Articles comprising nonwoven material formed using airlay system

Abstract

A structure includes a nonwoven material comprising fibers formed using an airlay system, wherein at least 90% of the nonwoven material by weight is specified fiber. The nonwoven material can have a plurality of regions, each region of the plurality of regions having a different color than each other adjacent region of the plurality of regions.

Description

ARTICLES COMPRISING NONWOVEN MATERIAL FORMED USING AIRLAY SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 63 / 674,943, filed July 24, 2024. the entirety of which is incorporated by reference herein.FIELD

[0002] This disclosure relates to articles comprising a nonwoven material formed using an airlay system.BACKGROUND

[0003] Traditional carding and airlaid nonwoven products strive to have a very homogeneous color. This is accomplished by the opening and carding equipment on a carding line and the opening equipment on an airlay line to create intimate blends of fiber components in which clumps of fiber are separated into individual fibers. Intimate blending not only produces a homogeneous color that, conventionally, is desirable, but is also advantageous because it creates the maximum amount of fiber entangling during a needling process, creating a product with desirable physical properties.

[0004] In particular, conventionally, airlay lines, when manufacturing flooring products, are used for repurposing waste materials that would adversely affect and damage the carding equipment on a carding line.SUMMARY

[0005] Disclosed herein, in one aspect, is a structure comprising a nonwoven material comprising fibers formed using an airlay system, wherein at least 50% of the nonwoven material by weight is specified fiber.

[0006] Also disclosed herein is a structure including a nonwoven material comprising at least two fibers formed using an airlay system, wherein the at least two fibers have different colors.

[0007] In one aspect, an assembly includes a structure as disclosed herein, wherein the nonwoven material comprises an upper surface and a lower surface. The assembly further includes a base material coupled to at least a portion of the lower surface of the nonwoven material.

[0008] In another aspect, an article includes a structure as disclosed herein, wherein the nonwoven material comprises an upper surface and a lower surface. The article further includes a cap material overlying at least a portion of the nonwoven material, wherein the cap material has an upper surface. The article comprises areas where the structure is needlepunched through the cap material so that the nonwoven material of the article is exposed above the upper surface of the cap material.

[0009] In another aspect, a method includes the step of entangling fibers using an airlay system to form a nonwoven material, wherein at least 90% of the fibers by weight are specified fibers.

[0010] Additional advantages of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory’ only and are not restrictive of the invention, as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The patent or application fde contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.

[0012] FIG. 1 shows an image of a nonwoven material formed on a carding machine, the nonwoven material having generally homogenous color.

[0013] FIG. 2 shows a close-up view of a nonwoven material formed on an airlay system to include regions with different colors.

[0014] FIG. 3 shows a larger area of the nonwoven material of FIG. 2.

[0015] FIG. 4 shows a schematic diagram of an assembly comprising a nonwoven material and base material coupled thereto.

[0016] FIG. 5 shows a schematic diagram of an article comprising nonwoven material and a cap layer positioned thereover, with portions of the nonwoven material needlepunched through the cap layer so that the nonwoven material is exposed above an upper surface of the cap layer in certain areas.

[0017] FIG. 6 shows a schematic diagram of an article comprising nonwoven material and a cap layer positioned thereover, with portions of the nonwoven material needlepunched through the cap layer so that the nonwoven material is exposed above an upper surface of the cap layer in certain areas.

[0018] FIG. 7 is a top view of an assembly including a cap layer with a nonwoven material as in FIG. 2 needlepunched therethrough to provide an aesthetic appearance.

[0019] FIG. 8 is a top view of an assembly including a cap layer with a nonwoven material as in FIG. 2 needlepunched therethrough to provide an aesthetic appearance.

[0020] FIG. 9 is a top view of an assembly including a cap layer with a nonwoven material as in FIG. 2 needlepunched therethrough to provide an aesthetic appearance.

[0021] FIG. 10 is a top view of an assembly including a cap layer with a nonwoven material needlepunched therethrough to provide an aesthetic appearance.

[0022] FIG. 11 is a schematic diagram illustrating the CIELAB color space.

[0023] FIG. 12 is a schematic diagram of a feed system for preparing fiber for deliver}’ to the airlay system.

[0024] FIG. 13 is an end view of the feed system of FIG. 12.

[0025] FIG. 14 is a schematic diagram of a system for forming a nonwoven material as disclosed herein.

[0026] It should be understood that the drawings provided herein are not necessarily to scale. Rather, the drawings are formatted to help aid the understanding of certain features disclosedherein. For example, the relative sizes of the depicted tufts and backing materials shown in the figures are not necessarily indicative of what would be seen in the tufted articles disclosed herein.DETAILED DESCRIPTION

[0027] The disclosed system and method may be understood more readily by reference to the following detailed description of particular embodiments and the examples included therein and to the Figures and their previous and following description.

[0028] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the present invention which will be limited only by the appended claims.

[0029] It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” further include plural references unless the context clearly dictates otherwise. Thus, for example, reference to “a region” constitutes disclosure of a single region and also constitutes disclosure of a plurality of regions, and so forth.

[0030] “Optional” or “optionally” means that the subsequently described event, circumstance, or material may or may not occur or be present, and that the description includes instances where the event, circumstance, or material occurs or is present and instances where it does not occur or is not present.

[0031] Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, also specifically contemplated and considered disclosed is the range from the one particular value and / or to the other particular value unless the context specifically indicates otherwise. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another, specifically contemplated embodiment that should be considered disclosed unless the context specifically indicates otherw ise. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint unless the context specifically indicates otherwise. Finally, it should be understood that all of the individual values and subranges of values contained within an explicitly disclosed range are also specificallycontemplated and should be considered disclosed unless the context specifically indicates otherwise. The foregoing applies regardless of whether in particular cases some or all of these embodiments are explicitly disclosed.

[0032] Optionally, in some aspects, when values are approximated by use of the antecedents “about,” “substantially,” or “generally,” it is contemplated that values within up to 15%, up to 10%. up to 5%, or up to 1% (above or below) of the particularly stated value or characteristic can be included within the scope of those aspects.

[0033] As used herein, the definition of the term “color” is referenced in terms of the CIELAB color scale, which was created by the International Commission on Illumination (CIE). The CIELAB color scale provides a uniform scale for measuring and comparing the color values of different samples. Three different color measurements are used to determine the CIELAB color value of a given sample: 1) a white-black color measurement; 2) a red- green color measurement; and 3) a yellow-blue color measurement. The white-black color measurement represents the amount of white present in the sample relative to the amount of black present in the sample. The red-green color measurement represents the amount of red present in the sample relative to the amount of green present in the sample. The yellow-blue color measurement represents the amount of yellow present in the sample relative to the amount of blue present in the sample. CIELAB color scale values can be obtained using color measurement instruments known in the art, including, for example, HunterLab color measurement instruments. When two “colors” are referred to as being the same or “substantially” the same or matching or “substantially” matching, it should be understood that each of the three color measurements (in the CIELAB scale) for the colors being compared are equal or substantially equal.

[0034] As used herein, the term “polymer” can comprise any suitable polymer such as, for example, a polyamide, a polyester, polylactic acid, polyurethane, polyvinyl chloride, polyolefin, acrylonitrile butadiene styrene, polystyrene, biopolymers, or a combination thereof. The polymer disclosed herein can be used to make the nonwoven material disclosed herein.

[0035] The term “polyamide,” as utilized herein, is defined to be any long-chain polymer in which the linking functional groups are amide (-CO-NH-) linkages. The term polyamide isfurther defined to include copolymers, terpolymers and the like as well as homopolymers and also includes blends of two or more polyamides. In one example, the polyamide can comprise one or more of nylon 6, nylon 66, nylon 10. nylon 612, nylon 12. nylon 11, or any combination thereof. In another example, the polyamide can comprise nylon 6 or nylon 66. In yet another example, the polyamide is nylon 6. In a yet further example, the polyamide is nylon 66.

[0036] As defined herein, the term “polyolefin” refers to any class of polymers produced from a simple olefin (also called an alkene with the general formula CnH2n) as a monomer. The polyolefin can comprise, for example, polyethylene, polypropylene, both homopolymer and / or copolymers, poly(l-butene), poly(3-methyl-l-butene), or poly(4- methyl- I -pentene) and the like, as well as combinations or mixtures of two or more of the foregoing. In one example, the polyolefin can comprise polyethylene or polypropylene. In another example, the polyolefin can comprise polyethylene. In yet another example, the polyolefin can comprise polypropylene.

[0037] As used herein, the term “polyester” refers to a category of polymers that contain the ester functional group in their main chain. Polyesters disclosed herein include naturally occurring chemicals, such as in the cutin of plant cuticles, as well as synthetics produced through step-growth polymerization. An non-limiting example of polyesters includes any long-chain synthetic polymer composed of at least 85% by weight of an ester of a substituted aromatic dicarboxylic acid, including but not restricted to substituted terephthalic units, p(-R- O-CO- CeH4-CO-O-)xand parasubstituted hydroxy -benzoate units, p(-R-O-CO-CeH4-O)x. In certain examples, the polyesters comprise polyethylene terephthalate (PET) homopolymer and copolymers, polypropylene terephthalate (PPT) homopolymer and copolymers and polybutylene terephthalate (PBT) homopolymer and copolymers, and the like, including those that contain comonomers such as cyclohexanedimethanol, cyclohexanedicarboxy lie acid, isophthalic acid, and the like.

[0038] As defined herein, the term “polyurethane” refers to any class of polymers composed of a chain of organic units joined by carbamate (urethane, R1-O-CO-NR2-R3, wherein Ri, R2, and R3 are the same or different) links.

[0039] As defined herein, the term “polysty rene” refers to any class of synthetic polymers produced from a simple sty rene as a monomer. It is understood that the term “poly styrene” includes isotactic, atactic, and syndiotactic polystyrenes. In some specific aspects, described are also co-polystyrenes including a high-impact polystyrenes (HIPS), acrylonitrile butadiene styrene (ABS) or copolymer of sty rene with acrylonitrile (SAN), or copolymer of sty rene with maleic acid (SMA).

[0040] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed apparatus, system, and method belong.

[0041] Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. In particular, in methods stated as comprising one or more steps or operations it is specifically contemplated that each step comprises what is listed (unless that step includes a limiting term such as “consisting of’), meaning that each step is not intended to exclude, for example, other additives, components, integers or steps that are not listed in the step.

[0042] As used herein, “specified fiber” is understood to mean fiber that has never been used in another article. That is, the “specified fiber” is fiber that is not being repurposed in its fiber form after previously being used in another article. As is understood in the art, airlay systems are conventionally used to form junk fiber -that is, fiber that has been used for another purpose and then is repurposed in its fiber form - into nonwoven material.Therefore, “specified fiber” should be understood to be fiber that is not junk fiber (i.e. fiber that has previously been used in another article). It is contemplated that the “specified fiber” can comprise recycled polymer. For example, the recycled polymer can come from fiber that is recycled from another article and spun into a new fiber to serve as specified fiber.Specified fiber can also be referred to as “intentional fiber,” as said specified fiber is formed provided for use with an airlay system, rather than being intended for another article and then being repurposed for provision to the airlay system. Disclosed herein are nonwoven materials comprising specified fiber formed using an airlay system.

[0043] Referring to FIGS. 2-3, a structure 10 comprises a nonwoven material 12, the nonwoven material comprising fibers formed using an airlay system, wherein at least 50% of the nonwoven material by weight is specified fiber. For example, in some aspects, the nonwoven material 12 can comprise at least 80%, 70%, 60%, or 50% specified fiber by weight. In further aspects, the nonwoven material 12 can comprise at least 90%, 95%, 97%, 98%, or 99% specified fiber by weight. Optionally, the nonwoven material 12 can be formed entirely, or substantially entirely, from specified fiber. In some aspects, the structure 10 can consist of, or consist essentially of, the nonwoven material 12. For example, in some aspects, the nonwoven article 12 can comprise lowmelt fiber, wherein portions of the lowmelt fiber are melted to adhere to other portions of the fiber, thereby providing bonds betw een fibers in addition to entanglement (as further described herein). The lowmelt fiber can have a relatively low melting point (e.g., from about 90 °C to about 220 °C) to permit the fiber to be efficiently melted for providing bonds. In other aspects, the structure 10 can comprise the nonwoven material and at least one or more back coatings that bond fibers of the nonwoven material 12 together. For example, the back coating can comprise polymer, such as latex or hotmelt. The back coating can be configured to adhere fibers of the non woven material 12 on one side of the nonwoven material (e.g., a bottom side).

[0044] It is contemplated that by using specified fiber, the color of the fiber and, thus, the color of the nonwoven material 12 can be controlled. Further, by using specified fiber, uniformity of the nonwoven material 12 can be maintained. Additionally, by using specified fiber, the structure of the nonwoven material 12 can be controlled. For example, the fiber denier and / or length can be predetermined or known within a predetermined range. This can contrast with repurposed fiber (traditionally provided to airlay systems), wherein fiber color, length, and denier are merely determined by what is available from salvaging the fiber from another article. Accordingly, the look and the structural properties of the non-woven material can be controlled.

[0045] In some aspects, the specified fiber can comprise polymer, wherein the polymer is 100% virgin polymer. In further aspects, the specified fiber can be formed entirely from 100% virgin polymer. In other aspects, the specified fiber can comprise recycled polymer. In exemplary aspects, the content (e.g., material) of the specified fiber can range from 0% recycled content to 100% recycled content, e.g.. from 0% to 50% recycled content, or from 50% to 100% recycled content, or from 20% to 80% recycled content.

[0046] In some aspects, the specified fiber can comprise a polyamide, a polyester, polylactic acid, polyurethane, polyvinyl chloride, polyolefin, acrylonitrile butadiene styrene, polystyrene, biopolymers, or a combination thereof. In exemplary aspects, the specified fiber can be at least 90% polyester, for example, 100% polyester. In one example, the polyester can be polyethylene terephthalate (PET).

[0047] Although the homogenous nature of nonwoven material formed on a carding machine, shown in FIG. 1, was conventionally found to be desirable, it was discovered that non- homogenous blending can achieve certain desirable aesthetics and novel appearances. Accordingly, in various aspects, and with reference to FIG. 3. the nonwoven material 12 can comprise a plurality of regions 14. each region of the plurality of regions having a different color than each other adjacent region of the plurality of regions. In some aspects, the different colors can be measured in accordance with the CIELAB color scale, schematically illustrated in FIG. 11. In exemplary' aspects, at least two adjacent regions of the plurality' of regions can differ by a AE* value of at least 11, or at least 20. or at least 50. Accordingly, in some aspects, the nonwoven material 12 can differ from a nonwoven material formed by a carding machine and having generally homogenous coloring, as illustrated in FIG. 1 . For example, the nonwoven material 12 can have a mottled pattern.

[0048] Referring also to FIG. 11, in some aspects, the plurality of regions 14 of the nonwoven material 12 can include a first region having a first color with a positive b-value, and a second region with a second color having a negative b-value on the CIELAB color scale. In some aspects, the plurality of regions 14 of the nonwoven material 12 can include a first region having a first color with a positive a-value, and a second region with a second color having a negative a-value on the CIELAB color scale. In further aspects, the plurality of regions 14 can include two, three, or four colors selected from different quadrants of the following quadrants of the CIELAB color scale: positive a, positive b; positive a, negative b; negative a, positive b; and negative a, negative b.

[0049] In some aspects, each region of the plurality^ of regions 14 can be formed by at least 90% by weight of fibers of a single color. Said single color can be within a AE* value of 20, or 10, or 5, or 4, or 3, or 2, or 1 as measured by the CIELAB color scale. For example, the single color can be fibers having a AE* value of 4 (e.g.. permitting a variation of + / -2 in any direction from a color specification). In various exemplary aspects, the plurality of regions14 can have respective areas from 0.1 cm2to 200 cm2, or from 0.2 cm2to about 100 cm2, or from about 0.3 cm2to about 30 cm2. In exemplary' aspects, one or more of the plurality' of regions can have respective areas from 0. 1 cm2to 1 cm2, or from 1 cm2to 10 cm2, or from 10 cm2to 100 cm2.

[0050] In some aspects, the plurality of regions 14 can comprise a first region 14a having a first color, and each other region contacting the first region (e.g., regions for 14b, 14c, and 14d) can have a color that is different from the first color. For example, at least one other region 14 can surround the first region, wherein each region of the at least one other region 14 has a color different from the first color. That is, each other region 14 contacting the first region can have a color that is different from the first color. For example, the first region 14a can contact one or more regions 14 of at least one other color, at least two different colors, at least three different colors, at least four different colors, or more.

[0051] In further aspects, the nonwoven material 12 can have regions 14 of at least two different colors within one square foot. In further aspects, the nonwoven material 12 can have regions 14 of at least two different colors within one yard. In further aspects, the nonwoven material 12 can have regions 14 of at least three different colors within one square foot. In further aspects, the nonwoven material 12 can have regions 14 of at least three different colors within one yard. In further aspects, the nonwoven material 12 can have regions 14 of at least four different colors within one square foot. In further aspects, the nonwoven material 12 can have regions 14 of at least four different colors within one yard.

[0052] In exemplary aspects, the adjacent regions of the plurality of regions 14 can be blended at adjoining edges. For example, the nonwoven material can further comprise transition regions between at least two adjacent regions, wherein the transition region comprises a mix of the different colors of the at least to adjacent regions. Optionally, the transition region can have a transverse dimension (e.g., a shortest dimension extending between two adjacent regions) from 1 mm to 5 mm. Minimizing the size of this transition region can increase contrast between adjacent regions. Increasing the size of the transition region can reduce contrast between adjacent regions. Accordingly, the size of the transition region can be controlled during formation of the nonwoven material 12 to achieve the desired aesthetic.

[0053] In some aspects, the plurality of regions 14 can have irregular shapes. In further aspects, the plurality of regions 14 can be provided in a randomly generated arrangement. For example, the plurality of regions 14 can be arranged in a non-repeating pattern. In some aspects, the plurality of regions 14 of the nonwoven material 12 can provide the aesthetic generally corresponding to that of a space-dyed article. In other aspects, the plurality' of regions 14 can be arranged in a repeating pattern. In some aspects, the plurality' of regions 14 can collectively provide at least three different colors, at least four different colors, at least five different colors, or more than five different colors.

[0054] More generally, the nonwoven material 12 can comprise non-homogeneously blended fibers, wherein different regions of the nonwoven material 12 correspond to express different colors. For example, it is further contemplated that multiple fibers can cooperate to express a particular color when viewed from a sufficient distance that individual fibers are indistinguishable. Accordingly, a particular color at a particular location can be formed by a plurality of fibers having different colors, yet the particular location, when viewed by a sufficient distance, can express the particular color.

[0055] In some aspects, the nonwoven material 12 can comprise different regions 14 with at least two colors differing on the CIELAB scale by a AE* value of at least 11. or at least 20. In some aspects, the nonwoven material 12 can comprise different regions 14 with at least three colors differing on the CIELAB scale by a AE* value of at least 1 1 , or at least 20, or at least 50, or at least 100. In some aspects, the nonwoven material 12 can comprise different regions 14 with at least four colors differing on the CIELAB scale by a AE* value of at least 11, or at least 20, or at least 50, or at least 100. In some aspects, the nonwoven material 12 can comprise different regions 14 with at least five differing on the CIELAB scale by a AE* value of at least 11, or at least 20, or at least 50, or at least 100. In further aspects, said two, three, four, five, or more different colors of the nonwoven material 12 can be provided within a square yard of the nonwoven material 12.

[0056] In some aspects, the nonwoven material has an upper surface 16 and a lower surface 18 defining a thickness therebetween. Optionally, the thickness can be from 1 / 16 inch to 1 / 2 inch (e.g., from 1 / 16 inch to 3 / 8 inch, or from 1 / 8 inch to 'A inch). In some aspects, the thickness can be from 0.2 inches to about ! inch. In further aspects, the thickness can be from 1 / 16 inch to 4 inches. Optionally, the non-woven material 12 can further be verticallylapped with a base material to provide an assembly with a greater thickness. In some aspects, the weight of the nonw oven material 12 can vary in different locations across the material. This can contrast with carded nonwoven materials. Optionally, in some aspects, the nonwoven material can comprise at least two different fiber weights.

[0057] In some aspects, the nonwoven material 12 formed on the airlay system can comprise at least two fibers. In some aspects, the nonwoven material 12 can have exactly two different colors of fibers. In further aspects. In other aspects, the nonwoven material 12 can have exactly three different colors of fibers. In exemplary aspects, the nonwoven material 12 can have four, five, six, or more different colors of fibers. Said colors can optionally differ by at least a AE* value of at least 11, or at least 20, or at least 50. or at least 100 on the CIELAB scale. In further aspects, the colors of fibers can comprise a first color with a positive b- value, and a second color having a negative b-value on the CIELAB color scale. In some aspects, the colors of fibers can comprise a first color with a positive a-value, and a second region with a second color having a negative a-value on the CIELAB color scale. In further aspects, the colors of fibers can comprise two. three, or four colors selected from different quadrants of the following quadrants of the CIELAB color scale: positive a, positive b; positive a, negative b; negative a, positive b; and negative a, negative b.

[0058] The at least two fibers can be heterogeneously distributed so that each fiber of the at least tw 'o fibers define at least one respective region of the nonwoven material 12 having the color of the respective fiber. For example, after being fed through the airlay system, the fibers can remain grouped in respective areas so to provide different regions with different colors (optionally, with blending of colors at transition regions between the boundaries of the different grouped fibers).

[0059] Also disclosed herein is a structure 10 comprising a nonwoven material 12, the nonwoven material comprising at least two fibers formed using an airlay system. The at least two fibers each have different respective colors. For example, the at least two different fibers can be arranged into a plurality of regions 14 as disclosed herein. Accordingly, unlike traditional nonwoven material formed by carding machines and airlay systems, the at least two fibers can be heterogeneously distributed. Said structure 10 can have at least two fibers, at least three fibers, at least four fibers, at least five fibers, or at least six fibers, each having a different color. In further aspects, the structure 10 can have exactly three fibers, exactly fourfibers, exactly fibers, exactly six fibers, or from two to six fibers, or from three to five fibers, each fiber having a respective color.Assembly Comprising Nonwoven Material

[0060] Referring to FIG. 4, an assembly 30 can comprise the nonwoven material 12 and a base material 32 coupled thereto. For example, the base material 32 can be coupled to the lower surface 18 of the nonwoven material 12. In some aspects, the nonwoven material 12 can be needlepunched, hydroentangled, or thermally bonded to the base material 32. In other aspects, the nonwoven material 12 can be coupled to the base material 32 via an adhesive. The base material 32 can provide, for example, dimensional stability, durability, or improved acoustic properties.

[0061] For example, the nonwoven material 12 can be coupled to a base material 32 having a greater rigidity than the nonwoven material 12 to provide a plank. In other aspects, the base material 32 can have a lower density than the nonwoven material 12. For example, it is contemplated that the base material 32 can be provided for desirable acoustic characteristics. In further aspects, the nonwoven material 12 can be densified from the upper surface 16 so that an upper portion of the nonwoven material provides a harder surface.

[0062] In some aspects, base material 32 can comprise a densified fiber batt. The densified fiber batt can comprise a first plurality of fibers having a first melting point and a second plurality of fibers. At least a portion of the second plurality of fibers can have a second melting point that is lower than the first melting point. In this way. during a densification step during which the fiber batt is heated, the second plurality of fibers, or the portion thereof having the second melting point, can soften (e.g., melt) to bind to the other fibers to form the densified fiber batt. In some optional aspects, an entirety of the second plurality of fibers can have the first melting point. For example, the second plurality of fibers can be low-melt fiber. Optionally, in these aspects, the first plurality of fibers can provide the color(s) of the nonwoven material 12, and the second plurality of fibers can be substantially colorless. In other optional aspects, the portion of the second plurality7of fibers that has the second melting point can be an outer portion of the fibers of the second plurality of fibers. For example, the second plurality of fibers can comprise a multi-component fiber, wherein the multicomponent fiber comprises a sheath and a core provided as a sheath core configuration, andwherein the sheath has the second melting point that is lower than the first melting point. In this way, during densifi cation the first portion of the second plurality of fibers can soften and bind to the first plurality of fibers, while the second portion of the second plurality of fibers do not melt. In various optional aspects, the first plurality of fibers comprise polypropylene, and the second plurality of fibers can comprise polyethylene. In other optional aspects, the first plurality of fibers and the second plurality of fibers can comprise polyethylene terephthalate (PET). In some optional aspects, the first and second plurality of fibers can be entangled.

[0063] In exemplary aspects, the first plurality of fibers can have a length from about one inch to about six inches, for from about two inches to about four inches, or from about 2.5 inches to about 3.5 inches, or about three inches. It is contemplated that a relatively longer length of the fibers can inhibit mixing of the fibers, thereby providing regions of different colors. In further exemplary aspects, the second plurality of fibers can have a length from about one inch to about six inches, for from about one inches to about three inches, or about two inches. In exemplary aspects, the first plurality of fibers can have a denier from about 5 to about 40, or from about 10 to about 20, or about 15. In exemplary aspects, the second plurality of fibers can have a denier from about 1 to about 10, or from about 2 to about 6, or about 4.

[0064] In other aspects, the base material 32 can comprise a nonwoven material formed by a carding machine. In this way, the properties and performance of a nonwoven material formed by a carding machine can be imparted to the non woven material 12 (formed by an airlay system).Articles Comprising Nonwoven Material and Cap Material

[0065] Referring to FIGS. 5-10, an article 50 can comprise a cap material 52 that is positioned over at least a portion of the upper surface 16 of the nonwoven material 12. The cap material 52 has an upper surface 54. The article 50 comprises areas where the nonwoven material 12 is needlepunched through the cap material 52 so that the nonwoven material is exposed above the upper surface 54 of the cap material 52 to form an aesthetic appearance of the article 50. That is. portions of the nonwoven material 12 needlepunched through the cap material 52 can be visible above the cap material 52.

[0066] In some aspects, the cap material 52 can be a woven material. In other aspects, the cap material 52 can be a nonwoven material. For example, the cap material 52 can be a nonwoven material formed by needlepunching. In some aspects, the cap material 52 can comprise polymer, such as a polyamide, a polyester, polylactic acid, polyurethane, polyvinyl chloride, polyolefin, acrylonitrile butadiene styrene, polystyrene, biopolymers, or a combination thereof. In exemplary' aspects, the cap material 52 can be at least 90% polyester, for example, 100% polyester.

[0067] In some aspects, the aesthetic appearance of the article 50 can comprise an upper surface 56 areas defined by the cap material 52 and areas defined at least partly by the structure 10 needlepunched through the cap material. Optionally, the areas defined by the article 10 needlepunched through the cap material 52 have irregular shapes. In further aspects, the areas defined by the structure 10 needlepunched through the cap material 52 can be provided in a randomly generated arrangement. The areas defined by the structure 10 needlepunched through the cap material 52 can be arranged in a non-repeating pattern. In other aspects, the areas defined by the structure 10 needlepunched through the cap material 52 can be arranged in a repeating pattern.

[0068] In some aspect, the areas defined at least partly by the structure 10 / nonwoven material 12 needlepunched through the cap material comprise areas defined entirety by the nonwoven material 12 needlepunched through the cap material. That is, within said areas, the amount of the nonwoven material 12 can be sufficiently dense to obscure any view of the cap material 52. In additional aspects, the article 50 can comprise areas where the structure needlepunched through the cap material has a sufficiently low height that both the cap material and the structure needlepunched through the cap material are visible.

[0069] In some aspects, the article 50 can have an upper surface 56 with at least three distinct colors. For example, the aesthetic appearance provided by the upper surface 56 of the article 50 can comprise a single color defined by the cap material 52 and at least two additional colors defined by the nonwoven material 12. In other aspects, the cap material 52 can comprise two or more colors. In further aspects, the nonwoven material 12 can comprise three or more colors. Optionally, the cap material 52 can be patterned. Accordingly, as illustrated in FIGS. 7-10, the article 50 can have an aesthetic appearance provided by the combination of the pattern of the nonwoven material 12 exposed above the upper surface 54of the cap material 52; the color of the nonwoven material 12 where the nonwoven material is exposed; and the color / colors / pattem of the cap material 52 itself.

[0070] Optionally, referring to FIG. 6, the article 50 can further comprise a base material 32 coupled to the lower surface 18 of the nonwoven material 12. For example, in some aspects, the nonwoven material 12 can be needl epunched through the cap material 50, and the base material 32 can subsequently be coupled to the nonwoven material. In other aspects, the nonwoven material 12 can be needlepunched through the cap material 50 with the base material 32 already positioned against the lower surface 18 of the base material 32. Accordingly, the article 50 can comprise or omit the base material 32.Methods of Forming Structures, Assemblies, and Articles as Disclosed Herein

[0071] A method of forming a structure 10 as disclosed herein comprises entangling fibers using an airlay system to form a nonwoven material. In these aspects, at least 90% of the fibers by weight are specified fibers. Conventional airlay systems include one or more structures for individualizing fiber. Such structures can blend fibers to inhibit regions of different color. Accordingly, in some aspects, a conventional airlay system can be modified to bypass or remove said structures for individualizing fiber. In this way, the airlay system can provide a nonwoven article with regions having different colors as disclosed herein. It is further contemplated that fiber can be nonuniformly mixed so that clumps of fiber of or expressing a particular color remain together as they are fed into the airlay system.

[0072] For example, a system for providing the structure 10 as disclosed herein can comprise a rake that delivers fiber clumps of a specific size to the airlay machine. Conventional airlay machines include a fine opener to inhibit fiber clumps from passing therethrough. The fine opener of the airlay can be removed or bypassed for feeding the fibers to the airlay machine.

[0073] Referring to FIGS. 12-13, a feed system 200 can comprise a conveyor 202 (e.g., an incline apron) configured to carry fiber along a conveyance axis 204 for feeding into an airlay machine. The feed system 200 can further comprise a roller 210 that is spaced from the conveyor 202 by a predetermined spacing. The roller 210 can be configured to push the fiber in a direction away from a direction of movement of the conveyance axis 204. Accordingly, the roller 210 can be a knockoff roller. In this way, the roller 210 can control an amount offiber provided to the airlay machine. The roller 210 can further control a structure of the fiber fed to the airlay machine. For example, the roll 210 can inhibit larger clumps of fiber from passing and / or break up clumps. In some aspects, the roller 210 can comprise one or more teeth, hooks, arms, pins, or projections configured to engage the fiber.

[0074] The feed system 200 can further comprise a second roller 220. In some aspects, the second roller 220 can be spaced a second predetermined spacing from the conveyor 202. In some aspects, the second roller 220 can rotate in the direction of movement of the conveyance axis. The second roller 220 can be a knockoff roller that removes the fiber from the conveyor 202. In some aspects, the second roller 220 can comprise one or more teeth, hooks, arms, pins, or projections configured to engage the fiber. Optionally, the second roller 220 can further control the structure of the fiber fed to the airlay machine. For example, the second roller 220 can control a size and shape of the clumps of fiber fed to the airlay machine.

[0075] In some aspects, the conveyor 202 can have an apex 206. For example, the conveyor 202 can be an incline apron. In some aspects, the conveyance axis 204 can extend upwardly to carry the fiber past the first roller 210. Accordingly, in some aspects, the first roller 210 can push fiber back against the direction of movement of the conveyance axis, and gravity can pull the fiber against the direction of conveyance. In some aspects, the first roller 210 can be on a first side of the apex 206, and the second roller 220 can be on a second side of the apex 206. Accordingly, in some aspects, gravity can carry fiber past the second roller 220.

[0076] In some aspects, a speed of the first roller 210 can be controlled to, in turn, control a quantity of fiber passing thereby. Similarly, a speed of the second roller 220 can be controlled. The speed of the second roller can be controlled to optimize removal of the fiber from the conveyor 202.

[0077] In some aspects, a plurality of feed systems 200 can cooperate to feed fiber to the airlay machine. For example, each feed system 200 can deliver fiber of a particular type (e.g., color). In this way, each system 200 can mix fiber. In some aspects, the feed systems can be configured to feed respective fiber in similar or different volumes and similar or different sizes of clumps. In other aspects, a single feed system 200 can feed fiber to theairlay system. For example, a mix of different colors of fiber can be provided to the single feed system 200.

[0078] Optionally, in these aspects, the feed system 200 can provide fiber to an airlay machine 260 (FIG. 14). For example, the fiber leaving the conveyor 202 can be collected in an accumulator 240, such as, for example, a weigh pan. The weigh pan can determine a weight of fiber collected therein. In this way, the amount of fiber from each feed system 200 can be controlled. The accumulator 240 can release the accumulated clumps of fiber for delivery to the fiber airlay machine 260. For example, the accumulator 240 can comprise a pair of arms 242 that are radially movable outwardly to release the fiber therein to a conveyor 255 below. The conveyor 255 can carry the fiber to the airlay machine 260 or to a blender 250 (FIG. 14) before the fiber is ultimately delivered to the airlay machine.

[0079] Referring to FIG. 14, in some aspects, a plurality' of feed systems 200 can be configured to control clump sizes for fibers fed thereto. Once the fibers are formed into particular clump sizes, the clumps of fibers can be mixed together. For example, the clumps of fibers can be mixed in a blender 250. The blender 250 can be, for example a container having a mixing element, such as a stirring arm movable therein. In additional aspects, the blender 250 can comprise a rotatable body that receives fiber therein, wherein rotation of the blender causes mixing of the clumps of fibers. In some aspects, the blender 250 can be a blending bin (e.g., a blending bin of an airlay machine as is know n in the art). In some aspects, the fiber can be provided to the blender 250 in a predetermined ratio. For example, the accumulators 240 (e.g., weigh pans) of each feed system 200 can provide a measure from each feed system 200 to achieve the predetermined ratio. The mixed fibers can be fed to the airlay machine 260.EXEMPLARY ASPECTS

[0080] In view of the described products, systems, and methods and variations thereof, herein below are described certain more particularly described aspects of the invention. These particularly recited aspects should not how ever be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular’7aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

[0081] Aspect 1 : A structure comprising: a nonwoven material comprising fibers formed using an airlay system, wherein at least 50% of the nonwoven material by weight is specified fiber.

[0082] Aspect 2: The structure of aspect 1, wherein the nonwoven material comprises a plurality of regions, each region of the plurality of regions having a different color than each other adjacent region of the plurality of regions.

[0083] Aspect 3: The structure of aspect 2, wherein each region of the plurality of regions is formed by at least 90% by weight of fibers of a single color.

[0084] Aspect 4: The structure of aspect 2 or aspect 3, wherein the plurality of regions have respective areas from 0. 1 cm2to 200 cm2.

[0085] Aspect 5: The structure of any one of aspects 2-4, wherein the nonwoven material further comprises transition regions between at least two adjacent regions, wherein the transition region comprises a mix of the different colors of the at least to adjacent regions.

[0086] Aspect 6: The structure of aspect 5, wherein the transition region has a transverse dimension from 1 mm to 5 mm.

[0087] Aspect 7 : The structure of any one of aspects 2-6, wherein the plurality of regions have irregular shapes.

[0088] Aspect 8: The structure of any one of aspects 2-7, wherein the plurality of regions are provided in a randomly generated arrangement.

[0089] Aspect 9: The structure of any one of aspects 2-8, wherein the plurality of regions are arranged in a non-repeating pattern.

[0090] Aspect 10: The structure of any one of aspects 2-7, wherein the plurality of regions are arranged in a repeating pattern.

[0091] Aspect 11 : The structure of any one of aspects 2-10. wherein the plurality of regions collectively provide at least three different colors.

[0092] Aspect 12: The structure of any one of aspects 2-10, wherein the plurality' of regions comprise at least two different fiber weights.

[0093] Aspect 13: The structure of any one of the preceding aspects, wherein the nonwoven material has an upper surface and a lower surface defining a thickness therebetween, wherein the thickness is from 0.200 inch to 0.500 inch.

[0094] Aspect 14: The structure of any one of the preceding aspects, wherein at least 90% of the nonwoven material by weight is specified fiber.

[0095] Aspect 15: A structure comprising: a nonwoven material comprising at least two fibers formed using an airlay system, wherein the at least two fibers have different colors.

[0096] Aspect 16: The structure of aspect 15, wherein the at least two fibers are heterogeneously distributed so that each fiber of the at least two fibers define at least one respective region of the nonwoven material having the color of the respective fiber.

[0097] Aspect 17: An assembly comprising: a structure as in any one of the preceding aspects, wherein the nonwoven material comprises an upper surface and a lower surface; and a base material coupled to at least a portion of the lower surface of the nonwoven material.

[0098] Aspect 18: The assembly of aspect 17, wherein the base material comprises a nonwoven material formed by a carding machine.

[0099] Aspect 19: The assembly of aspect 17, wherein the base material comprises a densified fiber batt.

[0100] Aspect 20: The assembly of any one of aspects 17-19. wherein the base material is coupled to the lower surface of the structure by needlepunching.

[0101] Aspect 21 : An article comprising: a structure as in any one of aspects 1-16, wherein the nonwoven material comprises an upper surface and a lower surface; anda cap material overlying at least a portion of the nonwoven material, wherein the cap material has an upper surface, wherein the article comprises areas where the structure is needlepunched through the cap material so that the nonwoven material of the article is exposed above the upper surface of the cap material.

[0102] Aspect 22: The article of aspect 21, wherein the cap material is woven.

[0103] Aspect 23: The article of aspect 21, wherein the cap material is a nonwoven material formed by needlepunching.

[0104] Aspect 24: The article of any one of aspects 21-23, wherein the article has an upper surface comprising: areas defined by the cap material; and areas defined at least partly by the nonwoven material needlepunched through the cap material.

[0105] Aspect 25: The article of aspect 24, wherein the areas defined by the structure needlepunched through the cap material have irregular shapes.

[0106] Aspect 26: The article of aspect 24, wherein the areas defined by the structure needlepunched through the cap material are provided in a randomly generated arrangement.

[0107] Aspect 27: The article of aspect 24, wherein the areas defined by the structure needlepunched through the cap material are arranged in a non-repeating pattern.

[0108] Aspect 28: The article of aspect 24, wherein the areas defined by the structure needlepunched through the cap material are arranged in a repeating pattern.

[0109] Aspect 29: The article of aspect 24, further comprising a base material coupled to the lower surface of the structure.

[0110] Aspect 30: The article of aspect 29, wherein the base material comprises a nonwoven material formed by a carding machine.

[0111] Aspect 31 : The article of aspect 29, wherein the base material comprises a densified fiber batt.

[0112] Aspect 32: The article of any one of aspects 24-31, wherein the areas defined at least partly by the nonwoven material needlepunched through the cap material comprise areas defined entirely by the nonwoven material needlepunched through the cap material.

[0113] Aspect 33: The article of any one of aspects 24-32, wherein the areas defined at least partly by the structure needlepunched through the cap material comprise areas where the structure needlepunched through the cap material has a sufficiently low height that both the cap material and the structure needlepunched through the cap material are visible.

[0114] Aspect 34: The article of any one of aspects 21-33, wherein article comprises an upper surface having at least three distinct colors.

[0115] Aspect 35: A method comprising: entangling fibers using an airlay system to form a nonwoven material, wherein at least 90% of the fibers by weight are specified fibers.

[0116] Aspect 36: The method of aspect 34, further comprising coupling a base material to a lower surface of the nonwoven material.

[0117] Aspect 37: The method of aspect 34, further comprising positioning a cap material on an upper surface of the nonwoven material; and needlepunching the nonwoven material through the cap material so that portions of the nonwoven material are exposed above an upper surface of the cap material.

[0118] It is to be understood that unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; and the number or type of aspects described in the specification. Thus, words denoting order, such as “first” or “next,” should be interpreted as optional aspects unless plain meaning or logic dictates otherwise.

Claims

1. CLAIMSThe following is claimed:

1. A structure comprising: a nonwoven material comprising fibers formed using an airlay system, wherein at least 50% of the nonwoven material by weight is specified fiber.

2. The structure of claim 1, wherein the nonwoven material comprises a plurality of regions, each region of the plurality of regions having a different color than each other adjacent region of the plurality of regions.

3. The structure of claim 2, wherein each region of the plurality of regions is formed by at least 90% by weight of fibers of a single color.

4. The structure of claim 2, wherein the plurality of regions have respective areas from 0. 1 cm2to 200 cm2.

5. The structure of claim 2, wherein the nonwoven material further comprises transition regions between at least two adjacent regions, wherein the transition region comprises a mix of the different colors of the at least to adjacent regions.

6. The structure of claim 5, wherein the transition region has a transverse dimension from 1 mm to 5 mm.

7. The structure of claim 2, wherein the plurality of regions have irregular shapes.

8. The structure of claim 2, wherein the plurality of regions are provided in a randomly generated arrangement.

9. The structure of claim 2, wherein the plurality of regions are arranged in a nonrepeating pattern.

10. The structure of claim 2, wherein the plurality of regions are arranged in a repeating pattern.

11. The structure of claim 2, wherein the plurality of regions collectively provide at least three different colors.

12. The structure of claim 2, wherein the plurality of regions comprise at least two different fiber weights.

13. The structure of claim 1, wherein the non woven material has an upper surface and a lower surface defining a thickness therebetween, wherein the thickness is from 0.200 inch to 0.500 inch.

14. The structure of claim 1, wherein at least 90% of the nonwoven material by w eight is specified fiber.

15. An assembly comprising: a structure as in any one of the preceding claims, wherein the nonwoven material comprises an upper surface and a lower surface; and a base material coupled to at least a portion of the lower surface of the nonw oven material.

16. The assembly of claim 15, wherein the base material comprises a nonwoven material formed by a carding machine.

17. The assembly of claim 15, wherein the base material comprises a densified fiber batt.

18. The assembly of claim 15, wherein the base material is coupled to the low er surface of the structure by needlepunching.

19. An article comprising: a structure as in any one of claims 1-14, wherein the non woven material comprises an upper surface and a lower surface; and a cap material overlying at least a portion of the nonwoven material, wherein the cap material has an upper surface, wherein the article comprises areas where the structure is needlepunched through the cap material so that the nonwoven material of the article is exposed above the upper surface of the cap material.

20. The article of claim 19, wherein the cap material is woven.

21. The article of claim 19, wherein the cap material is a nonwoven material formed by needlepunching.

22. The article of claim 19, wherein the article has an upper surface comprising: areas defined by the cap material; andareas defined at least partly by the nonwoven material needlepunched through the cap material.

23. The article of claim 22, wherein the areas defined by the structure needlepunched through the cap material have irregular shapes.

24. The article of claim 22, wherein the areas defined by the structure needlepunched through the cap material are provided in a randomly generated arrangement.

25. The article of claim 22, wherein the areas defined by the structure needlepunched through the cap material are arranged in a non-repeating pattern.

26. The article of claim 22, wherein the areas defined by the structure needlepunched through the cap material are arranged in a repeating pattern.

27. The article of claim 22, further comprising a base material coupled to the lower surface of the structure.

28. The article of claim 27, wherein the base material comprises a nonwoven material formed by a carding machine.

29. The article of claim 27, wherein the base material comprises a densified fiber batt.

30. The article of claim 22, wherein the areas defined at least partly by the nonwoven material needlepunched through the cap material comprise areas defined entirely by the nonwoven material needlepunched through the cap material.

31. The article of claim 22, wherein the areas defined at least partly by the structure needlepunched through the cap material comprise areas where the structure needlepunched through the cap material has a sufficiently low height that both the cap material and the structure needlepunched through the cap material are visible.

32. The article of claim 20, wherein article comprises an upper surface having at least three distinct colors.

33. A method comprising: entangling fibers using an airlay system to form a nonwoven material, wherein at least 90% of the fibers by weight are specified fibers.

34. The method of claim 33, further comprising coupling a base material to a lower surface of the nonwoven material.

35. The method of claim 33, further comprising positioning a cap material on an upper surface of the nonwoven material; and needlepunching the nonwoven material through the cap material so that portions of the nonwoven material are exposed above an upper surface of the cap material.

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