Methods for manufacturing a composite textile, textile or composite textile constructed using the method, roll good and article of apparel

Abstract

This disclosure relates to sustainable composite fabrics, and methods and systems for constructing composite fabrics and collecting and harvesting excess material (e.g., residual portions). In at least some instances, a first patterned sheet is cut from a first material layer, and a second patterned sheet is cut from a second material layer. Furthermore, the first patterned sheet can be separated from the first material layer, leaving a first residual portion, and the second patterned sheet can be separated from the second material layer, leaving a second residual portion. Once separated, the first patterned sheet can be stacked on top of the second patterned sheet, and the stacked patterned sheets can entangle to form a composite patterned sheet. The residual portion associated with the first material layer can be separated from and reused from the residual portion associated with the second material layer.

Description

Prior Art

[0001] Constructing a composite fabric (e.g., a composite nonwoven fabric) sometimes involves stacking material layers (e.g., a fiber web material layer and one or more other material layers) and then entangling the stacked material layers to form the composite fabric. After the stack of material layers has been entangled to form the composite fabric, one or more pattern pieces can be cut from the composite fabric (e.g., according to a pattern or template), and the one or more pattern pieces can then be used to form an article (e.g., clothing, footwear, bag, etc.). However, in some cases, collecting and reusing residual portions (e.g., portions of the composite fabric remaining after cutting the pattern pieces) can present challenges. For example, the material layers can be difficult to separate. Furthermore, when the material layers are separated, the residual portions associated with one material layer may include material (e.g., fibers) from another material layer, which can limit reusability. Summary of the Invention

[0002] The present disclosure relates to sustainable composite fabrics, as well as methods and systems for constructing composite fabrics and collecting and harvesting excess material (e.g., scraps). In at least some examples, a first pattern piece is cut from a first material layer, and a second pattern piece is cut from a second material layer. Furthermore, the first pattern piece can be separated from the first material layer, which can leave a first scrap, and the second pattern piece can be separated from the second material layer, which can leave a second scrap. Once separated, the first pattern piece can be stacked on top of the second pattern piece, and the stacked pattern pieces can be entangled to form a composite pattern piece. The scrap associated with the first material layer can be separated from the scrap associated with the second material layer and reused. Simple diagram description

[0003] The present disclosure relates to a composite fabric and a method and system for manufacturing the composite fabric.Examples will be described in detail below with reference to the drawings. [ FIG. 1A ] illustrates an example life cycle of an example composite fabric according to an example. [ FIG. 1B ] illustrates an example system for constructing at least a portion of a composite fabric according to examples of the present disclosure. [ FIG. 2A ] illustrates an operation for constructing a multi-layer pattern sheet according to an example of the present disclosure. [ FIG. 2B ] illustrates a cross-sectional view based on [ FIG. 2A ] according to an example of the present disclosure. [ FIG. 3 ] illustrates a fiber web remnant and operations associated with the fiber web remnant according to an example of the present disclosure. [FIGS. 4A] and [FIG. 4B] illustrate portions of a wearable article according to an example of the present disclosure. [ FIG. 5 ] includes a flow chart depicting steps associated with a method of manufacturing a composite fabric according to an example. Implementation Method

[0004] This embodiment relates to composite fabrics and methods and systems for manufacturing the same. At a high level, the subject matter described herein relates to sustainable composite fabrics and methods and systems for constructing the composite fabrics and for recovering and harvesting excess material (e.g., stubs). In at least some examples, a first material layer (e.g., a fiber web) is stacked on top of a second material layer.

[0005] In some cases, after the material layers are stacked, a first pattern piece is cut from the first material layer, and a second pattern piece is cut from the second material layer (e.g., the pattern pieces can be cut simultaneously by cutting through the stack). Additionally, the first pattern piece can be separated from the first material layer, which can leave a first residual portion, and the second pattern piece can be separated from the second material layer, which can leave a second residual portion.

[0006] Once separated from the residual portion, the first pattern piece and the second pattern piece can remain stacked (e.g., as a multi-layer pattern piece), and the stacked pattern pieces can be entangled, wrapped, or otherwise combined to form a composite pattern piece (e.g., by mechanical entanglement, thermal bonding, such as via a laser or heat press, etc.).

[0007] Furthermore, in some examples, when the first pattern piece and the second pattern piece are cut and separated, the first material layer and the second material layer are not entangled or intertwined (e.g., not subjected to mechanical entanglement, such as by a needle entanglement process, a hydroentanglement process, etc.). Thus, the remaining portion associated with the first material layer can be separated (e.g., peeled apart) from the remaining portion associated with the second material layer, and the remaining portion (or portions of the remaining portion) can be reused (e.g., recycled, reused, shredded, re-cut, re-pelletized, etc.).

[0008] In some examples, at least one material layer may comprise a nonwoven fabric (e.g., a fiber web formed from staple fibers, spunbond, hydroentangled, meltblown, etc.). Furthermore, both material layers may comprise nonwoven fabrics. In some cases, both material layers may comprise nonwoven materials formed using the same type of process (e.g., both material layers may comprise fiber webs formed from staple fibers, spunbond, hydroentangled, meltblown, etc.). In some cases, the material layers may comprise corresponding nonwoven fabrics formed using different processes, such that one nonwoven material layer is formed from one of staple fibers, spunbond filaments, hydroentangled filaments, or meltblown filaments, and the other nonwoven material layer is formed from a different type of staple fibers, spunbond filaments, hydroentangled filaments, or meltblown filaments. In some examples, the material layers may comprise material layers of a different type than the nonwoven fabric, such as other knitted fabrics, woven fabrics, films, etc. In some examples, the material layers may comprise a recyclable composite material comprising one or more different types of fabric layers.

[0009] Conventional methods associated with manufacturing composite fabrics (e.g., composite nonwoven fabrics) typically involve stacking and entangling a nonwoven layer (e.g., a fiber web) with one or more other material layers. In some cases, the nonwoven layer and the one or more other material layers may comprise different properties. For example, a nonwoven layer may comprise a fiber web stacked and entangling with one or more other fiber webs. In this case, the fiber web and the one or more other fiber webs may comprise various, respectively different properties. These respectively different properties may include, among other things, different fiber properties (e.g., denier, diameter, length, chemical composition, color properties, structure, shape, etc.) and different fiber web properties (e.g., basis weight, thickness, etc.). Furthermore, a fiber web (or multiple fiber webs) may be stacked and entangling with one or more other types of material layers, such as other nonwovens (e.g., spunbond, meltblown, etc.), films, webs, scrims, etc., which may also comprise various, respectively different properties. As indicated, stacked material layers (e.g., a fiber web with one or more other fiber webs and / or one or more other material layers) can be entangled to form a composite nonwoven fabric that can include properties resulting from the combined properties of the constituent material layers. Typically, after entanglement, pattern pieces can be cut from the composite nonwoven fabric and then removed from the composite nonwoven fabric for incorporation into a finished product (e.g., a wearable article, bag, etc.). However, once the pattern pieces are removed from the composite nonwoven fabric, separating the fiber web from the other material layers can be challenging. For example, due to entanglement, physically separating the fiber webs can be challenging. Furthermore, if the fiber web is separated from the entangled stack (e.g., by pulling the fiber web apart from the entangled stack), the fiber web can often include fibers, yarns, filaments, or other materials from the other layers with different properties, which can limit the usefulness of the fiber web for subsequent use. In some instances, the fiber web can be considered contaminated with materials from the other layers with different properties. Compared to conventional methods, the presently disclosed subject matter includes cutting pattern pieces from the fiber web prior to entanglement, which can allow the remaining portion of the fiber web to be more easily separated from other stacked layers and can increase the usefulness of the remaining portion in subsequent applications and / or for recycling.

[0010] As described above, examples of the present disclosure may include cutting pattern pieces from a fabric (or fabric layer) before the fabric is entangled, which can allow the remaining parts to be more easily separated from each other for subsequent applications. In at least one example, the present disclosure may include layering or stacking a nonwoven fabric (e.g., a fiber web, spunlace, spunbond, meltblown, etc.) with one or more other material layers (e.g., one or more other nonwovens, knits, wovens, and / or films, etc.) before cutting the pattern pieces. For example, the nonwoven fabric may include a fiber web that has been carded, lapped, and pre-needled, and then rolled onto a core as a fiber web roll. In some examples, the nonwoven fabric may include a homogeneous group of fibers (e.g., homogeneity based on one or more types of fibers or the distribution of different fiber types).

[0011] In addition, one or more other material layers (with which the fiber web is stacked) may also include corresponding rolls of material. In some examples, a length of the fiber web roll and a length of the one or more other material rolls may be unrolled (e.g., paid out), and the unrolled portions may be stacked or layered (e.g., one on top of the other).

[0012] In some examples, the fiber web and one or more other material layers may not comprise a roll, but may comprise other forms of material layers, such as rectangular or other garment shapes that can be stacked and from which pattern pieces can be cut. The other material layers may be manually positioned or automatically stacked relative to the one or more other layers.

[0013] The subject matter of the present disclosure may include various methods for material reabsorption (e.g., after stacking and cutting). In at least some examples, a portion of a nonwoven web (e.g., a fiber web) unwound from a first core may be attached to a second core that can be operated to roll up or rewind the unwound nonwoven fabric (e.g., after cutting a pattern piece). For example, the unwound portion of the nonwoven web may extend across the span, and the unwound edge may be attached to the second core. Furthermore, the second core may be attached to a drive assembly that rotates the second core with the unwound edge attached and unwound the nonwoven web from the first core. The drive assembly may include, for example, a hand crank attached to the second core, an electric motor that rotates the second core (e.g., via a belt), and the like.

[0014] In some examples, the portion of the nonwoven fabric that is unwound and extends between the core (e.g., the first core) and the second core of the web can be stacked or layered with one or more other material layers. In some examples, one or more other material layers can also be unwound and attached to respective other cores, which can also be operated to roll or rewind the material layers (e.g., after cutting the pattern piece). For example, these other second cores can also be coupled to a drive assembly (or to a separate drive assembly). Thus, one or more other material layers can also include an unwound portion that extends between the core (e.g., the first core) and the other roll or core, and can be stacked with the unwound portion of the fibrous web.

[0015] In at least some examples, once the nonwoven fabric is stacked with one or more other material layers, a pattern can be cut into the stacked material layers. This allows for the simultaneous creation of multiple pattern pieces (e.g., via the same cutting step). The pattern can be cut in a variety of ways. For example, a cutting tool (e.g., a knife, router, blade, die, laser, etc.) can simultaneously cut through the stacked material layers. In some examples, the cutting tool can traverse a pattern configured to create a shape associated with a pattern piece (e.g., a garment front pattern piece, a garment back pattern piece, an oversleeve pattern piece, a shoulder pattern piece, a yoke pattern piece, a footwear upper, etc.). In some examples, the cutting tool can include manual control. In some examples, the cutting tool can include automated control (e.g., computer numerical control).

[0016] Furthermore, the cutting tool may be associated with one or more other components. For example, the cutting tool may include a gantry that is positioned above the stacked material layers and supports the cutting tool as it traverses the pattern. In some examples, the cutting tool may include a laser (e.g., a CO2 laser) associated with a scanner that can be used to automatically detect characteristics of the material layers and adjust the laser accordingly.

[0017] In some examples, a negative pressure air source (e.g., a vacuum) can be operated on the stacked material layers at or near the area where the pattern piece is cut. Among other things, the negative pressure air can help hold the stacked material layers in place while the pattern piece is cut.

[0018] In some examples, after being cut, the plurality of pattern pieces (e.g., the non-woven pattern piece and one or more other pattern pieces associated with one or more other types of materials) can be separated from the stacked material layers. For example, the pattern pieces can fall from the stacked material layers (e.g., via gravity).

[0019] In some examples, the stacked material layers can be traversed across a surface (e.g., pulled by the rotation of a second core) to push the plurality of pattern pieces away from the stacked material layers, such that after the pattern pieces are removed, the stacked material layers include residual portions. In some examples, the surface can be or include a stationary rod. In some examples, the surface can be or include a roller. In some examples, the surface can include a rotating punch that presses the plurality of pattern pieces from the stacked material layers.

[0020] In some examples, when separated, the plurality of pattern pieces can remain stacked and the cut edges of the material layers can remain aligned. Additionally, once the plurality of pattern pieces are removed, the stacked layers can include residual portions that can remain attached to a second core configured to roll up the cut residual portions.

[0021] In at least some examples, after being separated from the stacked layers, multiple pattern pieces (e.g., a non-woven pattern piece and one or more other pattern pieces associated with one or more other types of materials) can be incorporated into a finished product. For example, as indicated, the multiple pattern pieces can remain stacked and aligned.

[0022] In some cases, the pattern pieces may undergo various processes to be incorporated into the finished product. For example, the pattern pieces may be entangled, wrapped, laminated, or otherwise combined with one another to form a composite fabric pattern piece. In some instances, the pattern pieces are mechanically entangled. In some instances, the pattern pieces are needle-punched. In some instances, the pattern pieces are fluid-entangled (e.g., with water or some other fluid medium). In some instances, the pattern pieces are laminated, such as by chemically bonding one layer to another. In some instances, the pattern pieces are thermally bonded (e.g., with a laser, heat press, etc.). In some instances, the pattern pieces are pressure-bonded.

[0023] Furthermore, some examples of the present disclosure may include processing the pattern piece using multiple, sequential assembly operations. For example, in some cases, the pattern piece may undergo an initial assembly operation configured to at least partially assemble the pattern piece (e.g., where "at least partially" may refer to assembling at least one region of the pattern piece, but not necessarily the entire contiguous surface of the pattern piece). Various techniques may be used to at least partially assemble the pattern piece. For example, the pattern piece may be entangled in one or more subregions of the pattern piece, and in particular, mechanically entangled (e.g., needle punching, fluid entanglement, etc.). Additionally or alternatively, the pattern piece may be welded, bonded with an adhesive, adhered, laser-treated, and / or otherwise assembled in one or more subregions. Furthermore, at least partially assembling the pattern piece can reduce the likelihood that the pattern pieces will become detached and / or misaligned, such as during the intermediate stages between the pattern piece being cut and ultimately incorporated into a finished product. Thus, the at least partially assembled pattern piece can be transported, stored, or otherwise handled before undergoing additional operations (e.g., entanglement, lamination, surface treatment, printing, etc.) for incorporation into a finished product.

[0024] In some examples, after the stacked pattern sheets are removed from the stacked material layers, the remaining portions (e.g., the non-woven web remaining portions and the one or more other material remaining portions) are at least partially rolled up (e.g., collected or rewound) via the corresponding second core. For example, as described above, the second core can be associated with a drive assembly that directly or indirectly drives (particularly rotates) the second core and winds the remaining portions around the second core.

[0025] Furthermore, the second core can be positioned (e.g., spaced apart) in such a manner that, when the material layer is rolled up, the layers of the residual portion are peeled away from each other. In some examples, when the pattern sheet is cut and separated, the nonwoven material layer (e.g., fibrous web) is not entangled or entangled with one or more other material layers (or is only minimally entangled or entangled with one or more other material layers). In this way, the residual portion associated with the nonwoven layer can be separated (e.g., peeled away) from the other material layers, allowing the nonwoven layer and / or the fibers, filaments, etc. included therein to be reused (e.g., recycled, reused, shredded, re-cut, re-pelletized, etc.).

[0026] In at least some examples, the nonwoven remnant can be at least partially reused in various ways (e.g., after being wound up on a second core). For example, as described above, the nonwoven web can include a homogeneous set of fibers before being cut into pattern pieces. In examples of the present disclosure, the nonwoven remnant can also include a homogeneous set of fibers (e.g., after the pattern pieces are cut and the nonwoven remnant is separated from other material layers) because the nonwoven remnant was not previously entangled (or only slightly entangled) with other material layers and can be separated from one or more other material layers. Thus, compared to other techniques where separating the nonwoven remnant is more challenging (e.g., due to a higher degree of entanglement), the nonwoven remnant of the present disclosure can include (e.g., provide) a homogeneous set of fibers (e.g., a higher percentage of a homogeneous set of fibers) for subsequent use. This homogeneous set of fibers can then be cut into additional pattern pieces, shredded, repelletized, etc. In some examples, the homogeneous set of fibers can include a set of fibers that includes a threshold percentage (e.g., by weight) of a desired set of fiber types. In some instances, the threshold percentage is based on industry standards for tolerances associated with variations in a group of fibers. In some instances, the threshold is about 90% or greater. In some instances, the threshold is about 95% or greater.

[0027] As used herein, the term "article of clothing" is intended to encompass articles worn by a wearer, which may also be referred to as "wearable articles." Wearable articles may include, among other things, upper body garments (e.g., tops, t-shirts, pullovers, hoodies, jackets, coats, vests, etc.), lower body garments (e.g., pants, shorts, leggings, pantyhose, bodysuits, etc.), hats, gloves, sleeves (e.g., arm sleeves, calf sleeves), footwear (e.g., shoe uppers), and the like. As used herein, the term "finished product" may include articles of clothing or wearable articles, equipment (such as bags), furniture, and other such items. As used herein, the term "roll stock" may include, for example, rolls of fabric, waste or remnants left after sheets are cut from a roll, and the like.

[0028] When referring to a wearable article, the term "inner-facing surface" means the surface that is configured to primarily face the wearer's body surface, and the term "outer-facing surface" means the surface that is configured to substantially face away from the wearer's body surface and toward the external environment. The term "innermost-facing surface" means the surface that is closest to the wearer's body surface relative to the other layers of the wearable article, and the term "outermost-facing surface" means the surface that is positioned farthest from the wearer's body surface relative to the other layers of the wearable article.

[0029] As used herein, the term "nonwoven fabric" refers to a fabric having fibers held together by mechanical and / or chemical interactions rather than being knitted, woven, braided, or otherwise structured. In one specific aspect, a nonwoven fabric comprises a collection of fibers that have been mechanically manipulated to form a mat-like material. In other words, the nonwoven fabric is made directly from fibers. A nonwoven fabric can include different fiber webs formed into a cohesive structure, wherein the different fiber webs can have different or similar fiber compositions and / or different properties.

[0030] Non-limiting examples of nonwoven fabrics include staple fiber nonwovens (e.g., formed by carding and needle entanglement or fluid entanglement), spunbond nonwovens, hydroentangled nonwovens, and meltblown nonwovens. In other words, the bonding of the fibers in the nonwoven fabric can be achieved using thermal bonding (with or without calendering), hydraulic entanglement, ultrasonic bonding, needle punching (needle felting), chemical bonding (e.g., using a binder such as a latex emulsion or solution polymer or binder fiber or powder), meltblown bonding (e.g., fibers are bonded during simultaneous fiber and web formation with air-weakened fiber entanglement), spunbonding, and any combination thereof.

[0031] The terms "web of fibers" or "fibrous web" refer to a layer of fibers prior to mechanical entanglement with one or more other fibrous webs. A fibrous web comprises fibers that have undergone a carding and bonding process, which typically aligns the fibers in one or more common directions extending along the x, y planes and achieves a desired basis weight. The fibrous web may also undergo a light needling process or mechanical entanglement process, which entangles the fibers of the web to a degree that forms a cohesive structure that can be manipulated (e.g., wound onto a roll, unwound from a roll, stacked, etc.). In examples, a "fibrous web roll" refers to fibers that have been formed into a cohesive structure (e.g., by carding, bonding, and / or light needling) and wound onto a core. The fibrous web may also 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 it has been mechanically entangled with one or more other fibrous webs (e.g., needle punching, hydroentanglement, air entanglement, etc.). As such, the entangled fibrous web may include fibers originally present in the fibrous web that formed the layer, as well as fibers present in the other fibrous webs that have been moved into the entangled fibrous web by the entanglement process.

[0032] Mechanical entanglement processes contemplated herein may include needle entanglement (commonly referred to as needling) using barbed or structured needles (e.g., forked needles), and / or fluid entanglement. In various aspects contemplated herein, needling may be utilized based on the low denier of the fibers used and the ability to fine-tune various parameters associated with the needling process. Needling typically uses barbed or pointed needles to reorient a proportion of the fibers from a generally horizontal orientation (one extending along the x, y plane) to a generally vertical orientation (one oriented in the z direction). With general reference to the needling process, a carded, overlapped, and pre-needled web may be stacked with other carded, overlapped, and pre-needled webs and other layers (such as an elastomeric layer) and passed between a base plate and a stripper plate positioned on opposite sides of the stacked web configuration.

[0033] Barbed needles attached to the needle plate move in and out of the stacked web configuration, and a stripper plate strips the fibers from the needles as they move in and out of the stacked web configuration. The distance between the stripper plate and the base plate can be adjusted to control web compression during needling. As the stacked web configuration moves in the machine direction along the conveyor system, the needle plate repeatedly engages and disengages the stacked web configuration, allowing the length of the stacked web configuration to be needled.

[0034] Aspects herein contemplate the use of multiple needle boards positioned sequentially at different points along a conveyor system, wherein different needle boards can engage the stacked web configuration from different sides (e.g., top and bottom) of the stacked web configuration as the stacked web configuration moves in the machine direction. Each engagement of the needle board with the stacked web configuration is referred to herein as a "pass."

[0035] Parameters associated with a particular needle plate can be adjusted to achieve the desired properties of the resulting needle-punched nonwoven fabric (e.g., basis weight, thickness, etc.). Different parameters can include stitch density (SD), which is the number of needles per cm² (n / cm²) used during the entangling process, and penetration depth (PD), which is the distance the needles penetrate the stacked web configuration before being withdrawn from the stacked web configuration. Parameters associated with the needling process, such as the spacing between the base plate and the stripper plate, and the transport speed of the stacked web configuration, can also typically be adjusted.

[0036] Examples of the present disclosure contemplate the use of barbed needles (needles having a predetermined number of barbs arranged along the length of the needle), but other needle types are also contemplated herein. The barbs on the needle "capture" fibers as the barbs move from a first side of a stacked web configuration to an opposing second side. Movement of the needle through the stacked web configuration effectively moves or propels the fibers captured by the barbs from a position near or at the first side to a position near or at the second side, further inducing physical interaction with other fibers, thereby "locking" the moved fibers into place, for example, through friction.

[0037] It is also contemplated herein that the needles can be threaded through the stacked web configuration from the second side toward the first side. In an exemplary aspect, the number of barbs on the needles that interact with the fibers can be based on the penetration depth of the needles. For example, when the penetration depth is a first amount, all barbs can interact with the fibers, and as the penetration depth decreases, fewer than all barbs can interact with the fibers.

[0038] In another exemplary aspect, the size of the barbs can be adjusted based on the denier of the fibers used in the web. For example, the barb size can be selected to engage with small denier (e.g., fine) fibers but not with large denier fibers, thereby selectively moving small denier fibers but not large denier fibers. In another example, the barb size can be selected to engage with both small and large denier fibers to move both fibers through the web.

[0039] After entanglement, the nonwoven fabric can include a first side and an opposing second side, both of which face outward relative to the interior of the nonwoven fabric and comprise the outermost surface of the nonwoven fabric. Thus, when viewing the nonwoven fabric, the first side and the second side are each fully visible. The first side and the second side can both extend along x,y planes that are generally parallel to and offset from each other. For example, the first side can be oriented in a first x,y plane, and the second side can be oriented in a second x,y plane that is generally parallel to and offset from the first x,y plane.

[0040] As used herein, the term "elastomeric layer" refers to a layer having stretch and recovery properties (e.g., elastic resiliency) along at least one orientation axis, including layers having stretch and recovery along a single orientation axis and layers having stretch and recovery along multiple orientation axes. Examples of orientation axes include the length direction, the width direction, the x-direction, the y-direction, and any direction that is angularly offset from the length direction, the width direction, the x-direction, and the y-direction.

[0041] The elastomeric layer can be formed from a thermoplastic elastomer (such as thermoplastic polyurethane (TPU), thermoplastic polyetherester elastomer (TPEE), a combination of TPU and TPEE, etc.). The elastomeric layer can include a spunbond layer, a meltblown layer, a film, a web, a scrim, etc. In exemplary aspects, the elastomeric layer can include spunbond TPEE or meltblown TPU. Non-woven elastomeric materials, such as spunbond TPEE or meltblown TPU, allow for lower basis weights than elastomeric films. Similarly, due to the fibrous nature of webs relative to films, they are generally more breathable and permeable, and they are generally more flexible (e.g., less stiff) than films. These factors (low basis weight, breathable and permeable, and flexible) make them ideal for use in the exemplary composite nonwoven fabrics described herein, particularly in the context of apparel where these factors are desirable characteristics.

[0042] When referring to fibers, the term denier or denier per fiber is a unit of measure for the linear mass density of the fiber, more specifically, the mass in grams per 9000 meters of fiber. In one exemplary aspect, the denier of a fiber can be measured using ASTM D1577-07. The diameter of a fiber can be calculated based on the denier of the fiber and the density of the fiber, and generally, the diameter of a fiber is directly related to the denier of the fiber (i.e., a fiber with a smaller denier has a smaller diameter).

[0043] As used in this disclosure, the terms "filament," "fiber," or "fibers" refer to a material or structure in the form of discrete, elongated pieces that are significantly larger than their width. Fibers can include natural, man-made, or synthetic fibers. Fibers can be produced by conventional techniques, such as extrusion, electrospinning, interfacial polymerization, drawing, and the like.

[0044] The fibers may include carbon fibers, boron fibers, silicon carbide fibers, titanium dioxide fibers, aluminum oxide fibers, quartz fibers, glass fibers such as E, A, C, ECR, R, S, D, and NE glass and quartz, etc. The fibers may be fibers formed from synthetic polymers capable of forming fibers, such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyester (e.g., polyethylene terephthalate (PET)), polyolefin (e.g., polyethylene, polypropylene), aromatic polyamide (e.g., aramid polymers such as para-aramid fiber and meta-aramid fiber), aromatic polyimide, polybenzimidazole, polyetherimide, polytetrafluoroethylene, acrylic, modified acrylic, poly(vinyl alcohol), polyamide, polyurethane, and copolymers such as polyether-polyurea copolymer, polyester-polyurethane, polyether block amide copolymer, etc. The fibers can be natural fibers (e.g., silk, wool, cashmere, vicuna, cotton, flax, hemp, jute, sisal). The fibers can be man-made fibers made from regenerated natural polymers such as rayon, lyocell, acetate, triacetate, rubber, and poly(lactic acid).

[0045] Fibers may include virgin fibers (fibers that are not recycled) and / or recycled fibers. Recycled fibers include "chopped product fibers" and "regranulated polymer fibers." As used herein, chopped product fibers include fibers that are a direct byproduct of shredding fiber-containing products (e.g., knitted, woven, nonwoven, etc.). In some examples, chopped product fibers can be obtained without pelletizing and extruding through processes that consume less energy, and thus, fabrics incorporating chopped product fibers can have a lower carbon footprint. Regranulated polymer fibers include fibers extruded from pelletized or chopped byproducts derived from polymer-containing sources (e.g., polymer-containing bottles or containers; knitted, woven, nonwoven polymer fiber products; roll stock; fabric manufacturing waste; fiber webs at various stages of carding, splicing, pre-needling, and needlepunching, etc.).

[0046] Fibers can have varying lengths. For example, man-made and synthetic fibers are typically extruded in substantially continuous strands. Alternatively, the fibers can be staple fibers, such as cotton fibers or extruded synthetic polymer fibers, which can be cut to form staple fibers of relatively uniform length. Staple fibers can have lengths ranging from approximately 1 mm to 100 cm or more, and any increments therein (e.g., 1 mm increments). In some examples, the length is between 30 mm and 60 mm. In some examples, the length is approximately 38 mm. In some examples, the length is approximately 51 mm.

[0047] Fibers can have any of a variety of cross-sectional shapes. Natural fibers can have a natural cross-section, or they can have a modified cross-sectional shape (e.g., using a process such as mercerizing). Man-made or synthetic fibers can be extruded to provide strands with a predetermined cross-sectional shape. The cross-sectional shape of a fiber can affect its properties, such as its softness, luster, and wicking ability. Fibers can have a circular or substantially circular cross-section. Alternatively, fibers can have a non-circular cross-section, such as flat, oval, octagonal, rectangular, wedge-shaped, triangular, dog-bone, multilobed, multi-channel, hollow, core-shell, or other shapes.

[0048] The fibers can be multicomponent fibers, such as fibers comprising two or more coextruded polymeric materials. The two or more coextruded polymeric materials can be extruded in a core-sheath, island, segmented, striped, or side-by-side configuration. The multicomponent fibers can be processed to form a plurality of smaller fibers (e.g., microfibers) from a single fiber, for example, by removing a sacrificial material.

[0049] As used herein, the term "yarn" refers to an assembly of one or more fibers wherein the strands are of considerable length and relatively small cross-section and suitable for use in the production of fabrics, either by hand or by machine, including fabrics made using weaving, knitting, crocheting, plaiting, sewing, embroidery, or rope-making techniques. Thread is a type of yarn commonly used for sewing.

[0050] Fibers and / or yarns can be manipulated in various ways (such as by knitting, weaving, braiding, and non-woven techniques) to construct a fabric. As used herein, a fabric or fabric layer can include knits, braids, non-wovens, braids, and films (e.g., extruded films).

[0051] As used herein, the term "silicone-coated fiber" may 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 may form a core and the silicone may form a sheath surrounding the core. In other example aspects, the term "silicone-coated fiber" may refer to a fiber having a discontinuous silicone coating in at least some areas along its length. For example, the fiber may be spray-coated with the silicone coating. In this regard, if a particular fiber web comprises 100% by weight silicone-coated fibers, it is contemplated herein that the fibers forming the web may have areas that do not include the silicone coating. It is contemplated herein that the silicone-coated fibers may be incorporated into a fiber web forming a composite nonwoven fabric. In other words, the silicone coating on the fibers is not applied to the fibers after the composite nonwoven fabric is formed using, for example, a silicone spray finish.

[0052] When referring to nonwoven fabrics, the terms "color" or "color characteristic," as used herein, generally refer to the observable color of the fibers forming the fabric. Such aspects contemplate that the color can be any color that can be imparted to a fiber 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, violet, white, black, and shades thereof. In one exemplary aspect, the color can be imparted to the fiber as it is formed (commonly referred to as solution dyeing). In solution dyeing, the color is added to the fiber as it is extruded, such that the color is integral to the fiber and is not added to the fiber in a post-forming step (e.g., by piece dyeing).

[0053] Aspects related to color also contemplate determining whether one color is different from another. In these aspects, color can include a digital color value that can be determined using an instrument that objectively measures and / or calculates the color value of an object by standardizing and / or quantifying factors that may affect color perception. Such instruments include, but are not limited to, spectroradiometers, spectrophotometers, and the like. Thus, aspects herein contemplate that the "color" of a fabric provided by a fiber can include a digital color value measured and / or calculated using a spectroradiometer and / or spectrophotometer. Furthermore, the digital color value can be associated with a color space or color model, which is a specific color organization that provides color representations for the digital color values, and thus, each digital color value corresponds to a single color represented in the color space or color model.

[0054] In these aspects, if the digital color values ​​of each color are different, it can be determined that one color is different from another color. Such a determination can be made by measuring and / or calculating the digital color values ​​of, for example, a first fabric having a first color using a spectroradiometer or a spectrophotometer, measuring and / or calculating the digital color values ​​of a second fabric having a second color using the same instrument (i.e., if the spectrophotometer is used to measure the digital color values ​​of the first color, the spectrophotometer is used to measure the digital color values ​​of the second color), and comparing the digital color values ​​of the first color to the digital color values ​​of the second color.

[0055] In another example, the determination can be made by measuring and / or calculating digital color values ​​of a first area of ​​the fabric using a spectroradiometer or spectrophotometer, measuring and / or calculating digital color values ​​of a second area of ​​the fabric having a second color using the same instrument, and comparing the digital color values ​​of the first color to the digital color values ​​of the second color. If the digital color values ​​are not equal, then the first color or first color characteristic is different from the second color or second color characteristic, and vice versa.

[0056] Furthermore, it is contemplated that the visual distinction between two colors can be related to the percentage difference between the digital color value of the first color and the digital color value of the second color, with the visual distinction increasing as the percentage difference between the color values ​​increases. Furthermore, the visual distinction can be based on a comparison between color representations of color values ​​in a color space or model. For example, when a first color has a digital color value corresponding to a representation of black or dark blue, and a second color has a digital color value corresponding to a representation of red or yellow, the visual distinction between the first color and the second color is greater than the visual distinction between the first color when the representation is red and the second color when the representation is yellow.

[0057] As used herein, the term "homogeneous" can describe fibers and a group of fibers and refers to the quality of having relatively uniform properties. The term "homogeneity" refers to the degree to which a fiber or a group of fibers is homogeneous. Homogeneity can be used to describe fibers or fiber webs at various stages of processing (e.g., entanglement), such as when the fibers or fiber webs are carded, spliced, pre-needled, entangled with other fiber webs, in composite nonwoven fabrics, in multi-layer patterned sheets, in fiber web remnants, chopped, re-extruded, etc. Homogeneity can be based on one or more properties, such as fiber length, denier, diameter, color characteristics, and chemical composition. Homogeneity can be measured in various ways. In one example, homogeneity can be based on measurements applied to individual fibers. In one example, homogeneity can be based on a unit area of ​​the fiber web, which can be defined as 1 cm x 1 cm (1 cm²).

[0058] The term "unit area" may describe a portion of a fabric used to evaluate a property of the fabric. In some examples, the unit area may comprise 1 cm x 1 cm (1 cm²), although other sizes may be used as needed or based on the property being evaluated. In some examples, a "unit volume" may be used to evaluate a property of a fabric, and the unit volume may comprise 1 cm x 1 cm x n, where n is the depth or thickness associated with the fabric. In some examples, n is the entire thickness of the fabric or the thickness of a layer within the fabric (e.g., the thickness of a fiber web within the fabric). Other unit volume sizes may also be used as needed or based on the property being evaluated.

[0059] Homogeneity can be measured in various ways, depending on the property being measured. For example, homogeneity can be determined by analyzing fibers within a unit area to measure one or more fiber properties (e.g., denier, diameter, length, color properties, chemical composition, etc.) and determining the percentage of fibers that share a common property. In some examples, material composition can be based on one or more of various known chemical analysis methods, and homogeneity can be based on the percentage of material within a unit area that shares a common chemical composition. Color properties can be determined as described elsewhere in this disclosure.

[0060] In at least some instances, homogeneity (e.g., the degree or relative amount of homogeneity) can be determined based on the average measured parameter in n number of regions of interest (ROIs) having a standard deviation from the mean equal to or less than "X" units. In some instances, a characteristic can be considered homogeneous when the standard deviation is 5.0 or less, and highly homogeneous when the standard deviation is 1.0 or less. In at least some instances, n can be at least 3 or greater.

[0061] For example, if within a fabric (e.g., a fiber web, a composite nonwoven fabric, etc.), the basis weights of four ROIs are 84, 87, 87, and 88, the average basis weight is 86.5, and the standard deviation is 1.73. In instances where homogeneity is based on a standard deviation of 5.0 or less, the fabric can be considered homogeneous based on basis weight. If the basis weights are 84, 85, 85, and 86, the average basis weight would be 85, the standard deviation would be 0.82, and where a standard deviation of 1.0 or less indicates high homogeneity, the fabric can be considered highly homogeneous relative to basis weight.

[0062] As used herein, the terms "pill" and "pilling" refer to the formation of small balls of fibers or fiber ends on the face of a nonwoven fabric. Pills can extend away from the surface plane of the face. Pills typically form during normal laundering and wear when fiber ends migrate through the face of a nonwoven fabric and become entangled with other fiber ends due to forces (e.g., abrasion). Pilling resistance of a fabric can be measured using standardized tests such as the Random Tumble and Martindale Pilling tests. As used herein, the term "pile" generally refers to the raised surface or pile of a fabric, which is composed of upright loops and / or ends of fibers extending in a common direction from the face of the fabric.

[0063] Various measurements related to the pre-entangled web and the resulting composite nonwoven fabric are provided herein. The thickness of the resulting composite nonwoven fabric can be measured using a precision thickness gauge. For example, to measure the thickness, the fabric can be positioned on a flat anvil and a pressure foot pressed against the fabric from the upper surface under a standard fixed load. The dial indicator on the precision thickness gauge provides an indication of the thickness in millimeters. Basis weight is measured using the ISO 3801 test standard and is expressed in grams per square meter (gsm). Fabric stiffness, which generally corresponds to drape, is measured using the ASTM D 4032 (2008) test standard and is expressed in kilograms-force (kgf). Textile growth and recovery are measured using the ASTM 2594 test standard and are expressed as a percentage.

[0064] As used herein, the term "stretch" refers to a fabric characteristic that increases a specified distance under a specified tension, and is typically expressed as a percentage of the original reference distance (i.e., resting length or width). As used herein, the term "growth" refers to the increase in a specified reference distance (i.e., resting length or width) upon release of tension after being stretched to a specified tension for a specified interval, and is typically expressed as a percentage of the original reference distance. As used herein, "recovery" refers to the fabric's ability to return to its original reference distance (i.e., its resting length or width), and is expressed as a percentage of the original reference distance. Thermal resistance, which typically corresponds to insulation characteristics, is measured using the ISO 11092 test standard and is measured in units of RCT (M² * K / W).

[0065] Unless otherwise stated, all measurements presented in this paper were made at standard ambient temperature and pressure (25 °C or 298.15 K and 1 bar) with the nonwoven fabric in a static (unstretched) state.

[0066] As used herein, unless otherwise indicated, the term "about" generally means within ±10% of the indicated value.

[0067] Referring to FIG. 1A , FIG. 1A is a schematic diagram illustrating an example lifecycle of a composite nonwoven fabric contemplated herein. Reference numeral 10 generally designates a first nonwoven layer 12, a second nonwoven layer 14, a third nonwoven layer 16, and an elastomeric layer 18 in a stacked configuration prior to entanglement. It is contemplated herein that, in some example aspects, one or more of the nonwoven layers may be optional. For example, in some instances, the composite nonwoven fabric may include only the first nonwoven layer 12 and a second material layer (e.g., the second nonwoven layer 14). One or more of the nonwoven layers may comprise a fiber web. Furthermore, the composite material may include additional material layers (e.g., one or more layers comprising a thermoplastic polymer material).

[0068] In an example, the fibers used to form the first, second, and third nonwoven layers 12, 14, and 16 may include recycled fibers. Additionally, in an example aspect, the elastomeric layer 18 may be formed from a recyclable material. Arrow 20 schematically represents an entangling step, in which the fibers in the first, second, and third nonwoven layers 12, 14, and 16 become entangled with one another, such that one or more fibers extend through the elastomeric layer 18 to form a cohesive composite nonwoven fabric 22. Arrow 24 schematically represents a processing step, in which the composite nonwoven fabric 22 is formed into a wearable article 26. While the wearable article 26 is illustrated as an upper body garment, it is contemplated herein that the wearable article 26 may take other forms, such as lower body garments, shoe uppers, hats, gloves, oversleeves, and the like.

[0069] At the end of the useful life of wearable article 26, it is contemplated that the wearer may return wearable article 26 to, for example, a manufacturer / retailer, where wearable article 26 may be partially or fully recycled, as indicated by arrow 28, to form chopped fibers and / or re-extruded fibers, which are used to form nonwoven fabrics, such as nonwoven layers 12, 14, and 16, and possibly an elastomeric layer (such as elastomeric layer 18), thereby forming a self-sustaining cycle. In some examples, one or more of the chopped fibers and re-extruded fibers may be combined with virgin fibers (e.g., virgin polyester fibers) to form the nonwoven fabric. This self-sustaining cycle reduces the carbon impact typically associated with making articles of apparel, including knitted, woven, and nonwoven articles of apparel. The life cycle associated with FIG. 1A may include various other stages or elements that contribute to sustainability and reduced carbon impact.

[0070] FIG. 1B includes at least some examples associated with the present disclosure and, at a high level, depicts a system 110 for constructing a composite fabric (e.g., the composite fabric used to construct wearable article 26 in FIG. 1A ). In some examples, system 110 can construct a pattern piece (e.g., multi-layer pattern piece 150) for constructing at least a portion of a wearable article (e.g., wearable article 26 in FIG. 1A ). Furthermore, in some cases, system 110 can enhance the ability to reuse residual parts as part of the cycle or life cycle described in conjunction with FIG. 1A .

[0071] In an example, FIG1B includes a yarn feeder assembly 112 configured to store fabric and / or feed the fabric to other portions of the system, and a collection assembly 114 configured to, for example, roll up the fabric after it has been processed by other portions of the system 110. Furthermore, FIG1B includes a first fabric 116, a second fabric 118, a third fabric 120, and / or a fourth fabric 122 extending between the yarn feeder assembly 112 and the collection assembly 114. The yarn feeder assembly 112 may include fewer fabrics (e.g., a single fabric such as 116 or two fabrics such as 116 and 118) and may include more fabrics or different fabrics (e.g., additional or different fabrics than 116, 118, 120, and 122).

[0072] In some examples, the system 110 may include a cutting assembly 124 positioned between the yarn feeding assembly 112 and the collecting assembly 114 and configured to cut pattern pieces from the first fabric 116, the second fabric 118, the third fabric 120, and the fourth fabric 122. Furthermore, the system 110 may include a transport assembly 126 to transport the pattern pieces cut from the first fabric 116, the second fabric 118, the third fabric 120, and / or the fourth fabric 122, and a pre-treatment assembly 128 to pre-treat the pattern pieces before incorporating them into a wearable article or other finished product (e.g., a bag).

[0073] According to one example, FIG. 1B includes four fabric layers. In some examples, system 110 can be used with one or more fabric layers. One or more of fabrics 116, 118, 120, and 122 can be omitted. Furthermore, one or more fabrics in addition to fabrics 116, 118, 120, and 122 can be added to the system.

[0074] In some instances, system 110 may include fewer subcomponents, such that one or more of the subcomponents of FIG. 1B may be omitted.

[0075] In some instances, system 110 may include different subcomponents, such that one or more of the subcomponents of Figure 1 B may be replaced. In some instances, system 110 may include additional subcomponents, such that one or more subcomponents may be added to those depicted in Figure 1B.

[0076] Additional or different subassemblies may include a pick and place subassembly that places the articles onto layers of the stack.

[0077] Additional or different subassemblies may include a fiber sprayer that deposits fibers (eg, staple fibers, hydroentangled, spunbond, or meltblown) onto the stacked layers.

[0078] Additional or different subassemblies may include an entangling head (eg, needles or fluid) that can entangling the fiber layers.

[0079] Additional or different subassemblies may include an embroidery head or a sewing head or a stitching head.

[0080] Additional or different subassemblies may include a print head, such as a print head for depositing ink or other colorants, or a 3D print head for depositing materials.

[0081] Additional or different subassemblies may include a laser head.

[0082] In some examples, the yarn feeder assembly 112 can include one or more support structures 130a and 130b for rotatably supporting the webs. For example, the support structures 130a and 130b can include a plurality of pins (e.g., extending between the support structures 130a and 130b), posts (e.g., extending from each support structure, but not necessarily connecting the support structures 130a and 130b), or other core connectors that can be inserted into openings on either side of the web core (hollow core) or otherwise attached to the core. According to an example, FIG. 1B depicts four webs associated with a respective one of the first fabric 116, the second fabric 118, the third fabric 120, and the fourth fabric 122.

[0083] The fabrics may include a variety of different fabrics. For example, at least one of fabrics 116, 118, 120, and 122 may include a nonwoven fiber web, such as a fiber web comprising entangled staple fibers. In some examples, at least one of fabrics 116, 118, 120, and 122 may include other types of nonwoven fabrics (e.g., spunbond, spunlace, meltblown, etc.). In some examples, at least one of fabrics 116, 118, 120, and 122 may include a woven fabric. In some examples, at least one of fabrics 116, 118, 120, and 122 may include a knitted fabric. In some examples, at least one of fabrics 116, 118, 120, and 122 may include a film. In some examples, at least one of fabrics 116, 118, 120, and 122 may include a web or scrim. In some examples, at least one of fabrics 116, 118, 120, and 122 may include a composite of multiple fabrics. In some cases, a composite of multiple fabrics can include two or more fabric layers that can be recycled together. For example, a two-layer composite can include a first nonwoven layer that includes polyester fibers laminated with a TPEE film, where the TPEE and polyester fibers can be recycled together. In some examples, at least one of fabrics 116, 118, 120, and 122 can include a carrier layer for supporting one or more other layers as they are co-fed through system 110.

[0084] As indicated, one or more of fabrics 116, 118, 120, and 122 may comprise fiber webs, and the fiber webs may have at least partially different properties that may be selected to achieve the desired final properties of the multi-layer pattern sheet 150. In other words, a first fiber web may comprise a first property, and a second material layer (e.g., a second fiber web or a nonwoven fabric formed by a nonwoven process other than entangled staple fibers or a knitted or woven fabric) may comprise a second property that corresponds to the first property (e.g., is the same type of property) and is different from the first property (e.g., has a different quality or amount). Examples of properties may include at least one of the chemical composition of the fibers, the average denier of the fibers, the average diameter of the fibers, the average length of the fibers, a surface coating applied to the respective webs, and / or the color of the fibers.

[0085] The properties of fabric 116 can be selected based on various criteria. For example, when fabric 116 is incorporated into a multi-layer pattern piece 150, these properties can be based on the fabric forming the outermost or innermost surface of the wearable article. In some examples, two or more of fabrics 116, 118, 120, and 122 can comprise corresponding fiber webs. In some examples, the fiber webs can be asymmetric (e.g., comprising one or more different properties). In some examples, the fiber webs can comprise the same properties. In some examples, any of fabrics 116, 118, 120, and 122 can comprise any fiber described herein, including any material (e.g., PET, polyamide, cotton, etc.), any shape, silicone-coated, monofilament, multi-component, virgin, recycled, chopped, regranulated, and the like.

[0086] In examples, any of the fabrics 116, 118, 120, and 122 can include various basis weights. For example, the basis weight can be from about 20 grams per square meter (gsm) to about 150 gsm, from about 35 gsm to about 65 gsm, from about 40 gsm to about 60 gsm, from about 45 gsm to about 55 gsm, or about 50 gsm.

[0087] In an example, any of fabrics 116, 118, 120, and 122 may include fibers having a staple length ranging from about 20 mm to about 110 mm, from about 30 mm to about 65 mm, from about 40 mm to about 60 mm, from about 45 mm to about 55 mm, or about 51 mm. The fibers may comprise a uniform length, such as when the fibers are formed from virgin extruded material (e.g., PET or polyamide) or re-extruded material (e.g., PET or polyamide) and cut into defined lengths. In other aspects, the fibers may comprise a variation in staple lengths, such as when the fibers are derived from a chopped fiber source. Any and all aspects, and any variations thereof, are contemplated within the various aspects herein.

[0088] In an example, any of fabrics 116, 118, 120, and 122 may include fibers having a denier greater than or equal to about 1.0 D, or from about 1.2 D to about 3.5 D, from about 1.2 D to about 1.7 D, from about 1.3 D to about 1.6 D, or about 1.5 D. Additionally, any of fabrics 116, 118, 120, and 122 may include fibers having a denier less than or equal to about 1 D. For example, the denier may be about 0.1 D, about 0.2 D, about 0.3 D, about 0.4 D, about 0.5 D, about 0.6 D, about 0.7 D, about 0.8 D, or about 0.9 D.

[0089] In an example, any of fabrics 116, 118, 120, and 122 can include fibers having at least one color characteristic. The color characteristic can be imparted to the fibers during, for example, an extrusion process, when the fibers are formed such that the fibers are solution-dyed. In one exemplary aspect, the color characteristic can be white, although other colors are contemplated herein.

[0090] In addition, any of the fabrics 116, 118, 120, and 122 can include or be an elastomeric layer. In an example, the elastomeric layer can have a basis weight of from about 20 gsm to about 150 gsm, from about 50 gsm to about 70 gsm, from about 55 gsm to about 65 gsm, or about 60 gsm.

[0091] Aspects herein contemplate forming the elastomeric layer from a thermoplastic polymer (e.g., a thermoplastic elastomer) such as thermoplastic polyurethane (TPU), thermoplastic polyetherester elastomer (TPEE), a combination of TPU and TPEE, etc. The elastomeric layer may include a spunbond layer, a meltblown layer, a film, a web, a scrim, etc.

[0092] In addition, the elastomer layer may include a TPEE spunbond layer or a TPU meltblown layer. Typically, the elastomer layer may be selected to provide the multilayer pattern sheet 150 with desired stretch and recovery properties and / or breathability.

[0093] In an example, the yarn feeder assembly 112 can passively feed or pay out fabric. For example, where the fabric is rotatably supported by the support structures 130a and 130b, the fabric can be paid out or extended by simply pulling on the free end of the fabric, which can cause the fabric roll to rotate on the support structures 130a and 130b.

[0094] In some examples, the yarn feeder assembly 112 can actively feed or pay out fabric. For example, one or more of the support structures 130a and 130b can include a rotatable crank or other mechanism that, when turned (e.g., manually or by a motor), also rotates the cores of the webs. In some examples, the support structures 130a and 130b can include a belt-driven mechanism that is attached to each of the cores and, when in operation, rotates the plurality of fabric webs.

[0095] In some examples, the yarn feeder assembly 112 may include alternative structures that are different from or in addition to the support structures 130a and 130b. For example, the yarn feeder assembly 112 may include upstream fabric processing equipment that forms the fabrics. For example, if one of the fabrics comprises a fiber web, the yarn feeder assembly 112 may include a carding machine, a splicer, and / or an entangling device or entangling assembly (e.g., for lighter pre-entanglement), allowing the fiber web to be fed directly into the system 110 without forming into a roll. In another example, the fabrics may comprise other nonwovens (such as hydroentangled or spunbond), and the yarn feeder assembly may include equipment for forming these nonwovens, allowing the nonwovens to be fed directly into the system 110 without forming into a roll.

[0096] In at least some examples, one or more of first fabric 116, second fabric 118, third fabric 120, and fourth fabric 122 can include a homogeneous composition with respect to a given property. For example, one or more of first fabric 116, second fabric 118, third fabric 120, and fourth fabric 122 can include a nonwoven fabric that includes a homogeneous composition of fibers, which can be determined based on a unit area having fibers containing at least 90% of a measured property (e.g., fiber length, fiber denier, fiber diameter, color property, or chemical composition). In some examples, the nonwoven fabric can include at least 95% homogeneity with respect to a measured property. In some examples, the nonwoven fabric can include at least 98% homogeneity with respect to a measured property.

[0097] In some examples, the first fabric 116, the second fabric 118, the third fabric 120, and / or the fourth fabric 122 can extend between the yarn feeder assembly 112 and the collection assembly 114. For example, the yarn feeder assembly 112 can include a first set of one or more cores (e.g., one for each fabric), and the collection assembly 114 can further include a second set of cores (e.g., one for each fabric) rotatably supported on support structures 132a and 132b. Furthermore, the first fabric 116, the second fabric 118, the third fabric 120, and the fourth fabric 122 can be unwound from the yarn feeder assembly 112 and attached to the corresponding cores of the collection assembly 114.

[0098] In some examples, the collection assembly 114 can actively wind up the fabric. For example, the core of the collection assembly can be manually rotated (e.g., by cranking), which in turn pulls the fabric from the feeder assembly 112 onto the core of the collection assembly 114. In some examples, the collection assembly 114 can automatically wind up the fabric. For example, one or more of the support structures 132a and 132b can include at least one motor that rotates the cores and, in operation, the plurality of webs. In some examples, the drive mechanism can include a motor (not shown) that moves a belt 134 attached to the rotatable core.

[0099] In some examples, one or more of the fabrics 116, 118, 120, and 122 can be extended between the yarn feeder assembly 112 and the collection assembly 114 in various ways. In at least some examples, sections of the fabrics 116, 118, 120, and / or 122 that are extended between the yarn feeder assembly 112 and the collection assembly 114 are stacked on top of each other to form a fabric stack (e.g., 136 includes the extended sections or portions). Among other things, arranging the fabrics 116, 118, 120, and / or 122 into the fabric stack 136 can facilitate the ability to simultaneously process multiple fabrics from two or more of the fabrics 116, 118, 120, and 122. For example, in some cases, the fabric stack 136 can be processed by the cutting assembly 124, which can simultaneously cut pattern pieces from two or more of the fabrics 116, 118, 120, and 122.

[0100] In some examples, one or more of the fabrics 116, 118, 120, and 122 can extend at least partially around one or more anchors (e.g., pins, rollers, etc.) positioned between the yarn feeder assembly 112 and the collection assembly 114. Among other things, these anchors can operate to change the direction in which the fabric extends, such as to direct the fabric into a specific processing area of ​​the system 110. Furthermore, the anchors can create tension along the fabric, which can reduce slack between the yarn feeder assembly 112 and the collection assembly 114. In some examples, the anchors can provide a common anchor point for directing the fabrics 116, 118, 120, and 122 into the fabric stack 136.

[0101] In some examples, the anchor can include one or more rollers, such as rollers 138, 140, and / or 142. For example, rollers 138 and 140 can compress fabrics 116, 118, 120, and / or 122 as they extend between roller 138, which can help the fabrics maintain a stacked arrangement.

[0102] Furthermore, as described above, these rollers 138 and 140 can operate to change the direction of fabric extension and help reduce slack. In some instances, system 110 may omit roller 140. In some instances, roller 142 can help direct the flow of the fabric and reduce slack in another area of ​​system 110, such as after a processing assembly positioned between rollers 138 and 142. For example, roller 142 can help direct the flow of the fabric and reduce slack before the fabric is taken up by collection assembly 114.

[0103] In at least some examples, rollers 138, 140, and 142 can increase the likelihood that fabrics 116, 118, 120, and 122 will include a stacked arrangement with relatively minimal entanglement. For example, even though fabrics 116, 118, 120, and 122 can be layered face-to-face and directly adjacent to each other, relatively minimal fiber or material transfer can occur between the various fabrics.

[0104] Rollers 138, 140, and 142 can be supported in various ways. For example, although not explicitly depicted in FIG. 1B , rollers 138, 140, and / or 142 can be supported on extensions or arms of support structures 130a, 130b, 132a, and / or 132b. In some examples, rollers 138, 140, and / or 142 can be attached to other additional support structures (e.g., support towers or brackets, not depicted in FIG. 1B ).

[0105] In some cases, the rollers 138, 140, and / or 142 may rotate or spin (in the direction of flow from the feeder assembly 112 to the collection assembly 114) as the fabric moves across the rollers 138, 140, and 142. In some instances, the rollers 138, 140, and 142 may remain stationary (e.g., not rotating or spinning), and the fabric may slide over the convex surfaces of the rollers.

[0106] As indicated, in some examples, two or more of the fabrics 116 , 118 , 120 , and 122 may be arranged into a fabric stack 136 , which may be further processed by components of the system 110 .

[0107] For example, the system 110 can include a cutting assembly 124. In some examples, the cutting assembly 124 can be arranged relative to rollers 138, 140, and / or 142, which can help direct the flow of the fabric stack 136 as it is fed into and collected from the cutting assembly 124.

[0108] Additionally, the cutting assembly 124 may include a support surface 144 that is arranged relative to the rollers 138, 140, and / or 142 in a manner configured to increase the likelihood that the fabric will remain relatively stacked and under tension. For example, the support surface 144 may include a relative height above the rollers 138 and 142 such that the fabric stack 136 may be relatively taut across the support surface 144 with minimal slack.

[0109] In at least some examples, cutting assembly 124 may include at least one cutting tool 146 disposed above support surface 144 such that fabric layup 136 is positioned between cutting tool 146 and support surface 144 .

[0110] Cutting tool 146 can be configured to cut a pattern into fabric stack 136. For example, cutting tool 146 can include computer numerical control (CNC) functionality. In some examples, cutting tool 146 can include a blade, a saw, a knife (e.g., a drag knife), a router, a laser (e.g., a CO2 laser), and / or a die, among others. In some examples, cutting tool 146 can be suspended from a gantry and moveable in the xy plane to follow the pattern and in the z direction to adjust the cutting depth. In some examples, cutting tool 146 can include a scanning laser.

[0111] In at least some examples, cutting tool 146 can simultaneously cut multiple layers (e.g., all layers) of fabric stack 136 to generate multiple pattern pieces, each pattern piece being from a corresponding fabric. In at least some examples, cutting assembly 124 can include a vacuum 148 that can apply negative pressure air to support surface 144. In some examples, the negative pressure air from vacuum 148 can reduce the likelihood that fabric stack 136 will shift while being cut.

[0112] In some cases, system 110 may simultaneously cut multiple layers (e.g., all layers) of fabric layup 136 to generate multiple pattern pieces. Furthermore, after cutting pattern pieces from two or more of fabrics 116, 118, 120, and 120, fabrics 116, 118, 120, and 120 may include a border or edge fabric portion surrounding the outside of the pattern pieces (beyond their peripheral edges).

[0113] Examples of the present disclosure include separating a pattern piece from surrounding portions, which can produce residual portions that remain attached to the collection component 114. For example, FIG. 1B depicts an example of a multi-layer pattern piece 150 that has been cut and separated from fabrics 116, 118, 120, and 122, with residual portions 116b, 118b, 120b, and 122b remaining attached to the collection component 114.

[0114] In some examples, the multi-layer pattern sheet 150 can be separated from the remaining portions 116b, 118b, 120b, and 122b in various ways. For example, the multi-layer pattern sheet 150 can be dropped from the remaining portions 116b, 118b, 120b, and 122b (e.g., due to gravity). In some cases, the multi-layer pattern sheet 150 can be pushed from the remaining portions 116b, 118b, 120b, and 122b by pulling the fabrics 116, 118, 120, and 122 over the rollers 142. In some examples, the rollers 142 can be pinned or include other protrusions that, when pressed into the fabric, can separate the multi-layer pattern sheet 150 from the remaining portions 116b, 118b, 120b, and 122b.

[0115] In at least some examples, the multi-layer pattern piece 150 can be received by a transport assembly 126, which can be configured to transport the multi-layer pattern piece 150 to one or more other assemblies for processing. For example, the transport assembly 126 can include a conveyor that can position the multi-layer pattern piece 150 relative to the other assemblies. As described above, the multi-layer pattern piece 150 can include pattern pieces that are cut from the fabric stack 136 at the same time, and therefore, the pattern pieces can include the same contour shape defined by the peripheral edges of the pattern pieces, and the peripheral edges of the pattern pieces can be aligned.

[0116] In at least some examples, the system 110 can include a pre-processing assembly 128 configured to prepare the multi-layer pattern sheet 150 for incorporation into a finished product (e.g., a wearable article, a bag, etc.). For example, the pre-processing assembly 128 can include one or more components for attaching together various pattern pieces of the multi-layer pattern sheet 150. In some examples, the pre-processing assembly 128 can attach together a portion of the multi-layer pattern sheet 150 (e.g., a region of the multi-layer pattern sheet 150 that is in the middle and smaller than the outline shape).

[0117] For example, in conjunction with FIG. 1B , reference view "A" depicts a plan view of a multi-layer pattern sheet 150 and illustrates a portion 152 of the stacked pattern sheets that can be attached by the pre-processing assembly 128. In some examples, the pre-processing assembly 128 can attach together at least a majority of the area formed by the contour shape of the multi-layer pattern sheet 150 (e.g., larger than the area 152). In at least some examples, attaching at least a portion of the multi-layer pattern sheet 150 together increases the likelihood that the stacked pattern sheets will remain stacked and aligned for subsequent processing. For example, the at least partially attached multi-layer pattern sheet 150 can be stably stored prior to subsequent processing (such as subsequent entanglement, thermal bonding, chemical surface treatment, embossing, debossing, printing, seaming, etc.).

[0118] The pre-treatment assembly 128 may include various components to attach the multi-layer pattern sheet 150 together (e.g., to attach at least the regions 152 together). For example, the pre-treatment assembly may include components for entangling fibers of at least a portion of the multi-layer pattern sheet 150. In some examples, the pre-treatment assembly 128 may include one or more needles for needling at least a portion of the multi-layer pattern sheet 150 together. In some examples, the pre-treatment assembly 128 may include one or more fluid jets (e.g., water jets) for fluid-entangling (e.g., hydroentangling) at least a portion of the multi-layer pattern sheet 150. In some examples, the pre-treatment assembly 128 may thermally bond at least a portion of the multi-layer pattern sheet 150. In some examples, the pre-treatment assembly 128 may laminate at least a portion of the multi-layer pattern sheet 150. In some examples, the pre-treatment assembly 128 may chemically bond at least a portion of the multi-layer pattern sheet 150.

[0119] In some examples, the pre-processing assembly 128 may include one or more needles for sewing together at least a portion of the multi-layer pattern sheet 150. In some examples, the pre-processing assembly 128 may include one or more heads for welding (e.g., sonic welding) together a portion of the multi-layer pattern sheet 150. In some examples, the pre-processing assembly 128 may include one or more heat sources (e.g., lasers) for thermally bonding at least a portion of the multi-layer pattern sheet 150 together.

[0120] In some examples, the pre-treatment assembly 128 may include one or more chemical bonding sources for chemically bonding at least a portion of the multi-layer pattern sheet 150 together (eg, via an adhesive).

[0121] In some cases, the pre-treatment assembly 128 operates to provide a stable connection, but does not necessarily refer to the only entanglement or connection before the multi-layer pattern sheet 150 is incorporated into the finished product. As such, this relatively lightweight operation (e.g., compared to a bidirectional multi-pass needling operation) can be easily implemented as a subassembly of the overall system 110 with relatively small footprint tools (e.g., a small fixed needler or other tool).

[0122] In at least some examples, the pre-processing assembly 128 can include one or more various other components for performing one or more various other operations associated with the multi-layer pattern sheet 150. For example, the pre-processing assembly can include: any pick-and-place subassemblies for placing elements onto the multi-layer pattern sheet 150; a fiber applicator or depositor for depositing fibers (e.g., staple fibers, hydroentangled fibers, spunbond fibers, or meltblown fibers) onto the multi-layer pattern sheet 150; an embroidery head, a sewing head, or a stitching head for adding stitches or other elements to the multi-layer pattern sheet 150; and a printing head, such as a 3D printing head for depositing ink or other colorants, or for depositing materials onto the multi-layer pattern sheet 150.

[0123] As described above, in at least some examples, the multi-layer pattern piece 150 is separated from one or more of the fabrics 116, 118, 120, and 122, leaving residual portions 116b, 118b, 120b, and 122b connected to the collection component 114. For example, FIG. 1B includes cutouts 154 associated with the respective portions of the fabric in which the pattern piece was located prior to separation. Furthermore, reference view B is provided in FIG. 1B and also includes a plan view of residual portion 116b having cutouts 155 (e.g., a different shape than cutouts 154, for example, for illustrative purposes). In some examples, residual portions 120b and 122b may also include cutouts that are not visible from the view in FIG. 1B.

[0124] In an example, the collection assembly 114 includes various cores spaced apart at intervals, configured to separate the fabric remnants 116b, 118b, 120b, and 122b as they are pulled away from the roller 142 and toward the collection assembly 114 (e.g., via a motorized belt 134 that rotates the cores). In contrast to conventional methods, because the fabric stack 136 includes minimal to no entanglements when unwound between the yarn feed assembly 112 and the collection assembly 114, the system 110 can separate one or more of the remnants 116b, 118b, 120b, and 122b with minimal transfer of material or fiber between layers. Thus, in some examples, one or more of the remnants 116b, 118b, 120b, and 122b can comprise (after separation) a homogeneous composition consistent with the corresponding fabric. That is, as described above, one or more of fabrics 116, 118, 120, and 122 may include a fabric having a set of fibers that includes at least about 90% of the measured properties (e.g., fiber length, fiber denier, color properties, material composition, etc.), and the corresponding remainder may also include a set of fibers that includes at least about 90% of the measured properties.

[0125] In at least some examples, relatively minimal material transfer can occur between fabrics. For example, even though residue portions 116b and 118b may not be entangled (or otherwise attached together), at least some material 156 (e.g., fibers) from fabric 118 / residue portion 118b can be transferred to residue portion 116b. That is, material 156 can include fibers from one fabric (e.g., 118) that are transferred (e.g., possibly loosely) to the surface of another fabric (e.g., 116), such as where fabric 118 comprises a nonwoven fibrous web and one or more staple fibers of fabric 118 are loosely transferred to the surface of fabric 116 (e.g., with less entanglement than if the staple fibers were mechanically entangled).

[0126] Material 156 can differ from the homogeneous composition of fabric 116 (e.g., when in a roll). For example, material 156 can have different chemical compositions, color characteristics, fiber characteristics (e.g., denier, diameter, length, shape, etc.), etc. However, in some instances, the amount of non-homogeneous material 156 can be relatively low compared to conventional methods of attempting to collect a residue portion (e.g., after the fabric has been mechanically entangled). Thus, even though residue portion 116b can have a lower degree of homogeneity based on the transferred material 156, residue portion 116b can still include at least 90% of the measured characteristics.

[0127] In examples, at least one of the residue portions 116b, 118b, 120b, and 122b can be reused in various ways. For example, fabric 116 may include a fiber web, and residue portion 116b may include a fiber web residue portion that may include a homogeneous set of fibers consistent with fabric 116. Compared to other techniques where separating the fiber web residue portion from other residue portions (e.g., 118b) is more challenging (e.g., due to a higher degree of entanglement), the fiber web residue portion 116b of the present disclosure may include (e.g., provide) a purer source of the homogeneous set of fibers (e.g., a higher percentage of the homogeneous set of fibers) for subsequent use. Furthermore, the purer source (e.g., purer than conventional methods for residue collection) of the homogeneous set of fibers may be cut into additional patterned pieces, shredded, repelletized, etc.

[0128] When cutting a pattern into the fabric stack 136, various factors may be considered. For example, in some cases, the cutting may be performed to optimize the use of the fabric stack 136, thereby generating multiple layers of pattern pieces that may include different shapes and sizes. These patterns may be rotated to ensure that the pattern fits (e.g., nests) within the footprint of the fabric stack 136.

[0129] In some examples, the pattern pieces can be spaced apart by a threshold distance configured to increase the likelihood that the residual portion will remain continuous. In some examples, the pattern pieces can be spaced apart by a distance ranging from about 20 mm to about 3 mm. In some examples, the pattern pieces can be spaced apart by a distance ranging from about 20 mm to about 3 mm. In some examples, the pattern pieces can be spaced apart by a distance of about 5 mm. Furthermore, the patterns can be spaced apart to increase the likelihood that the minimum margin (e.g., a portion of the residual portion remaining) will extend around the cutouts (e.g., 154 and 155).

[0130] For example, in some cases, one or more cuts (e.g., 154 and 155) can be spaced inward from an edge of the fabric (e.g., 115) so as to leave a minimal uncut margin 158 along the edge. In at least some examples, margin 158 can include a threshold width that is configured to increase the likelihood that the fabric will not break away from the core of collection assembly 114 when being collected. That is, in some cases, as the fabric is wound onto the core of collection assembly 114 (e.g., via rollers 142 on one side and via the core of collection assembly 114 on the other side), tension is applied to the fabric, and margin 158 can be used to maintain the structural integrity of the remaining portion and reduce the likelihood of the remaining portion tearing.

[0131] While remnant 116b is depicted with reference to view B, this margin can be maintained relative to the other remnants 118b, 120b, and 122b based on the aligned edges in stack 136. In some examples, this margin can include a distance ranging from about 30 mm to about 5 mm. In some examples, this margin can be about 10 mm. In some examples, margin 158 can be larger than the spacing between pattern pieces.

[0132] In at least some examples of the present disclosure, one or more runners can be cut along with these cuts (e.g., 154 and 155). That is, one or more cut-to-cut connectors can be cut into the stack 136, and the connectors can connect one cut (via the stacked layers) to another cut. For example, referring to reference view C (in FIG. 1B ), a first cut 155a can be connected to a second cut 155b via a runner 160 cut from the stack 136 (e.g., as part of the same operation associated with cutting cuts 155a and 155b). In some examples, the runner 160 can help transport the multi-layer pattern piece through subsequent processing operations (e.g., entanglement, chemical bonding, thermal bonding, surface treatment, printing, etc.), such as by providing instructions for maintaining the layers in place (e.g., spacing, orientation, etc.). In some examples, the runner 160 can help maintain smaller, multi-layer pattern pieces in place as the pattern pieces are transported (e.g., conveyed through a system). In some examples, the runners 160 may be removed from the multi-layer pattern sheet and recycled in a separate step.

[0133] In at least some examples, the present disclosure may include various fibrous webs and composite fabrics at various stages associated with a finished product (eg, a wearable article constructed with a multi-layer pattern piece 150) and associated with the construction of the finished product.

[0134] For example, referring to FIG. 2A , examples of the present disclosure include a multi-layer pattern piece 250 (e.g., which can be similar to the multi-layer pattern piece 150 ). The multi-layer pattern piece 250 includes a plurality of discrete pattern pieces 216, 218, 220, and 222 cut from a corresponding fabric (e.g., as described with respect to the cutting assembly 124 and the multi-layer pattern piece 150 ). Any of the pattern pieces 216, 218, 220, and 222 can include any type of fabric layer described with respect to FIG. 1B and the fabrics 116, 118, 120, and / or 122. For example, any of the pattern pieces 216, 218, 220, and 222 can include a fiber web (e.g., any of a variety of non-woven fiber webs), a knitted fabric, a woven fabric, a film, a web, a scrim, a composite, an elastomeric layer, a carrier layer, and the like. In some examples, the multi-layer pattern piece 250 can include fewer layers (e.g., only two or only three layers) or can include additional layers.

[0135] One or more discrete pattern pieces 216, 218, 220, and / or 222 include a peripheral edge that corresponds to the shape of the pattern cut by the cutting assembly (e.g., 124). For ease of description and illustration, pattern pieces 216, 218, 220, and 222 are depicted as rectangular. In examples, the shape of pattern pieces 216, 218, 220, and / or 222 can correspond to any pattern configured to construct a finished product. For example, a pattern piece can be associated with at least a portion of a wearable article (e.g., a lower body garment, an upper body garment, a footwear upper, etc.). For example, in association with an upper body garment, the pattern piece can be associated with the sleeve, front, back, shoulder, yoke, hood, etc. In association with an article of footwear, the pattern piece can be associated with the medial side, lateral side, underfoot portion, vamp, instep, tongue, toe box, heel area, collar, etc.

[0136] In at least some examples, the pattern pieces 216, 218, 220, and / or 222 of the multi-layer pattern piece 250 are attached together in an area 252 that is smaller than the area associated with the shape of the pattern pieces 216, 218, 220, and / or 222 (e.g., by at least one component 228 of the pre-treatment assembly, such as an entangling device for mechanically entangling fibers via needle punching or water jets, a laser, a heat press, etc.).

[0137] For example, region 252 may be entangled (e.g., needle punched or fluid entangled) or otherwise bonded or coupled such that at least some fibers 217 initially present in pattern sheet 216 (e.g., cross-section in FIG. 2B ) are at least partially displaced from pattern sheet 216 and at least partially pushed into one or more other pattern sheets 218 , 220 , and 222 .

[0138] In some examples, the entanglement (or other coupling) in zone 252 is performed only from one side of the multi-layer pattern sheet 250 and is applied to one side of the multi-layer pattern sheet 250 (e.g., needle entanglement is performed only on one side of the multi-layer pattern sheet). In this regard, the entanglement applied to zone 252 can include a lesser degree of needle entanglement than some conventional multi-pass entanglement processes, and this lighter application of entanglement can contribute to a more efficient and sustainable (e.g., less energy-intensive) process (e.g., compared to more complete multi-faceted entanglement). Furthermore, this lighter weight entanglement step (e.g., compared to a bidirectional multi-pass process) can be easily implemented as a subcomponent of the overall system 110, wherein the needle punch (e.g., 228) has a relatively small footprint.

[0139] Region 252 may include a higher percentage of fibers 217 displaced from pattern piece 216 (e.g., compared to other portions 258). In some examples, portions 258 of pattern pieces 216, 218, 220, and / or 222 may be disconnected from adjacent surfaces and may be relatively free of connecting structures (e.g., fibers entangled between pattern pieces).

[0140] Furthermore, in some examples, the thickness 260 of the multilayer pattern sheet 250 in the region 252 may be less than the thickness 262 associated with other portions of the multilayer pattern sheet 250 (e.g., because operation of the pre-processing assembly component 228 may not have compressed those other portions 258 on one side).

[0141] In at least some examples, other areas of the multi-layer pattern piece 250 may also be associated with at least some entanglement, which may include fibers that are more entangled than the fibers in portion 258. For example, peripheral edges 216b, 218b, 220b, and 222b may also include at least some fibers from one layer entangled with at least some fibers from another layer (e.g., 225). In some examples, the entanglement along peripheral edges 216b, 218b, 220b, and 222b may result from a cutting operation in which pattern pieces 216, 218, 222, and 225 are simultaneously cut from the respective fabrics. For example, where the cutting operation includes cutting the pattern piece with a knife, blade, or the like, the cutting tool may then mechanically entangle the fibers 225 as it traverses along the pattern associated with the pattern piece.

[0142] In some examples, the characteristics of a pre-processed multi-layer pattern sheet 250 having an attachment zone 252 and / or, in some examples, an entangled edge can provide various benefits. For example, the attachment zone 252 having entangled fibers 217 and the edge having entangled fibers 225 can stabilize the multi-layer pattern sheet 250 for further downstream processing. That is, in some examples, the system 110 can be associated with other systems that further process a larger portion (e.g., larger than the zone 252) of the multi-layer pattern sheet (such as through additional mechanical entanglement, surface treatment, chemical bonding, thermal bonding, embossing, debossing, etc.). Thus, the attachment zone 252 and one or more edges having entangled fibers 225 can increase the likelihood that the pattern sheets 216, 218, 220, and / or 222 will remain attached together as the multi-layer pattern sheet 250 and that the peripheral edges of the pattern sheets 216, 218, 220, and / or 222 will remain aligned. In some examples, seaming operations (e.g., when attaching a multi-layer pattern piece 250 to another multi-layer pattern piece) are improved by providing a cleaner edge for attachment and by maintaining alignment of the edges to create a cleaner aesthetic (e.g., compared to situations where the edges may not be fully aligned prior to seaming).

[0143] In at least some examples, zones 252 comprise a size and shape based on the arrangement of needles associated with the pretreatment assembly. Furthermore, zones 252 can be consistent across arrays of different multi-layer pattern pieces. For example, zones 252 can be triangular, rectangular, circular, and so on, and substantially identically shaped zones can be applied to various pattern pieces regardless of their shape. In other words, across an array of pattern pieces (e.g., for different wearable articles), identically shaped zones 252 can be formed in sleeve pattern pieces, hood pattern pieces, front pattern pieces, rear pattern pieces, footwear upper pattern pieces, and so on.

[0144] Referring now to FIG. 3 , additional examples associated with any of the remnant portions 116b, 118b, 120b, and 122b are described, and FIG. 3 depicts remnant portion 310. For example, remnant portion 310 may include the remnant portion after the pattern piece is cut by the cutting assembly 124 of FIG. 1B . Remnant portion 310 may include the remnant portion wound onto a core. Furthermore, remnant portion 310 may include remnant portions that have been collected or gathered in other ways (e.g., not necessarily on a core), such as by folding or stacking. In at least some examples, remnant portion 310 is configured to be reused to form other articles, such as by reusing fibers from remnant portion 310, cutting additional pattern pieces from remnant portion 310, shredding remnant portion 310 to form chopped article fibers, re-pelletizing fibers from remnant portion 310 (e.g., re-pelletizing polymer fibers), and the like.

[0145] In at least some examples, any residual portion 310 may include a fabric comprising a homogeneous set of fibers. For example, the homogeneous set of fibers may include a fiber web that has been carded, spliced, and possibly pre-needled (e.g., when formed into a fiber web roll), and is not yet entangled or is only minimally entangled with other fabrics. That is, as explained with respect to system 110, fabrics 116, 118, 120, and / or 122 are not entangled or are only minimally entangled (e.g., by fibers being loosely transferred to a surface), such that the fibers associated with residual portion 310 are homogeneous, having little or no fibers or materials from other fabrics after having been processed by system 110.

[0146] In some examples, residual portion 310 may include heterogeneous material 312 (e.g., based on minimal transfer from other fabrics when processed by system 110), and residual portion 310 may also include a threshold composition for determining whether the set of fibers in the residual portion is homogeneous. In some examples, the threshold is at least approximately 90% homogeneity with respect to a given characteristic. In some examples, the threshold is at least approximately 95% homogeneity with respect to a given characteristic. For example, heterogeneous material 312 may include different chemical compositions, color characteristics, fiber characteristics, etc. In some examples, residual portion 310 may include a set of homogeneous fibers, the set of homogeneous fibers including PET (e.g., virgin PET or recycled PET), and heterogeneous material 312 may include TPU, TPEE, or some other thermoplastic polymer.

[0147] The residual portion 310 can be reused in various ways. For example, the residual portion 310 (or fibers from the residual portion 310) can be re-pelletized 314, chopped 316, and / or cut 318 into additional pattern pieces. In some examples, the re-pelletized and / or chopped fibers from the residual portion can be mixed with virgin fibers to produce a composite nonwoven fabric. In at least some examples, the residual portion 310 (even with the heterogeneous material 312) can be reused in these various ways, and the resulting product (e.g., fiber web roll 320, pattern piece 322, etc.) can still include at least about 90% homogeneity.

[0148] Furthermore, in examples, a homogeneity of at least about 90% (or some other threshold as appropriate based on the target quality) can be sufficient to allow the resulting fabric or pattern piece to include a desired set of end properties, such as weight, thermal properties, stretch and recovery, good drape, interesting visual aesthetics, good abrasion resistance, and a soft hand, making the fabric ideal for forming wearable articles.

[0149] For example, when repelletized 314 (or pelletized), the portion or segment 312a may comprise a non-homogeneous material, and the collection of repelletized polymer fibers as a whole may still comprise at least about 90% homogeneity. In at least some examples, when chopped 316, at least some of the chopped fibers 312b may comprise non-homogeneous fibers that are a byproduct of chopped material 312, and the chopped fibers as a whole may still comprise at least 90% homogeneity.

[0150] Additionally, any regranulated polymer fibers or chopped fibers can be processed into a fiber web 320 (e.g., by carding, splicing, and pre-needling) that can include a non-homogeneous material 312d and still have at least about 90% homogeneity. In some examples, the fiber web 320 can then be processed using the system 110. In at least some examples, a patterned sheet 322 can be cut from the residual portion 310, and the patterned sheet 322 can include a non-homogeneous material 312c and still have at least about 90% homogeneity.

[0151] In at least some examples, the fiber web roll 320 or pattern piece 322 can be used to form a wearable article, such as an upper garment, lower garment, or footwear upper. For example, referring to FIG4 , a wearable article 410 is depicted that can include at least a portion 412 comprised of one or more pattern pieces derived from the fiber web roll 320 or pattern piece 322. In at least some examples, the wearable article 410 comprises a composite fabric that can include a fiber web (e.g., a fiber web pattern piece cut from the fiber web roll 320 or the fiber web pattern piece 322) mechanically entangled with one or more other fabric layers (e.g., one or more other fiber webs and / or elastomeric material layers and / or any other fabric layers described herein).

[0152] Thus, portion 412 of wearable article 410 can include a fiber web comprising a first set of fibers 414 (e.g., FIG. 4B and represented by thinner lines) and a second set of fibers 416 (e.g., FIG. 4B and represented by thicker lines), the second set of fibers 416 being heterogeneous relative to first set of fibers 414 and comprising less than 10% of portion 412. In this example, despite the heterogeneity of fibers 416, portion 412 can still include a set of desirable end properties, such as weight, thermal properties, stretch and recovery, good drape, attractive visual aesthetics, good abrasion resistance, and / or a soft hand, making the fabric ideal for forming a wearable article. Thus, articles associated with aspects of the present disclosure, such as 410, can contribute to sustainability by incorporating byproducts from residual portions (e.g., 310) into a finished product having desirable properties.

[0153] At least some examples of the present disclosure relate to methods for manufacturing composite fabrics or articles comprising composite fabrics. For example, referring to FIG5 , a flow chart outlines steps that may be performed as part of a method 500 for manufacturing a composite fabric. FIG5 also includes a set of depictions that provide examples and illustrate the illustrated steps, and the method is not limited to the subject matter depicted in these figures.

[0154] Method 500 may include stacking a fiber web adjacent to a material layer at 502. For example, element 504 may represent a fiber web, and element 506 may represent a material layer. In some examples, fiber web 504 may include a fiber web roll that has been carded, lapped, and pre-needled. In some examples, fiber web 504 may include other types of fiber webs in other nonwoven fabrics.

[0155] Material layer 506 may also include a fiber web, such as a fiber web roll. In some examples, element 504 is a first fiber web, and element 506 is a second fiber web. Furthermore, the first fiber web may include a first characteristic, and the second fiber web may include a second characteristic that corresponds to and is different from the first characteristic. In examples, the first characteristic and the second characteristic may include at least one of the chemical composition of the fibers, the average denier of the fibers, the average diameter of the fibers, the average length of the fibers, a surface coating applied to the respective webs, and the color of the fibers.

[0156] In some examples, material layer 506 can include any other type of fabric described in the present disclosure (e.g., other nonwovens, knits, weaves / wovens, films, webs, scrims, elastomeric layers, etc.). In some examples, additional material layers (e.g., a third material layer such as another fiber web, an elastomeric layer, and / or any other type of material layer described in the present disclosure) can also be stacked with fiber web 504 and material layer 506.

[0157] In an example, a third fiber web (not depicted) can include a third characteristic that corresponds to and is different from the first and second characteristics (e.g., at least one of the chemical composition of the fibers, the average denier of the fibers, the average diameter of the fibers, the average length of the fibers, a surface coating applied to the corresponding web, and the color of the fibers).

[0158] In some examples, the fiber web 504 and the material layer 506 may be stacked in conjunction with the operation of system 110. For example, the fiber web 504 may include fabric 116 and the material layer may include fabric 118, and the fiber web 504 and material layer 506 may include fabric layup 136. In some examples, the fiber web 504 and material layer 506 may be stacked in conjunction with operations other than system 110. For example, the fiber web 504 and material layer 506 may be segments of one material layer stacked on top of another (e.g., not necessarily processed by system 110).

[0159] In at least some examples, method 500 includes cutting the fiber web and material layer in a shape associated with the pattern at 508. For example, a cutting shape 510 associated with the pattern can be cut into the fiber web 504 and material layer 506.

[0160] In Figure 5, for illustrative purposes, the pattern is a rectangle, and the cut shape 510 can be any of a variety of different pattern pieces that can be used to construct a finished product, such as a wearable article. For example, the cut pattern 510 can include a portion of an upper garment, a portion of a lower garment, a portion of a footwear upper, or any other pattern piece described in this disclosure.

[0161] In at least some examples, cutting can include cutting by a cutting assembly 124, such as via a knife or any other cutting tool 146 described herein. Cutting can be performed while the fiber web 504 and the material layer 506 are in a stacked arrangement, such that the fiber web 504 and the material layer 506 can be cut at the same time (concurrently / simultaneously) via the same cutting operation.

[0162] In at least some examples, the result of cutting (at 508) can include a first portion and a residual portion. For example, the first portion can include a first scored portion (e.g., corresponding to shape 510) of element 504 (e.g., the first fiber web) and a second scored portion (e.g., also corresponding to shape 510) of element 506 (e.g., the second fiber web). Additionally, the residual portion can include the first residual portion of element 504 (e.g., the first fiber web) and the second residual portion of second element 506 (e.g., the second fiber web).

[0163] Furthermore, method 500 may include, at 512, separating the fiber web into a fiber web pattern piece comprising a shape associated with the pattern and a fiber web remnant. For example, fiber web 504 may be separated into fiber web pattern piece 514 and fiber web remnant 516. Furthermore, at 518, method 500 may include separating the material layer into a material layer pattern piece comprising a shape associated with the pattern and a material layer remnant while separating the fiber web. For example, material layer 506 may be separated into material layer pattern piece 520 and material layer remnant 522. In at least some examples, the pattern piece may be separated from the corresponding fabric by any of the strategies described herein, such as manual removal, gravity, via rollers 142, and the like.

[0164] The operations associated with 512 and 518 may be described in other ways. For example, operations 512 and 518 may include separating a portion from a remaining portion, where the portion is a multi-layer portion that includes a portion cut from element 504 (e.g., first scored portion 514) and a portion cut from element 506 (e.g., second scored portion 520), and the remaining portion is a multi-layer remaining portion that includes the remaining portions of elements 504 and 506 (e.g., 516 and 522).

[0165] In at least some examples, the pattern sheets 514 and 520 (e.g., the corresponding scored portions) can be entangled, such as by needling, fluid entangling, etc. For example, the pattern sheets 514 and 520 can be entangled via the pre-treatment assembly 128 or 228 (e.g., at least a portion of the pattern sheets 514 and 520).

[0166] In some examples, pattern pieces 514 and 520 are entangled via a multi-pass needling operation, which may result in a greater degree of entanglement than the operations associated with pre-treatment components 128 or 228. In at least some examples, after entanglement, pattern pieces 514 and 520 (e.g., multi-layer pattern pieces) can be constructed into an article of apparel, such as a wearable article.

[0167] In at least some examples, method 500 includes separating the fibrous web remnant from the material layer remnant at 524. For example, fibrous web remnant 516 can be separated from material layer remnant 522 using any of the techniques described herein. In some examples, fibrous web remnant 516 and material layer remnant 520 are separated by the winding action of a rotating core of collection assembly 114.

[0168] In some examples, the spacing of the cores and / or minimal to no entanglement between the fiber web remnant 516 and the material layer remnant 520 can improve the separability of the layers while minimizing the transfer of non-homogeneous material to the fiber web remnant 516. For example, in some examples, the fiber web remnant 516 can include less than about 10% by weight of fibers from the element 506 or the remnant 522. Thus, in some examples, the fiber web remnant 516 is well suited for reuse in various ways (e.g., recycling, repelletizing, shredding, cutting, etc.).

[0169] In at least some examples, at least one of residue portion 516 and residue portion 522 is recycled. For example, recycling can include any of the operations described herein, such as those described with respect to FIG. 3 . In some examples, recycling can include shredding the fiber web residue and using the shredded fibers to form another material layer (e.g., another fiber web or other nonwoven material layer). For example, the shredded fibers can be carded, spliced, etc. to form the fiber web. Furthermore, the shredded fibers can be blended with non-shredded fibers (e.g., fibers that have been extruded and cut but not shredded) to form the fiber web. In some cases, due to fiber breakage during the shredding process, new materials formed using the shredded fibers can include greater variability in fiber length. For example, in a fiber web including shredded fibers, the fibers can include fiber lengths ranging from 40 mm to 50 mm. In some examples, recycling can include pelletizing the fibers or re-pelletizing the fibers by converting them back to a pelletized form. The fibers can then be extruded from the recycled fibers or used in some other manner suitable for recycled material.

[0170] The operations in FIG5 may include one or more additional operations (not depicted) described in other parts of this disclosure. For example, these operations may include placing (e.g., with respect to pattern pieces 514 and 520), fiber deposition, printing, entanglement, sewing, etc., of additional elements to be combined therewith.

[0171] Sample Clauses

[0172] Item 1. A method comprising: stacking a fiber web adjacent to a material layer; cutting the fiber web and the material layer in a shape associated with a pattern; separating the fiber web into a fiber web pattern piece and a fiber web remnant, the fiber web pattern piece including the shape associated with the pattern; while separating the fiber web, separating the material layer into a material layer pattern piece and a material layer remnant, the material layer pattern piece including the shape associated with the pattern; and peeling the fiber web remnant from the material layer remnant.

[0173] Clause 2. A method according to clause 1, wherein: the fiber web comprises a first material and the material layer comprises a second material different from the first material; the method further comprises forming a second fiber web from fibers of the remaining portion of the fiber web; and the second fiber web comprises a certain amount of the second material, the amount of the second material being less than a threshold amount of the first material by weight.

[0174] Clause 3. The method of clause 2, wherein the threshold amount is approximately 5%.

[0175] Clause 4. The method of clause 2 or 3, wherein forming the second fiber web comprises regranulating the fibers of the fiber web remainder.

[0176] Clause 5. The method of any one of clauses 2 to 4, wherein: forming the second fibrous web comprises chopping the fibrous web remainder into chopped fibers; and forming the second fibrous web from the chopped fibers.

[0177] Clause 6. The method of any one of Clauses 2 to 5, wherein the fiber web and the material layer are cut simultaneously in the shape associated with the pattern.

[0178] Clause 7. The method according to any one of clauses 2 to 6 further comprises entangling the fibers of the fiber web pattern sheet with the material layer pattern sheet after separating the fiber web pattern sheet and the material layer pattern sheet from the respective residual portions.

[0179] Clause 8. The method of any one of clauses 2 to 7, further comprising entangling or bonding the fiber web pattern piece and the material layer pattern piece without entangling or bonding the respective residual portions.

[0180] A fabric or composite fabric constructed using the method of any one of clauses 1 to 8.

[0181] A coil comprising a residue originating from a method according to any one of clauses 1 to 8.

[0182] Item 9. A method comprising: extending an unfolded segment of a fiber web between a first rotatable core and a second rotatable core; stacking the unfolded segment of the fiber web adjacent to a material layer; cutting the unfolded segment of the fiber web and the material layer in a shape associated with a pattern; separating the fiber web into a fiber web pattern sheet and a fiber web remnant, the fiber web pattern sheet including the shape associated with the pattern; separating the material layer into a material layer pattern sheet and a material layer remnant, the material layer pattern sheet including the shape associated with the pattern, wherein the fiber web pattern sheet and the material layer pattern sheet are stacked and include multiple layers of pattern sheets; and winding the fiber web remnant onto the second rotatable core.

[0183] Item 10. The method according to Item 9 further includes: extending the unfolded segment of the material layer between a third rotatable core and a fourth rotatable core, wherein at least a portion of the unfolded segment of the material layer is stacked with the unfolded segment of the fiber web; and after cutting the material layer, winding the remaining portion of the material layer onto the fourth rotatable core.

[0184] Clause 11. A method according to clause 9 or clause 10, wherein: the fibers of the fiber web compositionally include a first material and 5% or less by basis weight of a second material, and the material layer compositionally includes the second material; and the method further comprises forming regranulated polymer fibers from the fiber web residue, wherein the regranulated polymer fibers compositionally include a certain amount of the first material and a certain amount of the second material, and the amount of the second material is less than about 5% of the amount of the first material.

[0185] Clause 12. The method of any one of clauses 9 to 11, further comprising: chopping the fiber web remainder into chopped fibers; and forming a second fiber web from the chopped fibers.

[0186] Clause 13. The method of any one of Clauses 9 to 12, wherein the fiber web and the material layer are cut simultaneously in the shape associated with the pattern.

[0187] Clause 14. The method according to any one of clauses 9 to 13, further comprising entangling fibers of the fiber web pattern sheet with the material layer pattern sheet after separating the fiber web pattern sheet and the material layer pattern sheet.

[0188] Clause 15. The method of any one of Clauses 9 to 14, wherein separating the fiber web comprises traversing the fiber web across rollers.

[0189] Clause 16. The method according to any one of clauses 9 to 15, further comprising applying negative pressure air to the unfolded section of the fiber web and the material layer when cutting the unfolded section of the fiber web and the material layer.

[0190] A fabric or composite fabric constructed using the method of any one of clauses 9 to 16.

[0191] A coil comprising a residue originating from a method according to any one of clauses 9 to 16.

[0192] Item 17. A system comprising: a fiber web extending between a first rotatable core and a second rotatable core; a material layer extending between a third rotatable core and a fourth rotatable core, wherein an unfolded portion of the fiber web is stacked with an unfolded portion of the material layer; a cutting tool positioned between the first rotatable core and the second rotatable core and configured to cut a pattern piece from the unfolded portion of the fiber web and the unfolded portion of the material layer; and a drive assembly configured to rotate the second core, which winds the fiber web after the pattern piece is cut.

[0193] Clause 18. The system of clause 17, further comprising one or more rollers positioned between the first rotatable core and the second rotatable core, wherein the unfolded portion of the fiber web and the unfolded portion of the material layer are at least partially wrapped around the one or more rollers.

[0194] Clause 19. The system of Clause 17 or Clause 18, further comprising a negative pressure source configured to apply negative pressure to the unfolded portion of the fiber web and the unfolded portion of the material layer.

[0195] Clause 20. The system of any one of clauses 17 to 19, wherein the drive assembly is configured to rotate the fourth core that winds the material layer after the pattern piece is cut.

[0196] Clause 21. A system according to any one of clauses 17 to 20, wherein: the fiber web pattern sheet cut from the unfolded portion of the fiber web and the material layer pattern sheet cut from the unfolded portion of the material layer include multi-layer pattern sheets; and the system also includes an entangling device for mechanically entangling the fibers of the fiber web pattern sheet with the multi-layer pattern sheet.

[0197] Clause 22. The system of any one of clauses 17 to 21, wherein the second core and the fourth core are spaced apart such that winding the fiber web separates the fiber web from the material layer after cutting the pattern sheet.

[0198] A fabric or composite fabric constructed using the system of any one of clauses 17 to 22.

[0199] A coil comprising a residue from a system according to any of clauses 17 to 22.

[0200] Clause 23. A method comprising: positioning a first fiber web on top of a second fiber web to form a stack, wherein: the first fiber web includes a first characteristic and the second fiber web includes a second characteristic, the second characteristic corresponding to and different from the first characteristic; and the first characteristic and the second characteristic include at least one of a chemical composition of the fibers, an average denier of the fibers, an average diameter of the fibers, an average length of the fibers, a surface coating applied to the respective webs, and a fiber color; cutting the stack to form a first portion and a residual portion, wherein: the first portion includes a first scored portion of the first fiber web and a second scored portion of the second fiber web, and the residual portion includes a first residual portion of the first fiber web and a second residual portion of the second fiber web; separating the first portion from the residual portion; entangling the first scored portion of the first fiber web with the second scored portion of the second fiber web; removing the second residual portion from the first residual portion, wherein after removal, the first residual portion includes less than 10% by weight of fibers from the second residual portion; and recycling at least one of the first residual portion and the second residual portion.

[0201] Clause 24. The method according to clause 23, wherein the first fiber web is obtained from a first unwinding roller and the second fiber web is obtained from a second unwinding roller, the first fiber web being unwound on top of the second fiber web.

[0202] Clause 25. The method of clause 23 or clause 24, further comprising cutting the stack to form at least a second portion, wherein the second portion comprises a third scored portion of the first fiber web and a fourth scored portion of the second fiber web.

[0203] Clause 26. The method of clause 25, wherein the first shape of the first portion is different from the second shape of the second portion.

[0204] Clause 27. The method of clause 25 or clause 26, wherein the first portion and the second portion are separated by a threshold distance.

[0205] Clause 28. The method of clause 27, wherein the first portion and the second portion are separated by a distance less than or equal to about 5 mm.

[0206] Clause 29. A method according to any one of clauses 25 to 28, wherein: the laminate includes a first longitudinal edge and a second longitudinal edge; and the first portion and the second portion are arranged on the inner side of the first longitudinal edge and the second longitudinal edge at a threshold.

[0207] Clause 30. The method of clause 29, wherein the threshold value is at least about 10 mm.

[0208] Clause 31. A method according to any one of clauses 25 to 30, wherein: the laminate includes a first longitudinal edge and a second longitudinal edge; the first portion and the second portion are arranged at a first distance inwardly of the first longitudinal edge and the second longitudinal edge; and the first portion and the second portion are separated from each other by a second distance, the second distance being less than the first distance.

[0209] Clause 32. The method of any one of Clauses 23 to 31, further comprising forming a third fiber web from chopped fibers from the first residual portion.

[0210] Clause 33. The method of Clause 32, wherein the third fibrous web comprises a blend of the chopped fibers and unchopped fibers.

[0211] Clause 34. A method according to any one of clauses 23 to 33, wherein: the second residual portion comprises fibers, the fibers comprising a thermoplastic polymer; and the method further comprises pelletizing the fibers of the second residual portion after removing the second residual portion from the first residual portion.

[0212] Clause 35. The method of any one of clauses 23 to 34, further comprising positioning a third layer of material between the first fiber web and the second fiber web before cutting the laminate, wherein the third layer of material comprises a third characteristic corresponding to and different from the first characteristic and the second characteristic.

[0213] A fabric or composite fabric constructed using the method of any one of clauses 23 to 35.

[0214] A coil comprising a residue originating from a method according to any one of clauses 23 to 35.

[0215] Item 36. A composite fabric comprising a first fabric layer comprising an entangled fibrous web; a second fabric layer mechanically entangled with the first fabric layer; a first region, the first region being in a central area of ​​the composite fabric; a second region, the second region comprising a margin along a terminal edge of the composite fabric; and a third region positioned between the first region and the second region, wherein the third region is less mechanically entangled than the first region, the second region, or both the first region and the third region.

[0216] Clause 39. A composite fabric according to clause 38, wherein the composite fabric is constructed by a method according to any one or more of clauses 1 to 16 or 23 to 35; and / or wherein the composite fabric is constructed using a system according to any one of clauses 17 to 22.

[0217] As used herein, the phrase "and / or" with respect to two or more elements should be interpreted as referring to only one element or a combination of elements. For example, "element A, element B, and / or element C" may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, "at least one of element A or element B" may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Furthermore, "at least one of element A and element B" may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

[0218] This detailed description is provided to satisfy statutory requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways and in conjunction with other current or future technologies to include different steps, different combinations of steps, different elements, and / or different combinations of elements similar or equivalent to those described in this disclosure. The embodiments herein are to be considered in all respects as illustrative and not restrictive. To this extent, alternative examples or implementations may become apparent to one of ordinary skill in the art to which the subject matter pertains without departing from the scope of the invention.

[0219] 10: First nonwoven layer 12, second nonwoven layer 14, third nonwoven layer 16 and elastomer layer 18 in a stacked configuration before entanglement 12: First non-woven layer 14: Second non-woven layer 16: The third non-woven layer 18: Elastomer layer 20: Arrow 22: Cohesive composite non-woven fabric 24: Arrow 26: Wearable products 28: Arrow 110: System 112: Yarn feeder assembly 114: Collection Components 115: Edge of fabric 116: First Fabric 116b: Remaining part 118: Second fabric 118b: Remaining part 120: Fabric 120b: Remaining part 122: Fabric 122b: Remaining part 124: Cutting components 126: Transport components 128: Preprocessing component 130: One or more support structures 130a: One or more support structures 130b: One or more support structures 132: Support structure 132a: Support structure 132b: Support structure 134: Belt with rotating core 136: Fabric Lamination 138: Roller 140: Roller 142: Roller 144: Support surface 146: Cutting tools 148: Vacuum 150:Multi-layer pattern piece 152: Part of stacked pattern pieces 154:Incision 155:Incision 155a: First incision 155b: Second incision 156: Materials 158:Edge 160: Runner 216: Multiple discrete pattern pieces 216b: Peripheral edge 217: Tangled Fibers 218: Multiple discrete pattern pieces 218b: Peripheral edge 220: Multiple discrete pattern pieces 220b: Peripheral edge 222: Multiple discrete pattern pieces 222b: Peripheral edge 225: Tangled Fibers 228: Components of pre-treatment element 250:Multi-layer pattern piece 252: District 258:Other parts 260:Thickness 262:Thickness 310: Remaining part 312: Heterogeneous materials 312a: Partial or segmental 312b: Some chopped fiber 312c: Heterogeneous materials 312d: Heterogeneous materials 314: Regranulation 316: chopped 318: Cutting 320: Fiber web roll 410: Wearable products 412: Part 414: The first group of fibers 416: The second group of fibers 502: 504: Remaining part 506: Remaining part 508: 510: Cutting pattern 512: Operation 514: Fiber web pattern sheet 516: Fiber web remainder 518: Operation 520: Remaining part of the material layer 522: Remaining part of the material layer 524:

Claims

1. A method for manufacturing composite fabrics, comprising: Stack a fiber web adjacent to a material layer; Before entanglement of the fiber web with the material layer, the fiber web and the material layer are cut into a shape associated with a pattern; the fiber web is separated into a fiber web pattern sheet and a fiber web residual portion, the fiber web pattern sheet including the shape associated with the pattern; while separating the fiber web, the material layer is separated into a material layer pattern sheet and a material layer residual portion, the material layer pattern sheet including the shape associated with the pattern; and the fiber web residual portion is peeled off from the material layer residual portion.

2. The method as described in request item 1, wherein: The fiber web includes a first material, and the material layer includes a second material different from the first material; the method further includes forming a second fiber web from the fibers of the remaining portion of the fiber web; and the second fiber web includes a certain amount of the second material, the amount of the second material being less than a threshold amount of the first material by weight.

3. The method as described in claim 2, wherein the threshold amount is approximately 5%.

4. The method as claimed in claim 2 or 3, wherein forming the second fiber web includes re-granulating the fibers in the residual portion of the fiber web.

5. The method as described in request item 2 or 3, wherein: Forming the second fiber web includes shredding the remaining portion of the fiber web into shredded fibers; and forming the second fiber web using the shredded fibers.

6. The method as claimed in claim 2 or 3, wherein the fiber web and the material layer are cut simultaneously in the shape associated with the pattern.

7. The method as claimed in claim 2 or 3 further includes, after separating the fiber web pattern sheet and the material layer pattern sheet from the respective residual portions, causing the fibers of the fiber web pattern sheet to become entangled with the material layer pattern sheet.

8. The method as described in claim 2 or 3 further includes entanglement or bonding of the fiber web pattern sheet and the material layer pattern sheet without entanglement or bonding of the respective residual portions.

9. A fabric or composite fabric constructed using the method described in any one of claims 1 to 8.

10. A roll material comprising a residual portion derived from any one of claims 1 to 8.

11. A garment article constructed using any one of claims 1 to 8.

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