KR20230170799A - Nonwoven textile garment arrays and methods of manufacturing the same - Google Patents

Abstract

Aspects herein relate to composite nonwoven fabrics comprising non-linear intertwined seams and methods and systems for making the same. The composite nonwoven fabric includes at least a first nonwoven layer, a second layer, and a filler material positioned between the first nonwoven layer and the second layer. When the composite nonwoven fabric is formed into a garment, the area between the non-linear intertwined seams can help provide insulation by storing and retaining heat, and the non-linear intertwined seams can prevent movement or drift of the filling. It can help you do this.

Description

NONWOVEN TEXTILE GARMENT ARRAYS AND METHODS OF MANUFACTURING THE SAME}

Aspects of the present disclosure relate to non-woven fabrics with non-linear entangled seams suitable for garments and methods and systems for making the same.

Traditional insulating garments typically consist of panels of fabric material (e.g., woven or braided fabrics) placed adjacent to each other, optionally applying adhesive to the panels of fabric material at predetermined locations, and sealing the fabric at the predetermined locations. It is formed by heat pressing and/or stitching the materials together to form a linear seam separating the baffles and filling the baffles with down or other type of insulating filler. These manufacturing methods can be expensive and time-intensive due to the variety of materials used to form the garment. In addition, for example, spinning the yarn used in the textile material, weaving or knitting the textile material using the yarn, applying adhesive, hot pressing or stitching the seam, and filling the baffle. The energy costs and carbon footprint associated with doing so are high, and the recyclability of the resulting garments may be limited due to the high number of heterogeneous materials. For each garment in a garment lot, if the textile material used to form the garment contains a type of repetitive visual arrangement of elements (e.g. visual arrangement of printed components, visual arrangement of seams, etc.) Material waste may occur in ensuring that each garment in a garment lot includes a visual arrangement of the elements in consistent locations on the garment to provide a uniform appearance.

Examples of embodiments of the present disclosure are described in detail below with reference to the accompanying drawings.
1 illustrates a first surface of an exemplary composite nonwoven fabric with non-linear intertwined seams in accordance with aspects herein.
FIG. 2A illustrates an opposing second surface of the first example of the composite nonwoven fabric of FIG. 1, wherein the second surface is formed of a woven fabric in accordance with aspects herein.
FIG. 2B illustrates an opposing second surface of a second example of the composite nonwoven fabric of FIG. 1 , where the second surface is formed of a nonwoven fabric in accordance with aspects herein.
FIG. 3 illustrates a cross-section of a composite nonwoven fabric taken at cut line 3-3 in FIG. 1 in accordance with an embodiment of the present disclosure.
4A shows an enlarged view of a portion of a first example non-linear intertwined seam according to aspects herein.
4B shows an enlarged view of a portion of a second example non-linear intertwined seam according to aspects herein.
FIG. 5 illustrates a side view of an exemplary entanglement system for making the composite nonwoven fabric of FIG. 1 in accordance with aspects herein.
FIG. 6A shows a front view of a first example entangling station that is part of the entangling system of FIG. 5 in accordance with aspects herein.
FIG. 6B shows a front view of an alternative example entanglement station that is part of the entanglement system of FIG. 5 in accordance with aspects herein.
Figures 7 and 8 show front views of additional example entanglement stations that are part of the entanglement system of Figure 5 in accordance with aspects herein.
9A and 9B illustrate example entanglement heads for use in the entanglement system of FIG. 5 in accordance with aspects herein.
FIG. 10A shows a schematic diagram of an example process for forming a non-linear entangled seam using the entangling station of FIG. 6A in accordance with aspects herein.
FIG. 10B shows a schematic diagram of an example process for forming a non-linear entangled seam using the entangling station of FIG. 6B in accordance with aspects herein.
11 illustrates an example process for manufacturing an array of garments having a common finished form, the array of garments comprising different visual arrangements of non-linear intertwined seams in accordance with aspects herein.
FIG. 12 illustrates an array of upper body garments formed using the example process of FIG. 11 in accordance with aspects herein.
FIG. 13 illustrates an array of lower body garments formed using the example process of FIG. 11 in accordance with aspects herein.
14 illustrates a first surface of an exemplary composite nonwoven fabric with non-linear intertwined seams that intersect each other in accordance with aspects herein.
FIG. 15 illustrates a cross-section taken at line 15-15 of FIG. 14 in accordance with aspects of the disclosure.
FIG. 16 illustrates an exemplary upper body garment with zoned insulation features, which exemplary upper body garment is formed using the composite nonwoven fabric of FIG. 14 in accordance with aspects herein.
17 illustrates an exemplary composite nonwoven fabric with discontinuous, non-linear, intertwined seams in accordance with aspects herein.
18 illustrates an exemplary single layer nonwoven fabric with a non-linear intertwined seam in accordance with aspects herein.
FIG. 19 shows a cross-section of the exemplary single layer nonwoven fabric of FIG. 18 according to aspects herein.

The subject matter of the invention is specifically described herein in order to satisfy legal requirements. However, the description itself is not intended to limit the scope of the present disclosure. Rather, the inventors have contemplated that the claimed or disclosed subject matter may be implemented in other ways, including other steps or combinations of steps similar to those described herein, in conjunction with other current or future technologies. Additionally, although the terms "step" and/or "block" may be used herein to encompass various elements of a method employed, the terms are used herein except where the order of the individual steps is not specified and unless otherwise specified. It should not be construed to imply any particular order among the various steps disclosed in.

Traditional insulating garments typically involve placing panels of fabric material (e.g., woven fabric or braided fabric) adjacent to each other, optionally applying adhesive to the panels of fabric material at predetermined locations, and sealing the fabric at the predetermined locations. It is formed by heat pressing and/or stitching the materials together to form linear seams separating the baffles, and then filling the baffles with down or other type of insulating filler. These manufacturing methods can be expensive and time-intensive due to the variety of materials used to form the garment. Additionally, the energy costs and carbon costs associated with, for example, spinning the yarns used in the textile material, using the yarns to weave or braid the textile material, applying adhesives, thermo-pressing or stitching seams, and filling baffles. The footprint is high, and the recyclability of the resulting garment may be limited due to the abundance of heterogeneous materials. When the textile material used to form a garment contains a repeating visual arrangement of elements (e.g., visual arrangement of printed components, visual arrangement of seams, etc.), a uniform appearance is required for each garment in a garment lot. Material waste may occur in ensuring that each garment in a garment lot includes a visual arrangement of the elements in consistent positions on the garment.

At a high level, aspects of the present disclosure relate to composite nonwoven fabrics with non-linear intertwined seams suitable for garments and methods and systems for making the same. In an exemplary embodiment, an entanglement system can be used to form the composite nonwoven fabric. In an exemplary embodiment, the entanglement system is arranged in series along the conveyance system to advance a stacked configuration of the layers used to form the composite nonwoven fabric along the surface of the conveyance system in the direction of material flow. It may include one or more entanglement stations that can be aligned. Each entangling station, in one exemplary embodiment, includes an actuator adapted to move in a direction perpendicular to the transport plane of the surface. Each entanglement station further includes one or more entanglement heads coupled to the actuator. In one aspect, the entangling head includes one or more entangling needles disposed in a structured arrangement in an exemplary aspect. In one example, movement of the actuator in a direction perpendicular to the transport plane of the surface causes the entanglement needle to engage a stacked configuration of the layers. In another example, the actuator may remain stationary, but actuate or move the entanglement head and/or entanglement needle in a direction perpendicular to the transport plane such that the entanglement needle engages the stacked configuration of the layers. there is. In another exemplary aspect, the entangling head is configured to emit one or more jets of pressurized fluid (e.g., water). In this example, the actuator may also remain stationary and discharge the fluid jet from the entanglement head.

In an exemplary embodiment, a carriage adapted to move in a direction non-parallel to the material flow direction may also be coupled to the entanglement head, directly or indirectly, by the actuator. Additionally or alternatively, the transport system may be adapted to move in a direction other than parallel to the material flow direction. Accordingly, in an exemplary embodiment, the entanglement head and delivery system may be arranged to move relative to each other in a direction non-parallel to the material flow direction.

In an exemplary embodiment, the entangling head can be positioned at a different location on each entangling station to contact different portions of the stacked structure as the stacked structure is transported along the surface of the transport system. For example, the first entanglement station may include a first entanglement head positioned at a first distance inwardly (i.e., perpendicular to the material flow direction) from a lateral edge of the surface of the conveyance system, and subsequent to the first entanglement station. The second entanglement station positioned may include a second entanglement head positioned at a second distance inwardly from the lateral edge of the transport system, which is different from the first distance.

In an exemplary embodiment, the stacked configuration of layers includes a first nonwoven layer, a second layer, and a filler material positioned between the first nonwoven layer and the second layer. The layered configuration is positioned on the surface of the transport system with the first nonwoven layer facing upward or towards the actuator, carriage and entanglement head of the first entanglement station and the second layer facing the surface of the transport system. In one exemplary embodiment, when the entanglement head includes an entanglement needle, while the composite nonwoven fabric is in a first stationary phase, the actuator causes the entanglement needle and, indirectly, the entanglement head to engage the entanglement needle. The entangling heads and/or entangling needles are moved in a direction perpendicular to the transport plane of the surface to engage the stack configuration and form a first entangling region. When the entangling needles engage the laminate configuration, the needles force fibers from the first nonwoven layer through the fill into the second layer. In another exemplary embodiment, when the entanglement head emits one or more pressurized fluid jets, while the stacked configuration is in a first stationary phase, the actuator actuates the entangling head to contact the stacked configuration to cause a first to discharge said one or more pressurized fluid jets forming an entanglement zone. Alternatively, the stack configuration can be continuously advanced while the entanglement head continuously discharges one or more fluid jets. In this embodiment, when the fluid jet contacts the laminate configuration, the pressure of the fluid jet forces the fibers from the first nonwoven layer through the filler into the second layer.

When entangling needles are used, the delivery system advances the layered configuration of first nonwoven layer, second layer and filler by a predetermined amount in the direction of the material flow. In an exemplary embodiment, the predetermined amount of advancement may be less than or equal to the dimensions of the entanglement head in the material flow direction. Additionally, the entanglement head and/or delivery system may move in a direction non-parallel to the material flow direction by a predetermined amount. In an exemplary embodiment, the predetermined amount of movement may be less than or equal to a dimension of the entanglement head in a direction non-parallel to the material flow direction. When the stacking configuration is in a second stationary phase and the entangling head includes an entangling needle, the actuator causes the entangling needle to engage the stacking configuration to form a second entangling region. is moved in a direction perpendicular to the transport plane of the surface. When the entanglement head is configured to discharge one or more pressurized fluid jets, the actuator operates the entanglement head to discharge one or more fluid jets to form a second entanglement region. The second entangling region extends from the first entangling region to form a non-linear entangled seam.

As the layered configuration continues to advance through the first entangling station, additional entanglement zones are formed extending from the first and second entanglement zones, forming a seemingly continuous entanglement seam in the material flow direction. By moving the entangling head and/or conveying system in a direction non-parallel to the material flow direction, the continuous entangled seam becomes non-linear in the material flow direction. In an exemplary aspect, the first and second entanglement regions can partially overlap, such that the overlap region represents a region where the entanglement needles and/or fluid jets engage the stacked configuration at least twice. In another exemplary aspect, the first and second entangled regions may be positioned immediately adjacent to each other without overlapping to form a seemingly continuous, non-linear, entangled seam. In another aspect, the first and second entangled regions may be spaced apart to form a discontinuous, non-linear, entangled seam. Any and all aspects and modifications thereof are considered to be within the scope of this disclosure.

The laminate configuration of the first nonwoven layer, the second layer and the fill continues through additional entangling stations where additional non-linear intertwined seams are formed that are separate and distinguishable from the non-linear intertwined seams formed by the first entangling stations. So you can move forward. In other words, the additional non-linear intertwined seams may be located at different locations along a direction that is not parallel to the material flow direction. Depending on the number of entangling stations in the entangling system, the resulting composite nonwoven fabric may have a short repeating visual arrangement of entangled seams, a long repeating optical arrangement of entangled seams, or no visual arrangement of entangled seams.

The resulting composite nonwoven fabric may include a plurality of non-linear intertwined seams extending in the direction of material flow in the fabric. As noted above, the intertwined seam represents the area where fibers extend from the first nonwoven layer through the fill into the second layer. In an exemplary embodiment, fibers can extend through the second layer to extend outwardly from the second surface of the composite nonwoven fabric. The composite nonwoven fabric further includes regions where the first nonwoven layer, the second layer, and the filler are substantially unentangled. The areas where the first nonwoven layer, the second layer and the filler are not substantially intertwined have a greater thickness than the intertwined seams. When the composite nonwoven fabric is formed into a garment, the areas where the first nonwoven layer, the second layer and the fill are substantially unentangled correspond to the "baffles" found in traditional insulating garments, and the intertwined seams allow the fill to become trapped during wear. It is constructed to provide warmth by storing and retaining heat, while helping prevent it from drifting or moving.

The systems, methods, fabrics and garments described herein offer many advantages. For example, the composite nonwoven fabrics are easy and fast to manufacture, requiring minimal materials (e.g., no adhesives, no stitching) and equipment (e.g., no heat press), and post-processing of lamination of fill material to the baffle as in traditional structures. No steps are required. This, in turn, reduces the carbon footprint associated with the manufacturing process. Additionally, the composite nonwoven fabric may be formed from the same or similar materials (i.e., materials from the same polymer class). In one exemplary embodiment, each of the first nonwoven layer, second layer, and filler can be formed from recycled polyester fibers. This allows the entire fabric to be easily recycled, for example by shredding, without the need for the shredded material to be sorted later to remove extraneous material. Additionally, since the non-linear seams are formed by an entangling process using, for example, recycled polyester fibers, the composite nonwoven fabric does not contain adhesives and/or threads used for stitching, which are the properties of the fabric prior to recycling. Reduces the need to remove parts.

In an exemplary embodiment, the garment resulting from the composite nonwoven fabric may be formed from materials of the same polymer class and the composite nonwoven fabric may not include disparate materials such as yarns, adhesives, etc. For example, it can be easily recycled through shredding. Additionally, material shredded from the garment can subsequently be formed into one or more of a first nonwoven layer, a second layer, and a filler to create a sustainable life cycle of the garment. In line with this, scrap pieces generated during the manufacture of garments from the composite nonwoven fabric can also be easily recycled by shredding, and the shredded material from the scrap is subsequently used in the first nonwoven layer, the second layer and the filler. It can be formed as one or more.

An additional advantage of using the entangled systems and manufacturing methods described above is the ability to create complex visual arrangements of intertwined seams. As used herein, a visual arrangement of intertwined seams is collectively created by the different shapes associated with each intertwined seam, the spacing between intertwined seams, the number of intertwined seams, the intertwined seam width, etc. To create a complex visual arrangement of entangled seams, the entangling heads can be positioned at different locations on the entangling stations, and the number and/or spacing of the entangling heads at different entangling stations can vary, with the entangling heads The resulting entanglement footprint can be varied, and movement of the entanglement head and/or delivery system in different directions that are not parallel to the material flow direction can be varied. Complex visual arrangements of intertwined seams may include arrangements in which intertwined seams may cross over, intersect, or be located closely together. In addition to creating interesting aesthetics, it is possible to create composite nonwoven fabrics of different thicknesses due to its ability to create areas where seams can cross, intersect or be located closely together. For example, areas where seams may cross or intersect each other represent instances where one or more entanglement heads from an entanglement station engage the composite nonwoven fabric multiple times. Accordingly, these areas may have a reduced thickness compared to other intertwined seam areas and areas in which the first nonwoven layer, second layer and filler are not substantially intertwined. When the composite nonwoven fabric is formed into a garment, these areas may be located adjacent to parts of the body that require less insulation (e.g., based on a heat map of the human body) because these regions are typically This is because compared to other areas, there is less loft and less insulation.

An additional advantage of utilizing the entangling systems and manufacturing methods described herein is the ability to produce fabrics that do not have short repeats in the visual arrangement of entangled seams, long repeats in the visual arrangement of entangled seams, or non-repeating visual arrangements of entangled seams. . This is achieved by varying the number of entanglement stations arranged in series along the conveyance system. The ability to create long repeats or no repeats using the entanglement system described herein addresses potential drawbacks of traditional garment manufacturing. Traditional garment production using fabrics with short visual arrangements of elements can result in material waste. This is because the pattern pieces used to form the garment are positioned in a way that produces a garment with the same arrangement of visual elements at the same location on the garment. This often results in a large amount of scrap. Composite nonwoven fabrics can be created with long or non-repeating visual arrangements of intertwined seams, minimizing material waste and producing a variety of garments with a common finished form but with different aesthetic properties due to the unique visual arrangement of intertwined seams. there is. Viewed as an array or lot of garments, a consumer may perceive the garments as having a common origin and/or a common manufacturer, but may select garments from the array of garments to suit their tastes with a visual arrangement of intertwined seams.

An additional aspect related to the entangling systems and manufacturing methods described herein is the ability to create non-linear, entangled seams in one or more single nonwoven layers. The ability to create intertwined seams in a single layer also has the advantage of being easy and quick to manufacture using minimal materials (e.g. no glue, no stitching) and equipment (e.g. no heat press). This, in turn, reduces the carbon footprint associated with the manufacturing process. Additionally, nonwoven fabrics may be formed from the same or similar materials (i.e., materials from the same polymer class). This allows the entire fabric to be easily recycled, for example by a shredding operation in which the shredded material does not need to be sorted later to remove extraneous material. Additionally, since the non-linear seams are formed by an entangling process using, for example, recycled polyester fibers, the non-woven fabric does not contain adhesives and/or threads used for stitching, which is the key to ensuring that these parts of the fabric are removed prior to recycling. Reduces the need to remove

A single nonwoven layer may include a single fiber layer (e.g., a lightly entangled fiber web), multiple fiber layers entangled with each other, a fiber layer intertwined with other materials such as an elastomer layer, a fabric layer, etc. In an exemplary embodiment, once the non-linear intertwined seam is created on an individual nonwoven layer, the nonwoven layer can be formed into, for example, an article of clothing. In another exemplary embodiment, different non-woven layers having non-linear, intertwined seams may be positioned adjacent to each other with optional additional layers (non-woven, knit, woven, film, etc.) positioned therebetween, and the different layers may be They can be held together using braiding, sewing, gluing, etc. Any and all aspects and modifications thereof are considered to be within the scope of this disclosure.

As used herein, the terms “garment” or “article of clothing” are intended to include articles worn by the wearer. Accordingly, the term refers to both upper body clothing (e.g. tops, t-shirts, pullovers, hoodies, jackets, coats, etc.) and lower body clothing (e.g. pants, shorts, tights, capris, unitards, etc.) ) may include. Clothing may also include hats, gloves, sleeves (arm cuffs, calf cuffs), footwear items such as shoe uppers, etc. When referring to a garment, the term "inner-facing surface" refers to the surface configured to face the surface of the wearer's body when the garment is worn as intended, and the term "outer-facing surface" refers to the surface configured to face the surface of the wearer's body. The term refers to a surface configured to face away from the wearer's body surface and toward the external environment when the garment is worn as intended. The term "innermost-facing surface" means the surface closest to the surface of the wearer's body with respect to the other layers of the garment, and the term "outermost-facing surface" means the surface closest to the surface of the wearer's body with respect to the other layers of the garment. refers to the surface located furthest from the body surface. The terms "pattern" or "pattern piece", as used in connection with constructing a garment, means that the pattern or pattern piece has a perimeter shape that corresponds to the structure of the finished garment, for example, sleeves, front bodice panels, collar, etc. it means. A pattern or pattern piece is a portion of fabric that has a perimeter shape that corresponds to the pattern or pattern piece on which parts of the fabric are assembled to form a garment, for example using traditional cut-and-sew construction. It is used when removing, extracting or cutting.

As used herein, the term "composite nonwoven fabric" encompasses any fabric comprising at least one nonwoven layer in combination with another layer, regardless of whether the layers may not be substantially adhered to each other except for intertwined seams. do. Accordingly, it is contemplated herein that composite nonwoven fabrics are formed entirely from nonwoven layers. Additionally, it is contemplated herein that nonwoven layers may be combined with other configurations such as fibrous materials, films, woven layers, knit layers, braided layers, etc. The term “composite nonwoven fabric” is contemplated herein to include a laminate configuration of layers and one or more intertwined seams joining the layers to form the laminate configuration at the seam region.

The term “nonwoven layer” refers to a layer in which the fibers are held together by mechanical and/or chemical interactions rather than in the form of a braid, weave, braided configuration, or other structured configuration. In certain embodiments, the nonwoven layer includes a collection of fibers that are mechanically or chemically manipulated to form a mat-like material. In other words, the nonwoven layer is made directly from fibers. The composite nonwoven fabrics described herein may include various layers formed in the form of a cohesive structure, and these various layers may have different or similar compositions of fibers or yarns and/or different properties. In one example, the first nonwoven layer and optionally the second layer can include a spunbond layer. As used herein, a spunbond layer is formed by spinning continuous filaments of molten polymer material onto a moving belt and joining the filaments together using, for example, a calendaring process. Spunbond nonwovens are typically soft to the touch and strong and durable. Additionally, spunbond nonwovens generally have a smooth surface suitable for printing, including digital printing using digital print heads. In another example embodiment, the first nonwoven layer and optionally the second layer can include a spunlace layer. As used herein, a spunlace layer comprises a web of fibers entangled, for example, by hydroentanglement. Aspects herein contemplate that the filler may comprise an entangled web of fibers forming a sheet-like material. In an exemplary embodiment, the fibers may be resin bonded to form a binding structure. Other aspects herein contemplate that the filler may include loose synthetic fibers/filaments, down, or a combination of any of these.

The term "substantially unentangled" when referring to a composite nonwoven fabric refers to an area of the composite nonwoven fabric where the layers are not entangled with each other so that the layers can move independently of one another or where one or more layers are lightly entangled with each other. The term "entangled seam" when referring to a composite nonwoven fabric refers to an area of the composite nonwoven fabric where the layers of the composite nonwoven fabric undergo mechanical entanglement with each other, for example by needlepunching or hydraulic entanglement. Therefore, the different layers of the composite nonwoven fabric in the seam area may contain not only the fibers originally present in a particular layer, but also fibers present in other layers, including additional nonwoven layers, or filler material transferred into the layers through the entanglement process. You can. When an intertwined seam is described as “non-linear,” it is contemplated herein that the distance between a non-linear intertwined seam and a linear edge of the composite nonwoven fabric may vary along the material flow direction of the nonwoven fabric. Aspects herein contemplate that the seam may include linear segments, curved segments, curvilinear segments, etc., which alone or in combination form a non-linear intertwined seam. In an exemplary embodiment, the distance between adjacent non-linear intertwined seams may vary along the material flow direction of the composite nonwoven fabric.

The mechanical entanglement process contemplated herein is a needle entanglement process (commonly known as needlepunching) using barbed or structured needles (e.g., forked needles), known herein as entanglement needles, or It may involve a fluid entanglement process known as hydraulic entanglement. Needlepunching typically uses intertwined needles to reposition a percentage of fibers from a horizontal orientation (orientation extending along the x, y plane) to a generally vertical orientation (orientation in the z direction). Referring to a general needlepunching process, the layers forming the composite nonwoven fabric can be stacked, and the entanglement needles associated with the entanglement head are passed in and out through the layered configuration. Accordingly, when describing an entanglement head engaging a non-woven fabric, it is contemplated herein that an entanglement needle associated with the entanglement head engages a non-woven fabric fabric. Stripper plates can be used to strip the fibers from the needles after they have moved in and out of the laminate configuration. Each engagement of the stack configuration and entanglement head is known herein as a “pass”. Parameters associated with the entanglement head can be adjusted to achieve the desired properties (e.g., basis weight, thickness, etc.) of the resulting composite nonwoven fabric, as described further below.

The barbs of the entanglement needles “capture” the fibers as they move from the first nonwoven layer through the laminate configuration. The movement of the entanglement needles effectively moves or pushes the fibers captured by the barbs from a position near or on the surface of the first nonwoven layer to a position near or on the surface of the second layer, and further removes other fibers. Helps to "lock" the displaced fibers in place, for example through friction. It is also contemplated herein that the entanglement needles may pass through the laminate configuration in a direction from the second layer toward the first nonwoven layer. It is also contemplated herein that the entanglement needles may pass through the laminate configuration from the first nonwoven layer toward the second layer and from the second layer toward the first nonwoven layer. Hydroentangling works similarly to needlepunching, except that instead of using entangling needles, a jet of pressurized fluid (e.g. water) is used to move the fibers through different layers. Parameters associated with the hydraulic entanglement process, such as pressure of the fluid jets, number of fluid jets, transport speed, etc., can be adjusted to achieve the desired degree of entanglement.

The term “entanglement head” is used herein to describe a structure comprising one or more entanglement needles in a defined arrangement and/or one or more orifices for discharging a jet of pressurized fluid in a defined arrangement. When the entanglement needles and/or fluid jets engage the composite nonwoven fabric through the entanglement head, they may form an entanglement footprint. As used herein, the term “entanglement footprint” is a structured arrangement of entanglement points created by entanglement heads on a composite nonwoven fabric. For example, depending on the predetermined arrangement of the entanglement needles and/or orifices of the entanglement head, the entanglement footprint may have a circular, square, rectangular, triangular, etc. shape.

As used herein, the term “material flow direction” means the direction in which the material advances along the conveying system. The direction of material flow is also known as the machine direction. Accordingly, when a composite nonwoven fabric is described as comprising a non-linear intertwined seam extending in the direction of material flow, the non-linear intertwined seam extends in the forward direction of the composite nonwoven fabric along the conveying system of the entanglement system. As described herein, when an entanglement head, or hydraulic entanglement, is used, the fluid jet may move in a direction perpendicular to the conveyance plane of the conveyance system. Stated another way, if the transport plane extends along the x, y plane and the material flow direction extends in the positive x direction, the entanglement head or fluid jet can move in the positive or negative z direction. When describing the carriage or conveying system moving in a direction other than parallel to the material flow direction, it is contemplated herein that the carriage and/or conveying system generally moves in the positive or negative y direction. This may also be known as cross-machine direction.

The fibers used to form the nonwoven layers and other layers contemplated herein may be formed from a number of different materials (e.g., cotton, nylon, etc.), including polyethylene terephthalate (PET), commonly known as polyester. . PET fibers may include virgin PET fibers (non-recycled fibers) and recycled PET fibers. Recycled PET fiber includes shredded PET fiber derived from shredded materials and re-extruded PET fiber (fiber re-extruded using recycled PET chips).

Various measurements for composite nonwoven fabrics are provided herein. The thickness of the resulting composite nonwoven can be measured using a precision thickness gauge. For example, to measure thickness, the fabric is placed on a flat anvil and a pressure foot is pressed from the top of the fabric under a standard static load. The dial indicator on the precision thickness gauge displays thickness in mm. Basis weight is measured using the ISO3801 test standard and has units of grams per square meter (gsm). In general, the thermal resistance corresponding to the insulation characteristic is measured using the ISO11092 test standard and has units of RCT (M ² *K/W). Unless otherwise stated, all measurements provided herein are taken on nonwoven fabrics at rest (unstretched) at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar).

1 shows a first surface 101 of a composite nonwoven fabric 100 where the first surface 101 is formed of a first nonwoven layer 110. In exemplary embodiments, first nonwoven layer 110 may include a spunbond or spunlace material, although other nonwoven constructions are also contemplated herein. Spunbond or spunlace materials are generally soft to the touch and durable, making them suitable for integration into clothing. First nonwoven layer 110 is formed of entangled fibers, as indicated by reference numeral 112. When composite nonwoven fabric 100 is incorporated into a garment, first surface 101 may be positioned as the innermost or innermost surface of the garment. Alternatively, first surface 101 may be positioned as the outermost surface or outermost surface of the garment.

Composite nonwoven fabric 100 also includes a second layer 114, described in more detail with respect to FIGS. 2A and 2B. Filler 116 is located between the first nonwoven layer 110 and the second layer 114. Filler 116 may include entangled fibers, lightly entangled fiber webs, carded webs, loose synthetic fibers, down, etc. that may be selectively resin bonded to maintain a more cohesive structure.

As shown in FIG. 1 , the composite nonwoven fabric 100 may include a plurality of non-linear intertwined seams 118 extending in the material flow direction 105 of the composite nonwoven fabric 100 . Intertwined seams 118 represent areas where fibers from different layers are intertwined. In one exemplary aspect, intertwined seam 118 represents an area where fibers from first nonwoven layer 110 extend through filler 116 and into second layer 114. Regions 122 of composite nonwoven fabric 100 located between intertwined seams 118 are such that first nonwoven layer 110, second layer 114, and filler 116 are substantially unentangled such that they are distinct layers. This area 122 represents an area that is not fixed or fixed to each other or is lightly fixed or fixed to each other. As shown, region 122 has more loft or greater thickness than intertwined seam 118, which may help store and retain heat when composite nonwoven fabric 100 is incorporated into a garment. . As a result, the intertwined seam 118 can help prevent the filling 116 from moving or drifting when a garment incorporating the composite nonwoven fabric 100 is worn.

At least with respect to the entangled seam 118a, the distance between the entangled seam 118a and the linear first edge 120 of the composite nonwoven fabric 100 varies along the material flow direction 105 of the composite nonwoven fabric 100. . For example, the first distance 124 between the intertwined seam 118a and the first edge 120 may be less than the second distance 126 between the intertwined seam 118a and the first edge 120. This also applies to the other intertwined seams 118 shown in Figure 1. As shown, intertwined seams 118 may include linear segments extending from one another, curves, and combinations thereof. The depiction of the shape of individual intertwined seams 118, the number of intertwined seams 118, the spacing between adjacent intertwined seams 118, and the overall visual arrangement of intertwined seams 118 are exemplary and allow intertwined seams 118 to be It is contemplated herein that other non-linear shapes, different numbers of intertwined seams 118, different spacings, and different overall visual arrangements of intertwined seams 118 may be included.

FIG. 2A shows an opposing second surface 201 of composite nonwoven fabric 100 where second surface 201 is formed by second layer 114 . In one example embodiment as shown in FIG. 2A , second layer 114 may include a woven layer, such as shown as example interlaced warp and weft yarns 210 . In this example, when composite nonwoven fabric 100 is incorporated into a garment, second layer 114 may be positioned to be the outermost or outermost surface of the garment. In general, woven materials have high resistance to abrasion and, due to their tight woven structure, can act as an effective wind barrier, making them suitable for forming the outward-facing surface of clothing. In an exemplary embodiment, the woven material may be treated with a durable water repellent agent to impart water resistance to the composite nonwoven fabric 100. A non-linear intertwined seam 118 is shown extending through the composite nonwoven fabric 100 and present on the second surface 201 of the fabric 100.

Figure 2B shows a second example where second layer 114 is formed from a non-woven material, such as a spunbond or spunlace material. The entangled fibers forming second layer 114 are indicated by reference numeral 212. Non-linear intertwined seam 118 extends through composite nonwoven fabric 100 to exist at second surface 201 of fabric 100 in FIG. 2B.

FIG. 3 shows a cross-section of composite nonwoven fabric 100 taken at cut line 3-3 in FIG. 1 . A first nonwoven layer 110 , a second layer 114 and a filler 116 are indicated, with the filler 116 positioned between the first nonwoven layer 110 and the second layer 114 . In region 122, each of first nonwoven layer 110, second layer 114, and filler 116 is substantially unentangled, such that first nonwoven layer 110, second layer 114, and filler ( 116 generally remains a separate, individual layer with a combined thickness 310 measured from first surface 101 to second surface 201 .

The fibers 112 from the first nonwoven layer 110 extend through the filler 116 and the second layer 114 in an interwoven seam 118 such that the interwoven seam 118 brings the different layers together in the seam area. It is shown as being fixed. In one example embodiment, the fibers 112 may extend through the second layer 114 to extend away from the second surface 201 of the composite nonwoven fabric 100, as shown in FIG. 3. In this example, the fibers 112 may be left unmodified so that the second surface 201 provides a fuzzy surface at the entangled seam 118. In other examples, fibers 112 may be removed, compressed, or melted. For example, a calendaring process may be used to compress the fibers 112 so that they do not extend from the second surface 201 . In another example, filler 116 may include low-melt fibers, and any low-melt fibers extending from second surface 201 may be removed by applying heat. Additionally, a shaving process may be used to remove fibers 112 if desired. In another exemplary embodiment, the fibers 112 may extend into the second layer 114, but the second layer (112) is substantially absent from the second surface 201 of the composite nonwoven fabric 100. 114) may not be extended.

The entangled seam has a thickness 312 in region 122 that is less than thickness 310 . In one exemplary aspect, thickness 310 may be from about 7 mm to about 15 mm, from about 8 mm to about 13 mm, from about 9 mm to about 11 mm, or about 10 mm. As used herein, the term “about” means within ±10% of the indicated value. In exemplary embodiments, thickness 312 may be from about 5 mm to about 0.2 mm, from about 4 mm to about 1 mm, from about 3 mm to about 1.5 mm, or about 2 mm. Accordingly, in an exemplary aspect, the thickness 312 of the intertwined seam 118 may be from about 5% to about 30% of the thickness 310 of the region 122.

FIG. 4A shows an enlarged view of one of the intertwined seams 118 of the composite nonwoven fabric 100 as viewed from the first surface 101 of the composite nonwoven fabric 100. The appearance of the intertwined seam 118 on the second surface 201 will be similar. FIG. 4A shows a first example way in which an entangled seam 118 may be formed. In an exemplary aspect, entangled seam 118 may be formed from separate entangled regions 410 that partially overlap one another at overlapping region 412 . Each of the distinct entanglement regions 410 has an entanglement footprint. For example, the entanglement footprint of entanglement region 410 is shown as having a circular shape, but this is exemplary and may be shaped according to the structured arrangement of the entanglement needles and/or orifices of the entanglement head used to form entanglement region 410. It changes. As shown, entanglement regions 410 extend from each other in a non-linear manner to form a seemingly continuous, non-linear, entangled seam.

Individual dots within entanglement areas 410 represent entanglement points 414 where entanglement needles or fluid jets engage composite nonwoven fabric 100 to entangle the fibers. The number of entanglement points 414 per cm2 may be known herein as stitch density. Stitch density depends, for example, on the number of entangling needles associated with the entangling head, the number of fluid jets emitted by the entangling head, the structured arrangement of the entangling needles and/or jet orifices, etc. Because a greater stitch density generally means a greater degree of fiber entanglement, a greater stitch density may result in a reduced thickness of the entangled seam 118 compared to a smaller stitch density.

Overlap area 412 represents an area where the entanglement head engages the composite nonwoven fabric two or more times. Accordingly, the number and/or density of entanglement points 414 within the overlapping region 412 is greater than the number and/or density of entanglement points 414 in the remainder of the entanglement region 410. In other words, the stitch density in overlap area 412 is greater than the stitch density in the remainder of entanglement area 410. As a result, overlap region 412 may have a reduced thickness compared to the remainder of entanglement region 410.

FIG. 4B shows a second example way in which the entangled seam 118 may be formed. In this aspect, the entanglement regions 410 extend from one another in a non-linear manner to form a seemingly continuous entangled seam. However, the entanglement regions 410 do not partially overlap each other as shown in FIG. 4A. Instead, the entanglement regions 410 are positioned directly adjacent to each other such that the entanglement points 414 of the first entanglement region 410 share a common boundary with the entanglement points 414 of the adjacent second entanglement region 410. can do. With respect to the non-linear intertwined seam 118, the intertwined seam 118 may include the configuration shown in FIG. 4A, the configuration shown in FIG. 4B, or a combination of the configurations shown in FIGS. 4A and 4B. It is also contemplated herein that the entanglement regions 410 may be spaced apart from each other to form discontinuous, non-linear, intertwined seams.

5 is a schematic side view of an example entanglement system 500. The depiction of the various components of the entangled system 500 is illustrative only and does not represent the actual configuration or structure of the components. The entanglement system 500 is configured to advance, for example, a stacked configuration of the first nonwoven layer 110, the second layer 114 and the filler 116 in the material flow direction indicated by arrows 516. ) and a transport system 512 having. As further described in connection with FIGS. 18 and 19 , in another aspect, the conveyance system 512 may advance a single nonwoven layer, such as first nonwoven layer 110, in the material flow direction 516. Transport system 512 may include transport systems known in the art, such as rollers, belts, etc. Advancement of the transport system 512 may include a stationary phase or a position and movement phase in the material flow direction 516 in exemplary embodiments. The duration of the stationary and moving phases can be adjusted to achieve one or more desired characteristics in the resulting composite nonwoven fabric. For example, the duration of the resting step can be adjusted to achieve some degree of entanglement of the resulting entangled seam. Stated differently, a longer rest phase may allow for more passages of the entangling needle in the entangling area, a greater stitch density in the entangling area, and a greater degree of entanglement in the entangling area. The advance distance during the transfer step can also be adjusted to achieve desired characteristics in the resulting composite nonwoven fabric. For example, increasing the advance distance during the migration phase can cause entanglement regions to become non-overlapping or even spaced apart from each other, while decreasing the advancement distance during the migration phase can increase the degree of overlap between adjacent entanglement regions. Transport speed during the transfer phase can be adjusted to increase or decrease production time.

Entanglement system 500 further includes a number of entanglement stations, such as entanglement stations 518 , 520 , and 522 . Although only three entanglement stations are shown, it is contemplated herein that there may be more or fewer entanglement stations than shown in Figure 5. Entanglement stations 518, 520, 522 are aligned in series along conveyance system 512 in material flow direction 516. In an exemplary embodiment, including a greater number of entangling stations in the entangling system 500 results in a composite nonwoven fabric with a visual arrangement of non-linear, intertwined seams that may or may not repeat at length. Including fewer entangling stations in the entangling system 500 results in a composite nonwoven fabric with a visual arrangement of short, repeating non-linear intertwined seams. Accordingly, the number of entanglement stations that are part of the entanglement system 500 can be tailored to achieve a desired repetition length of a visual arrangement of non-linear entanglement seams.

Components associated with different entanglement stations 518, 520, 522 may be substantially similar, such that descriptions of components associated with entanglement station 518 also apply to entanglement stations 520, 522. This will be explained here, with the understanding that it can be done. The entanglement station 518 includes a carriage 524 slidably coupled to, for example, a mount 526 . The carriage 524 is configured to move in a direction that is not parallel to the material flow direction 516. Alternatively, carriage 524 may not be used if transport system 512 is configured to move in a direction that is not parallel to material flow direction 516. In an exemplary embodiment, the carriage 524 and/or transport system 512 moves in a direction perpendicular to the material flow direction 516 (i.e., towards a second side edge opposite the first side edge of transport system 512). , in the positive and negative y directions).

The entanglement station 518 further includes an actuator 528 coupled to the carriage 524 . In one exemplary embodiment and as shown in FIG. 5 , the actuator 528 is configured to move in a direction perpendicular to the transport plane of the surface 514 of the transport system 512 as indicated by arrow 530. . In another exemplary embodiment, the actuator may remain stationary and the actuator may actuate the entanglement head and/or the entanglement needle to move in a direction perpendicular to the transport plane of the surface 514 of the transport system 512. You can. In another example embodiment, and as described in connection with FIG. 6B , the actuator 528 may remain stationary and the actuator may actuate the entanglement head to discharge a fluid jet. The entanglement head 532 is coupled to the actuator 528 and may be indirectly coupled to the carriage 524 via the actuator 528 . In the example shown in FIG. 5 , entanglement head 532 may include one or more entanglement needles 534 extending toward surface 514 of delivery system 512 . Although only one entanglement needle 534 is shown, it is contemplated herein that the entanglement head 532 may include multiple entanglement needles, as further described with respect to FIGS. 9A and 9B.

6A shows a front view of entanglement station 518 showing mount 526, carriage 524, actuator 528, entanglement head 532, and entanglement needle 534. Arrow 610 represents a first direction of movement of carriage 524 and/or transport system 512 in a direction non-parallel to material flow direction 516 and arrow 611 represents material flow direction 516 represents a second direction opposite the movement of the carriage 524 and/or transport system 512 in a direction that is not parallel to . In an exemplary embodiment, the first and second directions 610, 611 are perpendicular to the material flow direction 516.

A front view of the entanglement station 518 shows three generally evenly spaced entanglement heads 532a, 532b, 532c, where each of the three entanglement heads 532a, 532b, 532c forms a respective non-linear entanglement seam. It is meant to be formed. This is just an example, and it is contemplated herein that there may be more than three entanglement heads (532a, 532b, 532c) or fewer than three entanglement heads (532a, 532b, 532c). In addition, the gap between the entanglement heads 532a, 532b, and 532c is the distance between the first and second entanglement heads 532 among the entanglement heads 532a, 532b, and 532c. It may be changed to be larger than the gap between the second and third entanglement heads 532. As described in connection with FIGS. 9A and 9B, entanglement heads 532a, 532b, 532c may have different dimensions, different structured arrangements of entanglement needles and/or orifices, etc.

FIG. 6B shows an alternative entanglement station 612 that may be part of an entanglement system, such as entanglement system 500, that is adapted to create a composite structure by hydraulically entangling the layers instead of needlepunching the layers to create the composite structure. Shows a front view of . Accordingly, entanglement station 612 may be representative of multiple hydraulic entanglement stations that are part of entanglement system 500 .

The entanglement station 612 also includes a mount 614 to which the carriage 616 is slidably coupled, an actuator 618 coupled to the carriage 616, and an entanglement head 620 coupled to the actuator 618. Includes. The carriage 616 and/or transport system 512 is configured to move in a first direction not parallel to the material flow direction 516 and in a second direction opposite to and not parallel to the material flow direction 516, as indicated by arrows 622. It is supposed to go to (623). In an exemplary embodiment, directions 622 and 623 are perpendicular to material flow direction 516. In an exemplary aspect, actuator 618 may not move in a direction 530 perpendicular to the transport plane of surface 514. Instead, in an exemplary aspect, the actuator 618 is configured to actuate the entanglement head 620 to discharge one or more pressurized fluid jets 624 extending toward the surface 514 of the delivery system 512. In connection with this aspect, it is contemplated herein that delivery system 512 may intermittently advance as described above when fluid jets 624 are discharged when delivery system 512 is at rest. Alternatively, delivery system 512 may be continuously advanced and fluid jets 624 may be continuously released from entanglement head 620. Similar to the entanglement station 518, the number of entanglement heads 620 may be different than shown, the spacing between entanglement heads 620 may be different than shown, and the entanglement heads 620 may have different dimensions, may have different structured arrangements of orifices, etc.

7 shows a second entanglement station 520, which includes the same components as entanglement station 518 (e.g., mount 526, carriage 524, actuator 528). and entanglement head 532). Two entanglement heads 532d and 532e are shown for second entanglement station 520. In an exemplary embodiment, entanglement heads 532d and 532e may be positioned out of alignment with entanglement heads 532a, 532b and 532c in the material flow direction 516. As a result, the entanglement heads 532d and 532e engage the composite nonwoven fabric at different positions in a direction that is not parallel to the material flow direction 516 compared to the entanglement heads 532a, 532b and 532c. In other words, the entanglement heads 532d and 532e are configured to form a set of non-linear entangled seams that are distinct and separate from the non-linear entangled seams formed by the entanglement heads 532a, 532b and 532c. For example, entanglement head 532a can be offset by a first distance 613 from a first edge 660 of surface 514 of conveyance system 512 in a direction perpendicular to material flow direction 516, and entanglement The head 532d may be offset by a second distance 615 from the first edge 660 of the surface 514 of the conveyance system 512 in a direction perpendicular to the material flow direction 516, wherein the second distance (615) is greater than the first distance (613). As such, the spacing arrangement between the entangling heads 532d and 532e is different from the spacing arrangement between the entangling heads 532a, 532b and 532c. As shown, entanglement station 520 includes a different number of entanglement heads 532 than the number of entanglement heads 532 in entanglement station 518 . It is contemplated herein that the entanglement station 520 may include fewer entanglement heads than shown or more entanglement heads than shown. The dimensions of the entanglement heads 532e and 532d may be the same or different from the dimensions of the entanglement heads 532a, 532b and 532c. Additionally, the entanglement footprint created by entanglement heads 532e and 532d may be the same or different from the entanglement footprint created by entanglement heads 532a, 532b and 532c.

8 shows a third entanglement station 522, which includes the same components as entanglement stations 518 and 522. Two entanglement heads 532f and 532g are shown for third entanglement station 522. In an exemplary embodiment, entanglement heads 532f and 532g may be positioned so as not to be aligned with entanglement heads 532a, 532b, 532c, 532d and 532e in the material flow direction 516. Accordingly, entanglement heads 532f and 532g are configured to form another set of non-linear entangled seams that are distinct and separate from the non-linear entangled seams formed by entanglement heads 532a, 532b, 532c, 532d and 532e. In other words, entanglement heads 532f, 532g are offset from first edge 660 of surface 514 of conveyance system 512 by a distance that is different from the offset distance for entanglement heads 532a, 532b, 532c, 532d, 532e. Can be offset. Entanglement station 522 may include a different number of entanglement heads 532 than shown. The entanglement heads 532f and 532g may be spaced differently than shown. The dimensions of the entanglement heads 532f and 532g may be the same or different from the dimensions of the entanglement heads 532a, 532b, 532c, 532d and 532e. Additionally, the entanglement footprint created by entanglement heads 532f and 532g may be the same or different from the entanglement footprint created by entanglement heads 532a, 532b, 532c, 532d and 532e.

Although entanglement system 500 is shown as including a number of entanglement stations positioned in series along conveyance system 512 in material flow direction 516, entanglement system 500 may be configured to include one entanglement station 518. It is also contemplated herein that an entanglement station may be included. In this embodiment, the stacked configuration of first nonwoven layer 110, second layer 114, and filler 116 may be passed through entangling station 518 multiple times to form the resulting composite nonwoven fabric 100. You can. In this aspect, the positioning of the entanglement heads 532a, 532b, 532c can be adjusted between each pass such that different regions of the stack configuration are engaged by the entanglement heads 532a, 532b, 532c during each pass. Additionally, other entanglement heads may be added, existing entanglement heads may be removed (and so on). The movement of carriage 524 may also be adjusted during each pass so that entanglement heads 532a, 532b, and 532c engage different portions of the stack configuration.

The example entanglement system 500 shown in FIG. 5 and further described with respect to FIGS. 6A-8 can create a complex visual arrangement of non-linear intertwined seams extending in the material flow direction 516. The components and movements of the entanglement system 500 can be adjusted to create non-linear, intertwined seams that are closely spaced or further apart from each other. Additionally, system 500 may generate non-linear intertwined seams that intersect or intersect each other one or more times along the material flow direction of a particular intertwined seam. As further explained in connection with FIGS. 14-16 , this may be achieved in first and second directions 610 that are non-parallel or perpendicular to the material flow direction 516 (i.e., along the cross-section of the resulting composite nonwoven fabric). and 611) to create thickness differences in the resulting composite nonwoven fabric.

9A and 9B show bottom views of two example entanglement heads 920 and 922, respectively. Entanglement heads 920, 922 may be any of the entanglement heads described with respect to entanglement system 500 or entanglement station 612. Regarding the entanglement head 920, the entanglement head includes a structured arrangement of entanglement needles 924 or alternatively orifices 924 configured to discharge a fluid jet. The entanglement head 920 has an exemplary circular shape such that the entanglement needles 924 or orifices 924 form a circular entanglement footprint on the composite nonwoven fabric. The entanglement head 920 has a dimension 910 in the material flow direction and a dimension 912 in the first and second directions 610 and 611 that are non-parallel or perpendicular to the material flow direction 516. Because entanglement head 920 has a circular shape, dimensions 910 and 912 are equal to the diameter of entanglement head 920 and are all the same.

Entanglement head 922 also includes a structured arrangement of entanglement needles 926 or alternatively orifices 926 configured to emit a jet of water. The entanglement head 922 has an exemplary rectangular shape such that the entanglement needles 926 or orifices 926 form a rectangular entanglement footprint on the composite nonwoven fabric. The entanglement head 922 has a dimension 914 in the material flow direction 516 and a dimension 916 in first and second directions 610, 611 that are non-parallel or perpendicular to the material flow direction 516.

In an exemplary embodiment, the distance of advance of the conveyance system 512 in the material flow direction 516 during the movement phase of the entanglement system 500 may be less than or equal to the dimensions 910, 914 of each of the entanglement heads 920, 922. You can. This ensures that the entanglement areas created by the entanglement heads 920, 922 are directly adjacent to and/or overlap one another, forming a seemingly continuous, non-linear, entangled seam. Additionally, movement of the carriage 524 and/or transport system 5120 in the first and second directions 610, 611 that are non-parallel or perpendicular to the material flow direction 516 causes the respective entanglement heads 920, 922 ) may be smaller than or equal to the dimensions 912, 916. This also ensures that the entanglement areas created by the entanglement heads 920, 922 are directly adjacent to and/or overlap one another, forming a seemingly continuous, non-linear, entangled seam. The description of the shape of the entanglement heads 920, 922 is exemplary, and it is contemplated herein that the entanglement heads may have other shapes such as oval, square, triangular, etc.

10A and 10B each schematically illustrate a process for making a composite nonwoven fabric with non-linear intertwined seams, such as composite nonwoven fabric 100. Figure 10A shows a process that uses an entangling needle and can be performed at any of the entangling stations 518, 520, or 522. Figure 10B illustrates a process that utilizes hydraulic entanglement and may be performed, for example, at an entanglement station 612. With respect to both FIGS. 10A and 10B, coordinate systems are provided representing the x-direction, y-direction, and z-direction.

Referring to FIG. 10A , at step 1010, a stacked configuration of first nonwoven layer 110, second layer 114, and filler 116 is formed, with second layer 114 positioned toward surface 514. and the first nonwoven layer 110 is positioned on the surface 514 of the delivery system 512, spaced from the surface 514 by the filler 116. The transport system 512 and the stack configuration are in a first stationary stage or position such that the transport system 512 does not advance in the material flow direction 516 (i.e., the positive x direction). During the first stationary phase, the actuator 528 moves in a direction 530 perpendicular to the transport plane of surface 514 (i.e., the negative z direction) to lower the entanglement head 532 to engage the entanglement needle 534, and indirectly causes entanglement head 532 to engage a stacked configuration of first nonwoven layer 110 , second layer 114 and filler 116 . Alternatively, actuator 528 may actuate entanglement head 532 and/or entanglement needles 534 to cause entanglement needles 534 to move downward and engage the stack configuration. The interlocking forces the fibers from the first nonwoven layer through the filler 116 and into (or through) the second layer 114 to create a first entangled area 1012 as shown in step 1014. . First entanglement region 1012 may have an entanglement footprint that corresponds to the shape of a structured arrangement of entanglement needles 534 on entanglement head 532.

At step 1016, entanglement needles 534 are disengaged from the stacked configuration of first nonwoven layer 110, second layer 114, and filler 116, and delivery system 512 moves the stacked configuration into material flow. It advances by a distance (1018) in direction (516). In an exemplary aspect, the distance 1018 may be equal to or less than the dimension of the entanglement head 532 in the material flow direction 516. At step 1016, the carriage 524 moves a first distance in a first direction 610 (i.e., the negative y direction) non-parallel to the material flow direction 516, where the first distance is the material flow direction. It may be equal to or less than the dimensions of the entanglement head 532 in the first direction 610 that is not parallel to 516. Movement of carriage 524 may occur simultaneously with movement of conveyance system 512 in material flow direction 516, or after movement of conveyance system 512 in material flow direction 516 (i.e., conveyance system (512) may occur when it is in the second stationary phase. Alternatively or additionally, the transport system 512 may move a first distance in a first direction 610 that is not parallel to the material flow direction 516 .

At step 1022, the transport system 512 and the stack configuration are in a second rest state or position such that the transport system 512 does not advance in the material flow direction 516. The second rest state or position is advanced from the first rest state or position in the material flow direction 516. During the second stop phase, the actuator 528 moves again in a direction 530 perpendicular to the transport plane of surface 514 to lower entanglement head 532 so that entanglement needles 534 engage first nonwoven layer 110. , so as to engage with the stacked configuration of the second layer 114 and the filler 116. Due to movement of the carriage 524 and/or transport system 512, engagement of the entanglement needles 534 with the stack configuration causes a first entanglement region in a first direction 610 that is not parallel to the material flow direction 516. It occurs at a position offset from (1012). The second interlocking again forces the fibers from the first nonwoven layer 110 through the filler 116 and into (or through) the second layer 114 to create a second entanglement region (as shown in step 1024). 1026), thereby creating an apparently continuous, non-linear, intertwined seam 1028 in the composite nonwoven fabric 100. The second entanglement region 1026 may have an entanglement footprint that corresponds to the shape of the structured arrangement of entanglement needles 534 on the entanglement head 532. As shown at 1024, second entanglement region 1026 partially overlaps first entanglement region 1012. This is illustrative, and it is contemplated herein that the second entangled region 1026 may not partially overlap the first entangled region 1012.

The process depicted in FIG. 10A may include a plurality of stationary steps or positions advanced from one another in the direction of material flow, during which entanglement needles 534 move through first nonwoven layer 110, second layer 114, and so on. and the stacked configuration of the filling layer 116 to form entanglement regions extending from each other. Additionally, the process depicted in FIG. 10A may include multiple movement steps during which the conveyance system 512 moves the material flow direction ( The stack configuration is advanced in the material flow direction 516 by a distance less than or equal to the dimensions of the entanglement head 532 at 516). Additionally, the carriage 524 and/or transport system 512 may have multiple movements in a first direction 610 that is not parallel to the material flow direction 516 and a second direction 611 opposite (i.e., the positive y direction). You can run . The distance of movement of the carriage 524 and/or transport system 512 in the first direction 610 and the opposite second direction 611 may be adjusted such that the resulting entanglement areas partially overlap or extend directly from each other. It may be less than or equal to the dimensions of the entanglement head 532 in one direction (610) or an opposing second direction (611).

The process shown schematically in Figure 10B is similar to the process shown in Figure 10A but utilizes hydraulic entanglement to create a non-linear, entangled seam. In step 1050, a stacked configuration of first nonwoven layer 110, second layer 114 and filler 116 is formed, with second layer 114 positioned toward surface 514 and first nonwoven layer ( 110 is positioned on the surface 514 of the delivery system 512, spaced from the surface 514 by the filler 116. In one example aspect, the transport system 512 and the stack configuration are in a first rest state or position such that the transport system 512 does not advance in the material flow direction 516. During the first stop phase, the actuator 618 actuates the entanglement head 620 to discharge one or more pressurized fluid jets 1052 in a direction toward the surface 514 of the delivery system 512, as shown in step 1056. A first entangled region 1054 is formed as described above. In an exemplary embodiment, the actuator 618 may not move in a direction perpendicular to the transport plane of the surface 514 during the first stationary step, but positions the fluid jet 1052 closer to the first nonwoven layer 110. It is contemplated herein that the actuator 618 can move in a direction perpendicular to the transport plane of the surface 514 in order to do so. In another exemplary embodiment, the delivery system 512 may continue to advance in the material flow direction 516 while the actuator 618 continuously operates the entanglement head 620 to discharge one or more pressurized fluid jets 1052. there is. Fluid jet 1052 forces fibers from first nonwoven layer 110 through filler 116 and into (or through) second layer 114 to create first entangled area 1054. First entanglement region 1054 may have an entanglement footprint that corresponds to the shape of the structured arrangement of orifices on entanglement head 620.

At step 1058, transport system 512 advances the stack configuration a distance 1060 in material flow direction 516. In an exemplary aspect, the distance 1060 may be equal to or less than the dimension of the entanglement head 620 in the material flow direction 516. At step 1058, the carriage 616 and/or transport system 512 moves a first distance in a first direction 622 that is non-parallel to the material flow direction 516, where the first distance is the material flow direction. It may be equal to or smaller than the dimensions of the entanglement head 620 in a direction not parallel to 516. Movement of carriage 616 and/or transport system 512 may occur simultaneously with movement of transport system 512 in material flow direction 516, or movement of transport system 512 in material flow direction 516. (i.e., when transport system 512 is in a second rest stage or position advanced from the first stationary stage or position in the material flow direction).

At step 1064, the delivery system 512 and the stack configuration are in a second stationary stage or position, and the actuator 618 again actuates the entanglement head 620 to discharge the fluid jet 1052, causing the fluid jet ( 1052) engages a stacked configuration of first nonwoven layer 110, second layer 114, and filler 116. Due to the movement of the carriage 616, engagement of the fluid jet 1052 with the stack configuration occurs at a location offset from the first entanglement region 1054 in a direction 622 that is not parallel to the material flow direction 516. The second interlocking again forces the fibers from the first nonwoven layer 110 through the filler 116 and into (or through) the second layer 114 to form a second entanglement region (as shown in step 1066). 1068), thereby creating an apparently continuous, non-linear, intertwined seam 1070 in the composite nonwoven fabric 100 extending in the material flow direction 516. As shown at 1066, second entanglement region 1068 partially overlaps first entanglement region 1054. This is illustrative, and it is contemplated herein that the second entangled region 1068 may not partially overlap the first entangled region 1054.

The process depicted in FIG. 10B may include a plurality of stationary steps or positions during which fluid jet 1052 deposits first nonwoven layer 110, second layer 114, and fill layer 114. Interlocking with the configuration, they form entangled areas extending from each other. Additionally, the process depicted in FIG. 10B may perform multiple movement steps during which the conveyance system 512 moves the material flow direction 516 such that the resulting entanglement areas partially overlap or extend directly from each other. ) The fabric is advanced in the material flow direction 516 by a distance less than or equal to the dimension of the entanglement head 620 in ). Additionally, the carriage 616 and/or transport system 512 may perform a number of movements in a first direction 622 that is not parallel to the material flow direction 516 and a second direction 623 opposite. The distance of movement of the carriage 616 and/or transport system 512 in the first direction 610 and the opposing second direction 623 may be adjusted such that the resulting entanglement areas partially overlap or extend directly from each other. It may be less than or equal to the dimensions of the entanglement head 620 in one direction 610 or an opposing second direction 623.

As mentioned above, entanglement systems described herein, such as entanglement system 500, may include long repetitions of a visual arrangement of non-linear intertwined seams or even composite nonwoven fabrics 100 without repetitions of a visual arrangement of non-linear intertwined seams. Composite nonwoven fabrics such as can be produced. The resulting composite nonwoven fabric can be used to create an array of garments that have a common finished form but with diverse aesthetic properties due to the different visual arrangements of non-linear intertwined seams in the resulting garment. An array of garments may share common characteristics, such as a common finished shape, color, etc., so that a consumer can easily recognize the array of garments as coming from a common source (eg, a common manufacturer). However, a consumer may be able to select a garment from an array of garments having a desired visual arrangement of intertwined seams. Additionally, there can be less material waste when forming arrays of garments because the visual arrangement of non-linear intertwined seams is not long or repeated, ensuring that each garment contains the same visual arrangement of intertwined seams at the same location on the garment. This is because there is no need to lay out the pattern pieces in a guaranteed way.

Figure 11 schematically illustrates a method of manufacturing an array of garments that have a common finished form but differ in the visual arrangement of the non-linear intertwined seams. At step 1110, composite nonwoven fabric 100 is provided or obtained. In this example, composite nonwoven fabric 100 includes a first non-linear intertwined seam 1112 and a second non-linear intertwined seam 1114 extending in the material flow direction 516 of composite nonwoven fabric 100. In an exemplary embodiment, the distance between the first non-linear intertwined seam 1112 and the second non-linear intertwined seam 1114 varies along the material flow direction 516. For example, the first non-linear intertwined seam 1112 can be spaced a first distance 1111 from the second non-linear intertwined seam 1112 at a first location 1113 on the composite nonwoven fabric 100. At a second location 1115 on the composite nonwoven fabric 100, the first non-linear intertwined seam 1112 can be spaced a second distance 1117 from the second non-linear intertwined seam 1114, wherein the second non-linear intertwined seam 1112 Distance 1117 is greater than first distance 1111.

At step 1110, a first instance of pattern 1116 is removed, excised, and/or cut from composite nonwoven fabric 100, where pattern 1116 corresponds to the left sleeve of the upper body garment. Stated differently, in step 1110, first portion 1120 is removed from composite nonwoven fabric 100, where first portion 1120 has a shape corresponding to pattern 1116. Pattern 1116 is by way of example only, and it is contemplated herein that pattern 1116 may correspond to any portion of an upper body garment, lower body garment, shoe upper, headwear, etc.

Step 1118 shows first portion 1120 with pattern 1116 after being removed from composite nonwoven fabric 100. As shown, the first portion 1120 includes a first non-linear intertwined seam 1112 and a second non-linear intertwined seam 1114, wherein the first non-linear intertwined seam 1112 and the second non-linear intertwined seam 1114 The intertwined seam 1114 is located generally at a first location on the first portion 1120 and/or pattern 1116, as indicated by reference numeral 1119. At step 1122, first portion 1120 is integrated into first garment 1124. As shown in FIG. 11 , first non-linear intertwined seam 1112 and second non-linear intertwined seam 1114 are non-linear intertwined seams on first garment 1124, as generally referenced by reference numeral 1126. Provides a first visual arrangement.

At step 1128, a second instance of pattern 1116 is removed, excised, and/or cut from composite nonwoven fabric 100. The second instance of pattern 1116 includes a first non-linear intertwined seam 1112 and a second non-linear intertwined seam 1114. Stated differently, at step 1128, second portion 1132 is removed from composite nonwoven fabric 100, where second portion 1132 has a shape corresponding to pattern 1116. Step 1130 shows the second portion 1132 having the pattern 1116 after being removed from the composite nonwoven fabric 100. As shown, the second portion 1132 includes a first non-linear intertwined seam 1112 and a second non-linear intertwined seam 1114, wherein the first non-linear intertwined seam 1112 and the second non-linear intertwined seam 1114 The intertwined seam 1114 is located generally on the second portion 1132 and/or pattern 1116, as indicated by reference numeral 1131. At step 1134, second portion 1132 is integrated into second garment 1138, where second garment 1138 has the same finished form as first garment 1124. As shown in FIG. 11 , first non-linear intertwined seam 1112 and second non-linear intertwined seam 1114 are formed on a second garment 1138, generally referred to by reference numeral 1136. A second visual arrangement is provided, wherein the second visual arrangement of the non-linear intertwined seam 1136 is a different visual arrangement than the first visual arrangement of the non-linear intertwined seam 1126.

The process shown in FIG. 11 includes a first non-linear intertwined seam 1112 and a first non-linear intertwined seam 1112 at different locations on the pattern 1116 and providing different visual arrangements of the first and second non-linear intertwined seams 1112, 1114. may be repeated any number of times along the material flow direction 516 of composite nonwoven fabric 100 to form an array of garments with a second non-linear intertwined seam 1114. Although FIG. 11 only shows pattern 1116 applied to composite nonwoven fabric 100, additional pattern pieces may be formed from additional pattern pieces applied to composite nonwoven fabric 100 so that the resulting garment can be formed from additional pattern pieces applied to composite nonwoven fabric 100. It is contemplated herein that it can be applied to (100). In this aspect, the visual arrangement of the intertwined seams in different areas of the garment can be different, creating a variety of overall aesthetics. A process similar to that shown in Figure 11 can be used to form, for example, an array of lower body garments that have a common finished shape but differ in the visual arrangement of the non-linear intertwined seams.

In an exemplary embodiment, the scrap produced by the process shown in FIG. 11 may be shredded and then formed, for example, inside one or more of the first nonwoven layer 110, second layer 114, or filler 116. You can. This is possible because the materials forming composite nonwoven fabric 100 are in exemplary embodiments the same polymer class (e.g., recycled polyester). Additionally, since the composite nonwoven fabric 100 is formed without using extraneous materials such as threads, adhesives, etc., there is no need to remove a portion of the scrap material before shredding.

Figures 12 and 13 further illustrate garments produced from the process shown in Figure 11. FIG. 12 shows a front view of an array of torso garments in the form of a sleeveless top including a first torso garment 1210 and a second torso garment 1212 having a common finished shape. Although shown as a sleeveless top, it is contemplated herein that the upper body garment may include other forms such as vests, pullovers, hoodies, jackets, etc. First upper body garment 1210 includes neck opening 1214, waist opening 1216, first sleeve opening 1218, and second sleeve opening 1220. Likewise, second upper body garment 1212 includes neck opening 1222, waist opening 1224, first sleeve opening 1226, and second sleeve opening 1228. Additionally, although the non-linear intertwined seam is shown extending in a horizontal orientation (e.g., extending from the first sleeve opening 1218/1226 to the second sleeve opening 1220/1228), the non-linear intertwined seam It is contemplated herein that may extend in a vertical direction (e.g., extending from neck opening 1214/1222 to waist opening 1216/1224).

As shown, at least the front panel 1230 of the first upper garment 1210 and the front panel 1232 of the second upper garment 1212 may be formed from the same pattern pieces applied to the composite nonwoven fabric 100. . The front panel 1230 of the first upper body garment 1210 has a first non-linear intertwined seam 1234 and a second non-linear intertwined seam 1236 located at a first location 1238 on the first upper garment 1210. Includes. In an exemplary aspect, the first location 1238 is at a first position relative to each of the first non-linear intertwined seam 1234 and the second non-linear intertwined seam 1236 relative to the waist opening 1216 of the first upper body garment 1210. 1 It may correspond to the first distance 1237 measured from the front vertical center line of the upper body garment 1210. First non-linear intertwined seam 1234 and second non-linear intertwined seam 1236 provide a first visual arrangement of intertwined seams on first upper body garment 1210.

The front panel 1232 of the second upper garment 1212 has a first non-linear intertwined seam 1234 and a second non-linear intertwined seam 1236 located at a second location 1244 on the second upper garment 1212. and wherein the second location 1244 is different from the first location 1238. For example, the second location 1244 may be located at a position of the second upper body garment relative to each of the first non-linear intertwined seam 1234 and the second non-linear intertwined seam 1236 relative to the waist opening 1224 of the second upper body garment 1212. A second distance 1245 measured from the front vertical centerline of 1212 may correspond to a second distance 1245 for each of the first non-linear intertwined seam 1234 and the second non-linear intertwined seam 1236. is different from the first distance (1237). First non-linear intertwined seam 1234 and second non-linear intertwined seam 1236 provide a second visual arrangement of intertwined seams on second upper body garment 1212.

Although not shown, additional torso garments having a common completion form with first torso garment 1210 and second torso garment 1212 may be included in the array. Additional upper body garments in the array may provide different visual arrangements of the first non-linear intertwined seam 1234 and the second non-linear intertwined seam 1236. In other words, the first non-linear intertwined seam 1234 and the second non-linear intertwined seam 1234 may be located at different locations on the additional garment relative to the aforementioned pattern pieces used to form the front panel of the additional upper body garment. there is.

13 shows a front view of an array of lower body garments in the form of shorts including a first lower body garment 1310 and a second lower body garment 1312 having a common finished shape. Although shown as shorts, it is contemplated herein that lower body clothing may include other forms such as pants, capris, etc. The first lower body garment 1310 includes a waist opening 1314, a first leg opening 1316a, and a second leg opening 1316b. Likewise, second lower body garment 1312 includes waist opening 1322, first leg opening 1324a, and second leg opening 1324b. Additionally, although the non-linear intertwined seam is shown extending in a horizontal orientation, it is contemplated herein that the non-linear intertwined seam may extend in a vertical direction.

As shown, at least the front panel 1330 of the first lower body garment 1310 and the front panel 1332 of the second lower body garment 1312 may be formed from the same pattern pieces applied to the composite nonwoven fabric 100. . The front panel 1330 of the first lower body garment 1310 has a first non-linear intertwined seam 1334 and a second non-linear intertwined seam 1336 located at a first location 1338 on the first lower body garment 1310. Includes. In an exemplary aspect, the first location 1338 is at a first position relative to each of the first non-linear intertwined seam 1334 and the second non-linear intertwined seam 1336 relative to the waist opening 1314 of the first lower body garment 1310. 1 It may correspond to the first distance 1337 measured from the front vertical center line of the lower body garment 1310. First non-linear intertwined seam 1334 and second non-linear intertwined seam 1336 provide a first visual arrangement of intertwined seams on first lower body garment 1310.

The front panel 1332 of the second lower body garment 1312 has a first non-linear intertwined seam 1334 and a second non-linear intertwined seam 1336 located at a second location 1344 on the second lower body garment 1312. and wherein the second location 1344 is different from the first location 1338. For example, the second location 1344 may be located at the second lower body garment with respect to each of the first non-linear intertwined seam 1334 and the second non-linear intertwined seam 1336 relative to the waist opening 1322 of the second lower body garment 1312. A second distance 1345 measured from the front vertical centerline of 1312 may correspond to a second distance 1345 for each of the first non-linear intertwined seam 1334 and the second non-linear intertwined seam 1336. is different from the first distance (1337). First non-linear intertwined seam 1334 and second non-linear intertwined seam 1336 provide a second visual arrangement of intertwined seams on second lower body garment 1312.

Although not shown, additional lower body garments having a common completion form with first lower body garment 1310 and second lower body garment 1312 may be included in the array. Additional lower body garments in the array may provide different visual arrangements of the first non-linear intertwined seam 1334 and the second non-linear intertwined seam 1336. Stated differently, the first non-linear intertwined seam 1334 and the second non-linear intertwined seam 1234 may be located at different locations on the additional garment relative to the aforementioned pattern pieces used to form the front panel of the additional lower body garment. there is.

Although the garments depicted in the array of garments of FIGS. 12 and 13 include a different visual arrangement of intertwined seams, the garments in the array of garments produced by the systems and methods described herein may include the same visual arrangement of intertwined seams. It is considered herein that there is. For example, the entanglement system 500 can be configured to create short repetitions of a visual arrangement of entangled seams such that the composite nonwoven fabric can include multiple repetitions of a visual arrangement of entangled seams along the material flow direction 516. In this aspect, the pattern pieces can be applied to a composite nonwoven fabric to form a garment with the same visual arrangement of intertwined seams.

14 illustrates a second example composite nonwoven fabric 1400 formed, for example, from a first nonwoven layer 110, a second layer 114, and a filler 116. Composite nonwoven fabric 1400 can be formed according to the methods and systems described herein, including entanglement system 500. Composite nonwoven fabric 1400 includes non-linear intertwined seams 1410a, 1410b, 1410c, and 1410d extending in material flow direction 516. As shown, non-linear intertwined seams 1410a, 1410b intersect or crossover with each other at intersection 1412, and nonlinear intertwined seams 1410c, 1410d intersect or crossover with each other at intersection 1414, 1416. . Intersections 1412, 1414, 1416 represent areas where the entanglement head engages composite nonwoven fabric 1400 at least twice. As such, intersections 1412, 1414, and 1416 have a greater stitch density than the remainder of the non-linear intertwined seams 1410a, 1410b, 1410c, and 1410d. The greater stitch density at intersections 1412, 1414, 1416 compared to the rest of the non-linear intertwined seams 1410a, 1410b, 1410c, 1410d and between non-linear intertwined seams 1410a, 1410b, 1410c, 1410d. The thickness is further reduced compared to the extending region 1418.

This is shown in Figure 15, which is a cross-section of composite nonwoven fabric 1400 taken at perforation line 15-15. Region 1418 has a thickness 1514 measured from a first surface 1513 formed by first nonwoven layer 110 to an opposing second surface 1516 formed by second layer 114. Intersection 1412 has a thickness 1510 measured from first surface 1513 to opposite second surface 1516, and non-linear intertwined seams 1410c, 1410d extend from first surface 1513 to opposite second surface 1516. It has a thickness (1512) measured up to (1516). In an exemplary aspect, thickness 1514 is greater than thickness 1512 , which is greater than thickness 1510 . The ability to create varying thicknesses of composite nonwoven fabric 1400 in directions other than parallel to the material flow direction can be used to design high and low insulation zones as needed for garments incorporating composite nonwoven fabric 1400. . The insulating zone may have increased thickness (e.g., more loft) and may correspond to area 1418. The low-insulation zone may correspond to an area containing a plurality of intersections, such as intersections 1412, 1414, and 1416.

16 shows a back view of an example upper body garment 1600 having a torso portion 1610, where the torso portion 1610 includes a neck opening 1612 and a waist opening 1614. Upper body garment 1600 further includes an optional first sleeve 1616 and an optional second sleeve 1618. Although shown as a top with long sleeves, it is contemplated herein that upper body garment 1600 may be in the form of a vest, pullover, hoodie, jacket, etc.

The upper body garment includes a low-insulation region 1620 located in the central rear region of the torso portion 1610 and a high-insulation region 1622 located on either side of the low-insulation region 1620. The locations of the low-insulation zone 1620 and the high-insulation zone 1622 may be based, for example, on a heat map of the human body. For example, these maps may indicate that the mid-back of a human's torso generates a large amount of heat and may therefore require less insulation than other areas of the torso. Low-insulation zone 1620 includes a plurality of non-linear intertwined seams 1624a, 1624b, 1624c, 1624d extending in material flow direction 516. As shown, non-linear intertwined seams 1624a, 1624b, 1624c, and 1624d are generally closely spaced together and form a plurality of intersections as they extend from neck opening 1612 to waist opening 1614 of upper body garment 1600. Includes. This results in an overall increased stitch density in the low-insulation areas 1620 and an overall reduced thickness compared to other portions of the upper body garment 1600. In contrast, highly insulating region 1622 includes non-linear intertwined seams 1626a, 1626b, 1626c, 1626d. Nonlinear intertwined seams (1626a, 1626b, 1626c, 1626d) are generally further apart compared to nonlinear intertwined seams (1624a, 1624b, 1624c, 1624d), and nonlinear intertwined seams (1626a, 1626b, 1626c, 1626d) do not intersect with each other. As such, the high insulation region 1622 has an overall reduced stitch density and an overall increased thickness compared to the low insulation region 1620. In other words, the highly insulating zone 1622 has regions 1628a where the first nonwoven layer 110, second layer 114, and filler 116 are substantially unentangled compared to the low insulating zone 1620. 1628b, 1628c, 1628d) may contain a larger surface area occupied. The greater thickness and loft of regions 1628a, 1628b, 1628c, 1628d help trap and store heat.

The visual arrangement of non-linear intertwined seams in Figure 16 is merely an example, and it is contemplated herein that other visual arrangements may be formed by non-linear intertwined seams. Additionally, although the interwoven seam is shown extending vertically (eg, from the neck opening to the waist opening), the interwoven seam may be oriented horizontally on the garment. Additionally, upper body garment 1600 may include non-linear intertwined seams at locations on the upper body garment other than those shown. The depiction of upper body garment 1600 in FIG. 16 is intended to convey the idea that parameters associated with non-linear intertwined seams can be adjusted to achieve desired properties, including insulating properties. Parameters may include, for example, the spacing between adjacent non-linear intertwined seams (e.g., the larger the spacing, the larger the area 1628a, 1628b, 1628c, 1628d generally occupies a larger surface area of the upper body garment 1600), the non-linear intertwined seam The number of intersections between seams (e.g., more intersections increase stitch density and decrease thickness), the width of individual non-linear intertwined seams (e.g., the larger the width, the reduced thickness compared to a non-linear intertwined seam with a smaller width). ), etc. may be included.

17 shows an exemplary composite nonwoven fabric 1700 formed from a first nonwoven layer 110, a second layer 114, and filler 116. In an exemplary embodiment, composite nonwoven fabric 1700 includes non-linear intertwined seams 1710a, 1710b, and 1710c. Non-linear intertwined seam 1710a is similar to other non-linear intertwined seams discussed herein, for example, with respect to composite nonwoven fabric 100 and composite nonwoven fabric 1400. Non-linear intertwined seams 1710b, 1710c include discontinuous non-linear intertwined seams. For example, non-linear intertwined seam 1710b includes discontinuous segments 1712 that do not form an intertwined seam. Non-linear intertwined seam 1710c includes a number of discontinuous segments, such as discontinuous segment 1714 and discontinuous segment 1716. Additionally, the non-linear intertwined seam 1710c may have intertwined seam portions 1718 in the form of very short segments or even intertwined segments spaced apart from the remainder of the non-linear intertwined seam 1710c by discontinuous segments 1720 and 1722. Includes branches.

Discontinuous segments 1712, 1714, 1716, 1720, 1722 may be formed using the entanglement system 500 and methods described herein. For example, with respect to a discontinuous segment 1712, that segment may be subjected to one or more stopping steps such that the entanglement needle(s) 534 and/or orifices associated with the entanglement head 532 do not contact the composite nonwoven fabric 1700. While, a non-linear entangled seam 1710b may be formed by not actuating the entangling head 532 . The length of the discontinuous segments 1712, 1714, 1716, 1720, 1722 can be adjusted as desired by varying the number of stop steps during which the entanglement head 532 is deactivated.

In an exemplary embodiment, the entanglement head 532 is subsequently actuated and the carriage 524 and/or delivery system 512 are operated to produce discontinuous segments 1712, as shown for a non-linear entanglement seam 1710b. It is positioned to be aligned with the previously formed last entanglement region 1711 and the material flow direction 516, so that the next entanglement region 1713 is aligned with the last entanglement region 1711 and the material flow direction 516. Alternatively, and as shown for the discontinuous segment 1714 of the non-linear entangled seam 1710, if the entanglement head 532 is actuated after the discontinuous segment 1714 is formed, the carriage 524 and/or System 512 is offset in a first direction 610 from the last entanglement region 1715 formed before the discontinuous segment 1714 was created, such that the next entanglement region 1717 is offset from the last entanglement region 1715 in a first direction ( 610) can be offset. The carriage 524 and/or transport system 512 is configured to move the next entanglement area in a second direction 611 such that the next entanglement area is offset from the previous entanglement area in the second direction 611, as shown with respect to the discontinuous segment 1716. It is also contemplated herein that it may be positioned to be offset from .

With respect to entangled seam portion 1718, in an exemplary embodiment, entangled seam portion 1718 engages entanglement head 532 at least once after discontinuous segment 1720 is created and before discontinuous segment 1722 is created. It can be formed by operating it. The length of the entangling seam portion 1718 can be adjusted based on the number of times the entangling head 532 is actuated after the discontinuous segment 1720 is formed and before the discontinuous segment 1722 is formed. For example, actuating entanglement head 532 once or twice may create an entanglement point, while actuating entanglement head 532 three to ten times may create short entanglement segments.

Any combination of continuous non-linear intertwined seams and discontinuous non-linear intertwined seams are contemplated herein. In an exemplary embodiment, discontinuous segments may be created when increased loft and thickness of composite nonwoven fabric 1700 is desired. For example, when composite nonwoven fabric 1700 is incorporated into a garment, discontinuous, non-linear intertwined seams may be located in areas of the garment where a greater amount of insulation is desired. Additionally, the length of the discontinuous segments can be adjusted depending on the insulation needs (e.g., longer discontinuous segments provide more loft and more insulation, shorter discontinuous segments provide less loft and less insulation).

It is contemplated in aspects herein that instead of having separate layers or stacked configurations of material that are joined or secured together at the seam area using an entanglement process, an entangled seam may be used for a single layer of material comprising non-woven fibers. The term “single layer” refers to conveying a cohesive structure as opposed to separate layers that are not joined together before creating an intertwined seam as described herein. For example, Figure 18 shows an example nonwoven fabric 1800 with intertwined seams 1810, 1812, and Figure 19 shows a cross section of the nonwoven fabric 1800. Nonwoven fabric 1800 includes a single fiber layer comprising entangled fibers; Two or more layers of fibers (e.g. different staple length fibers, different denier fibers, different colored fibers, different fiber types, different fiber coatings, etc.); or it may comprise one or more layers of fibers with the same or disparate properties joined together with a film or structured fabric (e.g., knit, woven or braided fabric) through an entangling process or other processes such as bonding, adhesives, stitching, etc.

Non-linear intertwined seams 1810, 1812 may be formed through the entanglement process described above, and seams 1810, 1812 may be used to create areas of reduced thickness and/or create a visual array of intertwined seams. there is. In an exemplary aspect, nonwoven fabric 1800 may be combined with additional single layers of material. For example, nonwoven fabric 1800 can be placed adjacent to a structured fabric and joined to the fabric through entangling, stitching, bonding, adhesives, etc. One or more additional materials, such as filler, may be positioned between the nonwoven fabric 1800 and the structured fabric. In another example, nonwoven fabric 1800 can be placed adjacent to another single layer nonwoven fabric with intertwined seams and secured to that fabric through entangling, stitching, bonding, adhesives, etc. One or more additional materials, such as filler, may be positioned between nonwoven fabric 1800 and the additional single layer nonwoven fabric. Any and all aspects and modifications thereof are considered to be within the scope of this disclosure. Nonwoven fabric 1800 may be formed into various articles of clothing described herein, such as upper body garments, lower body garments, footwear (e.g., uppers), and the like. Articles of clothing of the same type may have different visual arrangements of intertwined seams as described herein.

The following sections present example embodiments of the concepts contemplated herein. Any one of the following terms may be combined in a multi-dependent manner such that it is dependent on one or more other terms. Additionally, any combination of dependent terms (terms that are explicitly dependent on a preceding term) may be made while remaining within the scope of the aspects contemplated herein. The following paragraphs are examples and not limiting.

Clause 1. A method of making a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and filler positioned between the first nonwoven layer and the second layer, wherein the composite nonwoven fabric is placed in a first position on an entanglement machine. forming a first entanglement region on the composite non-woven fabric, while engaging the entanglement head with the composite non-woven fabric; advancing the composite nonwoven fabric through the entangling machine in the direction of material flow; moving one or more of the entanglement head and the composite nonwoven fabric in a first direction non-parallel to the material flow direction; and forming a second entanglement region on the composite nonwoven fabric by causing the entanglement head to engage the composite nonwoven fabric while the composite nonwoven fabric is in a second position advanced from the first position in the material flow direction. wherein the second entangled region extends from the first entangled region to form a non-linear entangled seam.

Clause 2. The method of clause 1, wherein in each of the first and second entanglement zones, the fibers from the first nonwoven layer extend through the filler into the second layer.

Clause 3. The method of clause 1 or clause 2, wherein the first entangled region partially overlaps the second entangled region.

Clause 4. The method of any one of clauses 1 to 3, wherein the stitch density in the overlap region between the first entangled region and the second entangled region is greater than the stitch density in the remainder of the first entangled region and the second entangled region. How to be a big one.

Clause 5. The method of any one of clauses 1 to 4, wherein when the composite nonwoven fabric is in the first position, the entanglement head moves in a direction perpendicular to the surface plane of the composite nonwoven fabric.

Clause 6. The method of any one of clauses 1 to 5, further comprising: advancing the composite nonwoven fabric in the material flow direction following forming the second entanglement zone; moving one or more of the entanglement head or composite nonwoven fabric in a second direction non-parallel to the material flow direction; and forming a third entanglement region on the composite nonwoven fabric by causing the entanglement head to engage the composite nonwoven fabric while the composite nonwoven fabric is in a third position advanced from the second position in the material flow direction. and wherein the third entangling region extends from the second entangling region to form the non-linear entangled seam.

Clause 7. The method of clause 6, wherein the third entanglement region partially overlaps the second entanglement region.

Clause 8. The method of clause 6, wherein the third entangling area is located adjacent to the second entangling area.

Clause 9. The method of any one of clauses 6 to 8, wherein the second direction is opposite to the first direction.

Clause 10. A garment comprising: a first nonwoven layer having a material flow direction; second layer; a filler material positioned between the first nonwoven layer and the second layer; at least one area of the garment in which the first nonwoven layer, the second layer and the filler are substantially unentangled; and at least one non-linear intertwined seam extending along the material flow direction, wherein the at least one non-linear intertwined seam comprises one or more entangled regions extending from each other to form the at least one non-linear intertwined seam. and wherein the one or more entanglement areas include fibers from a first nonwoven layer extending through the filler and into the second layer.

Item 11. The garment according to item 10, wherein the second layer is a non-woven material.

Clause 12. The garment of clause 10 or clause 11, wherein the one or more areas of entanglement comprise separate areas.

Clause 13. The method of any one of clauses 10-12, wherein said at least one region of the garment in which the first nonwoven layer, the second layer, and the filler are substantially free of entanglement has a thickness of about 7 mm to about 15 mm. Clothing that is real.

Clause 14. The method of any one of clauses 10-13, wherein the thickness of the at least one non-linear intertwined seam is equal to the thickness of the at least one region of the garment in which the first nonwoven layer, the second layer and the fill are substantially unentangled. A garment that is from about 5% to about 30% of the thickness.

Item 15. The garment according to any one of items 10 to 14, wherein the filler is one or more of synthetic fiber sheets, loose synthetic fibers, and down.

Item 16. The garment according to items 10 and 12 to 15, wherein the second layer is a woven material.

Clause 17. The garment of clauses 10, 11 and 13-15, wherein the one or more entanglement regions partially overlap one another.

Clause 18. The garment of clauses 10-17, further comprising a plurality of additional non-linear intertwined seams, wherein the plurality of additional non-linear intertwined seams form a non-repeating visual arrangement of intertwined seams.

Clause 19. A composite nonwoven fabric, comprising: a first nonwoven layer having a material flow direction; second layer; a filler material positioned between the first nonwoven layer and the second layer; at least one region of the composite nonwoven fabric where the first nonwoven layer, the second layer and the filler are substantially unentangled; and at least one non-linear intertwined seam extending along the material flow direction, wherein the at least one non-linear intertwined seam includes one or more entangled regions extending from each other to form the at least one non-linear intertwined seam. and wherein the one or more entangled areas include fibers from a first nonwoven layer extending through the filler and into the second layer.

Clause 20. The composite nonwoven fabric of clause 19, wherein the second layer is a nonwoven material.

Clause 21. The composite nonwoven fabric of clauses 19 and 20, wherein the one or more entanglement zones comprise separate entanglement zones.

Clause 22. The method of clauses 19-21, wherein said at least one region of said composite nonwoven fabric in which the first nonwoven layer, the second layer and the filler are substantially unentangled has a thickness of from about 7 mm to about 15 mm. Composite non-woven fabric.

Clause 23. The method of any one of clauses 19-22, wherein the thickness of the at least one non-linear intertwined seam is such that the first non-woven layer, the second layer and the filler are substantially unentangled. The composite nonwoven fabric is about 5% to about 30% of the thickness of the area of.

Clause 24. The composite nonwoven fabric of any one of clauses 19 to 23, wherein the filler is one or more of synthetic fiber sheets, loose synthetic fibers and down.

Clause 25. The composite nonwoven fabric of any one of clauses 19 and 21-24, wherein the second layer is a woven material.

Clause 26. The composite nonwoven fabric of any one of clauses 19, 20, and 22-25, wherein the one or more entanglement regions partially overlap one another.

Clause 27. The method of any one of clauses 19-26, further comprising a plurality of additional non-linear intertwined seams, wherein the plurality of additional non-linear intertwined seams form a non-repeating visual arrangement of intertwined seams. , composite non-woven fabric.

Clause 28. An entangling system for forming at least one non-linear, intertwined seam on a composite nonwoven fabric, comprising a first entangling station, the first entangling station configured to intermittently advance the composite nonwoven fabric in a material flow direction. a transport system having a surface adapted to first actuator; a first entanglement head coupled to a first actuator, the first actuator being adapted to move the first entanglement head in a direction perpendicular to the transport plane of the transport system; and a first carriage coupled to the first entanglement head and configured to move in a first direction non-parallel to the material flow direction.

Clause 29. The entanglement system of clause 28, wherein the first direction is perpendicular to the material flow direction.

Clause 30. The entanglement system of clause 28 or clause 29, wherein the first carriage is further adapted to move in a second direction opposite to the first direction and not parallel to the material flow direction.

Clause 31. The entanglement system of clause 30, wherein the second direction is perpendicular to the material flow direction.

Clause 32. The entanglement system of any one of clauses 28-31, wherein the first entanglement head has a first dimension in the material flow direction.

Clause 33. The entanglement system of any one of clauses 28-32, wherein the advance distance of the transport system is less than or equal to the first dimension of the first entanglement head.

Clause 34. The entanglement system of any of clauses 28-33, wherein the first actuator is adapted to move in a direction perpendicular to the transport plane when the transport system is stationary.

Clause 35. The entanglement system of any of clauses 28-34, wherein the first carriage is indirectly coupled to the first entanglement head via a first actuator.

Clause 36. The method of any one of clauses 28-35, further comprising a second entangling station, the second entangling station having a surface adapted to intermittently advance the composite nonwoven fabric in the material flow direction. the transport system; second actuator; a second entanglement head coupled to a second actuator, the second actuator configured to move the second entanglement head in a direction perpendicular to the transport plane of the transport system; and a second carriage coupled to the second entanglement head and configured to move in a first direction non-parallel to the material flow direction.

Clause 37. The method of clause 36, wherein the first entanglement head is positioned at a first distance inwardly from the first edge of the surface of the delivery system, and the second entanglement head is positioned at a first distance inwardly from the first edge of the surface of the delivery system. An entangled system located at a second distance different from the first distance.

Clause 38. The entanglement system of clause 36 or clause 37, wherein the second entanglement station is located at a location subsequent to the first entanglement station in the material flow direction.

Clause 39. The entanglement system of any one of clauses 28-38, wherein the first entanglement head comprises a plurality of entanglement needles.

Clause 40. A method of making an array of garments having a common finished form, comprising obtaining a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and filler positioned between the first nonwoven layer and the second layer. wherein the composite nonwoven fabric includes at least a first non-linear intertwined seam and a second non-linear intertwined seam, each of the first non-linear intertwined seam and the second non-linear intertwined seam extending from one another and forming an apparently continuous non-linear an entangling area forming an entangled seam of, wherein the entangling area includes fibers from the first nonwoven layer extending through the filler into the second layer; removing a first instance of a pattern piece having a first non-linear intertwined seam and a second non-linear intertwined seam from the composite nonwoven fabric; forming a first garment using the first instance of the pattern piece, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location of the pattern piece; removing a second instance of the pattern piece having a first non-linear intertwined seam and a second non-linear intertwined seam from the composite nonwoven fabric; and forming a second garment using the second instance of the pattern piece, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location different from the first location of the pattern piece. A method comprising the steps:

Clause 41. The method of clause 40, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the material flow direction.

Clause 42. The method of clause 40 or clause 41, wherein the entanglement regions partially overlap each other.

Clause 43. The method of any one of clauses 40-42, further comprising: removing a third instance of a pattern piece having a first non-linear intertwined seam and a second non-linear intertwined seam from the composite nonwoven fabric; and forming a third garment using the third instance of the pattern piece, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are at a position of the pattern piece that is different from at least one of the first and second positions. The method further comprising the step of being located at a third location.

Clause 44. The method of any one of clauses 41-43, wherein the array of garments comprises an upper body garment.

Clause 45. The method of any one of clauses 41-43, wherein the array of garments comprises lower body garments.

Clause 46. An array of garments having a common finished form, wherein the array of garments is formed from a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and filler positioned between the first nonwoven layer and the second layer. wherein the composite nonwoven fabric includes at least a first non-linear intertwined seam and a second non-linear intertwined seam, each of the first non-linear intertwined seam and the second non-linear intertwined seam extending from each other and forming a respective first non-linear intertwined seam. an entangled seam of an entangled seam and an entangled area forming a second non-linear entangled seam, wherein the entangled area comprises fibers from the first nonwoven layer extending through the filler into the second layer. , a first garment formed from a first instance of a pattern piece taken from the composite nonwoven fabric, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location on the first garment; and a second garment formed from a second instance of a pattern piece taken from the composite nonwoven fabric, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location on the second garment. and wherein the second location is different from the first location relative to the pattern piece.

Clause 47. The array of garments of clause 46, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the material flow direction.

Clause 48. The array of garments of clause 46 or clause 47, wherein the entanglement regions partially overlap one another.

Clause 49. The method of any one of clauses 46-48, further comprising a third garment formed from a third instance of said pattern piece taken from said composite nonwoven fabric, wherein said garment has a first non-linear intertwined seam and a second non-linear intertwined seam. The array of garments wherein the seam is located at a third location on the third garment, wherein the third location is different from one or more of the first location and the second location with respect to the pattern piece.

Clause 50. The array of garments of any one of clauses 46-49, wherein the array of garments comprises an upper body garment.

Clause 51. The array of garments of any of clauses 46-49, wherein the array of garments comprises lower body garments.

Clause 52. A method of making an array of garments having a common finished form, comprising obtaining a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and filler positioned between the first nonwoven layer and the second layer. wherein the composite nonwoven fabric includes at least a first non-linear intertwined seam and a second non-linear intertwined seam, each of the first non-linear intertwined seam and the second non-linear intertwined seam extending from one another to form an apparently continuous non-linear intertwined seam. comprising an entangling area forming an entangled seam, wherein the entangling area includes fibers from the first nonwoven layer extending through the filler and into the second layer; removing a first portion having a first pattern from the composite nonwoven fabric, the first portion having a first non-linear intertwined seam and a second non-linear intertwined seam; forming a first garment using the first portion, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location on the first portion; removing a second portion having a first pattern from the composite nonwoven fabric, the second portion having a first non-linear intertwined seam and a second non-linear intertwined seam; and forming a second garment using the second portion, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location on the second portion that is different from the first location. How to.

Clause 53. The method of clause 52, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the material flow direction.

Clause 54. The method of clause 53, wherein the distance between the first non-linear intertwined seam and the second non-linear intertwined seam varies depending on the material flow direction, and the distance between the first non-linear intertwined seam and the second non-linear intertwined seam is A method wherein measurements are made in a direction that is not parallel to the material flow direction.

Clause 55. The method of any one of clauses 52-54, wherein the first non-linear intertwined seam and the second non-linear intertwined seam comprise different visual arrangements of the intertwined seams.

Clause 56. The method of any one of clauses 52-55, wherein the entanglement regions partially overlap one another.

Clause 57. The method of any one of clauses 52-56, wherein the array of garments comprises an upper body garment.

Clause 58. The method of any one of clauses 52-56, wherein the array of garments comprises lower body garments.

Clause 59. An array of garments having a common finish type, wherein the array of garments is formed from a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and filler positioned between the first nonwoven layer and the second layer. wherein the composite nonwoven fabric includes at least a first non-linear intertwined seam and a second non-linear intertwined seam, each of the first non-linear intertwined seam and the second non-linear intertwined seam extending from each other and forming a respective first non-linear intertwined seam. an entangled seam of an entangled seam and an entangled area forming a second non-linear entangled seam, wherein the entangled area comprises fibers from the first nonwoven layer extending through the filler into the second layer, comprising: A first garment formed from a first portion of the composite nonwoven fabric having a first pattern, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location on the first portion of the first garment. first garment; and a second garment formed from a second portion of the composite nonwoven fabric having a first pattern, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location on the second portion of the second garment. An array of garments, comprising a second garment, wherein the second position is different from the first position.

Clause 60. The array of garments of clause 59, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the material flow direction.

Clause 61. The method of clause 60, wherein the distance between the first non-linear intertwined seam and the second non-linear intertwined seam varies depending on the material flow direction, and the distance between the first non-linear intertwined seam and the second non-linear intertwined seam is An array of garments wherein measurements are taken in a direction other than parallel to the direction of material flow.

Clause 62. The array of garments of any of clauses 59-61, wherein the first non-linear intertwined seam and the second non-linear intertwined seam comprise different visual arrangements of the intertwined seams.

Clause 63. The array of garments according to any one of clauses 59-62, wherein the entanglement regions partially overlap one another.

Clause 64. The array of garments of any one of clauses 59-63, wherein the array of garments comprises an upper body garment.

Clause 65. The array of garments of any of clauses 59-63, wherein the array of garments comprises lower body garments.

Clause 66. An entangling system for forming at least one non-linear entangled seam on a composite nonwoven fabric, comprising a first entangling station, the first entangling station being configured to advance the composite nonwoven fabric in a material flow direction. a conveyance system having a surface; a first actuator configured to actuate a first entanglement head coupled to the first actuator; and a first carriage coupled to the first entanglement head and configured to move in a first direction non-parallel to the material flow direction.

Clause 67. The entanglement system of clause 66, wherein the first actuator is configured to actuate the first entanglement head to discharge one or more fluid jets.

Clause 68. The apparatus of clause 66, wherein the first entanglement head comprises an entanglement needle, and the first actuator is configured to move one or more of the first entanglement head and the entanglement needle in a direction perpendicular to the transport plane of the surface. entangled system.

Clause 69. The entanglement system of any one of clauses 66 to 68, wherein the first carriage is further adapted to move in a second direction opposite to the first direction and not parallel to the material flow direction.

Clause 70. The entanglement system of clause 69, wherein the second direction is perpendicular to the material flow direction.

Clause 71. The entanglement system of any of clauses 66-70, wherein the first entanglement head has a first dimension in the material flow direction.

Clause 72. The entangling system of clause 71, wherein the conveying system is adapted to advance the composite nonwoven fabric in the material flow direction, and the advancing distance of the conveying system is less than the first dimension of the first entangling head.

Clause 73. The entanglement system of any of clauses 66-72, wherein the first carriage is indirectly coupled to the first entanglement head via a first actuator.

Clause 74. The entanglement system of any of clauses 66-73, wherein the first entanglement station further comprises a plurality of additional entanglement heads coupled to the first actuator.

Clause 75. The entanglement system of clause 74, wherein the plurality of additional entanglement heads coupled to the first actuator are unevenly spaced from one another.

Clause 76. The conveying apparatus of any one of clauses 66-75, further comprising a second entangling station, the second entangling station having a surface adapted to advance the composite nonwoven fabric in the material flow direction. system; a second actuator configured to actuate a second entanglement head coupled to the second actuator; and a second carriage coupled to the second entanglement head and configured to move in a first direction non-parallel to the material flow direction.

Clause 77. The method of clause 76, wherein the first entanglement head is positioned at a first distance inwardly from the first edge of the surface of the delivery system, and the second entanglement head is positioned at a first distance inwardly from the first edge of the surface of the delivery system. An entangled system located at a second distance different from the first distance.

Clause 78. The entanglement system of clause 76 or clause 77, wherein the second entanglement station is located at a location subsequent to the first entanglement station in the material flow direction.

Clause 79. The entanglement system of any of clauses 76-78, wherein the second entanglement station further comprises a plurality of additional entanglement heads coupled to the second actuator.

Clause 80. The entanglement system of clause 79, wherein the spacing arrangement between the plurality of additional entanglement heads coupled to a second actuator is different than the spacing arrangement between the plurality of additional entanglement heads coupled to a first actuator. .

Clause 81. The entanglement system of clause 79 or clause 80, wherein the number of the plurality of additional entanglement heads coupled to the second actuator is different than the number of the plurality of additional entanglement heads coupled to the first actuator.

Clause 82. The entanglement system of any of clauses 76-81, wherein the dimensions of the second entanglement head are different from the dimensions of the first entanglement head.

Clause 83. The entanglement system of any of clauses 76-82, wherein the entanglement footprint created by the second entanglement head is different from the entanglement pattern created by the first entanglement head.

Clause 84. A method of making a nonwoven fabric, comprising: forming a first entanglement region on the nonwoven fabric by causing an entanglement head to engage the nonwoven fabric while the nonwoven fabric is in a first position on an entanglement machine; advancing the nonwoven fabric through the entangling machine in the direction of material flow; moving one or more of the entanglement head and the nonwoven fabric in a first direction non-parallel to the material flow direction; and forming a second entanglement region on the nonwoven fabric by causing the entanglement head to engage the nonwoven fabric while the nonwoven fabric is in a second position advanced from the first position in the material flow direction. , wherein the second entangled region extends from the first entangled region to form a non-linear entangled seam.

Clause 85. The method of clause 84, wherein in each of the first and second entanglement zones, the fibers forming the nonwoven fabric are caused to move from a generally horizontal orientation to a generally vertical orientation.

Clause 86. The method of clause 84 or clause 85, wherein the first entanglement region partially overlaps the second entanglement region.

Clause 87. The method of clause 86, wherein the stitch density in the overlap area between the first entangled region and the second entangled region is greater than the stitch density in the remainder of the first entangled region and the second entangled region.

Clause 88. The method of any one of clauses 84-87, wherein when the nonwoven fabric is in the first position, the entanglement head moves in a direction perpendicular to the surface plane of the nonwoven fabric.

Clause 89. The method of any one of clauses 84-88, wherein subsequent to forming a second entanglement zone, the step of advancing the nonwoven fabric in the direction of material flow; moving one or more of the entanglement head and the nonwoven fabric in a second direction opposite the first direction and not parallel to the material flow direction; and forming a third entanglement region on the nonwoven fabric by causing the entanglement head to engage the nonwoven fabric while the nonwoven fabric is in a third position advanced from the second position in the material flow direction. and a third entangling region extends from the second entangling region to form the non-linear entangled seam.

Clause 90. The method of clause 89, wherein the third entanglement region partially overlaps the second entanglement region.

Clause 91. A garment comprising: a non-woven fabric having a material flow direction; and at least one non-linear intertwined seam extending along the material flow direction, wherein the at least one non-linear intertwined seam comprises one or more entangled regions extending from each other to form the at least one non-linear intertwined seam. and wherein in each of the one or more entanglement zones, the fibers forming the nonwoven fabric have a substantially vertical orientation.

Clause 92. The garment of clause 91, wherein the one or more areas of entanglement comprise separate areas.

Clause 93. The garment of clause 91, wherein the one or more entanglement areas partially overlap one another.

Clause 94. The method of any one of clauses 91-93, further comprising a plurality of additional non-linear intertwined seams, wherein the plurality of additional non-linear intertwined seams form a non-repeating visual arrangement of intertwined seams. cloth.

Clause 95. The garment of any one of clauses 91-94, further comprising one or more additional layers secured to the nonwoven fabric by one or more of intertwining, stitching, bonding, and adhesive.

Clause 96. The garment of clause 95, wherein the one or more additional layers include one or more of a structured fabric, a nonwoven layer, a film, and a filler.

Clause 97. A nonwoven fabric having a material flow direction, comprising at least one non-linear intertwined seam extending along the material flow direction, wherein the at least one non-linear intertwined seam extends from one another to form at least one non-linear intertwined seam. A nonwoven fabric comprising one or more entangled areas forming an entangled seam, wherein in each of the one or more entangled areas, the fibers forming the nonwoven fabric have a generally vertical orientation.

Clause 98. The nonwoven fabric of clause 97, wherein the one or more entanglement areas comprise separate entanglement areas.

Clause 99. The nonwoven fabric of clause 97, wherein the one or more entanglement regions partially overlap one another.

Clause 100. The method of any one of clauses 97-99, further comprising a plurality of additional non-linear intertwined seams, wherein the plurality of additional non-linear intertwined seams form a non-repeating visual arrangement of intertwined seams. Non-woven fabric.

Clause 101. An array of garments having a common finished form, wherein the array of garments is formed from a non-woven fabric having at least a first non-linear intertwined seam and a second non-linear intertwined seam, the array of garments having a first non-linear intertwined seam and a second non-linear intertwined seam. wherein each of the non-linear intertwined seams includes an entanglement region extending from one another to form a respective first non-linear intertwined seam and a second non-linear intertwined seam, wherein the entanglement regions have a generally vertical orientation. An array of garments comprising fibers, comprising: a first garment formed from a first instance of a pattern piece taken from the nonwoven fabric, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location on the first garment. A first garment located at; and a second garment formed from a second instance of the pattern piece taken from the nonwoven fabric, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location on the second garment. and wherein the second location is different from the first location relative to the pattern piece.

Clause 102. The array of garments of clause 101, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the material flow direction.

Clause 103. The array of garments of clause 101 or clause 102, wherein the entanglement regions partially overlap one another.

Clause 104. The method of any one of clauses 101-103, further comprising a third garment formed from a third instance of the pattern piece taken from the nonwoven fabric, the first non-linear intertwined seam and the second non-linear intertwined seam. is located at a third location on the third garment, wherein the third location is different from at least one of the first location and the second location with respect to the pattern piece.

Clause 105. The array of garments of any one of clauses 101-104, wherein the array of garments comprises upper body garments.

Clause 106. The array of garments of any one of clauses 101-104, wherein the array of garments comprises lower body garments.

Clause 107. A method of manufacturing an array of garments having a common finished form, comprising obtaining a nonwoven fabric having at least a first non-linear intertwined seam and a second non-linear intertwined seam, wherein each of the entangled seams includes an entangled region extending from one another to form an apparently continuous, non-linear, entangled seam, wherein the entangled region comprises fibers having a generally vertical orientation; removing a first portion having a first pattern from the nonwoven fabric, the first portion having a first non-linear intertwined seam and a second non-linear intertwined seam; forming a first garment using the first portion, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location on the first portion; removing a second portion having a first pattern from the nonwoven fabric, the second portion having a first non-linear intertwined seam and a second non-linear intertwined seam; and forming a second garment using the second portion, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location on the second portion that is different from the first location. How to.

Clause 108. The method of clause 107, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the material flow direction.

Clause 109. The method of clause 108, wherein the distance between the first non-linear intertwined seam and the second non-linear intertwined seam varies depending on the material flow direction, and the distance between the first non-linear intertwined seam and the second non-linear intertwined seam is A method wherein measurements are made in a direction that is not parallel to the material flow direction.

Clause 110. The method of any one of clauses 107-109, wherein the first non-linear intertwined seam and the second non-linear intertwined seam comprise different visual arrangements of the intertwined seams.

Clause 111. The method of any one of clauses 107-110, wherein the entanglement regions partially overlap each other.

Clause 112. The method of any one of clauses 107-111, wherein the array of garments comprises upper body garments.

Clause 113. The method of any one of clauses 107-111, wherein the array of garments comprises lower body garments.

Clause 114. An array of garments having a common finished form, wherein the array of garments is formed from a non-woven fabric having at least a first non-linear intertwined seam and a second non-linear intertwined seam, the array of garments having a first non-linear intertwined seam and a second non-linear intertwined seam. Each of the non-linear intertwined seams includes entanglement regions extending from one another to form a respective first non-linear intertwined seam and a second non-linear intertwined seam, wherein in each of the entanglement regions, the fibers forming the non-woven fabric are generally An array of garments having a vertical orientation, comprising: a first garment formed from a first portion of the nonwoven fabric having a first pattern, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are a first garment positioned in a first position on the portion; and a second garment formed from the second portion of the nonwoven fabric having a first pattern, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location on the second portion of the second garment. An array of garments comprising a second garment, wherein the second location is different from the first location.

Clause 115. The array of garments of clause 114, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the material flow direction.

Clause 116. The method of clause 115, wherein the distance between the first non-linear intertwined seam and the second non-linear intertwined seam varies depending on the material flow direction, and the distance between the first non-linear intertwined seam and the second non-linear intertwined seam is An array of garments wherein measurements are taken in a direction other than parallel to the direction of material flow.

Clause 117. The array of garments according to any one of clauses 114-116, wherein the first non-linear intertwined seam and the second non-linear intertwined seam comprise different visual arrangements of the intertwined seams.

Clause 118. The array of garments according to any one of clauses 114-117, wherein the entanglement regions partially overlap one another.

Clause 119. The array of garments of any of clauses 114-118, wherein the array of garments comprises upper body garments.

Clause 120. The array of garments of any one of clauses 114-118, wherein the array of garments comprises lower body garments.

Aspects of the present disclosure have been described in an illustrative rather than restrictive sense. Alternative embodiments without departing from the scope will be apparent to those skilled in the art. Those skilled in the art may develop alternative means of implementing the foregoing improvements without departing from the scope of the present disclosure.

It will be understood that certain features and sub-combinations are useful and may be employed without reference to other features and sub-combinations and are considered within the scope of the claims. It is not necessary to perform all steps listed in the various figures in the specific order described.

Claims (19)

A method of manufacturing an array of garments having a common finished form, comprising:
Obtaining a composite nonwoven fabric comprising a first nonwoven layer, a second layer, and a filler positioned between the first nonwoven layer and the second layer, the composite nonwoven fabric having at least a first nonlinear intertwined seam and a second nonlinear wherein the first non-linear intertwined seam and the second non-linear intertwined seam each include an entangled region extending from the other to form an apparently continuous non-linear intertwined seam, the entangled region comprising the filler comprising fibers from the first nonwoven layer extending through and into the second layer;
removing a first instance of a pattern piece having a first non-linear intertwined seam and a second non-linear intertwined seam from the composite nonwoven fabric;
forming a first garment using the first instance of the pattern piece, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location of the pattern piece;
removing a second instance of the pattern piece having a first non-linear intertwined seam and a second non-linear intertwined seam from the composite nonwoven fabric; and
forming a second garment using the second instance of the pattern piece, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location different from the first location of the pattern piece. step
How to include . The method of claim 1, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the material flow direction. The method of claim 1, wherein the entanglement regions partially overlap one another. According to paragraph 1,
removing a third instance of the pattern piece having a first non-linear intertwined seam and a second non-linear intertwined seam from the composite nonwoven fabric; and
forming a third garment using the third instance of the pattern piece, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are at a second position of the pattern piece that is different from at least one of the first location and the second location. Step 3: Being placed in position
How to include more. 2. The method of claim 1, wherein the array of garments comprises upper body garments. 2. The method of claim 1, wherein the array of garments includes lower body garments. An array of garments having a common finished form,
The array of garments is formed from a composite non-woven fabric comprising a first non-woven layer, a second layer, and filler positioned between the first non-woven layer and the second layer, the composite non-woven fabric having at least a first non-linear intertwined seam and an entanglement region comprising a second non-linear intertwined seam, each of the first non-linear intertwined seam and the second non-linear intertwined seam extending from the other to form a respective first non-linear intertwined seam and a second non-linear intertwined seam; wherein the entanglement region includes fibers from the first nonwoven layer extending through the filler material and into the second layer, the array of garments comprising:
a first garment formed from a first instance of a pattern piece taken from the composite nonwoven fabric, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location on the first garment; and
A second garment formed from a second instance of a pattern piece taken from the composite nonwoven fabric, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location on the second garment. and wherein the second position is different from the first position relative to the pattern piece. 8. The array of garments of claim 7, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the direction of material flow. 8. The array of garments of claim 7, wherein the entanglement regions partially overlap one another. 8. The method of claim 7, further comprising a third garment formed from a third instance of the pattern piece taken from the composite nonwoven fabric, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a third location on the third garment. and wherein the third position is different from at least one of the first position and the second position relative to the pattern piece. 8. The array of garments of claim 7, wherein the array of garments comprises upper body garments. 8. The array of garments of claim 7, wherein the array of garments includes lower body garments. An array of garments having a common finish, comprising:
The array of garments is formed from a composite non-woven fabric comprising a first non-woven layer, a second layer, and filler positioned between the first non-woven layer and the second layer, the composite non-woven fabric having at least a first non-linear intertwined seam and an entanglement region comprising a second non-linear intertwined seam, each of the first non-linear intertwined seam and the second non-linear intertwined seam extending from the other to form a respective first non-linear intertwined seam and a second non-linear intertwined seam; wherein the entanglement region includes fibers from the first nonwoven layer extending through the filler material and into the second layer, the array of garments comprising:
A first garment formed from a first portion of the composite nonwoven fabric having a first pattern, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a first location on the first portion of the first garment. first garment; and
A second garment formed from a second portion of said composite nonwoven fabric having a first pattern, wherein the first non-linear intertwined seam and the second non-linear intertwined seam are located at a second location on the second portion of the second garment. An array of garments comprising a second garment, wherein the second location is different from the first location. 14. The array of garments of claim 13, wherein the first non-linear intertwined seam and the second non-linear intertwined seam each extend in the direction of material flow. 15. The method of claim 14, wherein the distance between the first non-linear intertwined seam and the second non-linear intertwined seam varies depending on the material flow direction, and the distance between the first non-linear intertwined seam and the second non-linear intertwined seam is An array of garments that is measured in a direction other than parallel to the direction of flow. 14. The array of garments of claim 13, wherein the first non-linear intertwined seam and the second non-linear intertwined seam comprise different visual arrangements of intertwined seams. 14. The array of garments of claim 13, wherein the entanglement regions partially overlap one another. 14. The array of garments of claim 13, wherein the array of garments comprises an upper body garment. 14. The array of garments of claim 13, wherein the array of garments includes lower body garments.