0146] Item 5: The method for producing a printed composite nonwoven fabric according to Item 4, wherein the printed part comprises at least one selected from a colorant and a sublimable dye.

[0147] Item 6. The method for producing a printed composite nonwoven fabric according to any one of items 1 to 5, wherein the printed layer is a spunlace layer.

[0148] Item 7: A method for producing a printed composite nonwoven fabric as described in Item 6, wherein after the composite structure is subjected to the needle entanglement process, at least some of the fibers of the first fiber web extend through the spunlace layer, a first portion of the printed part is incorporated into the first fiber web, and a second portion of the printed part is incorporated into the spunlace layer.

[0149] Item 8: A method for producing a printed composite nonwoven fabric according to item 7, wherein the second portion of the printed part is not incorporated into the first fiber web.

[0150] Item 9: The method for producing a printed composite nonwoven fabric according to Item 4, wherein the printed part comprises at least one selected from a colorant and a sublimable dye.

[0151] Item 10: The method for producing a printed composite nonwoven fabric according to any one of items 1 to 9, wherein the printed layer contains spunlace fibers.

[0152] Item 11: The method for producing a printed composite nonwoven fabric according to any one of items 1 to 9, wherein the printed layer includes a fiber web.

[0153] Item 12: The method for producing a printed composite nonwoven fabric according to any one of items 1 to 11, wherein the composite structure further comprises a second fiber web adjacent to the second surface of the inner layer.

[0154] Item 13: The method for producing a printed composite nonwoven fabric according to any one of items 1 to 12, wherein the printed part is on the first surface of the printing layer.

[0155] Item 14: A method for producing a printed composite nonwoven fabric according to any one of items 1 to 13, further comprising the step of printing the printed part onto an inner layer to form the printed layer before adjoining the first surface of the printed layer to the second surface of the first fiber web to form the composite structure.

[0156] Item 15: The method for producing a printed composite nonwoven fabric according to item 14, wherein the printing of the printed part is a sublimation printing process.

[0157] Item 16: A method for producing a printed composite nonwoven fabric according to any one of items 1 to 12, further comprising the step of forming a printed layer before placing the first surface of the printed layer adjacent to the second surface of the first fiber web to form a composite structure.

[0158] Item 17: A method for producing a printed composite nonwoven fabric according to Item 16, wherein the step of forming the printed layer includes the steps of applying a sublimable dye to the inner layer, and subjecting the applied sublimable dye and the inner layer to a temperature of about 185°C to about 205°C for about 0.5 seconds to about 1.5 seconds.

[0159] Item 18: A method for producing a printed composite nonwoven fabric according to any one of Items 1 to 17, wherein the needle entanglement process includes a first needle entanglement process having a first condition and a second needle entanglement process having a second condition different from the first condition.

[0160] Item 19: A method for producing a printed composite nonwoven fabric according to any one of items 1 to 18, wherein at least a portion of the printed parts incorporated into the first fiber web comprises one or more types of fibers of the printing layer, and the one or more types of fibers of the printing layer extend into the first fiber web.

[0161] Item 20: A method for producing a printed composite nonwoven fabric according to any one of items 1 to 19, wherein at least a portion of the printed parts incorporated into the first fiber web extend at least partially onto a first surface of the first fiber web.

[0162] Item 21: A method for producing a printed asymmetric composite nonwoven fabric, the method comprising: forming a printed part on an inner layer using a printing technology to form a printed layer; and, after using the printing technology, placing a first surface of the printed layer adjacent to a second surface of a first fiber web to form a composite structure; and subjecting the composite structure to a variable entanglement process, wherein after the variable entanglement process, at least a portion of the printed part and the first surface of the first fiber web at least partially form the first decorative surface side of the printed asymmetric composite nonwoven fabric.

[0163] Item 22: A method for producing a printed asymmetric surface composite nonwoven fabric according to Item 21, wherein the printing technique includes a step of applying a colorant to the first surface of the inner layer.

[0164] Item 23: A method for producing a printed asymmetric surface composite nonwoven fabric according to any one of items 22, wherein after the composite structure is subjected to an entanglement process, a first portion of the printed parts is incorporated into the first fiber web, and a second portion of the printed parts is excluded from being incorporated into the first fiber web.

[0165] Item 24. The method for printing an asymmetric surface composite nonwoven fabric according to Item 23, wherein the inner layer is a fiber web.

[0166] Item 25. The method for printing an asymmetric surface composite nonwoven fabric according to Item 23, wherein the inner layer is a spunlace layer.

[0167] Item 26: A method for printing an asymmetric surface composite nonwoven fabric according to Item 21, wherein the printing technique includes sublimation printing a sublimable dye onto the first surface of the inner layer.

[0168] Item 27: A method for printing an asymmetric surface composite nonwoven fabric according to Item 26, wherein after the composite structure is subjected to the variable entanglement process, the first portion of the sublimation-dyed inner layer is incorporated into the first fiber web to a greater extent than the second portion of the sublimation-dyed inner layer.

[0169] Item 28: The method for printing an asymmetric surface composite nonwoven fabric according to Item 27, wherein the inner layer is a fiber web.

[0170] Item 29: The method for printing an asymmetric surface composite nonwoven fabric according to Item 27, wherein the inner layer is a spunlace layer.

[0171] Item 30: A printed composite nonwoven fabric having a first decorative surface side, comprising a first fiber entangled web and an inner layer, wherein the first fiber entangled web has a first surface that at least partially forms the first decorative surface side and an opposing second surface, and the inner layer has a first surface that is disposed adjacent to the second surface of the first fiber entangled web, and the first surface comprises a printing element having a first portion and a second portion, and the first portion of the printing element is incorporated into the first fiber web to a greater extent than the second portion of the printing element.

[0172] Item 31. The printed composite nonwoven fabric according to item 30, wherein the inner layer is a fiber-entangled web.

[0173] Item 32. The printed composite nonwoven fabric according to Item 30, wherein the inner layer is a spunlace layer.

[0174] Item 33: The printed composite nonwoven fabric according to any one of items 30 to 32, wherein the printed part contains a sublimable dye or a colorant.

[0175] Item 34: A printed asymmetric composite nonwoven fabric having a first decorative surface side, the asymmetric nonwoven fabric comprising a first fiber-entangled web and an inner layer, the first fiber-entangled web comprising a first surface that at least partially forms the first decorative surface side and an opposing second surface, the inner layer having a first surface disposed adjacent to the second surface of the first fiber-entangled web, the first surface comprising a printed component having a first portion and a second portion, the first portion of the printed component at least partially forming the first decorative surface side, and the second portion of the printed component being excluded from the first fiber-entangled web.

[0176] Item 35. The printed asymmetric composite nonwoven fabric according to Item 34, wherein the inner layer comprises an internal fiber entangled web.

[0177] Item 36. The printed asymmetric composite nonwoven fabric according to Item 34, wherein the inner layer comprises an inner spunlace fiber web.

[0178] Item 37: The printed asymmetrical surface composite nonwoven fabric according to any one of items 34 to 36, wherein the printed part contains a sublimable dye or colorant.

[0179] Item 38: The printed asymmetric interfacial composite nonwoven fabric according to any one of items 34 to 37, further comprising a second fiber-entangled web.

[0180] Item 39. The printed asymmetric interfacial composite nonwoven fabric according to Item 38, further comprising an elastic layer located between the first entangled fiber web and the second entangled fiber web.

[0181] Item 40: The printed asymmetric interfacial composite nonwoven fabric according to any one of items 38 to 39, further comprising a third fiber-entangled web.

[0182] Item 41: An upper body garment comprising a first composite nonwoven fabric and a second composite nonwoven fabric, wherein the first composite nonwoven fabric comprises a first entangled fiber web and has a first edge, the second composite nonwoven fabric comprises a second entangled fiber web and has a second edge and a first seam, the first seam being formed along a portion of the first edge of the first composite nonwoven fabric adjacent to the second edge, and at least some of the fibers of the first entangled fiber web and at least some of the fibers of the second entangled fiber web being entangled to form the first seam, and the first seam being formed at a first seam position of the upper body garment.

[0183] Item 42: The upper body clothing item according to item 41, wherein the first seam position is located near a side portion of the upper body clothing item.

[0184] Item 43: The upper body clothing item according to item 41, wherein the first seam position is located near a collar portion of the upper body clothing item.

[0185] Item 44: The upper body clothing item according to item 41, wherein the first seam position is located near a sleeve portion of the upper body clothing item.

[0186] Item 45: The upper body garment according to any one of items 41 to 44, wherein the first composite nonwoven fabric further includes an adhesive layer along the first edge portion.

[0187] Item 46: The upper body clothing item according to any one of items 41 to 45, wherein the first composite nonwoven fabric includes a third edge portion, and the second composite nonwoven fabric includes a fourth edge portion adjacent to the third edge portion of the first composite nonwoven fabric.

[0188] Item 47: The upper body garment according to Item 46, further comprising a second seam formed along a portion of the third edge of the first composite nonwoven fabric adjacent to the fourth edge of the second composite nonwoven fabric, wherein at least some of the fibers of the first entangled fiber web and at least some of the fibers of the second entangled fiber web are entangled to form the second seam, and the second seam is formed at a second seam position of the upper body garment.

[0189] Item 48: The upper body clothing item according to item 47, wherein the first seam position is located near a side portion of the upper body clothing item, and the second seam position is located near a collar portion of the upper body clothing item.

[0190] Item 49: The upper body garment according to Item 47, wherein the first composite nonwoven fabric further comprises an adhesive layer along the third edge.

[0191] Item 50: A lower body garment comprising a first composite nonwoven fabric and a second composite nonwoven fabric, wherein the first composite nonwoven fabric has a first edge and comprises a first fiber-entangled web, the second composite nonwoven fabric comprises a second fiber-entangled web, and has a second edge and a first seam, the first seam being formed along a portion of the first edge of the first composite nonwoven fabric adjacent to the second edge, and at least some of the fibers of the first fiber-entangled web and at least some of the fibers of the second fiber-entangled web being entangled to form the first seam, the first seam being formed at a first seam position of the lower body garment.

[0192] Item 51: The lower body clothing item according to Item 50, wherein the first seam position is located near an outer portion of the lower body clothing item.

[0193] Item 52: The lower body clothing item according to item 50, wherein the first seam position is located near an inner portion of the lower body clothing item.

[0194] Item 53: The lower body clothing item according to item 50, wherein the first seam position is located near a waist portion of the lower body clothing item.

[0195] Item 54: The lower body garment according to any one of items 50 to 53, wherein the first composite nonwoven fabric further includes an adhesive layer along the first edge portion.

[0196] Item 55: The lower body clothing item according to any one of items 50 to 54, wherein the first composite nonwoven fabric includes a third edge portion, and the second composite nonwoven fabric includes a fourth edge portion adjacent to the third edge portion of the first composite nonwoven fabric.

[0197] Item 56: A lower body garment as described in Item 55, including a second seam formed along a portion of the third edge of the first composite nonwoven fabric adjacent to the fourth edge of the second composite nonwoven fabric, wherein at least some of the fibers of the first entangled fiber web and at least some of the fibers of the second entangled fiber web are entangled to form the second seam, and the second seam is formed at a second seam position of the lower body garment.

[0198] Item 57: The lower body garment according to Item 56, wherein the first composite nonwoven fabric further comprises an adhesive layer along the third edge.

[0199] Item 58. A method for manufacturing a garment, the garment comprising a first composite nonwoven fabric and a second composite nonwoven fabric, the method comprising the steps of: disposing a first fibrous web above a second fibrous web; mechanically entangling the fibers of the first fibrous web with the fibers of the second fibrous web to form a first entangled web and a second entangled web, the first entangled web and the second entangled web forming the first composite nonwoven fabric; disposing a third fibrous web above a fourth fibrous web; mechanically entangled the fibers of the third fibrous web with the fibers of the fourth fibrous web to form the third entangled web; a fourth fibrous web into a fourth entangled web, wherein the third entangled web and the fourth entangled web form a second composite nonwoven fabric; a fourth composite nonwoven fabric and a fourth composite nonwoven fabric are arranged so that a first edge of the first composite nonwoven fabric is adjacent to a second edge of the second composite nonwoven fabric; and a fourth composite nonwoven fabric and a fourth composite nonwoven fabric are arranged so that a first edge of the first composite nonwoven fabric is adjacent to a second edge of the second composite nonwoven fabric.

[0200] Item 59: The method for manufacturing a garment according to Item 58, wherein the garment is a garment for the upper body.

[0201] Item 60: The method for manufacturing a garment according to Item 58, wherein the garment is a garment for the lower body.

[0202] Item 61: A composite nonwoven fabric, comprising: a first region including a first entangled fiber web, a second entangled fiber web, and an elastic layer located between the first entangled fiber web and the second entangled fiber web; and a second region, wherein the second region includes a debossed portion including a plurality of fibers from the first entangled fiber web integrated into the elastic layer, and the second entangled fiber web.

[0203] Item 62. The composite nonwoven fabric according to Item 61, wherein the first entangled fiber web and the elastic layer collectively have a first thickness in the first region, and the debossed portion has a second thickness different from the first thickness.

[0204] Item 63. The composite nonwoven fabric according to Item 62, wherein the second thickness is about 50% less than the first thickness.

[0205] Item 64: The composite nonwoven fabric according to any one of items 61 to 63, wherein the first entangled fiber web has a first color, and the elastic layer has a third color different from the first color.

[0206] Item 65. The composite nonwoven fabric according to Item 64, wherein in the first region, the first color is visible and the third color is at least partially obscured from view.

[0207] Item 66: The composite nonwoven fabric according to any one of items 64 to 65, wherein the third color is visible in the second region.

[0208] Item 67: The composite nonwoven fabric according to any one of items 61 to 66, wherein in the first region, a first outward side of the composite nonwoven fabric is at least partially formed by a first wound fiber web, and in the second region, the first outward side is at least partially formed by a debossed portion.

[0209] Item 68: In the composite nonwoven fabric according to any one of items 61 to 67, the opposing second outward sides of the composite nonwoven fabric are formed by a second entangled fiber web in the first region and the second region.

[0210] Item 69. A method of applying a graphic to a composite nonwoven fabric, the composite nonwoven fabric comprising a first entangled fiber web having a first color, a second entangled fiber web having a second color, and an elastic layer having a third color positioned between the first entangled fiber web and the second entangled fiber web, the method comprising the steps of: applying one or more of heat and pressure to a second region on a first outward side of the composite nonwoven fabric such that the elastic layer forms a membrane that envelops a plurality of fibers from the first entangled fiber web; wherein after applying one or more of heat and pressure, the color on the first outward side in the second region is the third color and the color on the first outward side in the first region is the first color, and the second region forms a graphic on the first outward side of the composite nonwoven fabric.

[0211] Item 70: The method for applying a graphic to a composite nonwoven fabric according to Item 69, wherein on the opposite second outward side of the composite nonwoven fabric, the color of the composite nonwoven fabric is the second color of the first region and the second region.

[0212] Item 71: A method for applying a graphic to a composite nonwoven fabric according to any one of Items 69 to 70, wherein heat and pressure are applied simultaneously.

[0213] Item 72: A method for applying a graphic to the composite nonwoven fabric of any one of Items 69 to 71, wherein a deformable surface is positioned adjacent to an opposing second outward side of the composite nonwoven fabric while applying one or more of heat and pressure to a second region of the first outward side of the composite nonwoven fabric.

[0214] Item 73: A method for applying a graphic to the composite nonwoven fabric according to any one of Items 69 to 72, wherein a debossing tool applies one or more of heat and pressure to the second region of the composite nonwoven fabric.

[0215] Item 74: A method for applying a graphic to a composite nonwoven fabric according to Item 73, wherein the debossing tool is configured to apply heat to the second region of the first outward side of the composite nonwoven fabric at a temperature of about 170°C to about 190°C for about 28 to about 32 seconds.

[0216] Item 75: A method for applying a graphic to a composite nonwoven fabric according to any one of items 73 to 74, wherein the debossing tool is configured to apply heat to the second region of the first outward side of the composite nonwoven fabric at about 180°C for about 30 seconds.

[0217] Item 76: A method for applying a graphic to a composite nonwoven fabric according to any one of Items 69 to 75, wherein the thickness of the composite nonwoven fabric in the second region is about 50% less than the thickness of the composite nonwoven fabric in the first region.

[0218] Item 77 A method for applying a graphic to a composite nonwoven fabric according to any one of Items 69 to 76, wherein the thickness of the second entangled fiber web in the composite nonwoven fabric is within about 95% of the thickness of each of the first region and the second region.

[0219] Item 78: A method for applying a graphic to the composite nonwoven fabric according to any one of items 69 to 77, wherein at least the first color is different from the third color.

[0220] Item 79 A method for manufacturing a composite nonwoven fabric having a debossed portion, comprising: placing a debossing tool on a first outward side of the composite nonwoven fabric, the composite nonwoven fabric including a first entangled fiber web, a second entangled fiber web, and an elastic layer disposed between the first entangled fiber web and the second entangled fiber web; and applying the debossing tool to the first outward side of the composite nonwoven fabric to form a debossed portion.

[0221] Item 80. The method for manufacturing a composite nonwoven fabric according to Item 194, wherein a first outward side of the composite nonwoven fabric is at least partially formed by a first entangled fiber web.

[0222] Item 81: A method for producing a composite nonwoven fabric having a debossed portion according to any one of Items 79 to 80, wherein the debossed portion comprises a plurality of fibers from a first entangled fiber web integrated within an elastic layer.

[0223] Item 82: A method for producing a composite nonwoven fabric having a debossed portion according to any one of items 79 to 81, wherein the debossed portion is not present on the second outward side of the composite nonwoven fabric.

[0224] Item 83: A method for producing a composite nonwoven fabric having a debossed portion according to any one of items 79 to 82, wherein the first outward surface of the composite nonwoven fabric is a first color, and the debossed portion is a second color different from the first color.

[0225] Item 84: A method for producing a composite nonwoven fabric having a debossed portion according to any one of Items 79 to 83, wherein the debossing tool is configured to apply heat to the first outward side of the composite nonwoven fabric at a temperature of about 170°C to about 190°C for about 28 to about 32 seconds.

[0226] Item 85: A method for producing a composite nonwoven fabric having a debossed portion according to any one of items 79 to 84, wherein the debossing tool is configured to apply heat to the first outward side of the composite nonwoven fabric at about 180°C for about 30 seconds.

[0227] Item 86: A method for producing a composite nonwoven fabric having a debossed portion according to any one of Items 79 to 85, wherein the thickness of the composite nonwoven fabric in the debossed portion is half or less of the thickness of the composite nonwoven fabric in the region other than the debossed portion.

[0228] Item 87: A method for producing a composite nonwoven fabric having a debossed portion according to any one of Items 79 to 86, wherein the thickness of the second entangled fiber web in the composite nonwoven fabric is substantially the same in the debossed portion and in the area other than the debossed portion.

[0229] Item 88: An article of clothing, comprising a composite nonwoven fabric constituting at least a portion of the article of clothing, the composite nonwoven fabric comprising a first region and a second region, the first region comprising a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first entangled fiber web and the second entangled fiber web, the second region comprising a first debossed portion comprising a plurality of fibers from the first entangled fiber web integrated within the elastic layer, and the second entangled fiber web.

[0230] Item 89. The article of clothing according to Item 88, wherein the first debossed portion forms a first graphic.

[0231] Item 90: The clothing article according to any one of items 8 to 89, wherein the first debossed portion is visible on the outer surface of the clothing article.

[0232] Item 91: The clothing article according to any one of items 88 to 90, wherein the first debossed portion is not visible from the inner surface of the clothing article.

[0233] Item 92 The clothing article according to any one of items 88 to 91, further comprising a second debossed portion including a plurality of fibers from a second entangled fiber web integrated within the elastic layer.

[0234] Item 93: The article of clothing according to item 92, wherein the second debossed portion forms a second graphic that has an appearance different from the first graphic.

[0235] Item 94: The clothing article according to any one of items 92 to 93, wherein the second debossed portion is visible on the inner surface of the clothing article.

[0236] Item 95. The article of clothing according to Item 92, wherein the second debossed portion is not visible on the outer surface of the article of clothing.

[0237] Item 96: The clothing article according to any one of items 88 to 95, wherein the clothing article is an upper body garment.

[0238] Item 97 The article of clothing according to any one of items 88 to 95, wherein the article of clothing is a lower body garment.

[0239] Item 98: The clothing article according to any one of items 88 to 97, wherein the first entangled fiber web and the elastic layer have a first thickness in the first region, and the first debossed portion has a second thickness in the second region that is approximately 50% smaller than the first thickness.

[0240] Item 99: A composite nonwoven fabric comprising: a first region having a first entangled fiber web, a second entangled fiber web, an elastic layer, and the elastic layer disposed between the first entangled fiber web and the second entangled fiber web; and a second region debossed relative to the first region, the elastic layer being in the form of a film that encapsulates a plurality of fibers from the first entangled fiber web to form the debossed portion, and the second entangled fiber web being disposed below the debossed portion.

[0241] Item 100: The composite nonwoven fabric according to Item 99, wherein the debossed portion includes a matrix structure formed of a plurality of fibers and a film.

[0242] Item 101: The composite nonwoven fabric according to any one of items 99 to 100, wherein the debossed portion has a color different from that of the first region on the first outward side of the composite nonwoven fabric.

[0243] Item 102: The composite nonwoven fabric according to any one of Items 99 to 101, wherein the thickness of the second entangled fiber web in the composite nonwoven fabric is within about 95% of each of the first region and the second region.

[0244] Item 103: A composite nonwoven fabric having a first outward side and an opposite second outward side, the composite nonwoven fabric comprising: a first fiber entangled web having a first color; a second fiber entangled web having a second color; an elastic layer having at least a third color different from the first color; a first region having the elastic layer disposed between the first fiber entangled web and the second fiber entangled web; and a second region debossed relative to the first region, wherein, when viewed from the first outward side, the first region has a color substantially identical to the first color, and the second region has a color substantially identical to the third color.

[0245] Item 104. The composite nonwoven fabric according to Item 103, wherein when viewed from the second outward side, the color of the composite nonwoven fabric is substantially the same as the second color in the first region and the second region.

[0246] Item 105: The composite nonwoven fabric according to any one of items 103 to 104, wherein the thickness of the composite nonwoven fabric in the second region is about 50% smaller than the thickness of the composite nonwoven fabric in the first region.

[0247] Item 106: A composite nonwoven fabric, comprising: a first entangled fiber web comprising a first material having a first melting temperature; a second entangled fiber web comprising a second material having a second melting temperature; and an elastic layer comprising a third material having a third melting temperature that is about 40°C lower than the first melting temperature; wherein the composite nonwoven fabric comprises a first region in which the elastic layer is disposed between the first entangled fiber web and the second entangled fiber web; and a second region debossed relative to the first region, wherein in the second region, the elastic layer is in the form of a film that encapsulates a plurality of fibers from the first entangled fiber web to form a debossed portion, and the second entangled fiber web is disposed below the debossed portion.

[0248] Item 107: A composite nonwoven fabric according to Item 106, wherein the debossed portion includes a matrix structure formed of a plurality of fibers and a film.

[0249] Item 108: The composite nonwoven fabric according to any one of items 106 to 107, wherein the debossed portion has a color different from the first region on the first outward side of the composite nonwoven fabric.

[0250] Item 109: The composite nonwoven fabric according to any one of items 106 to 108, wherein the thickness of the debossed portion is about 50% less than the thickness of the first entangled fiber web and the elastic layer in the first region.

[0251] Item 110 is a composite nonwoven fabric, comprising a first entangled fiber web, a second entangled fiber web, and an elastic layer formed of elastic fibers having a melting temperature lower than that of the fibers forming at least the first entangled fiber web, the composite nonwoven fabric comprising a first region in which the elastic layer is disposed between the first entangled fiber web and the second entangled fiber web, and a second region debossed relative to the first region, in which the elastic layer is in the form of a film that wraps around a plurality of fibers from the first entangled fiber web to form a debossed portion, and the second entangled fiber web is disposed below the debossed portion.

[0252] Item 111. The composite nonwoven fabric according to claim 61, wherein each of the first entangled fiber web and the second entangled fiber web contains short fibers having a length shorter than the length of the elastic fibers forming the elastic layer.

[0253] Item 112. The composite nonwoven fabric according to any one of items 110 to 109, wherein the elastic fibers include at least one of meltblown fibers and spunbond fibers.

[0254] Item 113: The composite nonwoven fabric according to any one of items 108 to 112, wherein the debossed portion has a different color from the first region on the first outward side of the composite nonwoven fabric.

[0255] Item 114 A pleated structure comprising a composite nonwoven fabric including a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first entangled fiber web and the second entangled fiber web; an elastically recoverable structured fabric positioned near the outermost surface of the second entangled fiber web; and a plurality of pleats formed by the composite nonwoven fabric and the elastically recoverable structured fabric.

[0256] Item 115. The pleated structure of Item 114, further comprising an adhesive layer securing the elastically recoverable structured fabric to the second entangled fiber web in one or more first regions.

[0257] Item 116. The pleated structure according to Item 115, wherein the adhesive layer comprises a thermoplastic film.

[0258] Item 117: The pleated structure according to any one of items 115 to 116, wherein the adhesive layer has a thickness of about 2 mm.

[0259] Item 118: A pleated structure according to any one of items 114 to 117, wherein the elastically recoverable structured fabric is secured to the second entangled fiber web in one or more first regions and is not secured to the second entangled fiber web in one or more second regions.

[0260] Item 119: A pleated structure according to Item 118, wherein each of the one or more first regions has a length and a width that are greater than the width of the one or more first regions, and each of the one or more second regions has a length and a width that are greater than the width of the one or more second regions.

[0261] Item 120: The pleat structure according to any one of items 118 to 119, wherein the one or more first regions are separated from each other by one or more second regions.

[0262] Item 121. The pleat structure according to any one of items 118 to 120, wherein each of the one or more first regions has a longitudinal axis aligned parallel to the longitudinal axis of the one or more second regions.

[0263] Item 122: The pleat structure according to any one of items 118 to 121, wherein each of the one or more first regions has a longitudinal axis aligned parallel to the longitudinal axis of one or more pleats among the plurality of pleats.

[0264] Item 123. A method for manufacturing a composite nonwoven fabric having a plurality of pleats, comprising: applying tension to an elastically recoverable structured fabric to taut the elastically recoverable structured fabric; disposing the elastically recoverable structured fabric in a taut state on a surface of the composite nonwoven fabric; selectively securing the composite nonwoven fabric to the elastically recoverable structured fabric in one or more first regions; and releasing the tension applied to the elastically recoverable structured fabric to form a plurality of pleats.

[0265] Item 124. The method of item 123, wherein the elastically recoverable structured fabric is stretched between about 50% and about 60% of its rest length.

[0266] Item 125. The method of any one of Items 123-124, wherein the elastically recoverable structured fabric is stretched to about 55% of its rest length.

[0267] Item 126. The method according to any one of Items 123 to 125, wherein the elastically recoverable structured fabric comprises a knitted structure having a plurality of courses and a plurality of wales.

[0268] Item 127. The method of item 126, wherein the elastically recoverable structured fabric is stretched in the cross direction.

[0269] Item 128. The method according to any one of items 126 to 127, wherein the elastically recoverable structured fabric is stretched in the machine direction.

[0270] Item 129: The composite nonwoven fabric according to any one of items 69 to 72, comprising a first entangled fiber web, a second entangled fiber web, and an elastic layer located between the first entangled fiber web and the second entangled fiber web.

[0271] Item 130: The method of item 129, wherein the elastically recoverable structured fabric is secured to the outermost surface of the second entangled fiber web.

[0272] Item 131. The method according to any one of items 129 to 130, wherein the elastically recoverable structured fabric is not secured to the second entangled fiber web in one or more second regions.

[0273] Item 132 A method according to Item 131, wherein each of the one or more first regions has a length and a width that are greater than the width of the one or more first regions, and each of the one or more second regions has a length and a width that are greater than the width of the one or more second regions.

[0274] Item 133 The method according to any one of items 131 to 132, wherein the one or more first regions are separated from each other by one or more second regions.

[0275] Item 134. The method of any one of items 123 to 133, wherein the elastically recoverable structured fabric is maintained in a taut state in one or more first regions after the tension is released.

[0276] Item 135. A pleat structure in at least a first portion of a clothing article, comprising: a first composite nonwoven fabric including a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first entangled fiber web and the second entangled fiber web; a first elastically recoverable structured fabric positioned near a first outermost surface of the first composite nonwoven fabric; and a plurality of pleats formed by the first composite nonwoven fabric and the first elastically recoverable structured fabric.

[0277] Item 136. The pleated structure according to Item 135, wherein the article of clothing is an upper body garment.

[0278] Item 137. The pleated structure according to Item 135, wherein the article of clothing is a lower body garment.

[0279] Item 138: The pleat structure according to any one of items 135 to 137, comprising a second composite nonwoven fabric including a third entangled fiber web, a fourth entangled fiber web, and a second elastic layer located between the third entangled fiber web and the fourth entangled fiber web; a second elastically recoverable structured fabric located near a second outermost surface of the second composite nonwoven fabric; and a plurality of second pleats formed by the second composite nonwoven fabric and the second elastically recoverable structured fabric, wherein the second elastically recoverable structured fabric is in a surface-sharing relationship with the first elastically recoverable structured fabric.

[0280] Item 139: The pleat structure according to any one of items 135 to 137, wherein the plurality of first pleats are located on the outermost surface of the clothing article.

[0281] Item 140: The pleat structure according to any one of items 138 to 139, wherein the plurality of second pleats are located on the innermost surface of the clothing article.

Claims

1. 1. A method for applying graphics to a composite nonwoven fabric, the composite nonwoven fabric comprising a first entangled fiber web having a first color, a second entangled fiber web having a second color, and an elastic layer having a third color located between the first entangled fiber web and the second entangled fiber web, the method comprising: applying one or more of heat and pressure to a second region on a first outward-facing side of the composite nonwoven fabric so that the elastic layer forms a membrane that envelops a plurality of fibers from the first fiber-entangled web, wherein after applying one or more of heat and pressure, the color on the first outward-facing side of the second region is a third color, the color on the first outward-facing side of the first region is a first color, and the second region forms a graphic on the first outward-facing side of the composite nonwoven fabric; wherein the heat and pressure are applied simultaneously. method.

2. 10. The method of applying a graphic to a composite nonwoven fabric of claim 1, wherein a deformable surface is positioned adjacent to an opposing second outward-facing side of the composite nonwoven fabric while applying one or more of heat and pressure to the second region of the first outward-facing side of the composite nonwoven fabric.

3. 3. The method of applying a graphic to a composite nonwoven fabric according to claim 1 or 2, wherein on the opposing second outward facing side of the composite nonwoven fabric, the color of the composite nonwoven fabric is a second color in the first and second regions.

4. The method of applying graphics to a composite nonwoven fabric of any one of claims 1 to 3, wherein a debossing tool applies one or more of heat and pressure to the second region of the composite nonwoven fabric.

5. 5. The method of applying a graphic to a composite nonwoven fabric of claim 4, wherein the debossing tool is configured to apply heat to the second region of the first outward-facing side of the composite nonwoven fabric at a temperature of 170°C to 190°C for 28 to 32 seconds.

6. 6. The method of applying a graphic to a composite nonwoven fabric according to claim 4 or 5, wherein the debossing tool is configured to apply heat to the second region of the first outward-facing side of the composite nonwoven fabric at 180°C for 30 seconds.

7. The method for applying graphics to a composite nonwoven fabric according to any one of claims 1 to 6, wherein the thickness of the composite nonwoven fabric in the second region is 50% less than the thickness of the composite nonwoven fabric in the first region.

8. The method for applying a graphic to a composite nonwoven fabric according to any one of claims 1 to 7, wherein the thickness of the second entangled fiber web in the composite nonwoven fabric is within 95% of the thickness of each of the first region and the second region.

9. The method for applying graphics to a composite nonwoven fabric according to any one of claims 1 to 8, wherein at least the first color is different from the third color.

10. An article of clothing for the upper body, comprising: A composite nonwoven fabric constituting at least a portion of an upper-body garment, the composite nonwoven fabric comprising a first region and a second region, the first region comprising a first entangled fiber web, a second entangled fiber web, and an elastic layer positioned between the first entangled fiber web and the second entangled fiber web, the second region comprising a first debossed portion and the second entangled fiber web, the first debossed portion comprising a plurality of fibers from the first entangled fiber web integrated within the elastic layer, wherein the first debossed portion forms a first graphic; the first debossed portion is visible on the outer surface of the upper body clothing item; Upper body clothing.

11. The upper body garment of claim 10 , wherein the first debossed portion is not visible on the inner surface of the upper body garment.

12. 12. The upper body garment of claim 10 or 11, further comprising a second debossed portion comprising a plurality of fibers from the second entangled fiber web integrated within the elastic layer.

13. 13. The upper body apparel item of claim 12, wherein the second debossed portion defines a second graphic that is different in appearance from the first graphic.

14. The upper-body clothing item according to claim 12 or 13, wherein the second debossed portion is visible on an inner surface of the upper-body clothing item.

15. The upper body clothing item according to any one of claims 12 to 14, wherein the second debossed portion is not visible on an outer surface of the upper body clothing item.

16. The upper body clothing item of any one of claims 10 to 15, wherein the first entangled fiber web and the elastic layer have a first thickness in the first region, and the first debossed portion has a second thickness in the second region that is 50% smaller than the first thickness.

17. A composite nonwoven fabric, a first entangled fiber web; a second entangled fiber web; and an elastic layer formed of elastic fibers having a melting temperature lower than that of the fibers forming at least the first entangled fiber web, the composite nonwoven fabric including a first region in which the elastic layer is disposed between the first entangled fiber web and the second entangled fiber web, and a second region debossed relative to the first region, the second region in which the elastic layer is in the form of a film that encapsulates a plurality of fibers from the first entangled fiber web to form a debossed portion, and the second entangled fiber web is disposed below the debossed portion; A composite nonwoven fabric comprising:

18. 18. The composite nonwoven fabric of claim 17, wherein each of the first entangled fiber web and the second entangled fiber web comprises staple fibers having a length shorter than the length of the elastic fibers forming the elastic layer.

19. 19. The composite nonwoven fabric of claim 17 or 18, wherein the elastic fibers comprise at least one of meltblown fibers and spunbond fibers.

20. The composite nonwoven fabric of any one of claims 17 to 19, wherein the debossed portion has a different color than the first region of the first outward-facing side of the composite nonwoven fabric.

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