FLEXIBLE AND ELASTIC COMPOSITE NONWOVEN TEXTILE FOR WEARABLE ARTICLES AND METHODS OF MAKING THE SAME

CROSS REFERENCE TO RELATED APPLICATIONS

[0001]This application claims the priority benefit of U.S. Ser. No. 63/727,995 (filed Dec. 4, 2024), which is hereby incorporate herein by reference in its entirety.

BACKGROUND

[0002]Composite textiles can include multiple layers, such as fiber webs, other nonwoven layers (e.g., spunbond, meltblown, etc.), knit layers, woven layers, films, coatings, and the like. Various techniques can be used to join the different layers. Often, the composite textile can include properties that are enhanced as compared to the independent individual layers.

DETAILED DESCRIPTION OF DRAWINGS

[0003]The present systems and methods for a composite textile are described in detail below with reference to these figures described below.

[0004]FIG. 1 depicts a composite textile that can be used to construct at least part of various wearable articles, based on examples of this disclosure.

[0005]FIG. 2 depicts an enlarged view of a composite textile, based on examples of this disclosure.

[0006]FIG. 3 depicts operations that can be executed to construct a composite textile, based on examples of this disclosure.

[0007]FIG. 4 depicts a schematic of points of entanglement, based on examples of this disclosure.

[0008]FIG. 5 depicts a surface having macro undulations, based on examples of the present disclosure.

DETAILED DESCRIPTION

[0009]This detailed description is related to a composite textile that includes one or more nonwoven fiber webs (e.g., with asa fibers) joined to one or more functional layers (e.g., nonwoven layer with elastomeric continuous filaments). In at least some examples, the layers are joined by fiber plugs, which include bundles of staple-fiber portions extending through (and at least frictionally retained within) openings (e.g., needle-penetration openings) within the composite textile. In addition, the fiber plugs can have varied properties that are collectively optimized to impart desired systematic or overall properties (e.g., stretch properties) to the composite textile. For example, the fiber plugs can include different numbers of fibers and can be anchored at different depths within the composite textile, which can be varied to achieve desired overall properties.

[0010]Nonwoven textiles (e.g., nonwoven composite textiles) can include various advantages, such as capable of being manufactured in relative large quantities while using less energy and/or other resources. Some conventional nonwoven textiles include properties that are less conducive for use in lighter weight garments, such as basis weight, breathability, drape, bursting strength, and wicking properties.

[0011]In contrast to conventional nonwoven textiles, a composite textile of the present disclosure can include one or more nonwoven fiber webs (e.g., with staple fibers) joined to one or more functional layers (e.g., nonwoven layer with elastomeric continuous filaments), and the composite textile can include a set of properties conducive for use in lighter weight garments. For example, a composite textile of the present disclosure can be used as the only textile constructing the garment (or a portion of the garment), such that the composite textile includes both the innermost-facing surface and the outermost-facing surface. Stated differently, the composite textile might be used to construct the garment without any additional lining layer(s) or external layer(s).

[0012]In examples, some properties of the composite textile that are conducive for use as a garment can include (independently or in combination) a basis weight, elasticity and other stretch properties, breathability, drape or flexibility, bursting strength, pilling strength or resistance, wicking ability, and the like.

[0013]In examples, various elements of the composite textile can contribute to the collection of properties rendering the composite textile suitable for use in a garment, including a lightweight garment. In at least some examples, the composite textile can include a single fiber web joined to a continuous filament web, and each of the constituent layers can include respective basis weights that contribute to a desired overall basis weight.

[0014]In at least some examples, the layers (e.g., constituent layers) can include fibers with denier or fiber diameter that contribute to a desired amount of coverage (e.g., lower likelihood of transparency) at lower overall basis weights.

[0015]In at least some examples, the layers (e.g., constituent layers with lower basis weights) are joined by fiber plugs with varied properties, which are optimized to impart one or more desired properties to the composite textile. For example, the fiber plugs can include different numbers of fibers, different depths, and different ratios on one face as compared to the other face.

[0016]Having described at least some examples associated with the present disclosure, definitions are provided directly below related to those examples (and other examples described in other parts of this disclosure). These definitions can also include subject matter that can be claimed.

[0017]As used in this disclosure the terms “filament,” “fiber,” or “fibers” refer to materials or structures that are in the form of discrete elongated pieces that are significantly longer than they are wide. A fiber can include natural, manmade or synthetic fibers. The fibers may be produced by conventional techniques, such as extrusion, electrospinning, interfacial polymerization, pulling, and the like.

[0018]Fibers can include carbon fibers, boron fibers, silicon carbide fibers, titania fibers, alumina fibers, quartz fibers, glass fibers, such as E, A, C, ECR, R, S, D, and NE glasses and quartz, or the like. The fibers can be fibers formed from synthetic polymers capable of forming fibers such as poly(ether ketone), polyimide, polybenzoxazole, poly(phenylene sulfide), polyesters (e.g., polyethylene terephthalate (PET)), polyolefins (e.g., polyethylene, polypropylene), aromatic polyamides (e.g., an aramid polymer such as para-aramid fibers and meta-aramid fibers), aromatic polyimides, polybenzimidazoles, polyetherimides, polytetrafluoroethylene, acrylic, modacrylic, poly(vinyl alcohol), polyamides, polyurethanes, and copolymers such as polyether-polyurea copolymers, polyester-polyurethanes, polyether block amide copolymers, or the like. The fibers can be natural fibers (e.g., silk, wool, cashmere, vicuna, cotton, flax, hemp, jute, sisal). The fibers can be man-made fibers from regenerated natural polymers, such as rayon, lyocell, acetate, triacetate, rubber, and poly(lactic acid). The fibers can include organic polymers. The fibers can include inorganic material fibers.

[0019]The fibers may include virgin fibers (fibers that have not been recycled), and/or recycled fibers. Recycled fibers include “shredded-article fibers” and “re-pelletized-polymer fibers.” As used herein, shredded-article fibers include fibers that are direct by-products of shredding a fiber-containing article (e.g., knit, woven, nonwoven, etc.). In some examples, shredded-article fibers may be derived without pelletizing and extrusion through processes that consume less energy, and as such, textiles that incorporate shredded-article fibers may have a lower carbon footprint. Re-pelletized-polymer fibers include fibers that are extruded from pelletized or chipped by-products derived from polymer-containing sources (e.g., polymer-containing bottles or containers; polymer-fiber articles that are knit, woven, nonwoven; roll goods; textile manufacturing scrap; fiber webs at various stages of carding, lapping, pre-needling, and needling; etc.).

[0020]Fibers can have an indefinite length. For example, man-made and synthetic fibers are generally extruded in substantially continuous strands. Alternatively, the fibers can be staple fibers, such as, for example, cotton fibers or extruded synthetic polymer fibers can be cut to form staple fibers of relatively uniform length. The staple fiber can have a have a length of about 1 millimeter to 100 millimeters or more as well as any increment therein (e.g., 1 millimeter increments). In some examples, the length is between 30 mm and 60 mm. In some examples, the length is about 38 mm. In some examples, the length is about 51 mm.

[0021]A fiber can have any of a variety of cross-sectional shapes. Natural fibers can have a natural cross-section, or can have a modified cross-sectional shape (e.g., with processes such as mercerization). Man-made or synthetic fibers can be extruded to provide a strand having a predetermined cross-sectional shape. The cross-sectional shape of a fiber can affect its properties, such as its softness, luster, and wicking ability. The fibers can have round or essentially round cross sections. Alternatively, the fibers can have non-round cross sections, such as flat, oval, octagonal, rectangular, wedge-shaped, triangular, Y-shape, dog-bone, X-shape, clover shape, star shape, penta-lobal, other multi-lobal, multi-channel, saucer shape, serrated, hollow, core-shell, or other shapes.

[0022]Examples of the present disclosure can include “wicking fibers.” In some examples, a wicking fiber can include a fiber with a non-round cross section with surface features (e.g., grooves) that can move moisture via capillary action (e.g., along the fiber surface and/or in combination with an adjacent fiber). Examples of cross-sections that can impart and/or contribute to wicking can include, but are not limited to, flat, ribbon, rectangular, Y-shape, X-shape, star-shape, other multi-lobal, dog-bone shape, saucer shape, clover-shape, multi-channel surface, bean shape, and the like. In some examples, a wicking fiber can include a fiber with a wicking surface finish or other wicking treatment, such as fibers by Unifi Manufacturing, Inc. under the brand name Sorbtek. In some examples, wicking fibers are fibers that, based on AATCC 197, achieve 15 cm<30 minutes after three launderings. In some instances, a fiber is wicking based on it being more hydrophilic than another fiber in a same composite textile or in a fiber blend for a nonwoven textile.

[0023]Fibers can be processed. For example, the properties of fibers can be affected, at least in part, by processes such as drawing (stretching) the fibers, annealing (hardening) the fibers, and/or crimping or texturizing the fibers.

[0024]A fiber can be a multi-component fiber, such as one comprising two or more co-extruded polymeric materials. The two or more co-extruded polymeric materials can be extruded in a core sheath, islands-in-the-sea, segmented-pie, striped, or side-by-side configuration. A multi-component fiber can be processed in order to form a plurality of smaller fibers (e.g., microfibers) from a single fiber, for example, by remove a sacrificial material or by splitting via entanglement operations.

[0025]As used herein, the term “yarn” refers to an assembly formed of one or more fibers, wherein the strand has a substantial length and a relatively small cross-section, and is suitable for use in the production of textiles by hand or by machine, including textiles made using weaving, knitting, crocheting, braiding, sewing, embroidery, or ropemaking techniques. Thread is a type of yarn commonly used for sewing.

[0026]When referring to fibers, the term denier or denier per fiber is a unit of measure for the linear mass density of the fiber and more particularly, it is the mass in grams per 9000 meters of the fiber. In one example aspect, the denier of a fiber may be measured using ASTM D1577-07. The dtex of a fiber is the mass of an individual fiber in grams per 10,000 meter of fiber length. The diameter of a fiber may be calculated based on the fiber's denier and/or the fiber's dtex. For instance, the fiber diameter, d, in millimeters may be calculated using the formula: d=square root of dtex divided by 100. In general, the diameter of a fiber has a direct correlation to the denier of the fiber (i.e., a smaller denier fiber has a smaller diameter).

[0027]Fibers and/or yarns can be manipulated in various manners to construct a textile, such as through knitting, weaving, braiding, and nonwoven techniques. As used herein, a textile or textile layer can include knits, wovens, nonwovens, braids, and films (e.g., extruded films).

[0028]As used herein, the term “nonwoven textile” refers to a textile having fibers that are held together by mechanical and/or chemical interactions (e.g., formed using heat, solvent, adhesive, and any combination thereof) and typically without being in the form of a knit, woven, braided construction, or other structured construction. In a particular aspect, the nonwoven textile includes a collection of fibers that are mechanically manipulated to form a mat-like material. Stated differently nonwoven textiles are directly made from fibers. The nonwoven textile may include different webs of fibers formed into a cohesive structure, where the different webs of fibers may have a different or similar composition of fibers and/or different properties. Non-limiting examples of nonwoven textiles can include staple-fiber nonwovens (e.g., formed by carding and needle entanglement or fluid entanglement), spunbond nonwovens, spunlace nonwovens, and melt-blown nonwovens. Stated differently, bonding of the fibers in the nonwoven textile can be achieved with thermal bonding (with or without calendering), fluid-entanglement (e.g., hydro or air), ultrasonic bonding, needlepunching (needlefelting), chemical bonding (e.g., using binders such as latex emulsions or solution polymers or binder fibers or powders), meltblown bonding (e.g., fiber is bonded as air attenuated fibers intertangle during simultaneous fiber and web formation), spun-bond, and any combination thereof.

[0029]As used in this disclosure, the term “web of fibers” or “fiber web” refers to a layer of fibers prior to undergoing a mechanical entanglement process with one or more other webs of fibers or textiles (e.g., other knit, woven, nonwoven, or braided textile). The web of fibers can include fibers (e.g., staple fibers) that have undergone a carding and lapping process that generally aligns the fibers in one or more common directions that extend along an x, y plane and that achieves a desired basis weight. The web of fibers may also undergo a light needling process or mechanical entanglement process that entangles the fibers of the web to a degree such that the web of fibers forms a cohesive structure that can be manipulated (e.g., rolled on to a roller, un-rolled from the roller, stacked, and the like). In examples, a “fiber-web roll good” refers to fibers that have been formed into a cohesive structure (e.g., by carding, lapping, and/or light needling) and rolled onto a core. The web of fibers may also undergo one or more additional processing steps such as printing prior to being entangled with other webs of fibers to form the composite nonwoven textile.

[0030]As used herein, the term “entangled web of fibers” when referring to a composite textile refers to a web of fibers after it has undergone mechanical entanglement (e.g., needle entanglement, fluid entanglement (e.g., water entangled, air entangled), etc.) with one or more other material layers (e.g., fiber web, continuous filament web, knit textile, woven textile, etc.). As such, a web of entangled fibers may include fibers originally present in the web of fibers forming the layer as well as fibers that are present in other webs of fibers or textiles that have been moved through the entanglement process into the web of entangled fibers. An entangled web of fibers can also be referred to as an “entangled fiber web.” In addition, an entangled web of fibers can also be referred to as a “fiber-web constituent layer,” based on the fiber web being a part, layer, substratum, etc. of a composite textile formed at least in part by the post-entangled layers. Similarly, any layer within a composite textile can be referred to as a “constituent layer,” which can indicate that the layer has been combined as a part, layer, substratum, etc. of the composite textile and that at least some of the material included in the layer might still be present as a component of the given stratum.

[0031]Mechanical entanglement processes contemplated herein can include needle entanglement (commonly known as needlepunching) using barbed or structured needles (e.g., forked needles), and/or fluid entanglement (via jetted water or air). In aspects contemplated herein, needlepunching may be utilized based on the small denier of the fibers being used and the ability to fine tune different parameters associated with the needlepunching process. Needlepunching generally uses barbed or spiked needles to reposition a percentage of fibers from a generally horizontal orientation (an orientation extending along an x, y plane) to a generally vertical orientation (a z-direction orientation). Referring to the needlepunching process in general, the carded, lapped, and pre-needled webs may be stacked with other carded, lapped, and pre-needled webs and other layers such as a functional layer (e.g., elastomeric layer) and/or other textiles, and passed between a bed plate and a stripper plate positioned on opposing sides of the stacked web configuration.

[0032]Barbed needles, which are fixed to a needle board, pass in and out through the stacked web configuration, and the stripper plate strips the fibers from the needles after the needles have moved in and out of the stacked web configuration. The distance between the stripper plate and the bed plate may be adjusted to control web compression during needling. The needle board repeatedly engages and disengages from the stacked web configuration as the stacked web configuration is moved in a machine direction along a conveyance system such that the length of the stacked web configuration is needled.

[0033]Aspects herein contemplate using multiple needle boards sequentially positioned at different points along the conveyance system where different needle boards may engage the stacked web configuration from different faces of the stacked web configuration (e.g., an upper face and a lower face) as the stacked web configuration moves in the machine direction. Each engagement of a needle board with the stacked web configuration is known herein as a “pass.”

[0034]Parameters associated with particular needle boards may be adjusted to achieve desired properties of the resulting needled nonwoven textile (e.g., basis weight, thickness, and the like). The different parameters may include stitch density (SD) which is the number of needles per cm² (n/cm²) used during an entanglement pass and penetration depth (PD) which is how far the needle passes through the stacked web configuration before being pulled out of the stacked web configuration. Parameters associated with the needlepunching process in general may also be adjusted such as the spacing between the bed plate and the stripper plate and/or the speed of conveyance of the stacked web configuration.

[0035]Examples of this disclosure contemplate using a barbed needle (a needle having a pre-set number of barbs arranged along a length of the needle) although other needle types are contemplated herein. The barbs on the needle “capture” fibers as the barb moves from a first face to an opposing second face of the stacked web configuration. The movement of the needle through the stacked web configuration effectively moves or pushes fibers captured by the barbs from a location near or at the first face to a location near or at the second face and further causes physical interactions with other fibers helping to “lock” the moved fibers into place through, for example, friction.

[0036]It is also contemplated herein that the needles may pass through the stacked web configuration from the second face toward the first face. In example aspects, the number of barbs on the needle that interact with fibers may be based on the penetration depth of the needle. For example, all the barbs may interact with fibers when the penetration depth is a first amount, and fewer than all the barbs may interact with fibers as the penetration depth decreases.

[0037]In further example aspects, the size of the barb may be adjusted based on the denier of fibers used in the web(s). For example, the barb size may be selected so as to engage with small denier (e.g. fine) fibers but not with large denier fibers so as to cause selective movement of the small denier fibers but not the large denier fibers. In another example, the barb size may be selected so as to engage with both small denier and large denier fibers so as to cause movements of both fibers through the webs.

[0038]After entanglement, the nonwoven textile may include a first face and an opposite second face which both face outward with respect to an interior of the nonwoven textile and comprise the outermost faces of the nonwoven textile. As such, when viewing the nonwoven textile, the first face and the second face are each fully visible. The first face and the second face may both extend along x, y planes that are generally parallel and offset from each other. For instance, the first face may be oriented in a first x, y plane and the second face may be oriented in a second x, y plane generally parallel to and offset from the first x, y plane.

[0039]The term “functional layer” as used herein refers to a layer of material that can be combined with a textile layer (e.g., knit, woven, nonwoven, braided, etc.) to form a composite textile having one or more properties different than the textile layer alone. The functional layer can include various forms, such as a textile (e.g., knit, woven, nonwoven, braided, etc.) or a film.

[0040]The functional layer can be combined with, or bonded to, the textile layer in various manners. For example, the functional layer can be bonded via mechanical bonding, thermal bonding, and chemical bonding. An example of a mechanical bond can include fiber entanglement or some adhesives. An example of a thermal bond can include part of the textile layer and/or part of the functional layer being heated to at least a softening point and resolidifying after mixing with, or flowing around, the other layer. In some examples, thermal bonding can include via a hot melt film. In some examples, chemical bonding can include via an adhesive. Functional layers can be used to affect, or impart, various properties to the composite, such as elasticity (e.g., stretch and recovery), stability (e.g., the ability to stretch without breaking), abrasion resistance, water resistance, water repellency, water proofness, etc.

[0041]The term “elastomeric layer” as used herein refers to a functional layer that has stretch and recovery properties (e.g., is elastically resilient) in at least one orientational axis, which includes both a layer having stretch and recovery in a single orientational axis and a layer having stretch and recovery in multiple orientational axes. Examples of an orientational axis include a length direction, a width direction, an x-direction, a y-direction, and any direction angularly offset from a length direction, a width direction, an x-direction, and a y-direction. In some examples, a functional layer can include an elastomeric layer and can also impart other properties to the composite.

[0042]The elastomeric layer may be formed from thermoplastic polymers, such as thermoplastic elastomers (TPE). Examples of thermoplastic elastomers can include thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), combinations of TPU and TPEE and the like. Other examples of thermoplastic elastomers can include styrene block copolymers (TPE-S), thermoplastic polyolefins (TPO), thermoplastic vulcanisates (TPV), and melt processable rubber (MPR), thermoplastic polyether block amides (TPE-A). The elastomeric layer may comprise a spunbond layer, a meltblown layer, a film, a web, a scrim, and the like.

[0043]In example aspects, the elastomeric layer may include a nonwoven layer that is spunbond, meltblown, and the like. These elastomeric layers that are nonwoven can be referred to as “continuous filament webs,” in contrast to “fiber webs” that might include shorter staple fibers. In some examples, the elastomeric layer can include a spunbond TPEE or a meltblown TPU or a spunbond TPU. In some examples, the spunbond or meltblown continuous filament web can include a blend of a more elastomeric material (e.g., TPU, TPEE, etc.) and a less elastomeric material (e.g., polyester). For example, a more elastomeric material (e.g., TPU, TPEE, etc.) can be introduced via first nozzles and a less elastomeric material (e.g., polyester or polyamide) can be introduced via second nozzles. In some examples, nonwoven elastomeric materials such as a spunbond TPEE or a meltblown TPU or spunbond TPU allow for lower basis weights than elastomeric films. As well, they are generally more breathable and permeable due to the fibrous nature of the web versus a film, and they are generally more pliable (e.g., less stiff) than films. These factors (low basis weight, breathable and permeable, pliable) make them ideal for use in the example composite nonwoven textile described herein especially in the apparel context where these are desirable features.

[0044]In some examples, the elastomeric layer can include a fiber web that includes fibers (e.g., staple fibers) that compositionally comprise an elastomer, such as TPU or TPEE. For example, the fiber-web elastomeric layer can be carded and pre-needled prior to being bonded to one or more other fiber webs.

[0045]In some examples, the elastomeric layer can include a blend of continuous-length filaments (e.g., sometimes called infinite length) and staple fibers.

[0046]The term “composite textile” refers to a fabric that includes two or more different textile or material layers (e.g., a fiber web and a functional layer) that are joined into a material with enhanced properties. The layers can include various types of textiles, including knit, woven, nonwoven, braided, films, and the like. The layers can include coatings, sprays, prints, extrusions, and other depositions. The layers can be joined by various techniques and structures, such as laminating, coating, extrusion, interweaving, interknitting, entanglement (e.g., fluid and/or needle), and the like. In some examples, a composite textile can include one or more constituent layers. A constituent layer is a material layer within the composite textile. In some examples, a constituent layer can include properties or characteristics that are different from other constituent layers, while still existing as a part of the overall composite textile.

[0047]The term “unit area” can describe a portion of a textile used to assess properties of the textile. In some examples, a unit area can include a 1 cm×1 cm (1 cm²), although other sizes can be used, as necessary or dictated based on the property to be assessed. In some examples, a “unit volume” can be used to assess properties of a textile, and a unit volume can include a 1 cm×1 cm×n, where n is a depth or thickness associated with the textile. In some examples, n is the entire thickness of the textile or is the thickness of a layer within the textile (e.g., the thickness of a fiber web within the textile). Other dimensions of unit volumes can also be used, as necessary or dictated based on the property to be assessed.

[0048]The term “homogeneous,” as used herein, can describe a fiber and can describe a set of fibers and refers to the quality of having relatively uniform properties. The term “homogeneity” refers to the degree to which a fiber or a set of fibers is homogeneous. Homogeneity can be used to describe a fiber or a fiber web at various stages of processing (e.g., entanglement), such as when the fiber or fiber webs are carded, lapped, pre-needled, entangled with other fiber webs, in a composite nonwoven textile, in a multi-layer pattern piece, in a fiber-web remnant, shredded, re-extruded, and the like. Homogeneity can be based on one or more properties, such as fiber length, denier, diameter, color properties, and chemical composition. Homogeneity can be measured in various manners. In one example, homogeneity can be based on measurements applied to a single fiber. In some examples, homogeneity can describe a blend of fibers (e.g., a homogenous blend of fibers). In one example, homogeneity can be based on a unit area or unit volume of a fiber web.

[0049]Homogeneity can be measured in various manners, which can depend on what property is being measured. For example, homogeneity can be determined by analyzing the fibers within a unit area or unit volume to measure one or more properties (e.g., denier, diameter, shape, length, color property, chemical composition, etc.) of the fibers and determining what percentage of fibers include a common property. In some examples, material composition can be based on one or more various known methods of chemical analysis, and homogeneity can be based on what percentage of material within a unit area includes a common chemical composition. Color property can be determined as described in other parts of this disclosure.

[0050]In at least some examples, homogeneity (e.g., a degree or relative amount of homogeneity) can be determined based on an average measured parameter in n number of regions of interest (ROI) having a standard deviation equal to, or less than, “X” units of the average value. In some examples, a property can be considered homogenous when the standard deviation is 5.0 or less and can be considered highly homogenous when the standard deviation is 1.0 or less. In at least some examples, can be at least three or more.

[0051]For example, if within a textile (e.g., fiber web, composite nonwoven textile, etc.) four ROIs have a basis weight of 84, 87, 87, and 88, then the average basis weight is 86.5 and the standard deviation is 1.73. In examples, in which homogenous is based on a standard deviation of 5.0 or less, the textile can be deemed homogenous based on basis weight. If the basis weights were 84, 85, 85, and 86, then the average basis weight would be 85, the standard deviation would be 0.82, and where a standard deviation of 1.0 or less indicates highly homogenous, then the textile could be deemed highly homogenous with respect to basis weight.

[0052]The term “color” or “color property” as used herein when referring to the nonwoven textile generally refers to an observable color of fibers that form the textile. Such aspects contemplate that a color may be any color that may be afforded to fibers using dyes, pigments, and/or colorants that are known in the art. As such, fibers may be configured to have a color including, but not limited to red, orange, yellow, green, blue, indigo, violet, white, black, and shades thereof. In one example aspect, the color may be imparted to the fiber when the fiber is formed (commonly known as dope dyeing). In dope dyeing, the color is added to the fiber as it is being extruded such that the color is integral to the fiber and is not added to the fiber in a post-formation step (e.g., through a piece dyeing step). In some examples, a dye or a pigment can be applied to a fiber web via one or more various printing processes, such as screen printing, ink jet printing, sublimation, CO2 dyeing, heat transfer, heat/press printing, and the like.

[0053]Aspects related to a color further contemplate determining if one color is different from another color. In these aspects, a color may comprise a numerical color value, which may be determined by using instruments that objectively measure and/or calculate color values of a color of an object by standardizing and/or quantifying factors that may affect a perception of a color. Such instruments include, but are not limited to spectroradiometers, spectrophotometers, and the like. Thus, aspects herein contemplate that a “color” of a textile provided by fibers may comprise a numerical color value that is measured and/or calculated using spectroradiometers and/or spectrophotometers. Moreover, numerical color values may be associated with a color space or color model, which is a specific organization of colors that provides color representations for numerical color values, and thus, each numerical color value corresponds to a singular color represented in the color space or color model.

[0054]In these aspects, a color may be determined to be different from another color if a numerical color value of each color differs. Such a determination may be made by measuring and/or calculating a numerical color value of, for instance, a first textile having a first color with a spectroradiometer or a spectrophotometer, measuring and/or calculating a numerical color value of a second textile having a second color with the same instrument (i.e., if a spectrophotometer was used to measure the numerical color value of the first color, then a spectrophotometer is used to measure the numerical color value of the second color), and comparing the numerical color value of the first color with the numerical color value of the second color. In another example, the determination may be made by measuring and/or calculating a numerical color value of a first area of a textile with a spectroradiometer or a spectrophotometer, measuring and/or calculating a numerical color value of a second area of the textile having a second color with the same instrument, and comparing the numerical color value of the first color with the numerical color value of the second color. If the numerical color values are not equal, then the first color or the first color property is different than the second color or the second color property, and vice versa.

[0055]Further, it is also contemplated that a visual distinction between two colors may correlate with a percentage difference between the numerical color values of the first color and the second color, and the visual distinction will be greater as the percentage difference between the color values increases. Moreover, a visual distinction may be based on a comparison between colors representations of the color values in a color space or model. For instance, when a first color has a numerical color value that corresponds to a represented color that is black or navy and a second color has a numerical color value that corresponds to a represented color that is red or yellow, a visual distinction between the first color and the second color is greater than a visual distinction between a first color with a represented color that is red and a second color with a represented color that is yellow.

[0056]The term “pill” or “pilling” as used herein refers to the formation of small balls of fibers or fibers ends on a facing side of the nonwoven textile. The pill may extend away from a surface plane of the face. Pills are generally formed during normal wash and wear due to forces (e.g., abrasion forces) that cause the fiber ends to migrate through the face of the nonwoven textile and entangle with other fiber ends. A textile's resistance to pilling may be measured using standardized tests such as Random Tumble and Martindale Pilling tests. The term “pile” as used herein generally refers to a raised surface or nap of a textile consisting of upright loops and/or terminal ends of fibers that extend from a face of the textile in a common direction.

[0057]Various measurements are provided herein with respect to both the joined layers and the resulting composite nonwoven textile. Thickness of the resulting composite nonwoven may be measured using a precision thickness gauge. To measure thickness, for example, the textile may be positioned on a flat anvil and a pressure foot is pressed on to it from the upper surface under a standard fixed load. A dial indicator on the precision thickness gauge gives an indication of the thickness in mm.

[0058]In at least some examples, a textile of the present disclosure can include desired basis weight, which can be assessed via ISO3801 (e.g., method 5) testing standard and has the units grams per square meter (gsm).

[0059]In at least some examples, a textile of the present disclosure can include desired textile stiffness, which generally corresponds to drape, and can be assessed using ASTMD4032 (2008) testing standard and has the units kilogram force (Kgf).

[0060]Fabric growth and recovery can be measured using ASTM2594 testing standard and is expressed as a percentage.

[0061]The term “stretch” as used herein means a textile characteristic measured as an increase of a specified distance under a prescribed tension and is generally expressed as a percentage of the original benchmark distance (i.e., the resting length or width). In at least some examples, a textile of the present disclosure can include desired stretch property, which can be assessed using ASTM D2594 (e.g., loop and 5 lb weight). In some examples, textiles of this disclosure can include a minimum stretch of 20% in the length and 20% in the width. In some examples, the textiles can include a minimum stretch of less than 20% in the length and less than 20% in the width.

[0062]The term “growth” as used herein means an increase in distance of a specified benchmark (i.e., the resting length or width) after extension to a prescribed tension for a time interval followed by the release of tension and is usually expressed as a percentage of the original benchmark distance.

[0063]“Recovery” as used herein means the ability of a textile to return to its original benchmark distance (i.e., its resting length or width) and is expressed as a percentage of the original benchmark distance. In at least some examples, a textile of the present disclosure can include desired recovery property, which can be assessed using ASTM D2594 (e.g., loop and 5 lb weight). In some examples of this disclosure, the textile can recover, in its length, to at least 110% (e.g., 10% greater than the resting length) within 60 seconds after stretched by 15%. In some examples, the textile can recover, in its length, to at least 105% (e.g., 5% greater than the resting length) within 1 hour after being stretched by 15%. In some examples, the textile can recover, in its width, to at least 120% (e.g., 20% greater than the resting width) within 60 seconds after stretched by 30%. In some examples, the textile can recover, in its width, to 110% (e.g., 10% greater than the resting width) within 1 hour after being stretched by 30%. In examples, the textile can recover to a lesser extent or to a greater extent than these example percentages.

[0064]In at least some examples, a textile of the present disclosure can include desired thermal resistance (e.g., generally corresponding to insulation features), which can be measured using ISO11092 testing standard and has the units of RCT (M²*K/W).

[0065]Wicking describes the ability of a structure (e.g., fiber, yarn, or textile) to transport liquid (e.g., water, sweat, etc.) from one position or location to another position or location. In some instances, a structure can transport liquid via pores, capillaries, or interstices due to capillary action, surface tension, or other molecular forces. In the context of a textile, wicking can be associated with absorbing moisture that is close to the wearer and transporting the moisture away from the wearer. In at least some examples, wicking can be evaluated based on a horizontal wicking test in which a droplet of water is deposited on the surface of a horizontally laid flat fabric and the rate and extent of spread is measured. In some examples, wicking can be evaluated based on a vertical wicking test, in which a sample is hung vertically and the end of the sample is positioned in a liquid (e.g., water), after which the height to which the liquid is transported can be measured at given time intervals. An example of a test includes AATCC 197.

[0066]In at least some examples, a textile of the present disclosure can include desired air permeability, which can be assessed via ASTM D737 (e.g., Max. 200 CFM).

[0067]In at least some examples, a textile of the present disclosure can include desired bursting strength, which can be assessed via ASTM D 6797-2015 (e.g., 25 mm Ball Burster, where textile can withstand min. lbf.).

[0068]As used herein, the term “article of apparel” is intended to encompass articles worn by a wearer, which can also be referred to as “wearable articles”. Wearable articles can include, among other things, upper-body/upper-torso garments (e.g., tops, short-sleeved shirts, t-shirts, pullovers, hoodies, jackets, coats, vests, and the like), lower-body/lower-torso garments (e.g., pants, shorts, tights, capris, unitards, and the like), hats, gloves, sleeves (e.g., arm sleeves, calf sleeves), articles of footwear (e.g., uppers for shoes), and the like. As used herein, the term “finished goods” may include articles of apparel or wearable articles, equipment such as bags, furniture, and other such items. As used herein, the term “roll goods” may include, for example, rolls of textile, scraps or remnants remaining after pieces are cut from rolls, and the like.

[0069]The term “inner-facing surface” when referring to the wearable article means the surface that is configured to face mostly towards a body surface of a wearer, and the term “outer-facing surface” means the surface that is configured to face mostly away from the body surface of the wearer and toward an external environment. The term “innermost-facing surface” means the surface closest to the body surface of the wearer with respect to other layers of the wearable article, and the term “outermost-facing surface” means the surface that is positioned furthest away from the body surface of the wearer with respect to the other layers of the wearable article.

[0070]In some examples, reference can be made to a three-dimensional space including an “x” and a “y” and a “z” (e.g., axis, direction, orientation, etc.). Unless otherwise indicated, these references might not include precise relationships to one another and can refer to relative relationships. For example, x, y, and z axes are depicted in FIG. 1 to orient the composite textile to an x-y plane and a thickness in the z-direction. Any of the textiles or layers described in this disclosure can similarly be described with respect to x, y, and z.

[0071]As used herein, the terms “about” and “substantially” mean +/−10% of a given value, such as a linear dimension value (e.g., height, width, etc.) or a weight value. In addition, with respect to an angle or angular dimension, or the terms parallel and perpendicular, the terms “about” and “substantially” mean within 10 degrees. If the “about” or “substantially” is otherwise used, the terms include equivalents of the subject element, where appropriate.

[0072]Unless otherwise noted, all measurements provided herein are measured at standard ambient temperature and pressure (25 degrees Celsius or 298.15 K and 1 bar) with the nonwoven textile in a resting (un-stretched) state.

[0073]Various examples are described below with reference to the drawings, and the structure, relationship, and/or functioning of examples can, in some instances, be better understood by reference to this detailed description. However, examples associated with the subject matter of this application are not limited to those illustrated in the drawings or explicitly described below. The drawings might not necessarily be to scale. In some instances, for clarity, brevity, and/or simplicity details might have been omitted, which does not preclude the inclusion of those details in association with examples of this disclosure.

[0074]Referring now to FIG. 1, FIG. 1 depicts examples of wearable articles 110, any of which can include a composite textile 112 (e.g., composite nonwoven textile), which is shown in an enlarged view of the textile 112b. The enlarged view of the textile 112b is not necessarily to scale, and in some instances, the structures in the enlarged view could form at least part of a unit area or a unit volume. The enlarged view 112b also includes a portion 112c, which is also shown in a further enlarged view. The portion 112c is associated with a cross-section view taken at reference line A-A. When referring to the composite textile, reference might be made to reference numbers 112, 112b, and/or 112c. For the purposes of illustration and clarity, the representations in FIG. 1 might omit some elements that might otherwise be present in the composite textile (e.g., fibers, filaments, plugs, coatings, inks, thermal bonds, etc.).

[0075]In examples, the composite textile 112 can include at least one or more nonwoven layers 114 (e.g., nonwoven constituent layer) and a functional layer 116 (e.g., elastomeric constituent layer).

[0076]In examples, the composite textile 112 includes a first face 118, which is formed at least partially by the nonwoven layer 114, and a second face 120 that is formed at least partially by the functional layer 116.

[0077]In at least some examples, the first face 118 can include an outermost-facing surface of the wearable article 110, and the second face 120 can include an innermost-facing surface of the wearable article 110. As such, the outermost-facing surface of the wearable article 110 can include the nonwoven layer 114 (e.g., predominantly include staple fibers making up the nonwoven layer 114), and the innermost-facing surface can include the functional layer 116 (e.g., predominantly include continuous fibers or filaments making up the functional layer 116).

[0078]The nonwoven layer 114 can include any one or more of the types of nonwoven layers described in this disclosure and can include any one or more of the types of fibers with any one or more of the fiber properties described in this disclosure. In at least some examples, the nonwoven layer 114 includes a fiber web with staple fibers 122 (e.g., fiber web that has been processed, before being incorporated into the composite textile 112, such as by carding, lapping, and/or pre-needling).

[0079]The functional layer 116 can include any one or more of the types of elastomeric layers described in this disclosure, such a nonwoven textile with elastomeric continuous filaments 124 (e.g., spunbond or meltblown). In some examples, the continuous filaments 124 can be elastomeric, such as based on compositionally including an elastomer.

[0080]In examples of the present disclosure, the nonwoven layer 114 and the functional layer 116 are joined. In addition, the resulting composite textile 112 includes properties that satisfy criteria, which can be conducive for use in wearable articles. For example, the properties can includes basis weight (gsm), breathability, stretch properties, recovery properties, wicking properties, bursting strength, flexibility or drape, handfeel, softness, or any and all combinations. In examples of the present disclosure, the elements that join the nonwoven layer 114 to the functional layer 116 contribute to the composite textile including the desired properties. That is, the type of element(s) or constructions joining the layers, as well as the properties associated with those elements (e.g., size, quantity, position, etc.), at least partially contribute to the composite textile 112 having at least some desired properties.

[0081]In at least some examples, the composite textile 112 can include fiber plugs 126 (e.g., fiber plugs 126a-126g), which include bundles of staple-fiber portions extending through openings within the composite textile 112, and the fiber plugs 126 can at least partially join the layers. That is, the composite textile 112 can include openings 128 extending at least partially in the z-direction, and a fiber plug 126a-126g (also collectively referenced as “fiber plugs 126”) can include a bundle of staple-fiber portions that are frictionally retained within the opening. In some examples, an opening can include a needle-penetration opening that is formed by a needle (e.g., on a needle-punch head or machine) penetrating into a face of, and at least partially through, the composite textile 112. In addition, the staple-fiber portions of the fiber plug can be inserted into, and retained within, the needle-penetration opening by the needle barbs engaging the staple-fiber portions and pushing them into the needle-penetration opening, after which the needle is retracted while the fiber plug remains frictionally retained in in the needle-penetration opening (e.g., by frictionally engaging the other fibers of the nonwoven layer 114 and/or frictionally engaging the functional layer 116).

[0082]In at least some examples, the fiber plugs 126 can contribute to joining the nonwoven layer 114 to the functional layer 116. For example, the fiber plugs 126 can each include at least some fiber portions (e.g., fiber portions 130 associated with the fiber plug 126d) that are positioned in the nonwoven layer 114, as well as the portions 132 that are part of the bundle and that are frictionally retained in the openings as part of the fiber plug 126. As such, the fiber plugs 126 operate to anchor the nonwoven layer 114 to the functional layer 116.

[0083]In at least some examples, the fiber plugs 126 can join the nonwoven layer 114 to the functional layer 116 without overly limiting the stretch properties associated with the functional layer 116. For example, the fiber plugs 126 can be pushed through the nonwoven layer 114 and at least partially into the functional layer 116 without necessarily wrapping around, or tying tightly onto, the fibers 124 of the functional layer 116. Stated differently, as a needle pushes fibers 122 from the nonwoven layer 114 at least partially into the functional layer 116, the fibers 124 of the functional layer 116 can spread apart based on the tip of the needle pushing the fibers 124 to the sides of the needle. As the fibers 124 of the functional layer 116 are spread apart, the fibers 122 of the nonwoven layer 114 captured in the barbs can be moved into the opening 128 and retained in the opening 128 after the needle is retracted.

[0084]In some examples, the fiber portions 132 in the plug can include a loop structure, formed by the needle barb pushing down into the textile and then retracting with the fiber frictionally retained in position. In some examples, the fibers portions in a fiber plug might not include a loop portion and can extend to a terminal end that is inside the plug or that is pushed through the opposite face. In examples, the fibers 124 of the functional layer 116 can frictionally engage the fibers 132 of the plug 126 (e.g., including the loop portion) after the needle is removed, such as by extending around the plug and without being so entwined that stretch properties of the fibers 124 are overly restricted. In examples, based on the engagement of the plugs and the functional layer 116, the functional layer 116 can still retain stretch properties, such indicated with arrows 134.

[0085]In at least some examples, the fiber plugs 126 can introduce, in the x-y orientations/plane, increased mechanical stretch properties associated with the nonwoven layer 114. For example, in some instances the fibers 122 of the nonwoven layer 114 can compositionally include a non-elastic polymer material (e.g., organic polymer material such as polyester or polyamide, inorganic polymer material, etc.) or a natural fiber that does not include inherent stretch properties. As such, if the fibers 122 are mostly oriented in the x-y plane and only to a relatively limited extent in the z-direction (e.g., after carding, lapping, etc.), then the nonwoven layer 114 can have limited stretch properties in one or more directions. As such, by oriented at least some portions of the fibers in the z-direction, including some fibers with loop portions in the plugs, at least some additional mechanical stretch properties can be introduced, as indicated by arrows 136.

[0086]In examples of this disclosure, the fiber plugs 126 can include one or more properties that are varied and impart desired properties to the composite textile 112. That is, one or more properties associated with the fiber plugs 126 can be balanced to include sufficient connection between the layers and added mechanical stretch to the nonwoven layer 114, without too much plugging or entanglement that can potentially overly disrupt the functional layer 116 and impede stretch and recovery associated with the functional layer 116.

[0087]Referring to FIG. 2, a composite textile 212 is depicted that can be similar to (or the same as) the composite textile 112 and that can include fiber plugs 226a-226c and 227a-227b with varied properties. For example, the composite textile 212 includes at least one or more nonwoven layers 214 (e.g., nonwoven constituent layer) and a functional layer 216 (e.g., elastomeric constituent layer). In addition, the composite textile 212 includes a first face 218, which can include an outermost-facing surface of a wearable article, and a second face 220, which can include an inner-most facing surface of a wearable article. The nonwoven layer 214 can include any one or more of the types of nonwoven layers described in this disclosure and can include any one or more of the types of fibers 222 (e.g., staple fibers) with any one or more of the fiber properties described in this disclosure. The functional layer 216 can include any one or more of the types of elastomeric layers described in this disclosure, such a nonwoven textile with elastomeric continuous filaments 224 (e.g., spunbond or meltblown).

[0088]The fiber plugs 226a-226c and 227a-227b joining the nonwoven layer 214 to the functional layer 216 can include one or more different properties as compared with one another, and in examples of this disclosure, the varied properties are balanced to impart desired properties to the composite textile 212. For example, a first fiber plug 226a can include a first fiber-plug z-dimension measurement unit (z-dimension scalar), such as the distance 236, and a second fiber plug 226b can include a second fiber-plug z-dimension measurement unit (z-dimension scalar), such as the distance 238, that is different from the first z-dimension measurement unit.

[0089]A z-dimension measurement or scalar can be determined in various manners and can include a distance or length. In some examples, a z-dimension unit can include a length of a fiber plug. In some examples, a z-dimension unit can include a distance of a terminal end (e.g., the distal-most fiber) of the fiber plug relative to the first face 218. In some examples, a z-dimension unit can include a distance of the terminal end of the fiber plug relative to the second face 220. In some examples, a z-dimension unit (or quantity) can include a combination of plug length, distance from the first face 218, and/or distance from the second face 220. In at least some instances, z-dimension measurement units can be determined using high-magnification imaging of a cross section. For example, based on the enlarged image, a reference line can be determined (e.g., reference line 234) that is based on a position of the second face 220 by passing the reference line through at least two co-linear points along the second face 220, and the positions of the relative terminal ends of the fiber plugs can be compared (e.g., by comparing the distance 236 to the distance 238).

[0090]Plugs with varied z-dimensional scalars can contribute to the properties of the composite textile 212 in various manners. For example, plugs with larger z-dimensional scalars can operate to both connect the layers and displace fibers 222 of the nonwoven layer 214 in the z-direction, which can increase stretch properties associated with the nonwoven layer 214. In some instances, if all plugs included the same or similar z-dimensional scalars (e.g., extending beyond the second face) then there is an increased likelihood that the composite textile 212 might have diminished stretch properties, such as if the elastomeric layer 214 is too disrupted by increased number of plugs with large z-dimensional scalars (e.g., relative to the second face). As such, by including fiber plugs with varied z-dimensional scalar, the composite textile 212 can include sufficient bonding between the layers, more fibers 222 in the z-direction, without overly limiting stretch associated with the functional layer 216 (e.g., such as might otherwise occur due to overly disrupting the structure of the elastomeric layer, disrupting bonds between continuous filament fibers, breaking fibers, tying fibers, and the like).

[0091]In at least some examples, a z-dimension measurement unit associated with a fiber plug can be associated with depth of a needle-penetration opening. For example, a needle-penetration opening can include an opening depth that extends from a face of the composite textile (e.g., the side from which the needle entered during a down stroke) to a bottom of the opening (e.g., the position to which the point reached before starting the reciprocating upstroke). In some examples, a z-dimension measurement unit of a fiber plug can correspond a depth of the needle-penetration opening in which the fiber plug is retained.

[0092]In at least some examples, fiber plugs of the composite textile 212 can vary based on a quantity of fibers in the fiber plug. For example, the fiber plug 226a can include a first quantity of fibers and the fiber plug 226c can include a second quantity of fibers, which is different than the first quantity of fibers (e.g., less than the first quantity of fibers).

[0093]In at least some instances, a quantity of fibers in a plug can be determined using high-magnification imaging of a cross section. In some examples, fiber quantities can be determined (e.g., counted) in a cross-section similar to FIG. 2 (e.g., the x-z plane). In some examples, fiber quantities can be determined (e.g., counted) in a cross-section in the x-y plane (e.g., similar to reference view A-A in FIG. 1).

[0094]Plugs with varied fiber quantities can contribute to the properties of the composite textile 212 in various manners. For example, plugs with larger fiber quantities can operate to both connect the layers and displace fibers of the nonwoven layer 214 in the z-direction, which can increase stretch properties associated with the nonwoven layer 214. In some instances, if all plugs included large quantities of fibers then there is an increased likelihood that the composite textile 212 might have diminished stretch properties, such as if the elastomeric layer 214 is too disrupted by increased number of fibers (e.g., portions of staple fibers) extending in the z-direction and down into the functional layer 216. As such, by including fiber plugs with varied fiber quantities, the composite textile 212 can include sufficient bonding between the layers, more fibers 222 in the z-direction, without overly limiting stretch associated with the functional layer 216.

[0095]In at least some examples of the present disclosure, fiber plugs can extend from either face. For example, the fiber plug (e.g., 226a) can extend from the first face 218 towards the second face 220, whereas the fiber plugs 227a and 227b can extend from the second face 220 towards the first face 218. In some examples, staple fibers that form plugs 227a and 227b extending from the second face 220 originate on the other side of the elastomeric layer 214 and are available to form the plugs 227a and 227b extending from the second face 220 once plugs extending from the first face 218 have been formed.

[0096]In examples, plugs 227a and 227b extending from the second face 220 towards the first face 218 can contribute in various ways to the properties of the composite textile 212. For example, the plug 227a and 227b can increase mechanical stretch properties associated the constituent fibers of the respective plugs, which can reduce the likelihood of those fibers impeding stretch along the second face 220. In addition, the plugs 227a and 227b can reduce the “hairiness” associated with the second face 220 and/or the propensity to pill by inserting the fibers (and potentially the fiber ends) back into the elastomeric layer 214 (e.g., tucking the fibers back in).

[0097]In at least some examples, the plugs from the first face (e.g., 226a) can have different properties as compared with the plugs from the second face (e.g., 227a). For example, the plugs (e.g., 227a) extending from the second face 220 can include a smaller z-dimensional measurement unit or scalar as compared to at least some of the plugs 226a-226c extending from the first face 218. The smaller z-dimensional measurement unit can help to optimize properties. For example, the smaller z-dimensional measurement unit can allow for the fibers of those plugs to increase the mechanical stretch of those fibers and also tuck those fibers in, without significantly wrapping around, tying up, or locking down the elastomeric continuous filaments.

[0098]In some instances, at least some plugs from the second face (e.g., 227a) can have fewer quantities of fibers, as compared with some plugs from the first face (e.g., 226a). As explained above, the fibers constructing the plugs from the second face typically originate in another plug extending from the first face, and as such, the fibers in the plugs from the second face can be a subset of fibers (e.g., a subset of the larger quantity of fibers constructing the plugs extending from the first face 218). In addition, in some instances, at least some plugs that extend from the second face can have a smaller z-dimensional measurement unit (e.g., based on the plug extending shallower into the composite textile 212).

[0099]In at least some examples, a fiber of the nonwoven layer 214 can be associated with multiple plugs. For example, a fiber 222a (shown in dashed line for easier viewing) can be associated with two or more plugs extending from the first face 218 towards the second face (e.g., the plugs 226a and 226b). In some examples, a fiber 222b (shown in dashed line for easier viewing) can be associated with a plug extending from the first face (e.g., 226a) and with a plug extending from the second face (e.g., 227a). In some examples, a fiber can be associated with one or more plugs extending from the first face 218 towards the second face 220, one or more plugs extending from the second face 220 towards the first face 218, and any and all combinations thereof.

[0100]In at least some examples, the quantities of plugs extending from the first face and the quantities of plugs extending from the second face contribute to the properties of the composite textile 212. In addition, the relative quantities as between the plugs from the first face and the plugs from the second face can also contribute to the properties. In at least some examples, the composite textile 212 can include (e.g., in a unit area or unit volume) a greater quantity of plugs (e.g., 226a-226c) extending from the first face 218 as compared to the quantity of plugs (e.g., 227a and 227b) extending from the second face 220. In some examples, the quantities can be represented as a ratio of at least 2:1 of the quantity of plugs (e.g., 226a) extending from the first face 218 to the quantity of plugs (e.g., 227a) extending from the second face 220. In some examples, the ratio is at least 3:1. In some examples, the ratio is at least 4:1. In examples, the ratio contributes to the properties of the composite textile, such as by providing sufficient joining, staple fibers in the z-direction (e.g., for improved mechanical stretch), and reduced hairiness, without overly disrupting the functional layer 216 in a manner that impedes stretch.

[0101]In at least some examples, the needle-penetration openings can have varied properties that contribute to the properties of the composite textile 212. Examples of properties that can be different as between needle-penetration openings can include size (e.g., depth and/or width) and shape (e.g., in a cross section take along x-y, y-z, or x-z). In at least some examples, the properties of the needle-penetration openings (e.g., the varied properties) can directly affect the breathability of the composite textile or air permeability. In addition, these properties can be optimized to achieve desired thermal resistance. In addition, the properties can relate to how tightly the fibers of the composite textile 212 frictionally engage the fiber plugs, which can impact stretch and recovery and drape.

[0102]In some examples, the composite textile 212 can include one or more needle-penetration openings that extend entirely through the thickness of the composite textile 212. In some examples, the composite textile 212 can include needle-penetration openings that extend only partially through the thickness of the composite textile 212. For instance, some needle-penetration openings can extend, from the first face 218, entirely through the nonwoven layer 214 and partially through the functional layer 216. Some needle-penetration openings can extend, from the first face 218, entirely thorough the nonwoven layer 214 and terminate at an interface with the functional layer 216 (e.g., the needle-penetration opening does not extend into the functional layer 216). In some instances, needle-penetration openings can extend, from the first face 218, only partially through the nonwoven layer 214. In addition, in examples needle-penetration openings extending from the second face 220 can extend entirely through the functional layer 216 and partially through the nonwoven layer 214. Some needle-penetration openings can extend, from the second face 220, entirely thorough the functional layer 216 and terminate at an interface with the nonwoven layer 214 (e.g., the needle-penetration opening does not extend into the nonwoven layer 214). In some instances, needle-penetration openings can extend, from the second face 220, only partially through the functional layer 216.

[0103]In examples, needle-penetration openings can include varied shapes. For example, some needle-penetration openings can be (e.g., based on a cross section in the x-y plane) more ovular, whereas other can be more circular. In examples, more ovular openings can, in some instances, more tightly frictionally engage around a fiber plug, as compared to a more circular opening. In addition, needle-penetration openings can include varied widths, in which case openings with smaller width might more tightly frictionally engage around a fiber plug. In at least some examples, more ovular or elongated needle-penetration openings can be created by applying tension to the functional layer 216 as the composite textile 212 is needle punched (e.g., where tension is applied to also keep the layers taught during the needle punching). In addition, in some instances, more circular needle-penetration openings can be generated as the composite textile is needle-punched more in subsequent passes based on the layers stretching to a lesser extent under tension. In at least some examples, one or more needle-penetration openings can taper in cross-dimensional width as the opening extends from one face towards the opposing face. For example, a needle-penetration opening can taper from a larger cross dimension near the first face 218 to a smaller cross dimension closer to the second face 220.

[0104]In at least some examples, the composite textile 112/212 can include various material properties, which can be related to the structures and properties of the nonwoven layer 114/214 and the functional layer 116/216. In some instances, the material properties are well suited for a wearable article, such as the wearable articles 110. For example, the composite textile 112/212 can be well suited for a t-shirt material or an undergarment based on one or more various properties, such as basis weight, breathability or air permeability, moisture management (e.g., wicking properties), and the like.

[0105]In at least some examples, the composite textile 112/212 can include a basis weight in a range of about 90 grams/m² (gsm) to about 140 gsm or about 95 gsm to about 130 gsm or about 100 gsm to about 120 gsm. In some examples, the composite textile 112/212 can include a basis weight of about 90 gsm, or about 95 gsm, or about 100 gsm, or about 105 gsm, or about 110 gsm, or about 115 gsm, or about 120 gsm, or about 125 gsm, or about 130 gsm, or about 135 gsm, or about 140 gsm. These are some examples, and the composite textile 112/212 can include a basis weight that is higher or lower than these values.

[0106]In examples, the basis weight of the composite textile 112/212 can be based on various elements, such as the basis weights of the nonwoven layer 114/214 and the functional layer 116/216. In some examples, the basis weight can be based on the number of fiber plugs. In some examples, the basis weight can be based on construction operations, such as the extent of needle punching (e.g., where more needle punching can often decrease the basis weight based on material growth). In some instances, the basis weight of the composite textile 112/212 can be based on the denier or diameter of the fibers of the nonwoven layer 114/214 and the denier or diameter of the fibers of the functional layer 116/216.

[0107]The nonwoven layer 114/214 can include fibers having any of the properties described in this disclosure. In at least some examples, the nonwoven layer 114/214 can include staple fibers. In addition, the staple fibers can include a denier that is in a range of about 0.7D to about 1.5D; or in a range of about 0.8D to about 1.2D; or in a range of about 0.9D to about 1.1D. In some examples, the staple fibers can include a denier that is about 0.7D, about 0.8D, about 0.9D, about 1.0D, about 1.1D, about 1.2D, about 1.3D, about 1.4D, or about 1.5D. In some examples, a lower denier can, when included in a lower basis weight composite textile, provide enhanced coverage and reduce transparency associated with the composite. For example, for a same basis weight, fibers with a 0.9D or with a 1.2D can provide better coverage as compared to fibers with a 1.5D (e.g., with the same compositional material). These are some examples, and the staple fibers an include a denier that is higher or lower than these values.

[0108]In at least some examples, the nonwoven layer 114 can include a fiber web (e.g., staple fiber web) that, prior to joining with the composite textile, includes a basis weight in a range of about 50 gsm to about 100 gsm, or about 60 gsm to about 80 gsm. In some examples, the fiber web can include a basis weight of about 60 gsm, or about 65 gsm, or about 70 gsm, or about 75 gsm, or about 80 gsm, or about 85 gsm, or about 90 gsm, or about 95 gsm, or about 100 gsm. These are some examples, and the fiber web can include a basis weight that is higher or lower than these values.

[0109]In some examples, the composite textile 112/212 that includes plugs with varied properties and needle-penetration openings is well suited for lower basis weights fiber webs in the nonwoven layer 114/214. For example, including larger plugs (e.g., more fibers and/or longer plugs) and smaller plugs (e.g., fewer fibers and/or shorter plugs) optimizes the fibers that are available (e.g., during needle punching) to be moved in the z-direction without over-needling the composite.

[0110]In some examples, fibers 122/222 of the nonwoven layer 114/214 can include silicone. For example, the fibers 122/222 can include a silicone coating. In some examples, the fibers 122/222 can include a silicone impregnation or a silicone-impregnated backbone. In some examples, the fibers 122/222 can be silicone-infused fibers. In at least some examples, a fiber can be formed by a dispersion (e.g., solid dispersion) of a first synthetic polymer (e.g., polyester or PET or polyamide) with a silicone polymer. For example, fibers can be formed by a solid dispersion of the first synthetic polymer and silicone. In at least some examples, the first synthetic polymer and the silicone can be mixed or blended prior to the resulting polymer matrix being extruded into the fiber form. In some examples, fibers can be “infused” with silicone (e.g., silicone-infused fibers), and as used herein “infused” describes that the silicone is included in the solid dispersion that forms the fiber. In some examples, the silicone can be homogenously mixed throughout the solid dispersion (e.g., the silicone mixed with one or more other synthetic polymers, such as polyester or polyamide). In addition, the silicone can be included in various amounts, and in some examples, the fiber comprises between 0.1 and 20 weight % silicone (and one or more other synthetic polymers). In at least some examples, the silicone is present at room temperature (25° C.) in the form of dispersed, compacted inclusions which as a result of thermoplastic processing, e.g. by blending in the melt extruder, are distributed substantially homogeneously in the polymer matrix of the polymer fibers. In examples, the silicone may or may not chemically bond with other polymers in the solid dispersion.

[0111]In some examples, fibers 122/222 of the nonwoven layer 114/214 can include wicking fibers, such as fibers with a wicking finish and/or fibers with a non-circular cross section that facilitates a capillary effect. For example, fiber plugs (e.g., 226a-226c) can include at least some fibers with having wicking properties. In some examples, the fiber plugs with the wicking fibers can operate as wicking conduits to quickly transport moisture (e.g., sweat) away from the second face 220, which can be an innermost-facing surface of the wearable article. In addition, the fibers can move the moisture to the first face 218 (e.g., the outermost-facing surface) where the moisture can evaporate (e.g., evaporate from the wicking fiber as the wicking fiber transitions from the fiber plug to more of an x-y orientation near the face 218).

[0112]In some examples, fibers 122/222 of the nonwoven layer 114/214 can includes a blend of fibers. For example, the blend of fibers can include first fibers having a first property and second fibers having a second property that is different than the first property. In some examples, the blend can include third fibers, fourth fibers, or any number of fibers with different properties.

[0113]In some examples, a property that can be different can include denier or diameter. In some examples, a property that can be different can include silicone-related properties (e.g., coating and/or impregnation). In some examples, a property that can be different can include wicking-related properties (e.g., wicking finish and/or non-circular cross section having capillary action).

[0114]Blends of first fibers and second fibers can include various percentages by weight (e.g., by weight of the nonwoven layer 114/214). For example, a blend can include, as between first fibers and second fibers, various percentages, such as 10:90; 20;80; 25:75; 30:70; 40:60; 50:50; 60:40; 70:30; 75:25; 80:20; and 10:90.

[0115]In some examples, first fibers of the nonwoven layer 114/214 can include silicone (e.g., silicone coating or silicone impregnation or silicone infused) and second fibers might not include any silicone.

[0116]In some examples, first fibers of the nonwoven layer 114/214 can include a wicking finish and second fibers might not include any wicking finish.

[0117]In some examples, first fibers of the nonwoven layer 114/214 can include a non-circular cross section and second fibers include a circular cross section.

[0118]In examples, the functional layer 116/216 can include any of the properties of an elastomeric layer described in this disclosure. In at least some examples, the functional layer 116/216 can include fibers or filaments that are inherently elastic, such as based on a compositional material. In some examples, the compositional material is an elastomer. The elastomer can include a thermoplastic polymer, such as thermoplastic elastomers (TPE). Examples of thermoplastic elastomers can include thermoplastic polyurethane (TPU), thermoplastic polyether ester elastomer (TPEE), combinations of TPU and TPEE and the like.

[0119]In examples, the functional layer 116/216 can include a continuous filament web, such as meltblown nonwoven web, a spundbond nonwoven web, or a combination thereof.

[0120]In some examples, the functional layer 116/216 can include a basis weight that is conducive to (e.g., that contributes to) a relatively lightweight composite textile. For example, the functional layer 116/216 can include a basis weight in a range of about 30 gsm to about 90 gsm, or about 45 gsm to about 75 gsm, or about 60 gsm.

[0121]In some examples, the functional layer 116/216 can include fibers (e.g., continuous length fibers) having a diameter that is larger than the fibers in the nonwoven layer 114/214. For example, the denier of the fibers 120/220 can be less than or equal to 1.5D, whereas the denier of the fibers 124/224 can be equal to or greater than 4.5D. In some examples, the denier of the fibers 120/220 can be less than or equal to 1.2D, whereas the denier of the fibers 124/224 can be equal to or greater than about 6D. In some examples, the larger denier of the fibers 124/224 can increase the likelihood that those fibers will not be captured by needle barbs (e.g., during the entanglement process), which can reduce the likelihood of the elastomeric fibers being disrupted (e.g., ruptured) and can reduce the tendency of the barbs to be clogged with material (e.g., TPU) of the fibers 124/224.

[0122]In some examples, the fiber plug structure and the varied properties among the fiber plugs can contribute to an operationally in-tact structure of the functional layer 116/216 after the layers have been joined by way of needle punching, even though the fiber web 114/214 is only on one side and the layers have relatively low basis weights.

[0123]The composite textile 112/212 can include various properties that are based at least partially on the structures described with respect to FIGS. 1 and 2.

[0124]In at least one example, the composite textile 112/212 includes a maximum stiffness of about 0.10 kgf to about 0.40 kgf (e.g., based on ASTM D 4032-2008, Pneumatic Actuator, Digital Gage With 25 kgf Capacity), or about 0.15 kgf to about 0.35 kbf, or at least 0.3 kgf. In some instances, the stiffness can be lower than, or greater than these example values.

[0125]In at least one example, the composite textile 112/212 includes a thermal resistance of at least 49 M2K/KW (e.g., based on ISO 11092-2014). In some instances, the thermal resistance can be lower than, or greater than these example values.

[0126]In at least one example, the composite textile 112/212 includes a maximum air permeability of about 150 CFM to about 250 CFM (e.g., based on ASTM D737). In some instances, the air permeability can be lower than, or greater than, these example values.

[0127]In at least one example, the composite textile 112/212 includes a bursting strength of at least 35 lbf (e.g., based on ASTM D 6797-2015, 25 mm Ball Burster). In some examples, the composite textile 112/212 can include a bursting strength of at least 50 lbf. In some instances, the bursting strength can be lower than, or greater than, these example values.

[0128]In at least one example, the composite textile 112/212 includes stretch (e.g., based on ASTM D2594, loop and 5 lb weight), of at least 10% in the length and at least 10% in the width. In at least one example, the composite textile 112/212 includes stretch of at least 15% in the length and at least 15% in the width. In at least one example, the composite textile 112/212 includes stretch of at least 20% in the length and at least 20% in the width. In some instances, the stretch can be lower than, or greater than, these example values.

[0129]In at least one example, the composite textile 112/212 includes recovery (e.g., based on ASTM D2594, loop and pull with 5 lb weight), to at least 10% of a resting length within 60 seconds of being stretched by 15%; to at least 5% of a resting length within one hour of being stretched by 15%; to at least 20% of a resting width within 60 seconds of being stretched by 30%; and/or to at least 10% of a resting width within one hour of being stretched by 30%. In some instances, the recovery can be lower than, or greater than, these example values.

[0130]In at least one example, the composite textile 112/212 includes wicking properties. For example, based on a vertical wicking test, the composite textile 112/212 can include (e.g., after 5 min) wicking in the length of at least 1 cm and wicking in the width of at least 1 cm. In some examples, the composite textile 112/212 can include wicking in the length of at least 3 cm and wicking in the width of at least 3 cm. In some examples, the composite textile 112/212 can include wicking in the length of at least 5 cm and wicking in the width of at least 5 cm. In some examples, the composite textile 112/212 can include wicking in the length of at least 7 cm and wicking in the width of at least 7 cm.

[0131]In at least one example, the composite textile 112/212 includes drying properties, such as based on AATCC 201. In some examples, the max dry time is less than about 30 minutes, or less than about 25 minutes, or less than about 20 minutes, or less than about 15 minutes.

[0132]In at least some examples, the first face 118/218 and/or the second face 1202/220 can include a chemical binder, which can include a deposit bonded to fibers on the face. In some examples, the first face 218 can include a first amount of the chemical binder, and the second face 220 can include a second, lower amount, or no chemical binder at all. Examples of a chemical binder can include adhesive materials that are used to hold fibers together. The chemical binder joins fibers together at fiber intersections and fiber bonding results. In one example aspect, the chemical binder may form an adhesive film that bonds the fibers together at, for example, fiber intersections. Because the fibers are adhered together, the terminal ends of the fibers are less prone to migration and pilling and the overall pilling resistance of the composite textile can be increased.

[0133]In examples, chemical binders can include polymers and may include vinyl polymers and copolymers, acrylic ester polymers and copolymers, rubber and synthetic rubber, and natural binders such as starch. The chemical binder may be applied in an aqueous dispersion, an oil-based dispersion, a foam dispersion, and the like. In example aspects, a base coating or primer may be applied to the composite nonwoven textile before application of the chemical binder. In one example aspect, the chemical binder may include an oil-based polyurethane binder. The chemical binder may compositionally comprise an oil-based dispersion of a polyurethane binder, a polyurethane binder in a dispersion that contains silica, and combinations thereof. In example aspects, the use of silica reduces the friction between fibers to which the chemical binder is applied, which can make the fibers less likely to pill when exposed to abrasion or external friction (i.e., they slide more easily relative to each other). The term “chemical bonding site,” as used herein refers to the location of the chemical bond and it furthers refers to the chemical binder itself as applied to the composite nonwoven textile at the chemical bonding site.

[0134]In at least some examples, a chemical binder can be applied using a gravure roller with a pattern (e.g., engraved pattern). In example aspects, the engraved pattern can be selected such that an average size of each cell, and its corresponding chemical bonding site on the composite nonwoven textile ranges from about 0.1 mm to about 1 mm. As used herein, the term “size” when referring to chemical bonding sites refers generally to the surface area occupied by the chemical bonding site. For example, if the chemical bonding site has a circular shape, the size of the chemical bonding site would be generally equal to πr2. In examples, a distance between adjacent cells, and the corresponding chemical bonding sites on the composite nonwoven textile ranges from about 0.5 mm to about 6 mm, from about 1 mm to about 5 mm, or about 1.1 mm to about 4 mm. As used herein, the term “distance” is generally measured from a center of a first chemical bonding site to a center of a second chemical bonding site.

[0135]Using a rotogravure system, is just one example way of applying a liquid form of the chemical binder to the composite nonwoven textile 112/214. Other application methods can include spraying the chemical binder, and/or applying the chemical binder as a foam or powder. In these example aspects, a mask may be used in areas of the composite nonwoven textile 112/212 where the chemical binder is not desired. An additional application method includes digitally printing the chemical binder on to the composite nonwoven textile. Digital printing may be desirable, in some aspects, where a zonal application of the chemical binder is desired. For example, a computer program may be used to instruct the digital printer to print the chemical binder in a desired pattern including a pattern where the density of chemical bonding sites is greater in a first area (e.g., unit area) of the composite nonwoven textile compared to a second area of the composite nonwoven textile 120.

[0136]In at least some examples, the first face 118/218 of the composite nonwoven textile 112/212 may have a first color property and the chemical bonding sites may have a second color property different from the first color property (e.g., where the chemical binder applied at the chemical bonding sites includes a dye or a pigment). In some instances, the second color property of the plurality of chemical bonding sites in combination with the first color property of the first face 118/218 may provide an interesting visual aesthetic.

[0137]Various methods and operations can be executed to construct the composite textile 112 and 212. Referring to FIG. 3, a series of steps or operations are pictorially represented that can be performed in a method 300. For example, at operation 302, a nonwoven layer 304 can be stacked with a functional layer 306 (e.g., elastomeric layer), to form stacked layers 308. The nonwoven layer 304 can include a first face of the stacked layers and the functional layer 306 can include a second face.

[0138]In examples, the nonwoven layer 304 can include any of the nonwoven layers described in this disclosure (e.g., a fiber web with staple fibers having any of the properties described in this disclosure). For instance, in some cases, the nonwoven layer 304 can include a staple fibers (e.g., single type of staple fiber or blend of fibers having different properties) having a denier less than or equal to 1.5D in a fiber web with a basis weight of about 80 gsm. In some instances, the denier can be about 1.2D or about 0.9D. In some instances, at least some of the fibers can include wicking fibers. The functional layer 306 can include any of the elastomeric layers described herein (e.g., a continuous filament web) or other functional layers. In some examples, elastomeric layer 306 can include spunbond or meltblown fibers compositionally comprising an elastomer (e.g., TPU or TPEE) with a basis weight of about 60 gsm. In some examples, the denier or the diameter of the continuous filament fibers can be larger than the fibers of the nonwoven layer 304 (e.g., at least 2× larger or at least 3× larger or at least 4× larger).

[0139]In at least some examples, tension is applied (e.g., in the machine direction) to at least the functional layer 306, and in some cases to the stacked layers 308, during the operations 302. As such, when needle-penetration openings are formed and plugs are inserted, the needle-penetration openings can include an elongated shape (e.g., elongated in the machine direction), which can be at least partially retained in the composite textile after the tension is released.

[0140]In examples, at 310, a needle-entanglement operation can be performed on the stacked layers 308 from the direction of the nonwoven layer 304 towards the functional layer 306 (e.g., from the first face towards the second face). For example, as part of a needle-entanglement operation, needles 312 positioned adjacent the nonwoven layer 304 can be transited through the nonwoven layer 304 and towards the functional layer 306, which can form needle-penetration openings. As the needles transit, one or more of the needles can engage or hook fibers or portions of fibers (e.g., a barb of a needle can catch one or more fibers) and move the engaged portion of the fiber at least partially into the functional layer 306 to form a fiber plug (e.g., 314) in the needle-penetration opening. Once the needle is retracted, the fiber plug is frictionally retained in the needle-penetration opening.

[0141]The operations associated with step 310 can have various needling parameters, such as stitch density (SD) and penetration depth (PD). For example, step 310 can include a stitch density of greater than 150 stitches/cm² . In some examples, the SD can be about 200/cm². In some example, the SD can be less than 300/cm². In some examples, the SD can be less than 250/cm². In some examples, the PD is at least about 12 mm, or another PD that is sufficient to push at least part of a fiber through the second face.

[0142]In at least some examples, tension is applied (e.g., in the machine direction) to the stacked layers during the operations associated with step 310. As such, when needle-penetration openings are formed and plugs are inserted, the needle-penetration openings can include an elongated shape (e.g., elongated in the machine direction), which can be at least partially retained in the composite textile after the tension is released. In at least some instances, the elongated shape formed during operations 310 can be longer and/or more ovular as compared to the openings formed in subsequent entanglement operations.

[0143]The method 300 can include, at 316, executing a second entanglement pass from the direction of the nonwoven layer 304, which can include at least one different needling parameter, as compared to step 310. For example, because at step 316 there are fewer fibers available to engage in the needle barbs (since they have already been needled in step 310) the operation 316 can include a PD (e.g., 10 mm) that is lower than the needling associated with 310. In at least some examples, the lower PD can reduce the likelihood of empty barbs entering the composite and potentially breaking fibers, such as the continuous filaments of the functional layer (since breaking those filaments could reduce stretch properties associated with the elastomeric layer). In examples in which the fibers of the functional layer include a larger diameter than the fibers of the nonwoven layer, the larger diameter can also reduce the likelihood of the fibers being captured in the needle barbs. In at least some examples, the operation 316 can, based on the shallower PD, form fiber plugs 318 having different properties (e.g., shorter and/or with less fibers) that still are effective to join the layers, position fibers in the z-direction, and not overly disrupt the functional layer or limit its stretch properties. Step 316 can include a stitch density of greater than 150 stitches/cm². In some examples, the SD can be about 200/cm². In some example, the SD can be less than 300/cm². In some examples, the SD can be less than 250/cm².

[0144]In at least some examples, tension is applied (e.g., in the machine direction) to the stacked layers during the operations associated with step 316. As such, when needle-penetration openings are formed and plugs are inserted, the needle-penetration openings can include an elongated shape (e.g., elongated in the machine direction), which can be at least partially retained in the composite textile after the tension is released. In at least some instances, the elongated shape formed during operations 316 can be shorter and/or more circular as compared to the openings formed in operations 310. For example, even though tension can be applied during operations 316, the amount of elongation during the operations 316 can be reduced (as compared to elongation in 310) based on the layers being more connected when tension is applied during operations 316 (as compared to the lesser amount of connection when tension is applied in operations 310).

[0145]The method 300 can include, at 320, executing a third entanglement pass, which can include at least one different needling parameter, as compared to steps 310 and 316. For example, the third pass can be from the direction of the second face, in which case, the needling can operate to both position fibers in the z-direction (improving mechanical stretch of the fibers and creating fiber plugs 322) and tuck fibers back into the composite to reduce hairiness.

[0146]In examples associated with the operations at 320, to reduce the likelihood of overly disrupting the fibers of the layers 304 and/or 306 with empty barbs, the PD can also be reduced. For example, because at step 320 the fibers being targeted for needling mostly (e.g., only) include fibers from the layer 304 that were pushed through the second face, the operation 320 can include a PD (e.g., 8 mm or 6 mm or 4 mm) that is lower than the needling associated with 310 and/or 316. In at least some examples, the lower PD can reduce the likelihood of empty barbs entering the composite and potentially breaking fibers, such as the continuous filaments of the functional layer (since breaking those filaments could reduce stretch properties associated with the elastomeric layer). In examples in which the fibers of the functional layer include a larger diameter than the fibers of the nonwoven layer, the larger diameter can also reduce the likelihood of the fibers being captured in the needle barbs. In at least some examples, the operation 320 can, form fiber plugs 322 having different properties as compared with the plugs 314 and/or 318 (e.g., shorter and/or with less fibers) that still are effective to join the layers, position fibers in the z-direction, and not overly disrupt the functional layer or limit its stretch properties. Step 320 can include a stitch density of greater than 150 stitches/cm² . In some examples, the SD can be about 200/cm². In some examples, the SD can be less than 300/cm². In some examples, the SD can be less than 250/cm².

[0147]In at least some examples, tension is applied (e.g., in the machine direction) to the stacked layers during the operations associated with step 320. As such, when needle-penetration openings are formed and plugs are inserted, the needle-penetration openings can include an elongated shape (e.g., elongated in the machine direction), which can be at least partially retained in the composite textile after the tension is released. In at least some instances, the elongated shape formed during operations 320 can be shorter and/or more circular as compared to the openings formed in operations 310 and/or 316. For example, even though tension can be applied during operations 320, the amount of elongation during the operations 320 can be reduced (as compared to elongation in 310 and 316) based on the layers being more connected when tension is applied during operations 320 (as compared to the lesser amount of connection when tension is applied in operations 310 and 316).

[0148]In some examples, the operations associated with step 320 can include the only pass from the second face.

[0149]The method 300 can include, at 324, executing at least a fourth entanglement pass from the direction of the first face, which can include at least one different needling parameter, as compared to steps 310 and 316. For example, the needling operations at 324 can include a lower PD as compared with the needling parameters at 310 and 316 (e.g., 8 mm or 6 mm or 4 mm). In at least some examples, the lower PD can reduce the likelihood of empty barbs entering the composite and potentially breaking fibers, such as the continuous filaments of the functional layer (since breaking those filaments could reduce stretch properties associated with the elastomeric layer). In at least some examples, the operation 324 can, form fiber plugs 326 having different properties as compared with the plugs 314 and/or 318 (e.g., shorter and/or with less fibers) that still are effective to join the layers, position fibers in the z-direction, and not overly disrupt the elastomeric layer or limit its stretch properties. Step 324 can include a stitch density of greater than 150 stitches/cm² . In some examples, the SD can be about 200/cm². In some examples, the SD can be less than 300/cm². In some examples, the SD can be less than 250/cm².

[0150]In at least some examples, tension is applied (e.g., in the machine direction) to the stacked layers during the operations associated with step 324. As such, when needle-penetration openings are formed and plugs are inserted, the needle-penetration openings can include an elongated shape (e.g., elongated in the machine direction), which can be at least partially retained in the composite textile after the tension is released. In at least some instances, the elongated shape formed during operations 324 can be shorter and/or more circular as compared to the openings formed in operations 302, 310, and/or 320. For example, even though tension can be applied during operations 324, the amount of elongation during the operations 324 can be reduced (as compared to elongation in 302 and 310 and 320) based on the layers being more connected when tension is applied during operations 324 (as compared to the lesser amount of connection when tension is applied in operations 302 and 310 and 320).

[0151]In at least some examples, the method 300 can include, at step 328, one or more additional needling passes from the direction of the first face (e.g., a fifth pass and possibly a sixth pass), which can include at least one different needling parameter, as compared to steps 310, 316, and 324. For example, the needling operations in these subsequent passes can include a lower PD as compared with the needling parameters at 324 (e.g., 4 mm). In addition, these subsequent passes can include a stitch density of greater than 150 stitches/cm² . In some examples, the SD can be about 200/cm². In some examples, the SD can be less than 300/cm². In some examples, the SD can be less than 250/cm². In at least some examples, the needling operations associated with 324 (e.g., with a lower PD) even out the first face by tucking fiber portions into the nonwoven layer 304 without overly disrupting the fibers of the composite and overly reducing stretch properties.

[0152]Subsequent to one or more of the operations or steps associated with the method 300, a composite textile can include various elements, such as the composite textile 412 of FIG. 4. The composite textile 412 can include any one or more of the features or elements described with respect to the composite textile 112 and/or 212. For example, the composite textile 412 can include a nonwoven constituent layer 414 and a functional constituent layer 416 (e.g., elastomeric). In addition, the composite textile 412 can include a first face 418, which can correspond with the first face 118, and a second face 420, which can correspond with the second face 120.

[0153]In examples, the relatively darker regions 450 on the first face 418 can represent positions at which the first face 418 was penetrated by a needle, and as such, the regions 450 can also represent portions of plugs or plug positions. As illustrated, the stitch density and distribution are such that the regions 450 represent stitches or plugs that are arranged into lines of various contours shapes and lengths. The dark portions 450 are for illustration purposes, and in reality, the plugs may or may not completely merge as depicted. In some instances, fibers in the regions 450 may be oriented more in the z direction as compared with other regions. In contrast, the relatively light regions 452 can represent positions on the first face 418 that may not have been penetrated by a needle, or were less penetrated, such as where there may not be a plug and where fibers might be oriented more in the x-y plane. Similarly, the relatively dark regions 454 on the second face 420 can represent positions at which the second face 420 was penetrated by a needle, whereas the relatively light regions 456 can represent positions on the second face 420 that may not have been penetrated by a needle.

[0154]In at least some examples, the composite textile 412 can be subject to heat in one or more post processes, such as when a chemical binder is applied and/or due to thermal bonding operations and/or one or more other processes. In addition, when the heat is removed and the composite textile cools, a resulting composite textile can have different properties as compared to the composite textile 412. For example, referring to FIG. 5, the composite textile 512 can include an example of a composite textile after the composite textile 412 is subjected to heat. For illustration purposes the depiction of the portion of the textile in FIG. 5 can represent a magnification or enlargement, as compared to the portion of the textile in FIG. 4. In at least some examples, a property associated with the composite textile 512 (e.g., after the composite cools) can include macro undulations 560 on the first face 518 (e.g., which can correspond with the first face 418). The macro undulations 560 can include surface wrinkles, puckerings, or crinkles and can be constructed of one or more fiber portions. That is, the macro undulations can include surface contours having displacement in the z direction, and the displaced portions can be formed by collections of fiber portions. In this sense, the undulations can be “macro” in that they are structures that are larger than the size of the fibers themselves. In some instances, the macro undulations 560 can provide an interesting (e.g., desired or pleasing) surface ornamentation, which can be suited for used in an apparel article, such as where the face with the macro undulations is on an outermost facing surface.

[0155]In at least some examples, macro undulations are absent from the second face 520, even though they are present on the first face 518.

[0156]In at least some examples, macro undulations are on the second face 520 to a lesser extent as compared to on the first face 518. For example, any macro undulations might be (as compared to macro undulations on the first face 518) smaller (e.g., less pronounced in the z direction) and/or more spaced apart.

[0157]In some examples, and not being bound by any theory, the macro undulations on the first face 518 can be formed at least partially by the fiber portions associated with the regions 452 lofting or extending outward when continuous fibers associated with the functional constituent layer 416 are, after the heating step, cooled and potentially shrink. In contrast, the fiber portions associated with the regions 450 might tend to remain more fixed (based on the plugs frictionally retained in the composite textile) and may not loft or expand as much (e.g., after the heat is removed and the continuous fibers associated with the functional constituent layer 416 potentially shrink). The differential expanding and lofting on the first face 418/518 may contribute to the formation of the macro undulations. In addition, since the second face 420/520 can be predominantly formed by the continuous fibers, there might be less differential expansion (more consistent size change across the face 420/520) and thus fewer or no macro undulations.

EXAMPLE CLAUSES

[0158]As used herein, a recitation of “and/or” with respect to two or more elements should be interpreted to mean only one element, or a combination of elements. For example, “element A, element B, and/or element C” may include only element A, only element B, only element C, element A and element B, element A and element C, element B and element C, or elements A, B, and C. In addition, “at least one of element A or element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B. Further, “at least one of element A and element B” may include at least one of element A, at least one of element B, or at least one of element A and at least one of element B.

[0159]Clause 1. A composite textile comprising: a fiber-web constituent layer that comprises a first face of the composite textile and that comprises staple fibers; an elastomeric nonwoven constituent layer that comprises a second face of the composite textile, which is opposite to the first face, wherein the elastomeric nonwoven constituent layer is joined to the fiber-web constituent layer by fiber plugs that include bundles of staple-fiber portions extending into needle-penetration openings; and the fiber plugs comprising a first plug comprising a first quantity of staple-fiber portions and a second plug comprising any second quantity of staple-fiber portions that is less than the first quantity of staple-fiber portions.

[0160]Clause 2. The composite textile of clause 1, wherein the first plug comprises a first plug length, and wherein the second plug comprises a second plug length, which is less than the first plug length.

[0161]Clause 3. The composite textile of clause 1 or clause 2, wherein a staple fiber of the fiber-web constituent layer comprises a first portion arranged in the first plug and a second portion arranged in the second plug.

[0162]Clause 4. The composite textile of any of clauses 1 through 3, wherein the first plug extends from the first face and into a first needle-penetration opening; and wherein the second plug extends from the first face and into a second needle-penetration opening.

[0163]Clause 5. The composite textile of clause 4 further comprising, a third plug comprising a third quantity of staple-fiber portions that extend, from the second face, into a third needle-penetration opening.

[0164]Clause 6. The composite textile of clause 5, wherein the third quantity is less than the first quantity.

[0165]Clause 7. The composite textile of clause 6, wherein the third quantity is less than the second quantity.

[0166]Clause 8. The composite textile of clause 6, wherein the third quantity is greater than the second quantity.

[0167]Clause 9. The composite textile of any of clauses 5 through 8, wherein a staple fiber of the fiber-web constituent layer comprises a first portion positioned in the first plug and a second portion positioned in the third plug.

[0168]Clause 10. The composite textile of any of clauses 5 through 9, wherein the composite textile comprises, in a unit volume, a numerical sum of the first quantity and the second quantity; and wherein the numerical sum is higher than the third quantity.

[0169]Clause 11. The composite textile of clause 10, wherein in the unit volume a ratio of the first quantity to the second quantity is at least 2:1.

[0170]Clause 12. The composite textile of any of clauses 1 through 3, wherein the first plug extends from the first face and into a first needle-penetration opening; and wherein the second plug extends from the second face and into a second needle-penetration opening.

[0171]Clause 13. The composite textile of any of clauses 1 through 12, wherein the composite textile comprises, in a unit volume, a first quantity of first plugs and a second quantity of second plugs, which is greater than the first quantity of first plugs.

[0172]Clause 14. The composite textile of any of clauses 1 through 13, wherein the first plug extends into a first needle-penetration opening and the second plug extends into a second needle-penetration opening, which comprises, as compared to the first needle-penetration opening, one or more different properties.

[0173]Clause 15. The composite textile of clause 14, wherein the one or more different properties comprise a size, and wherein the first needle-penetration opening is larger than the second needle-penetration opening.

[0174]Clause 16. The composite textile of clause 15, wherein the first needle-penetration opening is deeper than the second needle-penetration opening.

[0175]Clause 17. The composite textile of clause 15, wherein the first needle-penetration opening is wider than the second needle-penetration opening.

[0176]Clause 18. The composite textile of clause 14, wherein the one or more different properties comprise a shape.

[0177]Clause 19. The composite textile of clause 18, and wherein the first needle-penetration opening is more ovular than the second needle penetration opening and the second needle-penetration opening is more circular than the first needle-penetration opening.

[0178]Clause 20. A composite textile comprising: a fiber-web constituent layer that comprises a first face of the composite textile and that comprises staple fibers comprising a denier less than or equal to 1.5D; and an elastomeric nonwoven constituent layer that comprises a continuous filament web and that comprises a second face of the composite textile, which is opposite to the first face, wherein the elastomeric nonwoven constituent layer is joined directly to the fiber-web constituent layer by staple fibers of the fiber-web constituent layer extending at least partially through the elastomeric nonwoven constituent layer; and wherein the composite textile comprises a basis weight in a range of about 90 gsm to 120 gsm.

[0179]Clause 21. The composite textile of clause 20, wherein the composite textile comprises a stiffness in a range of about 0.10 kgf to about 0.40 kgf.

[0180]Clause 22. The composite textile of clause 20 or clause 21, wherein the composite textile comprises an air permeability in a range of about 150 CFM to about 250 CFM.

[0181]Clause 23. The composite textile of any of clauses 20 through 22, wherein the composite textile comprises a bursting strength of at least 35 lbf

[0182]Clause 24. The composite textile of any of clauses 20 through 23, wherein the composite textile comprises a stretch property of at least 5% in the machine direction and in the cross direction.

[0183]Clause 25. The composite textile of any of clauses 20 through 24, wherein the composite textile comprises a recovery property permitting the composite textile to recover to a length of at least 110% after being stretched to 115%.

[0184]Clause 26. The composite textile of any one or more of clauses 1 through 25, wherein the staple fibers comprise wicking fibers.

[0185]Clause 27. The composite textile of clause 26, wherein the wicking fibers comprise a wicking finish.

[0186]Clause 28. The composite textile of clause 26 or clause 27, wherein the wicking fibers comprise one or more non-circular cross-section profiles.

[0187]Clause 29. The composite textile of clause 28, wherein the one or more non-circular cross-section profiles comprise a rectangular cross section.

[0188]Clause 30. The composite textile of clause 28 or clause 29, wherein the one or more non-circular cross-section profiles comprises a multi-lobal cross section.

[0189]Clause 31. The composite textile of clause 30, wherein the multi-lobal cross section comprises tri-lobal, Y-shape, quad-lobal, X-shape, star shape, or penta-lobal.

[0190]Clause 32. The composite textile of clause any one or more of clauses 28 through 31, wherein the one or more non-circular cross-section profiles comprises a bone-shape, a saucer shape, or a clover shape.

[0191]Clause 33. The composite textile of any one or more of clauses 1 through 32, wherein the staple fibers comprise silicone-treated fibers.

[0192]Clause 34. The composite textile of clause 33, wherein the silicone-treated fibers comprise a silicone finish.

[0193]Clause 35. The composite textile of clause 33 or clause 34, wherein the silicone-treated fibers comprise a silicone impregnation.

[0194]Clause 36. The composite textile of any one or more of clause 1 through clause 35, wherein the first face comprises a plurality of discrete chemical binding sites.

[0195]37. The composite textile of any one or more of clauses 1 through 36, wherein the elastomeric nonwoven constituent layer comprises a spundbond layer or a meltblown layer.

[0196]Clause 38. The composite textile of clause 37, wherein the elastomeric nonwoven constituent layer comprises a thermoplastic elastomer.

[0197]Clause 39. The composite textile of clause 38, wherein the elastomeric nonwoven constituent layer comprises a TPU.

[0198]Clause 40. The composite textile of clause 38, wherein the elastomeric nonwoven constituent layer comprises a TPEE.

[0199]Clause 41. The composite textile of any one or more of clauses 1 through 40, wherein: the composite textile comprises a portion of a wearable article; the first face comprises an outermost-facing surface of the wearable article configured to face away from a wearer when the wearable article is donned; and the second face comprises an innermost-facing surface of the wearable article configured to face towards the wearer when the wearable article is donned.

[0200]Clause 42. The composite textile of clause 41, wherein the wearable article comprises an upper-body garment, a lower-body garment, or a footwear article.

[0201]Clause 43. The composite textile of clause 42, wherein the wearable article comprises a T-shirt.

[0202]Clause 44. The composite textile of any one or more of clauses 1 through 19, wherein the staple fibers comprise a denier in a range of about 0.9D to about 1.5D.

[0203]Clause 45. The composite textile of clause 44, wherein the denier is less than or equal to 1.2D.

[0204]Clause 46. The composite textile of any one or more of clauses 1 through 19, wherein the composite textile comprises a basis weight in a range of about 90 gsm to 140 gsm.

[0205]Clause 47. The composite textile of any one or more of clauses 1 through 46, wherein the first face comprises a dimensional relief comprising wrinkle-like macro-undulations.

[0206]Clause 48. A method comprising: arranging, as a stacked layering, a fiber web with an elastomeric nonwoven layer, wherein the fiber web comprises a basis weight in a range of about 65 gsm to about 80 gsm and the elastomeric nonwoven layer comprises a basis weight of about 60 gsm; and wherein the fiber web comprises a first face of the stacked layering and the elastomeric nonwoven layer comprises a second face of the stacked layering; executing, from a side of the fiber web, a first needle-entanglement pass comprising a first needle penetration depth; and executing, from a side of the elastomeric nonwoven layer and subsequent to the first needle-entanglement pass, a second needle-entanglement pass comprising a second needle penetration depth, which is less than the first needle penetration depth.

[0207]Clause 49. The method of clause 48, wherein the first needle-entanglement pass comprises a first stitch density of at least 150 n/cm² and the second needle-entanglement pass comprises a second stitch density of at least 150 n/cm².

[0208]Clause 50. The method of clause 49, wherein the first needle-entanglement pass comprises a first stitch density of at least 200 n/cm² and the second needle-entanglement pass comprises a second stitch density of at least 200 n/cm².

[0209]Clause 51. The method of clause 48 further comprising, executing, from the side of the fiber web, a third needle-entanglement pass temporally between the first needle-entanglement pass and the second needle-entanglement pass.

[0210]Clause 52. The method of clause 51, wherein the third needle-entanglement pass comprises a third needle penetration depth that is greater than the second needle penetration depth.

[0211]Clause 53. The method of clause 51, wherein the third needle-entanglement pass comprises a third needle penetration depth that is less than the first needle penetration depth.

[0212]Clause 54. The method of clause 51, wherein the third needle-entanglement pass comprises a third stitch density that is similar to a second stitch density associated with the second needle-entanglement pass.

[0213]Clause 55. The method of clause 51, wherein the third needle-entanglement pass comprises a third stitch density that is greater than a second stitch density associated with the second needle-entanglement pass.

[0214]Clause 56. The method of clause 48 further comprising, executing, from the side of the fiber web, one or more fourth needle-entanglement passes temporally after the second needle-entanglement pass.

[0215]Clause 57. The method of clause 56, wherein the one or more fourth needle-entanglement passes comprises a fourth needle penetration depth that is less than the second needle penetration depth.

[0216]Clause 58. An apparel article configured to be donned by a wearer, the apparel article comprising: a composite textile comprising: an outermost face and an innermost face; the outermost face oriented, relative to other portions of the composite textile, farthest away from the wearer's skin surface; the innermost face oriented, relative to other portions of the composite textile, closest to the wearer's skin surface; a fiber-web constituent layer that comprises the outermost face and that comprises staple fibers; and an elastomeric nonwoven constituent layer that comprises the innermost face.

[0217]Clause 59. The apparel article of claim 58, wherein the elastomeric nonwoven constituent layer is joined to the fiber-web constituent layer by fiber plugs that include bundles of staple-fiber portions extending into needle-penetration openings.

[0218]Clause 60. The apparel article of claim 59, wherein the fiber plugs comprise a first plug comprising a first quantity of staple-fiber portions and a second plug comprising any second quantity of staple-fiber portions that is less than the first quantity of staple-fiber portions.

[0219]Clause 61. The apparel article of any of claims 58 to 60, wherein the apparel article comprises an upper-body garment.

[0220]Clause 62. The apparel article of claim 61, wherein the upper-body garment comprises a t-shirt.

[0221]Clause 63. The apparel article of any of claims 58 to 62, wherein the outermost face comprises a first unit area having wrinkle-like macro undulations.

[0222]Clause 64. The apparel article of claim 63, wherein the innermost face comprises a second unit area that opposes the first unit area on an opposite side of the composite textile and that is free of wrinkle-like macro undulations.

[0223]Clause 65. The apparel article of any of claims 58 to 64, wherein the composite textile comprises any of the elements of claims 1 to 47.

[0224]Clause 66. The apparel article of any of claims 58 to 65, wherein the outermost face comprises a plurality of chemical bonding sites that comprise a discrete deposit of a chemical binder.

[0225]Clause 67. The apparel article of claim 66, wherein the chemical binder comprises a dye or a pigment having a different color than the staple fibers.

[0226]Clause 68. The apparel article of any of claims 58 to 67, wherein the staple fibers are dope dyed.

[0227]Clause 69. The apparel article of any of claims 58 to 68, wherein the composite textile comprises a sublimation-printed dye.

[0228]Clause 70. The apparel article of any of claims 58 to 67, wherein the composite textile comprises a larger number of fiber end portions of the staple fibers on the outermost face as compared to the innermost face.

[0229]Clause 71. A t-shirt comprising: a composite textile comprising: a fiber-web constituent layer that comprises staple fibers, wherein at least some fibers of the staple fibers comprise wicking fibers; and an elastomeric nonwoven constituent layer that is joined to the fiber-web constituent layer by fiber plugs, which include bundles of staple-fiber portions extending into needle-penetration openings.

[0230]Clause 72. The t-shirt of claim 71, wherein the composite textile comprises: an outermost face oriented, relative to other portions of the composite textile, farthest away from a wearer's skin surface; an innermost face oriented, relative to other portions of the composite textile, closest to the wearer's skin surface.

[0231]Clause 73. The t-shirt of claim 72, wherein: the elastomeric nonwoven constituent layer comprises the innermost face; the fiber-web constituent layer comprises the outermost face; or the elastomeric nonwoven constituent layer comprises the innermost face and the fiber-web constituent layer comprises the outermost face.

[0232]Clause 74. The t-shirt of any of claims 71 to 73, wherein at least some of the fiber plugs comprise at least a portion of the wicking fibers, and wherein the at least the portion of the wicking fibers is arranged in a z direction.

[0233]Clause 75. The t-shirt of any of claims 71 to 74, wherein the staple fibers comprise a denier less than or equal to 1.5D.

[0234]76. The t-shirt of any of claims 71 to 75, wherein the composite textile comprises a basis weight in a range of 90 gsm to 120 gsm.

[0235]Clause 77. The t-shirt of any of claims 71 to 76, wherein the outermost face comprises a first unit area having wrinkle-like macro undulations.

[0236]Clause 78. The t-shirt of claim 77, wherein the innermost face comprises a second unit area that opposes the first unit area on an opposite side and that is free of wrinkle-like macro undulations.

[0237]Clause 79. The t-shirt of any of claims 71 to 78, wherein the composite textile comprises any of claims 1 to 47.

[0238]This detailed description is provided in order to meet statutory requirements. However, this description is not intended to limit the scope of the invention described herein. Rather, the claimed subject matter may be embodied in different ways, to include different steps, different combinations of steps, different elements, and/or different combinations of elements, similar or equivalent to those described in this disclosure, and in conjunction with other present or future technologies. The examples herein are intended in all respects to be illustrative rather than restrictive. In this sense, alternative examples or implementations can become apparent to those of ordinary skill in the art to which the present subject matter pertains without departing from the scope hereof.