NONWOVEN ENTANGLEMENT SYSTEM AND METHODS OF MANUFACTURE

Aspects herein are directed to a composite nonwoven textile that includes non-linear entangled seams and method and systems for producing the same. The composite nonwoven textile includes at least a first nonwoven layer, a second layer, and a fill material positioned between the first nonwoven layer and the second layer. When the composite nonwoven textile is formed into a garment, the regions between the non-linear entangled seams may help store and retain heat to provide insulation, and the non-linear entangled seams may help prevent shifting or drift of the fill material.

TECHNICAL FIELD

Aspects herein are directed to a nonwoven textile with non-linear entangled seams suitable for garments and methods and systems for producing the same.

BACKGROUND

Traditional insulating garments are generally formed by positioning panels of textile materials (e.g., woven or knit textiles) adjacent to each other, optionally applying an adhesive to the panels of textile materials at predetermined locations, heat pressing and/or stitching the textile materials together at the predetermined locations to form linear seams that separate baffles, and filling the baffles with down or other types of thermally insulating fill materials. This construction method may be expensive due to the number of different materials used to form the garment and may also be time intensive. Moreover, the energy costs and carbon footprint associated with, for example, spinning the yarns used in the textile materials, weaving or knitting the textile materials using the yarns, applying the adhesive, heat pressing or stitching the seams, and filling the baffles may be high and the recyclability of the resulting garment may be limited due to the presence of a large number of disparate materials. When the Page1of81textile materials used to form the garment include some type of repeating visual arrangement of elements (e.g., a visual arrangement of printed components, a visual arrangement of seams, and the like), there may be material waste to ensure that each garment in a garment lot includes the visual arrangement of elements at a consistent location on the garment in order to present a uniform appearance for each garment in the garment lot.

DETAILED DESCRIPTION

Traditional insulating garments are generally formed by positioning panels of textile materials (e.g., woven or knit textiles) adjacent to each other, optionally applying an adhesive to the panels of textile materials at predetermined locations, heat pressing and/or stitching the textile materials together at the predetermined locations to form linear seams that separate baffles, and filling the baffles with down or other types of thermally insulating fill materials. This construction method may be expensive due to the number of different materials used to form the garment and may also be time intensive. Moreover, the energy costs and carbon footprint associated with, for example, spinning the yarns used in the textile materials, weaving or knitting the textile materials using the yarns, applying the adhesive, heat pressing or stitching the seams, and filling the baffles may be high and the recyclability of the resulting garment may be limited due to the presence of a large number of disparate materials. When the textile materials used to form the garment include some type of repeating visual arrangement of elements (e.g., a visual arrangement of printed components, a visual arrangement of seams, and the like), there may be material waste to ensure that each garment in a garment lot includes the visual arrangement of elements at a consistent location on the garment in order to present a uniform appearance for each garment in the garment lot.

At a high level, aspects herein are directed to a composite nonwoven textile having non-linear entangled seams suitable for garments and methods and systems for producing the same. In example aspects, an entanglement system may be used to form the composite nonwoven textile. The entanglement system, in example aspects, may include one or more entanglement stations that may be aligned serially along a conveyance system that is adapted to advance a stacked configuration of layers used to form the composite nonwoven textile along a surface of the conveyance system in a material flow direction. Each entanglement station includes an actuator that, in one example aspect, is adapted to move in a direction perpendicular to the plane of conveyance of the surface. Each entanglement station further includes one or more entanglement heads coupled to the actuator. In one aspect, the entanglement heads include one or more entanglement needles arranged, in example aspects, in a structured arrangement. In one example, movement of the actuator in the direction perpendicular to the plane of conveyance of the surface causes the entanglement needles to engage the stacked configuration of layers. In another example, the actuator may remain stationary but actuate or cause the entanglement head and/or the entanglement needles to move up and down in a direction perpendicular to the plane of conveyance such that the entanglement needles engage the stacked configuration of layers. In another example aspect, the entanglement heads are adapted to emit one or more pressurized jets of fluid such as water. In this example, the actuator may also remain stationary and cause the jets of fluid to be emitted from the entanglement heads.

In example aspects, a carriage may also coupled to the entanglement heads, either directly or indirectly by way of the actuator, where the carriage is adapted to move in directions non-parallel to the material flow direction. Additionally or alternatively, the conveyance system may be adapted to move in directions non-parallel to the material flow direction. Thus, in example aspects, the entanglement heads and the conveyance system may be adapted to move relative to each other in directions non-parallel to the material flow direction.

In example aspects, the entanglement heads may be positioned at different locations on the respective entanglement stations in order to make contact with different portions of the stacked configuration as the stacked configuration is conveyed along the surface of the conveyance system. For instance, a first entanglement station may include a first entanglement head positioned a first distance inward (i.e., perpendicular to the material flow direction) from a side edge of the surface of the conveyance system, and a second entanglement station that is positioned subsequent to the first entanglement station may include a second entanglement head positioned a second distance inward from the side edge of the conveyance system where the second distance is different from the first distance.

In example aspects, the stacked configuration of layers includes a first nonwoven layer, a second layer, and a fill material positioned between the first nonwoven layer and the second layer. The stacked configuration is positioned on the surface of the conveyance system such that the first nonwoven layer faces upward or toward the actuator, the carriage, and the entanglement head of a first entanglement station and the second layer faces toward the surface of the conveyance system. In one example aspect when the entanglement head includes entanglement needles, while the composite nonwoven textile is in a first stationary phase, the actuator causes the entanglement head and/or the entanglement needles to move in a direction perpendicular to a plane of conveyance of the surface such that the entanglement needles, and indirectly the entanglement head, engage with the stacked configuration to form a first entanglement area. When the entanglement needles engage with the stacked configuration, the needles drive fibers from the first nonwoven layer through the fill material and into the second layer. In another example aspect when the entanglement head emits one or more pressurized jets of fluid, while the stacked configuration is in the first stationary phase, the actuator actuates the entanglement head to emit the one or more jets of fluid that contact the stacked configuration to form the first entanglement area. Alternatively, the stacked configuration may be continually advanced while the entanglement head continually emits one or more jets of fluid. In these aspects, when the jets of fluid contact the stacked configuration, the pressure of the jets drives fibers from the first nonwoven layer through the fill material and into the second layer

When entanglement needles are used, the conveyance system then advances the stacked configuration of the first nonwoven layer, the second layer and the fill material in the material flow direction by a predefined amount. In example aspects, the predefined amount of advancement may be less than or equal to a dimension of the entanglement head in the material flow direction. Additionally, the entanglement head and/or the conveyance system may move in a direction non-parallel to the material flow direction by a predefined amount. In example aspects, the predefined amount of movement may be less than or equal to a dimension of the entanglement head in the direction non-parallel to the material flow direction. While the stacked configuration is in a second stationary phase and when the entanglement head includes entanglement needles, the actuator causes the entanglement head and/or the entanglement needles to move in the direction perpendicular to the plane of conveyance of the surface such that the entanglement needles engage with the stacked configuration to form a second entanglement area. When the entanglement head is adapted to emit one or more pressurized jets of fluid, the actuator actuates the entanglement head to emit the one or more jets of fluid to form the second entanglement area. The second entanglement area extends from the first entanglement area to form a non-linear entangled seam.

As the stacked configuration continues to advance through the first entanglement station, additional entanglement areas are formed that extend from the first and second entanglement areas such that the apparent continuous entangled seam is formed in the material flow direction. By moving the entanglement head and/or the conveyance system in directions non-parallel to the material flow direction, the continuous entangled seam becomes non-linear in the material flow direction. In example aspects, the first and second entanglement areas may partially overlap such that the overlap area represents an area where the entanglement needles and/or jets of fluid engage with the stacked configuration at least two times. In other example aspects, the first and second entanglement areas may not overlap but be positioned directly adjacent to each other to form an apparent continuous non-linear entangled seam. In still other aspects, the first and second entanglement areas may be spaced apart to form a discontinuous non-linear entangled seam. Any and all aspects, and any variation thereof, are contemplated as being within the scope herein.

The stacked configuration of the first nonwoven layer, the second layer, and the fill material may continue to advance through additional entanglement stations where additional non-linear entangled seams are formed that may be separate and distinct from the non-linear entangled seams formed by the first entanglement station. Stated differently, the additional non-linear entangled seams may be positioned at different locations along a direction non-parallel to the material flow direction. Depending on the number of entanglement stations in the entanglement system, the resulting composite nonwoven textile may have a short repeat of a visual arrangement of entangled seams, a long repeat of a visual arrangement of entangled seams, or no repeat of a visual arrangement of entangled seams.

The resulting composite nonwoven textile may include a plurality of non-linear entangled seams that extend in a material flow direction of the textile. As described, the entangled seams represent areas where fibers from the first nonwoven layer extend through the fill material and into the second layer. In example aspects, the fibers may extend through the second layer such that they extend outward from the second surface of the composite nonwoven textile. The composite nonwoven textile further includes regions where the first nonwoven layer, the second layer, and the fill material are substantially unentangled. The regions where the first nonwoven layer, the second layer, and the fill material are substantially unentangled have a greater thickness than the entangled seams. When the composite nonwoven textile is formed into a garment, the regions where the first nonwoven layer, the second layer, and the fill material are substantially unentangled would correspond to the “baffles” found in traditional insulating garments and are configured to store and retain heat to provide warmth while the entangled seams help to keep the fill material from drifting or shifting during wear.

The systems, methods, textiles, and garments described herein provide a number of advantages. For example, the composite nonwoven textile is easy and fast to manufacture requiring a minimal amount of materials (e.g., no adhesives, no stitching) and equipment (e.g., no heat press), and does not require post-processing steps where fill material is deposited into the baffles as with traditional constructions. This, in turn, reduces the carbon footprint associated with the manufacturing process. Moreover, the composite nonwoven textile may be formed of the same or similar materials (i.e., materials in the same polymer class). In one example aspect, each of the first nonwoven layer, the second layer, and the fill material may be formed from recycled polyester fibers. This allows the whole textile to be easily recycled by, for instance, shredding where the shredded material does not subsequently need to be sorted to remove disparate materials. Further, because the non-linear seams are formed by an entanglement process using, for instance, the recycled polyester fibers, the composite nonwoven textile does not include adhesives and/or threads used in stitching which reduces the need to remove these portions of the textile prior to recycling.

In example aspects, because the composite nonwoven textile may be formed of materials in the same polymer class and because the composite nonwoven textile may not include disparate materials such as threads, adhesives, and the like, a resulting garment formed from the composite nonwoven textile may be easily recycled by, for instance, shredding. Moreover, the shredded materials from the garment may subsequently be formed into one or more of the first nonwoven layer, the second layer, and the fill material to create a sustainable lifecycle for the garment. In line with this, scrap pieces generated during the making of the garment from the composite nonwoven textile may also be easily recycled by shredding, and the shredded materials from the scrap may subsequently be formed into one or more of the first nonwoven layer, the second layer, and the fill material.

An additional advantage of using the entanglement system and manufacturing methods described above is the ability to create complex visual arrangements of entangled seams. As used herein, the visual arrangement of entangled seams is collectively produced by the different shapes associated with each of the entangled seams, the spacing between the entangled seams, the number of the entangled seams, the width of the entangled seams, and the like. To create complex visual arrangements of the entangled seams, the entanglement heads may be positioned at different locations on the entanglement stations, the number and/or spacing of the entanglement heads at the different entanglement stations may be varied, the entanglement footprint produced by the entanglement heads may be varied, and the movement of the entanglement heads and/or the conveyance system in different directions non-parallel to the material flow direction may be varied. The complex visual arrangements of entangled seams may include those where entangled seams may cross-over each other, intersect, or be positioned closely together. Besides producing an interesting aesthetic, the ability to create areas where seams may cross-over each other, intersect, or be positioned closely together allows for the generation of a differential thickness of the composite nonwoven textile. For example, the areas where seams may cross-over each other or intersect represent instances where one or more entanglement heads from the entanglement stations engage with the composite nonwoven textile multiple times. Thus, these areas may have a reduced thickness compared to other entangled seam areas and compared to regions where the first nonwoven layer, the second layer, and the fill material are substantially unentangled. When the composite nonwoven textile is formed into a garment, these areas may be positioned adjacent to portions of the human body needing less insulation (based on, for example, heat maps of the human body) since these areas generally have less loft and less insulating properties compared to other regions of the composite nonwoven textile.

A further advantage of using the entanglement system and method of manufacturing described herein is the ability to produce a textile having a short repeat of the visual arrangement of entangled seams, a long repeat of the visual arrangement of entangled seams, or no repeat of the visual arrangement of entangled seams. This is accomplished by varying the number of entanglement stations aligned serially along the conveyance system. The ability to create a long repeat or no repeat using the entanglement system described herein addresses a potential disadvantage of traditional garment-making. Traditional garment-making that uses textiles with a short repeating visual arrangement of elements may generate material waste. This is because the pattern pieces used to form the garment are positioned in such a way to produce garments that have the same visual arrangement of elements at the same location on the garments. This often results in a high amount of scrap. The ability to create the composite nonwoven textile such that it has a long repeat or no repeat of the visual arrangement of entangled seams allows for the production of an array of garments having a common finished form but with a varied aesthetic due to a unique visual arrangement of entangled seams while having minimal material waste. When viewed as a garment array or lot, a consumer would recognize the garments as having a common origin and/or a common manufacturer but would be able to select a garment from the array that has a visual arrangement of entangled seams to their liking.

A further aspect related to the entanglement system and methods of manufacturing described herein is the ability to create non-linear entangled seams on one or more single nonwoven layers. The ability to create entangled seams on single layers also has advantages including easy and fast manufacturing with a minimal amount of materials (e.g., no adhesives, no stitching) and equipment (e.g., no heat press). This, in turn, reduces the carbon footprint associated with the manufacturing process. Moreover, the nonwoven textile may be formed of the same or similar materials (i.e., materials in the same polymer class). This allows the whole textile to be easily recycled by, for instance, shredding where the shredded material does not subsequently need to be sorted to remove disparate materials. Further, because the non-linear seams are formed by an entanglement process using, for instance, the recycled polyester fibers, the nonwoven textile does not include adhesives and/or threads used in stitching which reduces the need to remove these portions of the textile prior to recycling.

The single nonwoven layer may include a single fiber layer (e.g., a lightly entangled fiber web), multiple fiber layers that are entangled with each other, fiber layers entangled with other materials such as elastomeric layers, textile layers, and the like. In example aspects, once the non-linear entangled seams are created on an individual nonwoven layer, the nonwoven layer may be formed into, for example, an article of apparel. In other example aspects, different nonwoven layers having non-linear entangled seams may be positioned adjacent to each other with optional additional layers (nonwoven, knit, woven, films, and the like) positioned therebetween, and the different layers may be secured together using entanglement, sewing, bonding, and the like. Any and all aspects, and any variation thereof, are contemplated as being within the scope herein.

As used herein, the term “garment” or “article of apparel” is intended to encompass articles worn by a wearer. As such, they may include upper-body garments (e.g., tops, t-shirts, pullovers, hoodies, jackets, coats, and the like), and lower-body garments (e.g., pants, shorts, tights, capris, unitards, and the like). Garments may also include hats, gloves, sleeves (arm sleeves, calf sleeves), articles of footwear such as uppers for shoes, and the like. The term “inner-facing surface” when referring to the garment means the surface that is configured to face towards a body surface of a wearer when the garment is worn as intended, and the term “outer-facing surface” means the surface that is configured to face away from the body surface of the wearer and toward an external environment when the garment is worn as intended. The term “innermost-facing surface” means the surface closest to the body surface of the wearer with respect to other layers of the garment, 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 garment. The term “pattern” or “pattern piece” used in relation to constructing a garment means that the pattern or pattern piece has a perimeter shape that corresponds to a structure on a finished garment such as, for example, a sleeve, a front torso panel, a collar, and the like. The pattern or pattern piece is used when removing, extracting, or cutting portions of a textile that have a perimeter shape corresponding to the pattern or pattern piece where the portions of the textile are assembled to form a garment using, for example, a traditional cut-and-sew construction.

As used herein, the term “composite nonwoven textile” encompasses any textile that includes at least one nonwoven layer in combination with other layers whether the layers may be substantially unaffixed from each other except for the entangled seams. Thus, it is contemplated herein that the composite nonwoven textile be entirely formed from nonwoven layers. It is also contemplated herein that a nonwoven layer may be combined with other constructions such as fibrous materials, films, woven layers, knit layers, braided layers, and the like. It is contemplated herein that the term “composite nonwoven textile” encompasses a stacked configuration of layers and one more entangled seams that join the layers forming the stacked configuration at the seam areas.

The term “nonwoven layer” refers to a layer where fibers are held together by mechanical and/or chemical interactions without being in the form of a knit, woven, braided construction, or other structured construction. In a particular aspect, the nonwoven layer includes a collection of fibers that are mechanically or chemically manipulated to form a mat-like material. Stated differently the nonwoven layer is directly made from fibers. The composite nonwoven textile described herein may include different layers formed into a cohesive structure, where the different layers may have a different or similar composition of fibers or yarns and/or different properties. In one example, the first nonwoven layer and optionally the second layer may include a spunbond layer. As used herein, a spunbond layer is formed by spinning continuous filaments of a polymer material that have been melted onto a moving belt and bonding the filaments together using, for instance, a calendaring process. Spunbond nonwovens typically have a soft hand and are strong and durable. They also generally have a smooth surface suitable for printing including digital printing with digital printing heads. In another example aspect, the first nonwoven layer and optionally the second layer may include a spunlace layer. As used herein, a spunlace layer includes a web of fibers that are entangled by way of, for example, hydroentanglement. Aspects herein contemplate that the fill material may comprise an entangled web of fibers that forms a sheet-like material. In example aspects, the fibers may be resin bonded to form a cohesive structure. Other aspects herein contemplate that the fill material includes loose synthetic fibers/filaments, down, or a combination of any of the above.

The term “substantially unentangled” when referring to the composite nonwoven textile refers to a region of the composite nonwoven textile in which the layers have not been entangled with each other such that the layers are independently movable with respect to each other or in which one or more of the layers have been lightly entangled with each other. The term “entangled seam” when referring to the composite nonwoven textile refers to an area of the composite nonwoven textile in which the layers of the composite nonwoven textile have undergone mechanical entanglement with each other by way of, for example, needlepunching or hydroentanglement. As such, the different layers of the composite nonwoven textile in the seam area may include fibers originally present in a particular layer as well as fibers that are present in other layers, including additional nonwoven layers, or fill material that have been moved through the entanglement process into the layer. When describing that the entangled seam is “non-linear” it is contemplated herein that the distance between a non-linear entangled seam and a linear edge of the composite nonwoven textile may vary along a material flow direction of the nonwoven textile. Aspects herein contemplate that the seam may include linear segments, curved segments, curvilinear segments, and the like that alone or in combination form the non-linear entangled seam. In example aspects, the distance between adjacent non-linear entangled seams may vary along a material flow direction of the composite nonwoven textile.

The mechanical entanglement process contemplated herein may include needle entanglement (commonly known as needlepunching) using barbed or structured needles (e.g., forked needles) known herein as entanglement needles, or fluid entanglement which is known herein as hydroentanglement. Needlepunching generally uses entanglement 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 layers forming the composite nonwoven textile may be stacked, and entanglement needles associated with an entanglement head pass in and out through the stacked configuration. Thus, when describing that an entanglement head engages with a nonwoven textile, it is contemplated herein that the entanglement needles associated with the entanglement head engage with the nonwoven textile. A stripper plate may be used that strips the fibers from the needles after the needles have moved in and out of the stacked configuration. Each engagement of the entanglement head with the stacked configuration is known herein as a “pass.” Parameters associated with entanglement head may be adjusted to achieve desired properties of the resulting composite nonwoven textile (e.g., basis weight, thickness, and the like) as explained further below.

The barbs on the entanglement needle “capture” fibers as the barb moves from the first nonwoven layer through the stacked configuration. The movement of the entanglement needle effectively moves or pushes fibers captured by the barbs from a location near or at the surface of the first nonwoven layer to a location near or at the surface of the second layer and further causes physical interactions with other fibers helping to “lock” the moved fibers into place through, for example, friction. It is also contemplated herein that the entanglement needles may pass through the stacked configuration from the second layer in a direction toward the first nonwoven layer. It is also contemplated herein that the entanglement needles may pass through the stacked configuration from the first nonwoven layer toward the second layer and from the second layer toward the first nonwoven layer. Hydroentanglement works similar to needlepunching except instead of using entanglement needles, pressurized jets of a fluid (e.g., water) move the fibers through the different layers. Parameters associated with the hydroentanglement process such as the pressure of the fluid jets, the number of fluid jets, the rate of conveyance, and the like, may be adjusted to achieve a desired degree of entanglement.

The term “entanglement head” is used herein to describe a structure that includes one or more entanglement needles in a defined arrangement and/or one or more orifices for emitting pressurized jets of fluid in a defined arrangement. When the entanglement needles and/or jets of fluid engage with a composite nonwoven textile via the entanglement head, they may form an entanglement footprint. As used herein, the term “entanglement footprint” is the structured arrangement of entanglement points produced by an entanglement head on the composite nonwoven textile. For example, depending on the defined arrangement of the entanglement needles and/or orifices in the entanglement head, the entanglement footprint may have a circular shape, a square shape, a rectangular shape, a triangular shape, and the like.

The term “material flow direction” as used herein means the direction at which a material advances along a conveyance system. The material flow direction may also be known as the machine direction. Thus, when describing that a composite nonwoven textile includes non-linear entangled seams that extend in the material flow direction, the non-linear entangled seams extend in the direction of advancement of the composite nonwoven textile along a conveyance system of an entanglement system. As described herein, an entanglement head, or jets of fluid when hydroentanglement is used, may move in a direction perpendicular to a plane of conveyance of the conveyance system. To describe this differently, if the plane of conveyance extends along an x, y plane, and the material flow direction extends in a positive x-direction, then the entanglement head or the jets of fluid may move in a positive or negative z-direction. When describing that a carriage or the conveyance system moves in directions non-parallel to the material flow direction, it is contemplated herein that the carriage and/or the conveyance system move in a generally positive or negative y-direction. This also may be known as the cross-machine direction.

Fibers used to form the nonwoven layers and other layers contemplated herein may be formed of a number of different materials (e.g., cotton, nylon and the like) including polyethylene terephthalate (PET) commonly known as polyester. The PET fibers may include virgin PET fibers (fibers that have not been recycled), and recycled PET fibers. Recycled PET fibers include shredded PET fibers derived from shredded articles and re-extruded PET fibers (fibers that are re-extruded using recycled PET chips).

Various measurements are provided herein with respect to the 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. Basis weight is measured using ISO3801 testing standard and has the units grams per square meter (gsm). Thermal resistance, which generally corresponds to insulation features, is measured using ISO11092 testing standard and has the units of RCT (M2*K/W). 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.

FIG.1depicts a first surface101of a composite nonwoven textile100where the first surface101is formed of a first nonwoven layer110. In example aspects, the first nonwoven layer110may include a spunbond or spunlace material although other nonwoven constructions are contemplated herein. Spunbond or spunlace materials generally have a soft hand and are durable making them suitable for incorporation into a garment. The first nonwoven layer110is formed from entangled fibers as indicated by reference numeral112. When the composite nonwoven textile100is incorporated into a garment, the first surface101may be positioned as an inner-facing surface or an innermost-facing surface of the garment. Alternatively, the first surface101may be positioned as an outer-facing surface or an outermost-facing surface of the garment.

The composite nonwoven textile100also includes a second layer114which will be described in greater detail with respect toFIGS.2A and2B. A fill material116is positioned between the first nonwoven layer110and the second layer114. The fill material116may include a fiber sheet having entangled fibers that may optionally be resin bonded to maintain a more cohesive structure, a lightly entangled web of fibers, a carded web, loose synthetic fibers, down, and the like.

As shown inFIG.1, the composite nonwoven textile100may include a plurality of non-linear entangled seams118that extend in a material flow direction105of the composite nonwoven textile100. The entangled seams118represent areas where fibers from the different layers are entangled with each other. In one example aspect, the entangled seams118represent areas where fibers from the first nonwoven layer110extend through the fill material116and into the second layer114. Regions122of the composite nonwoven textile100that are located between the entangled seams118represent regions where the first nonwoven layer110, the second layer114, and the fill material116are substantially unentangled such that the different layers are not secured or affixed or are lightly secured or affixed to one another at the regions122. As shown, the regions122have more loft or a greater thickness than the entangled seams118and may help to store and retain heat when the composite nonwoven textile100is incorporated into a garment. In turn, the entangled seams118may help to prevent shifting or drift of the fill material116when a garment incorporating the composite nonwoven textile100is worn.

With respect to at least entangled seam118a, a distance between the entangled seam118aand a linear first edge120of the composite nonwoven textile100varies along the material flow direction105of the composite nonwoven textile100. For example, a first distance124between the entangled seam118aand the first edge120may be less than a second distance126between the entangled seam118aand the first edge120. This also holds true for the other entangled seams118shown inFIG.1. As depicted, the entangled seams118may include linear segments that extend from each other, curves, and combinations of the above. The depiction of the shape of the individual entangled seams118, the number of entangled seams118, the spacing between adjacent entangled seams118, and the overall visual arrangement of the entangled seams118is illustrative and it is contemplated herein that the entangled seams118may include other non-linear shapes, a different number of entangled seams118, different spacing, and a different overall visual arrangement of the entangled seams118.

FIG.2Aillustrates an opposite second surface201of the composite nonwoven textile100where the second surface201is formed by the second layer114. In one example aspect as shown inFIG.2A, the second layer114may include a woven layer as indicated by the example interlaced warp and weft yarns210. In this example, when the composite nonwoven textile100is incorporated into a garment, the second layer114may be positioned to be an outer-facing surface or an outermost-facing surface of the garment. Woven materials in general have a high resistance to abrasion and may act as an effective wind barrier due to the tight weave construction making them suitable for forming outer-facing surfaces of garments. In example aspects, the woven material may be treated with a durable water repellant to impart water resistance properties to the composite nonwoven textile100. The non-linear entangled seams118are shown extending through the composite nonwoven textile100such that they are present on the second surface201of the textile100.

FIG.2Billustrates a second example where the second layer114is formed from a nonwoven material such as a spunbond or spunlace material. Entangled fibers forming the second layer114are indicated by reference numeral212. The non-linear entangled seams118extend through the composite nonwoven textile100such that they are present on the second surface201of the textile100inFIG.2B.

FIG.3depicts a cross-section of the composite nonwoven textile100taken at cut line3-3ofFIG.1. The first nonwoven layer110, the second layer114, and the fill material116are indicated where the fill material116is positioned between the first nonwoven layer110and the second layer114. At the regions122, each of the first nonwoven layer110, the second layer114, and the fill material116are substantially unentangled such that the first nonwoven layer110, the second layer114, and the fill material116remain generally separate and distinct layers having a combined thickness310as measured from the first surface101to the second surface201.

The fibers112from the first nonwoven layer110are shown extending through the fill material116and the second layer114at the entangled seams118such that the entangled seams118secure the different layers together at the seam areas. In one example aspect, the fibers112may extend through the second layer114such that they extend away from the second surface201of the composite nonwoven textile100as shown inFIG.3. In this example, the fibers112may be left unmodified such that the second surface201presents a fuzzy surface at the entangled seams118. In another example, the fibers112may be removed, compressed, or melted. For example, a calendaring process may be used to compress the fibers112such that they do not extend from the second surface201. In another example, the fill material116may include low-melt fibers, and any low-melt fibers extending from the second surface201may be removed by the application of heat. Additionally, a shaving process could be used to remove the fibers112if desired. In another example aspect, the fibers112may extend into the second layer114but not extend through the second layer114such that the fibers112are generally not present on the second surface201of the composite nonwoven textile100.

The entangled seams have a thickness312that is less than the thickness310at the regions122. In one example aspect, the thickness310may be from about 7 mm to about 15 mm, from about 8 mm to about 13 mm, from about 9 mm to about 11 mm, or about 10 mm. As used herein, the term “about” means within ±10% of an indicated value. In example aspects, the thickness312may be from about 5 mm to about 0.2 mm, from about 4 mm to about 1 mm, from about 3 mm to about 1.5 mm, or about 2 mm. As such, in example aspects, the thickness312of the entangled seams118may be from about 5% to about 30% of the thickness310of the regions122.

FIG.4Aillustrates an enlarged view of one of the entangled seams118of the composite nonwoven textile100as viewed form the first surface101of the composite nonwoven textile100. A view of the entangled seam118from the second surface201would be similar.FIG.4Aillustrates a first example way that the entangled seam118may be formed. In example aspects, the entangled seam118may be formed from discrete entanglement areas410that partially overlap each other at overlap areas412. Each of the discrete entanglement areas410has an entanglement footprint. For instance, the entanglement footprint of the entanglement areas410is depicted as having a circular form but this is illustrative and dependent on the structured arrangement of the entanglement needles and/or orifices in the entanglement head used to form the entanglement areas410. As shown, the entanglement areas410extend from each other in a non-linear manner to form an apparent continuous non-linear entangled seam.

The individual dots within the entanglement areas410represent entanglement points414where either an entanglement needle or a fluid jet engages with the composite nonwoven textile100to entangle fibers. The number of the entanglement points414per cm2may be known herein as a stitch density. The stitch density is dependent upon, for example, the number of entanglement needles associated with the entanglement head, the number of fluid jets emitted by the entanglement head, the structured arrangement of the entanglement needles and/or jet orifices, and the like. A greater stitch density may result in a reduced thickness at the entangled seams118compared to a lesser stitch density since a greater stitch density generally means a greater degree of fiber entanglement.

The overlap areas412represent areas where the entanglement head engages with the composite nonwoven textile more than one time. As such, the number and/or density of the entanglement points414within the overlap areas412is greater than the number and/or density of the entanglement points414at remaining portions of the entanglement areas410. Stated differently, the stitch density of the overlap areas412is greater than the stitch density at remaining portions of the entanglement areas410. A result of this is that the overlap areas412may have a reduced thickness as compared to remaining portions of the entanglement areas410.

FIG.4Billustrates a second example way that the entangled seam118may be formed. In this aspect, the entanglement areas410extend from one another in a non-linear manner to form an apparent continuous entangled seam. The entanglement areas410, however, do not partially overlap each other as inFIG.4A. Instead, the entanglement areas410may be positioned directly adjacent to each other such that an entanglement point414of a first entanglement area410may share a common border with an entanglement point414of an adjacent second entanglement area410. With respect to the non-linear entangled seams118, the entangled seams118may include the configuration shown inFIG.4A, the configuration shown inFIG.4B, or a combination of the configurations shown inFIG.4AandFIG.4B. It is also contemplated herein that the entanglement areas410may be spaced apart from one another to form a discontinuous non-linear entangled seam.

FIG.5is a schematic depiction of a side view of an example entanglement system500. The depiction of the different components of the entanglement system500is illustrative only and does not represent the actual configuration or structure of the components. The entanglement system500includes a conveyance system512having a surface514adapted to advance a stacked configuration of, for example, the first nonwoven layer110, the second layer114, and the fill material116in a material flow direction as indicated by arrows516. As described further with respects toFIGS.18and19, in another aspect, the conveyance system512may advance a single nonwoven layer, such as the first nonwoven layer110in the material flow direction516. The conveyance system512may include conveyance systems known in the art such as rollers, belts, and the like. The advancement of the conveyance system512may, in example aspects, include stationary phases or positions and movement phases in the material flow direction516. The duration of the stationary phases and movement phases may be adjusted to achieve one or more desired features in the resulting composite nonwoven textile. For example, the duration of the stationary phases may be adjusted to achieve more or less entanglement of the resulting entangled seams. Stated differently, longer stationary phases may allow for more passes of entanglement needles at an entanglement area, a greater stitch density at the entanglement area, and a greater degree of entanglement at the entanglement area. The distance of advancement during the movement phases may also be adjusted to achieve a desired feature in the resulting composite nonwoven textile. For example, increasing the distance of advancement during the movement phases may cause the entanglement areas to not overlap or even be spaced apart from each other while decreasing the distance of advancement during the movement phases may increase the amount of overlap between adjacent entanglement areas. The speed of conveyance during the movement phases may be adjusted to increase and/or decrease production times.

The entanglement system500further includes a number of entanglement stations such as entanglement stations518,520, and522. Although only three entanglement stations are depicted, it is contemplated herein that there may a greater number or a fewer number of entanglement stations than shown inFIG.5. The entanglement stations518,520, and522are aligned serially along the conveyance system512in the material flow direction516. In example aspects, including a greater number of entanglement stations in the entanglement system500creates a resulting composite nonwoven textile having a long repeat or no repeat of the visual arrangement of non-linear entangled seams. Including a fewer number of entanglement stations in the entanglement system500creates a resulting composite nonwoven textile having a short repeat of the visual arrangement of non-linear entangled seams. Thus, the number of entanglement stations that are part of the entanglement system500may be customized to achieve a desired repeat length of the visual arrangement of non-linear entangled seams.

The components associated with the different entanglement stations518,520, and522may be substantially similar and, as such, the components associated with the entanglement station518will be described herein with the understanding that the description of the components also applies to the entanglement stations520and522. The entanglement station518includes a carriage524slidably coupled to, for example, a mount526. The carriage524is adapted to move in directions non-parallel to the material flow direction516. Alternatively, the carriage524may not be used when the conveyance system512is adapted to move in directions non-parallel to the material flow direction516. In example aspects, the carriage524and/or the conveyance system512are adapted to move in directions perpendicular to the material flow direction516toward both a first side edge and an opposite second side edge of the conveyance system512(i.e., in a positive and negative y-direction).

The entanglement station518further includes an actuator528coupled to the carriage524. In one example aspect and as shown inFIG.5, the actuator528is adapted to move in a direction perpendicular to a plane of conveyance of the surface514of the conveyance system512as indicated by arrow530. In other example aspects, the actuator may remain stationary and the actuator may actuate entanglement heads and/or entanglement needles to move in the direction perpendicular to the plane of conveyance of the surface514of the conveyance system512. In still other example aspects, and as described in relation toFIG.6B, the actuator528may remain stationary and the actuator may actuate entanglement heads to emit jets of fluid. An entanglement head532is coupled to the actuator528and may be indirectly coupled to the carriage524by way of the actuator528. In the example shown inFIG.5, the entanglement head532may include one or more entanglement needles534that extend toward the surface514of the conveyance system512. Although only one entanglement needle534is depicted, it is contemplated herein that the entanglement head532may include multiple entanglement needles as further described with respect toFIGS.9A and9B.

FIG.6Adepicts a front view of the entanglement station518depicting the mount526, the carriage524, the actuator528, the entanglement head532, and the entanglement needle534. Arrow610represents a first direction of movement of the carriage524and/or conveyance system512in the direction non-parallel to the material flow direction516, and arrow611represents an opposite second direction of movement of the carriage524and/or conveyance system512in the direction non-parallel to the material flow direction516. In example aspects, the first and second directions610and611are perpendicular to the material flow direction516.

The front view of the entanglement station518depicts three entanglement heads532a,532b, and532cspaced generally evenly apart where the three entanglement heads532a,532b, and532care each adapted to form a respective non-linear entangled seam. This is illustrative only and it is contemplated herein that there may be more than the three entanglement heads532a,532b, and532cor fewer than the three entanglement heads532a,532b, and532c. As well, the spacing between the entanglement heads532a,532b, and532cmay vary such that a spacing between a first and second entanglement head532of the entanglement heads532a,532b, and532cmay be greater than a spacing between the second and a third entanglement head532of the entanglement heads532a,532b, and532c. As explained with respect toFIGS.9A and9B, the entanglement heads532a,532b, and532cmay have different dimensions, a different structured arrangement of entanglement needles and/or orifices, and the like.

FIG.6Bdepicts a front view of an alternative entanglement station612that may be part of an entanglement system such as the entanglement system500that is adapted to hydroentangle layers to create a composite structure instead of needlepunching the layers to create a composite structure. As such the entanglement station612may be representative of multiple hydroentanglement stations that are part of the entanglement system500.

The entanglement station612also includes a mount614to which a carriage616is slidably coupled, an actuator618coupled to the carriage616, and an entanglement head620coupled to the actuator618. The carriage616and/or conveyance system512is adapted to move in a first direction non-parallel to the material flow direction516as indicated by arrow622and in an opposite second direction623non-parallel to the material flow direction516. In example aspects, the directions622and623are perpendicular to the material flow direction516. In example aspects, the actuator618may not move in the direction530perpendicular to the plane of conveyance of the surface514. Instead, in example aspects, the actuator618is adapted to actuate the entanglement head620to emit one or more pressurized jets of fluid624that extend toward the surface514of the conveyance system512. With respect to this aspect, it is contemplated herein that the conveyance system512may intermittently advance as described above where the jets of fluid624are emitted when the conveyance system512is in a stationary phase. Alternatively, the conveyance system512may be continually advanced and the jets of fluid624may be continually emitted from the entanglement head620. Similar to the entanglement station518, the number of entanglement heads620may be different from that shown, the spacing between entanglement heads620may vary from that shown, and the entanglement heads620may have different dimensions, a different structured arrangement of orifices, and the like.

FIG.7depicts the second entanglement station520where the second entanglement station520includes the same components as the entanglement station518(e.g., mount526, carriage524, actuator528, and entanglement head532). Two entanglement heads532dand532eare depicted for the second entanglement station520. In example aspects, the entanglement heads532dand532emay be positioned such that they do not align in the material flow direction516with the entanglement heads532a,532b, and532c. The result of this is that the entanglement heads532dand532eare adapted to engage with the composite nonwoven textile at different locations in a direction non-parallel to the material flow direction516as compared to the entanglement heads532a,532b, and532c. Stated differently, the entanglement heads532dand532eare adapted to form a set of non-linear entangled seams that are distinct and separate from the non-linear entangled seams formed by the entanglement heads532a,532b, and532c. For instance, the entanglement head532amay be offset from a first edge660of the surface514of the conveyance system512in a direction perpendicular to the material flow direction516by a first distance613, and the entanglement head532dmay be offset from the first edge660of the surface514of the conveyance system512in the direction perpendicular to the material flow direction516by a second distance615where the second distance615is greater than the first distance613. As such, a spacing arrangement between the entanglement heads532dand532ediffers from a spacing arrangement between the entanglement heads532a,532b, and532c. As shown, the entanglement station520includes a different number of entanglement heads532than the number of entanglement heads532at the entanglement station518. It is contemplated herein that the entanglement station520may include fewer entanglement heads than shown or a greater number of entanglement heads than shown. The dimensions of the entanglement heads532eand532dmay be the same or different from the dimensions of the entanglement heads532a,532b, and532c. Additionally, the entanglement footprint produced by the entanglement heads532eand532dmay be the same or different from the entanglement footprint produced by the entanglement heads532a,532b, and532c.

FIG.8depicts the third entanglement station522where the third entanglement station522includes the same components as the entanglement stations518and522. Two entanglement heads532fand532gare depicted for the third entanglement station522. In example aspects, the entanglement heads532fand532gmay be positioned such that they do not align in the material flow direction516with the entanglement heads532a,532b,532c,532d, and532e. Thus, the entanglement heads532fand532gare adapted to form another set of non-linear entangled seams that are distinct and separate from the non-linear entangled seams formed by the entanglement heads532a,532b,532c,532d, and532e. Stated differently, the entanglement heads532fand532gmay be offset from the first edge660of the surface514of the conveyance system512by distances that are different than the distances of offset for the entanglement heads532a,532b,532c,532d, and532e. The entanglement station522may include a different number of entanglement heads532than that shown. The entanglement heads532fand532gmay also be spaced differently from that shown. The dimensions of the entanglement heads532fand532gmay be the same or different from the dimensions of the entanglement heads532a,532b,532c,532d, and532e. In addition, the entanglement footprint produced by the entanglement heads532fand532gmay be the same or different from the entanglement footprint produced by the entanglement heads532a,532b,532c,532d, and532e.

Although the entanglement system500is depicted as including multiple entanglement stations positioned serially along the conveyance system512in the material flow direction516, it is also contemplated herein that the entanglement system500may include one entanglement station such as the entanglement station518. In this aspect, the stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116may be passed through the entanglement station518multiple times to form the resulting composite nonwoven textile100. In this aspect, the positioning of the entanglement heads532a,532b, and532cmay be adjusted between each pass such that different areas of the stacked configuration are engaged by the entanglement heads532a,532b, and532cduring each pass. As well, different entanglement heads may be added, existing entanglement heads may be removed, and the like. The movement of the carriage524may also be adjusted during each pass such that the entanglement heads532a,532b, and532cengage with different portions of the stacked configuration.

The illustrative entanglement system500shown inFIG.5and described further with respect toFIGS.6A-8may produce a complex visual arrangement of non-linear entangled seams that extend in the material flow direction516. The components and movements of the entanglement system500may be adjusted to create non-linear entangled seams that are spaced closely together or are spaced further apart. Additionally, the system500may create non-linear entangled seams that cross over each other or intersect one or more times along a particular entangled seam's material flow direction. As described further with respect toFIGS.14-16, this creates a differential thickness of a resulting composite nonwoven textile in the first and second directions610and611non-parallel or perpendicular to the material flow direction516(i.e., along a cross-section of the resulting composite nonwoven textile).

FIGS.9A and9Bdepict bottom up views of two example entanglement heads920and922respectively. The entanglement heads920and922may be any of the entanglement heads described in relation to the entanglement system500or the entanglement station612. With respect to the entanglement head920, it includes a structured arrangement of entanglement needles924or, alternatively, orifices924adapted to emit jets of fluid. The entanglement head920has an example circular shape such that the entanglement needles924or orifices924are adapted to form a circular entanglement footprint on a composite nonwoven textile. The entanglement head920has a dimension910in the material flow direction and a dimension912in the first and second directions610and611non-parallel or perpendicular to the material flow direction516. Because the entanglement head920has a circular shape, the dimensions910and912are equivalent to the diameter of the entanglement head920and are equal.

The entanglement head922also includes a structured arrangement of entanglement needles926or, alternatively, orifices926adapted to emit jets of water. The entanglement head922has an example rectangular shape such that the entanglement needles926or orifices926are adapted to form a rectangular entanglement footprint on a composite nonwoven textile. The entanglement head922has a dimension914in the material flow direction516and a dimension916in the first and second directions610and611non-parallel or perpendicular to the material flow direction516.

In example aspects, the distance of advancement of the conveyance system512in the material flow direction516during the movement phases of the entanglement system500may be less than or equal to the dimensions910and914of the respective entanglement heads920and922. This ensures that the entanglement areas produced by the entanglement heads920and922are directly adjacent to each other and/or overlap to form an apparent continuous non-linear entangled seam. Further, the movement of the carriage524and/or conveyance system5120in the first and second directions610and611non-parallel or perpendicular to the material flow direction516may be less than or equal to the dimensions912and916of the respective entanglement heads920and922. This further ensures that the entanglement areas produced by the entanglement heads920and922are directly adjacent to each other and/or overlap to form the apparent continuous non-linear entangled seam. The depiction of the shapes of the entanglement heads920and922is illustrative and it is contemplated herein that the entanglement heads may have other shapes such as oval, square, triangular, and the like.

FIGS.10A and10Brespectively schematically depict processes for manufacturing a composite nonwoven textile having non-linear entangled seams such as the composite nonwoven textile100.FIG.10Adepicts a process that uses entanglement needles and may be carried out at any of the entanglement stations518,520, or522.FIG.10Bdepicts a process that uses hydroentanglement and may be carried out at, for instance, the entanglement station612. With respect to bothFIG.10AandFIG.10B, a coordinate system is provided indicating an x direction, a y direction and a z direction.

Referring toFIG.10A, at a step1010, a stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116is positioned on the surface514of the conveyance system512such that the second layer114is positioned against the surface514and the first nonwoven layer110is spaced apart from the surface514by the fill material116. The conveyance system512and the stacked configuration are in a first stationary phase or position such that the conveyance system512is not advancing in the material flow direction516(i.e., the positive x-direction). During the first stationary phase, the actuator528moves in the direction530perpendicular to the plane of conveyance of the surface514(i.e., a negative z-direction) such that the entanglement head532is lowered causing the entanglement needle534, and indirectly the entanglement head532, to engage with the stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116. Alternatively, the actuator528may actuate the entanglement head532and/or the entanglement needle534such that the entanglement needle534moves downward to engage with the stacked configuration. The engagement drives fibers from the first nonwoven layer through the fill material116and into (or through) the second layer114creating a first entanglement area1012as shown in step1014. The first entanglement area1012may have an entanglement footprint corresponding to the shape of the structured arrangement of the entanglement needles534on the entanglement head532.

At a step1016, the entanglement needle534disengages from the stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116, and the conveyance system512advances the stacked configuration in the material flow direction516by a distance1018. In example aspects, the distance1018may be equal to or less than the dimension of the entanglement head532in the material flow direction516. At the step1016, the carriage524moves a first distance in the first direction610non-parallel to the material flow direction516(i.e., a negative y-direction) where the first distance may be equal to or less than the dimension of the entanglement head532in the first direction610non-parallel to the material flow direction516. The movement of the carriage524may occur simultaneously with the movement of the conveyance system512in the material flow direction516or it may occur after the movement of the conveyance system512in the material flow direction516(i.e., when the conveyance system512is in a second stationary phase). Alternatively, or in addition to, the conveyance system512may move the first distance in the first direction610non-parallel to the material flow direction516.

At a step1022, the conveyance system512and the stacked configuration are in a second stationary phase or position such that the conveyance system512is not advancing in the material flow direction516. The second stationary phase or position is advanced from the first stationary phase or position in the material flow direction516. During the second stationary phase, the actuator528again moves in the direction530perpendicular to the plane of conveyance of the surface514such that the entanglement head532is lowered causing the entanglement needle534to engage with the stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116. Because of the movement of the carriage524and/or conveyance system512, the engagement of the entanglement needle534with the stacked configuration occurs at a location offset from the first entanglement area1012in the first direction610non-parallel to the material flow direction516. The second engagement again drives fibers from the first nonwoven layer110through the fill material116and into (or through) the second layer114creating a second entanglement area1026as shown in step1024to create an apparent continuous non-linear entangled seam1028in the composite nonwoven textile100. The second entanglement area1026may have an entanglement footprint corresponding to the shape of the structured arrangement of the entanglement needles534on the entanglement head532. As shown at1024, the second entanglement area1026partially overlaps the first entanglement area1012. This is illustrative, and it is contemplated herein that the second entanglement area1026may not partially overlap the first entanglement area1012.

The process depicted inFIG.10Amay include a plurality of stationary phases or positions that are advanced from each other in the material flow direction during which the entanglement needle534engages with the stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116to form entanglement areas that extend from one another. As well, the process depicted inFIG.10Amay include a plurality of movement phases during which the conveyance system512advances the stacked configuration in the material flow direction516a distance that is less than or equal to the dimension of the entanglement head532in the material flow direction516such that the resulting entanglement areas partially overlap or directly extend from one another. Moreover, the carriage524and/or the conveyance system512may execute multiple movements in the first direction610non-parallel to the material flow direction516and in the opposite second direction611(i.e., the positive y-direction). The distance of movement of the carriage524and/or conveyance system512in the first direction610and the opposite second direction611may be less than or equal to the dimension of the entanglement head532in the first direction610or the opposite second direction611such that the resulting entanglement areas partially overlap or directly extend from one another.

The process schematically depicted inFIG.10Bis similar to that shown inFIG.10Abut utilizes hydroentanglement to create non-linear entangled seams. At a step1050, a stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116is positioned on the surface514of the conveyance system512such that the second layer114is positioned against the surface514and the first nonwoven layer110is spaced apart from the surface514by the fill material116. In one example aspect, the conveyance system512and the stacked configuration are in a first stationary phase or position such that the conveyance system512is not advancing in the material flow direction516. During the first stationary phase, the actuator618actuates the entanglement head620to emit one or more pressurized jets of fluid1052in a direction toward the surface514of the conveyance system512to form a first entanglement area1054as shown in step1056. In example aspects, the actuator618may not move in a direction perpendicular to the plane of conveyance of the surface514during the first stationary phase though it is contemplated herein that the actuator618may move in the direction perpendicular to the plane of conveyance of the surface514in order to position the jets of fluid1052closer to the first nonwoven layer110. In another example aspect, the conveyance system512may continually advance in the material flow direction516while the actuator618continually actuates the entanglement head620to emit the one or more pressurized jets of fluid1052. The jets of fluid1052drive fibers from the first nonwoven layer110through the fill material116and into (or through) the second layer114creating the first entanglement area1054. The first entanglement area1054may have an entanglement footprint corresponding to the shape of the structured arrangement of the orifices on the entanglement head620.

At a step1058, the conveyance system512advances the stacked configuration in the material flow direction516by a distance1060. In example aspects, the distance1060may be equal to or less than the dimension of the entanglement head620in the material flow direction516. At the step1058, the carriage616and/or the conveyance system512moves a first distance in the first direction622non-parallel to the material flow direction516where the first distance may be equal to or less than the dimension of the entanglement head620in the direction non-parallel to the material flow direction516. The movement of the carriage616and/or conveyance system512may occur simultaneously with the movement of the conveyance system512in the material flow direction516or it may occur after the movement of the conveyance system512in the material flow direction516(i.e., when the conveyance system512is in a second stationary phase or position that is advanced from the first stationary phase or position in the material flow direction).

At a step1064, the conveyance system512and the stacked configuration are in a second stationary phase or position, the actuator618again actuates the entanglement head620to emit the jets of fluid1052such that the jets of fluid1052engage with the stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116. Because of the movement of the carriage616, the engagement of the jets of fluid1052with the stacked configuration occurs at a location offset from the first entanglement area1054in the direction622non-parallel to the material flow direction516. The second engagement again drives fibers from the first nonwoven layer110through the fill material116and into (or through) the second layer114creating a second entanglement area1068as shown in step1066to create an apparent continuous non-linear entangled seam1070in the composite nonwoven textile100that extends in the material flow direction516. As shown at1066, the second entanglement area1068partially overlaps the first entanglement area1054. This is illustrative, and it is contemplated herein that the second entanglement area1068may not partially overlap the first entanglement area1054.

The process depicted inFIG.10Bmay include a plurality of stationary phases or positions during which the jets of fluid1052engage with the stacked configuration of the first nonwoven layer110, the second layer114, and the fill material116to form entanglement areas that extend from one another. As well, the process depicted inFIG.10Bmay execute a plurality of movement phases during which the conveyance system512advances the textile in the material flow direction516a distance that is less than or equal to the dimension of the entanglement head620in the material flow direction516such that the resulting entanglement areas partially overlap or directly extend from one another. Moreover, the carriage616and/or the conveyance system512may execute multiple movements in the first direction622non-parallel to the material flow direction516and in the opposite second direction623. The distance of movement of the carriage616and/or conveyance system512in the first direction610and the opposite second direction623may be less than or equal to the dimension of the entanglement head620in the first direction610or the opposite second direction623such that the resulting entanglement areas partially overlap or directly extend from one another.

As described earlier, the entanglement systems described herein, such as the entanglement system500, may create a composite nonwoven textile, such as the composite nonwoven textile100that includes a long repeat of a visual arrangement of non-linear entangled seams or even no repeat of a visual arrangement of non-linear entangled seams. The resulting composite nonwoven textile may be used to create an array of garments having a common finished form but having a varied aesthetic due to different visual arrangements of the non-linear entangled seams on the resulting garments. The array of garments may share features in common, such as the common finished form, color, and the like, such that a consumer would readily recognize the array of garments as coming from a common source (e.g., a common manufacturer). However, the consumer would be able to select a garment from the array of garments that has a desired visual arrangement of the entangled seams. Further, because there is a long repeat or even no repeat of a visual arrangement of non-linear entangled seams, there may be less material waste when forming the array of garments since the pattern pieces do not have to be positioned in such a way to ensure that each garment includes the same visual arrangement of entangled seams at the same location on the garment.

FIG.11schematically illustrates a method of manufacturing an array of garments having a common finished form but different visual arrangements of non-linear entangled seams. At a step1110, the composite nonwoven textile100is provided or obtained. The composite nonwoven textile100, in this example, includes a first non-linear entangled seam1112and a second non-linear entangled seam1114both extending in the material flow direction516of the composite nonwoven textile100. In example aspects, a distance between the first non-linear entangled seam1112and the second non-linear entangled seam1114varies along the material flow direction516. For example, the first non-linear entangled seam1112may be spaced apart from the second non-linear entangled seam by a first distance1111at a first location1113on the composite nonwoven textile100. At a second location1115on the composite nonwoven textile100, the first non-linear entangled seam1112may be spaced apart from the second non-linear entangled seam1114by a second distance1117, where the second distance1117is greater than the first distance1111.

At the step1110, a first instance of a pattern1116is removed, excised, and/or cut from the composite nonwoven textile100where the pattern1116corresponds to a left sleeve for an upper-body garment. Stated differently, at the step1110, a first portion1120is removed from the composite nonwoven textile100, where the first portion1120has a shape corresponding to the pattern1116. The pattern1116is illustrative only, and it is contemplated herein that the pattern1116may correspond to any portion of an upper-body garment, a lower-body garment, a shoe upper, an article of headwear, and the like.

Step1118illustrates the first portion1120having the pattern1116after it has been removed from the composite nonwoven textile100. As shown, the first portion1120includes the first non-linear entangled seam1112and the second non-linear entangled seam1114where the first non-linear entangled seam1112and the second non-linear entangled seam1114are positioned at a first location on the first portion1120and/or pattern1116as indicated generally by the reference numeral1119. At a step1122, the first portion1120is incorporated into a first garment1124. As shown inFIG.11, the first non-linear entangled seam1112and the second non-linear entangled seam1114present a first visual arrangement of non-linear entangled seams on the first garment1124as generally referenced by the numeral1126.

At a step1128, a second instance of the pattern1116is removed, excised, and/or cut from the composite nonwoven textile100. The second instance of the pattern1116includes the first non-linear entangled seam1112and the second non-linear entangled seam1114. Stated differently, at the step1128, a second portion1132is removed from the composite nonwoven textile100where the second portion1132has a shape corresponding to the pattern1116. Step1130illustrates the second portion1132having the pattern1116after it has been removed from the composite nonwoven textile100. As shown, the second portion1132includes the first non-linear entangled seam1112and the second non-linear entangled seam1114, where the first non-linear entangled seam1112and the second non-linear entangled seam1114are positioned at a second location on the second portion1132and/or pattern1116as indicated generally by the reference numeral1131. At a step1134, the second portion1132is incorporated into a second garment1138where the second garment1138has the same finished form as the first garment1124. As shown inFIG.11, the first non-linear entangled seam1112and the second non-linear entangled seam1114present a second visual arrangement of non-linear entangled seams on the second garment1138as generally referenced by the numeral1136where the second visual arrangement of non-linear entangled seams1136is a different visual arrangement than the first visual arrangement of non-linear entangled seams1126.

The process depicted inFIG.11may be repeated any number of times along the material flow direction516of the composite nonwoven textile100to form an array of garments having the first non-linear entangled seam1112and the second non-linear entangled seams1114positioned at different locations on the pattern1116and presenting different visual arrangements of the first and second non-linear entangled seams1112and1114. AlthoughFIG.11only depicts the pattern1116being applied to the composite nonwoven textile100, it is contemplated herein that additional pattern pieces may be applied to the composite nonwoven textile100such that a resulting garment may be formed from the additional pattern pieces applied to the composite nonwoven textile100. In this aspects, the visual arrangement of entangled seams at different regions of the garment may differ from each other to produce a varied overall aesthetic. A process similar to that shown inFIG.11may be used to form, for example, an array of lower-body garments having a common finished form but different visual arrangements of non-linear entangled seams.

In example aspects, scrap produced by the process depicted inFIG.11may be shredded and subsequently formed into, for example one or more of the first nonwoven layer110, the second layer114, or the fill material116. This is possible due to the materials forming the composite nonwoven textile100being of the same polymer class in example aspects (e.g., recycled polyester). Further, because the composite nonwoven textile100is formed without using disparate materials such as threads, adhesives, and the like, there is no need to remove portions of the scrap material before shredding.

FIGS.12and13further illustrate garments produced from the process shown inFIG.11.FIG.12illustrates a front view of an array of upper-body garments in the form of a sleeveless top including a first upper-body garment1210and a second upper-body garment1212having a common finished form. Although shown as a sleeveless top, it is contemplated herein that the upper-body garments may include other forms such as a vest, a pullover, a hoodie, a jacket, and the like. The first upper-body garment1210includes a neck opening1214, a waist opening1216, a first sleeve opening1218, and a second sleeve opening1220. Similarly, the second upper-body garment1212includes a neck opening1222, a waist opening1224, a first sleeve opening1226, and a second sleeve opening1228. Further, although the non-linear entangled seams are shown extending in a horizontal orientation (in a direction extending, for example, from the first sleeve opening1218/1226to the second sleeve opening1220/1228) it is contemplated herein that the non-linear entangled seams may extend in a vertical direction (in a direction extending, for example, from the neck opening1214/1222to the waist opening1216/1224).

As depicted, at least a front panel1230of the first upper-body garment1210and a front panel1232of the second upper-body garment1212may be formed from the same pattern piece applied to the composite nonwoven textile100. The front panel1230of the first upper-body garment1210includes a first non-linear entangled seam1234and a second non-linear entangled seam1236positioned at a first location1238on the first upper-body garment1210. In example aspects, the first location1238may correspond to a first distance1237as measured at a front vertical midline of the first upper-body garment1210for each of the first non-linear entangled seam1234and the second non-linear entangled seam1236relative to the waist opening1216of the first upper-body garment1210. The first non-linear entangled seam1234and the second non-linear entangled seam1236present a first visual arrangement of entangled seams on the first upper-body garment1210.

The front panel1232of the second upper-body garment1212further includes the first non-linear entangled seam1234and the second non-linear entangled seam1236positioned at a second location1244on the second upper-body garment1212where the second location1244is different from the first location1238. For example, the second location1244may correspond to a second distance1245as measured at a front vertical midline of the second upper-body garment1212for each of the first non-linear entangled seam1234and the second non-linear entangled seam1236relative to the waist opening1224of the second upper-body garment1212where the second distance1245for each of the first non-linear entangled seam1234and the second non-linear entangled seam1236is different from the first distance1237. The first non-linear entangled seam1234and the second non-linear entangled seam1236present a second visual arrangement of entangled seams on the second upper-body garment1212.

Although not shown, there may be additional upper-body garments included in the array where the additional upper-body garments have a common finished form with the first upper-body garment1210and the second upper-body garment1212. The additional upper-body garments in the array may present a different visual arrangement of the first non-linear entangled seam1234and the second non-linear entangled seam1236. Stated differently, the first non-linear entangled seam1234and the second non-linear entangled1236may be positioned at different locations on the additional garments relative to the pattern piece described above that is used to form the front panel of the additional upper-body garments.

FIG.13illustrates a front view of an array of lower-body garments in the form of a short including a first lower-body garment1310and a second lower-body garment1312having a common finished form. Although shown as a short, it is contemplated herein that the lower-body garments may include other forms such as a pant, a capri, and the like. The first lower-body garment1310includes a waist opening1314, a first leg opening1316a, and a second leg opening1316b. Similarly, the second lower-body garment1312includes a waist opening1322, a first leg opening1324a, and a second leg opening1324b. Further, although the non-linear entangled seams are shown extending in a horizontal orientation, it is contemplated herein that the non-linear entangled seams may extend in a vertical direction.

As depicted, at least a front panel1330of the first lower-body garment1310and a front panel1332of the second lower-body garment1312may be formed from the same pattern piece applied to the composite nonwoven textile100. The front panel1330of the first lower-body garment1310includes a first non-linear entangled seam1334and a second non-linear entangled seam1336positioned at a first location1338on the first lower-body garment1310. In example aspects, the first location1338may correspond to a first distance1337as measured at a front vertical midline of the first lower-body garment1310for each of the first non-linear entangled seam1334and the second non-linear entangled seam1336relative to the waist opening1314of the first lower-body garment1310. The first non-linear entangled seam1334and the second non-linear entangled seam1336present a first visual arrangement of entangled seams on the first lower-body garment1310.

The front panel1332of the second lower-body garment1312further includes the first non-linear entangled seam1334and the second non-linear entangled seam1336positioned at a second location1344on the second lower-body garment1312where the second location1344is different from the first location1338. For example, the second location1344may correspond to a second distance1345as measured at a front vertical midline of the second lower-body garment1312for each of the first non-linear entangled seam1334and the second non-linear entangled seam1336relative to the waist opening1322of the second lower-body garment1312where the second distance1345for each of the first non-linear entangled seam1334and the second non-linear entangled seam1336is different from the first distance1337. The first non-linear entangled seam1334and the second non-linear entangled seam1336present a second visual arrangement of entangled seams on the second lower-body garment1312.

Although not shown, there may be additional lower-body garments included in the array where the additional lower-body garments have a common finished form with the first lower-body garment1310and the second lower-body garment1312. The additional lower-body garments in the array may present a different visual arrangement of the first non-linear entangled seam1334and the second non-linear entangled seam1336. Stated differently, the first non-linear entangled seam1334and the second non-linear entangled seam1336may be positioned at different locations on the additional garments relative to the pattern piece described above that is used to form the front panel of the additional lower-body garments.

Although the garments depicted in the garment arrays ofFIGS.12and13include different visual arrangements of entangled seams, it is contemplated herein that garments in a garment array produced by the systems and methods described herein may include the same visual arrangement of entangled seams. For example, the entanglement system500may be configured to generate a short repeat of a visual arrangement of entangled seams such that a composite nonwoven textile may include multiple repeats of the visual arrangement of entangled seams along the material flow direction516. In this aspect, pattern pieces may be applied to the composite nonwoven textile to form garments having the same visual arrangement of entangled seams.

FIG.14depicts a second example composite nonwoven textile1400formed from, for example, the first nonwoven layer110, the second layer114, and the fill material116. The composite nonwoven textile1400may be formed according to the methods and systems described herein including the entanglement system500. The composite nonwoven textile1400includes non-linear entangled seams1410a,1410b,1410c, and1410dextending in the material flow direction516. As shown, the non-linear entangled seams1410aand1410bintersect or cross-over each other at intersection point1412, and the non-linear entangled seams1410cand1410dintersect or cross-over each other at intersection points1414and1416. The intersection points1412,1414, and1416represent areas where an entanglement head engages with the composite nonwoven textile1400at least two times. As such, the intersection points1412,1414, and1416have a greater stitch density than remaining portions of the non-linear entangled seams1410a,1410b,1410c, and1410d. The greater stitch density at the intersection points1412,1414, and1416causes a further reduced thickness compared to remaining portions of the non-linear entangled seams1410a,1410b,1410c, and1410dand compared to regions1418that extend between the non-linear entangled seams1410a,1410b,1410c, and1410d.

This is shown inFIG.15which is a cross-section of the composite nonwoven textile1400taken at cut line15-15. The regions1418have a thickness1514as measured from a first surface1513formed by the first nonwoven layer110to an opposite second surface1516formed by the second layer114. The intersection point1412has a thickness1510as measured from the first surface1513to the opposite second surface1516, and the non-linear entangled seams1410cand1410dhave a thickness1512as measured from the first surface1513to the opposite second surface1516. In example aspects, the thickness1514is greater than the thickness1512, which is greater than the thickness1510. The ability to create a varied thickness of the composite nonwoven textile1400in a direction non-parallel to the material flow direction may be used to engineer in high-insulation zones and low-insulation zones where needed on a garment incorporating the composite nonwoven textile1400. The insulation zones may have an increased thickness (e.g., more loft) and may correspond to the regions1418. The low-insulation zones may correspond to areas that include multiple intersection points such as the intersection points1412,1414, and1416.

FIG.16depicts a back view of an example upper-body garment1600having a torso portion1610where the torso portion1610includes a neck opening1612and a waist opening1614. The upper-body garment1600further includes an optional first sleeve1616and an optional second sleeve1618. Although shown as a top having long sleeves, it is contemplated herein that the upper-body garment1600may be in the form of a vest, a pullover, a hoodie, a jacket, and the like.

The upper-body garment includes a low-insulation zone1620located at a central back region of the torso portion1610and high-insulation zones1622located on either side of the low-insulation zone1620. The location of the low-insulation zone1620and the high-insulation zones1622may be based on, for example, heat maps of the human body. For instance, these maps may indicate that the central back torso of a human generates a high amount of heat and, as such, may require less insulation than other areas of the torso. The low-insulation zone1620includes a plurality of non-linear entangled seams1624a,1624b,1624c, and1624dextending in the material flow direction516. As depicted, the non-linear entangled seams1624a,1624b,1624c, and1624dare generally spaced close together and include multiple intersection points as they extend from the neck opening1612to the waist opening1614of the upper-body garment1600. This results in an overall increased stitch density in the low-insulation zone1620and an overall reduced thickness compared to other portions of the upper-body garment1600. By contrast, the high-insulation zones1622include non-linear entangled seams1626a,1626b,1626c, and1626d. The non-linear entangled seams1626a,1626b,1626c, and1626dare generally spaced further apart compared to the non-linear entangled seams1624a,1624b,1624c, and1624d, and the non-linear entangled seams1626a,1626b,1626c, and1626ddo not intersect each other. As such, the high-insulation zones1622have an overall reduced stitch density and an overall increased thickness than the low-insulation zone1620. Stated differently, the high-insulation zones1622may include a greater surface area occupied by regions1628a,1628b,1628c, and1628dwhere the first nonwoven layer110, the second layer114, and the fill material116are substantially unentangled as compared to the low-insulation zone1620. The greater thickness and loft of the regions1628a,1628b,1628c, and1628dhelp to trap and store heat.

The visual arrangement of the non-linear entangled seams inFIG.16is illustrative only, and it is contemplated herein that other visual arrangements may be formed by the non-linear entangled seams. Moreover, although the entangled seams are shown extending vertically (e.g., from a neck opening to a waist opening, the entangled seams may be oriented horizontally on the garment). In addition, the upper-body garment1600may include non-linear entangled seams at different locations on the upper-body garment than those shown. The depiction of the upper-body garment1600inFIG.16is meant to convey the concept that parameters associated with the non-linear entangled seams may be adjusted to achieve desired properties including insulation properties. The parameters may include, for example, a spacing between adjacent non-linear entangled seams (e.g., greater spacing results in the regions1628a,1628b,1628c, and1628doccupying an overall greater surface area of the upper-body garment1600), the number of intersection points between the non-linear entangled seams (e.g., more intersection points results in an increased stitch density and a reduced thickness), the width of the individual non-linear entangled seams (e.g., a greater width results in a reduced thickness compared to non-linear entangled seams having a smaller width), and the like.

FIG.17depicts an example composite nonwoven textile1700formed from the first nonwoven layer110, the second layer114, and the fill material116. In example aspects, the composite nonwoven textile1700includes non-linear entangled seams1710a,1710b, and1710c. The non-linear entangled seam1710ais similar to other non-linear entangled seams discussed herein with respect to, for instance, the composite nonwoven textile100and the composite nonwoven textile1400. The non-linear entangled seams1710band1710cinclude discontinuous non-linear entangled seams. For example, the non-linear entangled seam1710bincludes a discontinuous segment1712in which no entangled seam is formed. The non-linear entangled seam1710cincludes multiple discontinuous segments such as a discontinuous segment1714and a discontinuous segment1716. Further, the non-linear entangled seam1710cincludes an entangled seam portion1718that is in the form of a very short segment or even a point of entanglement that is spaced apart from remaining portions of the non-linear entangled seam1710cby a discontinuous segment1720and a discontinuous segment1722.

The discontinuous segments1712,1714,1716,1720, and1722may be formed using the entanglement system500and the methods described herein. For example, with respect to the discontinuous segment1712, it may be formed by not actuating the entanglement head532forming the non-linear entangled seam1710bduring one or more stationary phases such that the entanglement needle(s)534and/or orifice(s) associated with the entanglement head532does not come into contact with the composite nonwoven textile1700. The length of the discontinuous segments1712,1714,1716,1720, and1722may be adjusted as desired by varying the number of stationary phases in which the entanglement head532is not actuated.

In example aspects, when the entanglement head532is subsequently actuated and as shown with respect to the non-linear entangled seam1710b, the carriage524and/or conveyance system512may be positioned to align in the material flow direction516with a last entanglement area1711formed before the discontinuous segment1712is generated such that a next entanglement area1713is aligned in the material flow direction516with the last entanglement area1711. Alternatively, and as shown with respect to the discontinuous segment1714of the non-linear entangled seam1710, when the entanglement head532is actuated after the discontinuous segment1714is formed, the carriage524and/or conveyance system512may be positioned to be offset in the first direction610from a last entanglement area1715formed before the discontinuous segment1714is generated such that a next entanglement area1717is offset in the first direction610from the last entanglement area1715. It is also contemplated herein that the carriage524and/or conveyance system512may be positioned to be offset in the second direction611such that a subsequent entanglement area is offset in the second direction611from a previous entanglement area as shown with respect to the discontinuous segment1716.

With respect to the entangled seam portion1718, in example aspects, the entangled seam portion1718may be formed by actuating the entanglement head532at least one time after the discontinuous segment1720is generated and before the discontinuous segment1722is generated. The length of the entangled seam portion1718may be adjusted based on the number of times the entanglement head532is actuated after the discontinuous segment1720is formed and before the discontinuous segment1722is formed. For example, actuating the entanglement head532one or two times may produce a point of entanglement while actuating the entanglement head532between three to ten times may produce a short segment of entanglement.

Any combination of continuous non-linear entangled seams and discontinuous non-linear entangled seams are contemplated herein. In example aspects, discontinuous segments may be created when increased loft and thickness of the composite nonwoven textile1700is desired. For example, when the composite nonwoven textile1700is incorporated into a garment, discontinuous non-linear entangled seams may be positioned in areas of the garment for which a higher amount of insulation is desired. Moreover, the length of the discontinuous segments may be adjusted according to insulation needs (e.g., longer discontinuous segments equals more loft and more insulation and shorter discontinuous segments equals less loft and less insulation).

Aspects herein contemplate that instead of having a stacked configuration of discrete layers or materials that are joined or secured together at seam areas using an entanglement process, entangled seams may be used on a single layer of a material that includes nonwoven fibers. The term “single layer” is meant to convey a cohesive structure as opposed to separate layers that are not joined together prior to the creation of the entangled seams as described herein. For example,FIG.18depicts an example nonwoven textile1800having entangled seams1810and1812, andFIG.19depicts a cross-section of the nonwoven textile1800. The nonwoven textile1800may include a single fiber layer comprising entangled fibers; two or more fiber layers having the same or disparate properties (e.g., different staple length fibers, different denier fibers, different colored fibers, different fiber types, different fiber coatings, and the like) that are joined together through an entanglement process (e.g., needlepunching or hydroentanglement) or other processes such as bonding, adhesives, stitching, and the like; or one or more fiber layers having the same or disparate properties that are joined together with films or structured textiles (e.g., knit, woven, or braided textiles) through an entanglement process or other processes such as bonding, adhesives, stitching, and the like.

The non-linear entangled seams1810and1812may be formed through the entanglement processes described above, and the seams1810and1812may be used to create areas of reduced thickness and/or to create a visual arrangement of entangled seams. In example aspects, the nonwoven textile1800may be combined with additional single layers of material. For example, the nonwoven textile1800may be positioned adjacent to a structured textile and joined thereto through entanglement, stitching, bonding, adhesives, and the like. One or more additional materials such as a fill material may be positioned between the nonwoven textile1800and the structured textile. In another example, the nonwoven textile1800may be positioned adjacent to another single layer nonwoven textile having entangled seams and secured thereto through entanglements, stitching, bonding, adhesives, and the like. One or more additional materials such as a fill material may be positioned between the nonwoven textile1800and the additional single layer nonwoven textile. Any and all aspects, and any variation thereof, are contemplated as being within the scope herein. The nonwoven textile1800may be formed into different articles of apparel as described herein such as upper-body garment, lower-body garments, articles of footwear (e.g., uppers), and the like. The articles of apparel of a same type may have different visual arrangements of entangled seams as described herein.

The following clauses represent example aspects of concepts contemplated herein.

Any one of the following clauses may be combined in a multiple dependent manner to depend from one or more other clauses. Further, any combination of dependent clauses (clauses that explicitly depend from a previous clause) may be combined while staying within the scope of aspects contemplated herein. The following clauses are examples and are not limiting.

Clause 1. A method of manufacturing a composite nonwoven textile comprising a first nonwoven layer, a second layer, and a fill material positioned between the first nonwoven layer and the second layer, the method comprising: while the composite nonwoven textile is in a first position on an entanglement machine, causing an entanglement head to engage the composite nonwoven textile to form a first entanglement area on the composite nonwoven textile; advancing the composite nonwoven textile in a material flow direction through the entanglement machine; moving one or more of the entanglement head and the composite nonwoven textile in a first direction non-parallel to the material flow direction; and while the composite nonwoven textile is in a second position advanced from the first position in the material flow direction, causing the entanglement head to engage the composite nonwoven textile to form a second entanglement area on the composite nonwoven textile, the second entanglement area extending from the first entanglement area to form a non-linear entangled seam.

Clause 2. The method of manufacturing the composite nonwoven textile according to clause 1, wherein at each of the first entanglement area and the second entanglement area, fibers from the first nonwoven layer extend through the fill material and into the second layer.

Clause 3. The method of manufacturing the composite nonwoven textile according to any of clauses 1 through 2, wherein the first entanglement area partially overlaps the second entanglement area.

Clause 4. The method of manufacturing the composite nonwoven textile according to any of clauses 1 through 3, wherein a stitch density at the overlap area between the first entanglement area and the second entanglement area is greater than a stitch density at remaining portions of the first entanglement area and the second entanglement area.

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

Clause 6. The method of manufacturing the composite nonwoven textile according to any of clauses 1 through 5, further comprising: subsequent to forming the second entanglement area, advancing the composite nonwoven textile in the material flow direction; moving one or more of the entanglement head or the composite nonwoven textile in a second direction non-parallel to the material flow direction; and while the composite nonwoven textile is in a third position advanced from the second position in the material flow direction, causing the entanglement head to engage the composite nonwoven textile to form a third entanglement area on the composite nonwoven textile, the third entanglement area extending from the second entanglement area to form the non-linear entangled seam.

Clause 7. The method of manufacturing the composite nonwoven textile according to clause 6, wherein the third entanglement area partially overlaps the second entanglement area.

Clause 8. The method of manufacturing the composite nonwoven textile according to clause 6, wherein the third entanglement area is positioned adjacent to the second entanglement area.

Clause 9. The method of manufacturing the composite nonwoven textile according to any of clauses 6 through 8, wherein the second direction is opposite the first direction.

Clause 10. A garment comprising: a first nonwoven layer having a material flow direction; a second layer; a fill material positioned between the first nonwoven layer and the second layer; at least one region of the garment where the first nonwoven layer, the second layer, and the fill material are substantially unentangled; and at least one non-linear entangled seam extending along the material flow direction, the at least one non-linear entangled seam comprising one or more entanglement areas extending from each other to form the at least one non-linear entangled seam, wherein the one or more entanglement areas comprise fibers from the first nonwoven layer that extend through the fill material and into the second layer.

Clause 11. The garment according to clause 10, wherein the second layer is a nonwoven material.

Clause 12. The garment according to any of clauses 10 through 11, wherein the one or more entanglement areas comprise discrete areas.

Clause 13. The garment according to any of clauses 10 through 12, wherein a thickness of the at least one region of the garment where the first nonwoven layer, the second layer, and the fill material are substantially unentangled is from about 7 mm to about 15 mm.

Clause 14. The garment according to any of clauses 10 through 13, wherein a thickness of the at least one non-linear entangled seam is from about 5% to about 30% of the thickness of the at least one region of the garment where the first nonwoven layer, the second layer, and the fill material are substantially unentangled.

Clause 15. The garment according to any of clauses 10 through 14, wherein the fill material is one or more of a sheet of synthetic fibers, loose synthetic fibers, and down.

Clause 16. The garment according to clause 10 and clauses 12 through 15, wherein the second layer is a woven material.

Clause 17. The garment according to clauses 10 through 11 and clauses 13 through 15, wherein the one or more entanglement areas partially overlap each other.

Clause 18. The garment according to clauses 10 through 17, further comprising a plurality of additional non-linear entangled seams, wherein the plurality of additional non-linear entangled seams forms a non-repeating visual arrangement of entangled seams.

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

Clause 20. The composite nonwoven textile according to clause 19, wherein the second layer is a nonwoven material.

Clause 21. The composite nonwoven textile according to clauses 19 through 20, wherein the one or more entanglement areas comprise discrete entanglement areas.

Clause 22. The composite nonwoven textile according to clauses 19 through 21, wherein a thickness of the at least one region of the composite nonwoven textile where the first nonwoven layer, the second layer, and the fill material are substantially unentangled is from about 7 mm to about 15 mm.

Clause 23. The composite nonwoven textile according to any of clauses 19 through 22, wherein a thickness of the at least one non-linear entangled seam is from about 5% to about 30% of the thickness of the at least one region of the composite nonwoven textile where the first nonwoven layer, the second layer, and the fill material are substantially unentangled.

Clause 24. The composite nonwoven textile according to any of clauses 19 through 23, wherein the fill material is one or more of a sheet of synthetic fibers, loose synthetic fibers, and down.

Clause 25. The composite nonwoven textile according to any of clause 19 and clauses 21 through 24, wherein the second layer is a woven material.

Clause 26. The composite nonwoven textile according to any of clauses 19 through 20 and clauses 22 through 25, wherein the one or more entanglement areas partially overlap each other.

Clause 27. The composite nonwoven textile according to any of clauses 19 through 26, further comprising a plurality of additional non-linear entangled seams, wherein the plurality of additional non-linear entangled seams forms a non-repeating visual arrangement of entangled seams.

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

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

Clause 30. The entanglement system according to any of clauses 28 through 29, wherein the first carriage is further adapted to move in a second direction non-parallel to the material flow direction, the second direction opposite the first direction.

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

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

Clause 33. The entanglement system according to any of clauses 28 through 32, wherein a distance of advancement of the conveyance system is less than or equal to the first dimension of the first entanglement head.

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

Clause 35. The entanglement system according to any of clauses 28 through 34, wherein the first carriage is indirectly coupled to the first entanglement head by way of the first actuator.

Clause 36. The entanglement system according to any of clauses 28 through 35, further comprising: a second entanglement station comprising: the conveyance system having the surface adapted to intermittently advance the composite nonwoven textile in the material flow direction; a second actuator; a second entanglement head coupled to the second actuator, the second actuator adapted to cause the second entanglement head to move in a direction perpendicular to the plane of conveyance of the conveyance system; and a second carriage coupled to the second entanglement head, the second carriage adapted to move in the first direction non-parallel to the material flow direction.

Clause 37. The entanglement system according to clause 36, wherein the first entanglement head is positioned a first distance inward from a first edge of the surface of the conveyance system and the second entanglement head is positioned a second distance inward from the first edge of the surface of the conveyance system, the second distance different from the first distance.

Clause 38. The entanglement system according to any of clauses 36 through 37, wherein the second entanglement station is positioned at a location subsequent to the first entanglement station in the material flow direction.

Clause 39. The entanglement system according to any of clauses 28 through 38, wherein the first entanglement head includes a plurality of entanglement needles.

Clause 40. A method of manufacturing an array of garments having a common finished form, the method comprising: obtaining a composite nonwoven textile comprising a first nonwoven layer, a second layer, and a fill material positioned between the first nonwoven layer and the second layer, the composite nonwoven textile including at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising entanglement areas extending from each other to form an apparent continuous non-linear entangled seam, wherein the entanglement areas comprise fibers from the first nonwoven layer extending through the fill material and into the second layer; removing a first instance of a pattern piece from the composite nonwoven textile, the first instance of the pattern piece having the first non-linear entangled seam and the second non-linear entangled seam; using the first instance of the pattern piece to form a first garment, the first non-linear entangled seam and the second non-linear entangled seam positioned at a first location of the pattern piece; removing a second instance of the pattern piece from the composite nonwoven textile, the second instance of the pattern piece having the first non-linear entangled seam and the second non-linear entangled seam; and using the second instance of the pattern piece to form a second garment, the first non-linear entangled seam and the second non-linear entangled seam positioned at a second location of the pattern piece, the second location different from the first location.

Clause 41. The method of manufacturing the array of garments according to clause 40, wherein the first non-linear entangled seam and the second non-linear entangled seam each extend in a material flow direction.

Clause 42. The method of manufacturing the array of garments according to any of clauses 40 through 41, wherein the entanglement areas partially overlap each other.

Clause 43. The method of manufacturing the array of garments according to any of clauses 40 through 42, further comprising: removing a third instance of the pattern piece from the composite nonwoven textile, the third instance of the pattern piece having the first non-linear entangled seam and the second non-linear entangled seam; and using the third instance of the pattern piece to form a third garment, the first non-linear entangled seam and the second non-linear entangled seam positioned at a third location of the pattern piece, the third location different from one or more of the first location and the second location.

Clause 44. The method of manufacturing the array of garments according to any of clauses 41 through 43, wherein the array of garments includes upper-body garments.

Clause 45. The method of manufacturing the array of garments according to any of clauses 41 through 43, wherein the array of garments includes lower-body garments.

Clause 46. An array of garments having a common finished form, the array of garments formed from a composite nonwoven textile comprising a first nonwoven layer, a second layer, and a fill material positioned between the first nonwoven layer and the second layer, the composite nonwoven textile including at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising entanglement areas extending from each other to form the respective first non-linear entangled seam and the second non-linear entangled seam, wherein the entanglement areas comprise fibers from the first nonwoven layer extending through the fill material and into the second layer, the array of garments comprising: a first garment formed from a first instance of a pattern piece taken from the composite nonwoven textile, the first non-linear entangled seam and the second non-linear entangled seam positioned at a first location on the first garment; and a second garment formed from a second instance of the pattern piece taken from the composite nonwoven textile, the first non-linear entangled seam and the second non-linear entangled seam positioned at a second location on the second garment, the second location different from the first location relative to the pattern piece.

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

Clause 48. The array of garments according to any of clauses 46 through 47, wherein the entanglement areas partially overlap each other.

Clause 49. The array of garments according to any of clauses 46 through 48, further comprising a third garment formed from a third instance of the pattern piece taken from the composite nonwoven textile, the first non-linear entangled seam and the second non-linear entangled seam positioned at a third location on the third garment, the third location different from one or more of the first location and the second location relative to the pattern piece.

Clause 50. The array of garments according to any of clauses 46 through 49, wherein the array of garments includes upper-body garments.

Clause 51. The array of garments according to any of clauses 46 through 49, wherein the array of garments includes lower-body garments.

Clause 52. A method of manufacturing an array of garments having a common finished form, the method comprising: obtaining a composite nonwoven textile comprising a first nonwoven layer, a second layer, and a fill material positioned between the first nonwoven layer and the second layer, the composite nonwoven textile including at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising entanglement areas extending from each other to form an apparent continuous non-linear entangled seam, wherein the entanglement areas comprise fibers from the first nonwoven layer extending through the fill material and into the second layer; removing a first portion having a first pattern from the composite nonwoven textile, the first portion having the first non-linear entangled seam and the second non-linear entangled seam; using the first portion to form a first garment, the first non-linear entangled seam and the second non-linear entangled seam positioned at a first location on the first portion; removing a second portion having the first pattern from the composite nonwoven textile, the second portion having the first non-linear entangled seam and the second non-linear entangled seam; and using the second portion to form a second garment, the first non-linear entangled seam and the second non-linear entangled seam positioned at a second location on the second portion, the second location different from the first location.

Clause 53. The method of manufacturing the array of garments according to clause 52, wherein the first non-linear entangled seam and the second non-linear entangled seam each extend in a material flow direction.

Clause 54. The method of manufacturing the array of garments according to clause 53, wherein a distance between the first non-linear entangled seam and the second non-linear entangled seam varies along the material flow direction, wherein the distance between the first non-linear entangled seam and the second non-linear entangled seam is measured in a direction non-parallel to the material flow direction.

Clause 55. The method of manufacturing the array of garments according to any of clauses 52 through 54, wherein the first non-linear entangled seam and the second non-linear entangled seam include different visual arrangements of entangled seams.

Clause 56. The method of manufacturing the array of garments according to any of clauses 52 through 55, wherein the entanglement areas partially overlap each other.

Clause 57. The method of manufacturing the array of garments according to any of clauses 52 through 56, wherein the array of garments include upper-body garments.

Clause 58. The method of manufacturing the array of garments according to any of clauses 52 through 56, wherein the array of garments include lower-body garments.

Clause 59. An array of garments having a common finished form, the array of garments formed from a composite nonwoven textile comprising a first nonwoven layer, a second layer, and a fill material positioned between the first nonwoven layer and the second layer, the composite nonwoven textile including at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising entanglement areas extending from each other to form the respective first non-linear entangled seam and the second non-linear entangled seam, wherein the entanglement areas comprise fibers from the first nonwoven layer extending through the fill material and into the second layer, the array of garments comprising: a first garment formed from a first portion of the composite nonwoven textile having a first pattern, the first non-linear entangled seam and the second non-linear entangled seam positioned at a first location on the first portion of the first garment; and a second garment formed from a second portion of the composite nonwoven textile having the first pattern, the first non-linear entangled seam and the second non-linear entangled seam positioned at a second location on the second portion of the second garment, the second location different from the first location.

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

Clause 61. The array of garments according to clause 60, wherein a distance between the first non-linear entangled seam and the second non-linear entangled seam varies along the material flow direction, wherein the distance between the first non-linear entangled seam and the second non-linear entangled seam is measured in a direction non-parallel to the material flow direction.

Clause 62. The array of garments according to any of clauses 59 through 61, wherein the first non-linear entangled seam and the second non-linear entangled seam include different visual arrangements of entangled seams.

Clause 63. The array of garments according to any of clauses 59 through 62, wherein the entanglement areas partially overlap each other.

Clause 64. The array of garments according to any of clauses 59 through 63, wherein the array of garments include upper-body garments.

Clause 65. The array of garments according to any of clauses 59 through 63, wherein the array of garments include lower-body garments.

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

Clause 67. The entanglement system according to clause 66, wherein the first actuator is adapted to actuate the first entanglement head to emit one or more jets of a fluid.

Clause 68. The entanglement system according to clause 66, wherein the first entanglement head includes an entanglement needle, and wherein the first actuator is adapted to move one or more of the first entanglement head and the entanglement needle in a direction perpendicular to a plane of conveyance of the surface.

Clause 69. The entanglement system according to any of clauses 66 through 68, wherein the first carriage is further adapted to move in a second direction non-parallel to the material flow direction, the second direction opposite the first direction.

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

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

Clause 72. The entanglement system according to clause 71, wherein the conveyance system is adapted to advance the composite nonwoven textile in the material flow direction, and wherein a distance of advancement of the conveyance system is less than the first dimension of the first entanglement head.

Clause 73. The entanglement system according to any of clauses 66 through 72, wherein the first carriage is indirectly coupled to the first entanglement head by way of the first actuator.

Clause 74. The entanglement system according to any of clauses 66 through 73, the first entanglement station further comprising a plurality of additional entanglement heads coupled to the first actuator.

Clause 75. The entanglement system according to clause 74, wherein the plurality of additional entanglement heads coupled to the first actuator are non-uniformly spaced apart from each other.

Clause 76. The entanglement system according to any of clauses 66 through 75, further comprising: a second entanglement station comprising: the conveyance system having the surface adapted to advance the composite nonwoven textile in the material flow direction; a second actuator adapted to actuate a second entanglement head coupled to the second actuator; and a second carriage coupled to the second entanglement head, the second carriage adapted to move in the first direction non-parallel to the material flow direction.

Clause 77. The entanglement system according to clause 76, wherein the first entanglement head is positioned a first distance inward from a first edge of the surface of the conveyance system and the second entanglement head is positioned a second distance inward from the first edge of the surface of the conveyance system, the second distance different from the first distance.

Clause 78. The entanglement system according to any of clauses 76 through 77, wherein the second entanglement station is positioned at a location subsequent to the first entanglement station in the material flow direction.

Clause 79. The entanglement system according to any of clauses 76 through 78, the second entanglement station further comprising a plurality of additional entanglement heads coupled to the second actuator.

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

Clause 81. The entanglement system according to any of clauses 79 through 80, wherein a number of the plurality of additional entanglement heads coupled to the second actuator differs from a number of the plurality of additional entanglement heads coupled to the first actuator.

Clause 82. The entanglement system according to any of clauses 76 through 81, wherein a dimension of the second entanglement head is different from a dimension of the first entanglement head.

Clause 83. The entanglement system according to any of clauses 76 through 82, wherein an entanglement footprint produced by the second entanglement head is different from an entanglement pattern produced by the first entanglement head.

Clause 84. A method of manufacturing a nonwoven textile comprising: while the nonwoven textile is in a first position on an entanglement machine, causing an entanglement head to engage the nonwoven textile to form a first entanglement area on the nonwoven textile; advancing the nonwoven textile in a material flow direction through the entanglement machine; moving one or more of the entanglement head and the nonwoven textile in a first direction non-parallel to the material flow direction; and while the nonwoven textile is in a second position advanced from the first position in the material flow direction, causing the entanglement head to engage the nonwoven textile to form a second entanglement area on the nonwoven textile, the second entanglement area extending from the first entanglement area to form a non-linear entangled seam.

Clause 85. The method of manufacturing the nonwoven textile according to clause 84, wherein at each of the first entanglement area and the second entanglement area, fibers forming the nonwoven textile are caused to move from a generally horizontal orientation to a generally vertical orientation.

Clause 86. The method of manufacturing the nonwoven textile according to any of clauses 84 through 85, wherein the first entanglement area partially overlaps the second entanglement area.

Clause 87. The method of manufacturing the nonwoven textile according to clause 86, wherein a stitch density at the overlap area between the first entanglement area and the second entanglement area is greater than a stitch density at remaining portions of the first entanglement area and the second entanglement area.

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

Clause 89. The method of manufacturing the nonwoven textile according to any of clauses 84 through 88, further comprising: subsequent to forming the second entanglement area, advancing the nonwoven textile in the material flow direction; moving one or more of the entanglement head and the nonwoven textile in a second direction non-parallel to the material flow direction, the second direction opposite the first direction; and while the nonwoven textile is in a third position advanced from the second position in the material flow direction, causing the entanglement head to engage the nonwoven textile to form a third entanglement area on the nonwoven textile, the third entanglement area extending from the second entanglement area to form the non-linear entangled seam.

Clause 90. The method of manufacturing the nonwoven textile according to clause 89, wherein the third entanglement area partially overlaps the second entanglement area.

Clause 91. A garment comprising: a nonwoven textile having a material flow direction; and at least one non-linear entangled seam extending along the material flow direction, the at least one non-linear entangled seam comprising one or more entanglement areas extending from each other to form the at least one non-linear entangled seam, wherein at each of the one or more entanglement areas, fibers forming the nonwoven textile have a generally vertical orientation.

Clause 92. The garment according to clause 91, wherein the one or more entanglement areas comprise discrete areas.

Clause 93. The garment according to clause 91, wherein the one or more entanglement areas partially overlap each other.

Clause 94. The garment according to any of clauses 91 through 93, further comprising a plurality of additional non-linear entangled seams, wherein the plurality of additional non-linear entangled seams forms a non-repeating visual arrangement of entangled seams.

Clause 95. The garment according to any of clauses 91 through 94, further comprising one or more additional layers secured to the nonwoven textile by one or more of entanglement, stitching, bonding, and adhesives.

Clause 96. The garment according to clause 95, wherein the one or more additional layers comprise one or more of a structured textile, a nonwoven layer, a film, and a fill material.

Clause 97. A nonwoven textile having a material flow direction, the nonwoven textile comprising: at least one non-linear entangled seam extending along the material flow direction, the at least one non-linear entangled seam comprising one or more entanglement areas extending from each other to form the at least one non-linear entangled seam, wherein at each of the one or more entanglement areas, fibers forming the nonwoven textile have a generally vertical orientation.

Clause 98. The nonwoven textile according to clause 97, wherein the one or more entanglement areas comprise discrete entanglement areas.

Clause 99. The nonwoven textile according to clause 97, wherein the one or more entanglement areas partially overlap each other.

Clause 100. The nonwoven textile according to any of clauses 97 through 99, further comprising a plurality of additional non-linear entangled seams, wherein the plurality of additional non-linear entangled seams forms a non-repeating visual arrangement of entangled seams.

Clause 101. An array of garments having a common finished form, the array of garments formed from a nonwoven textile having at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising entanglement areas extending from each other to form the respective first non-linear entangled seam and the second non-linear entangled seam, wherein the entanglement areas comprise fibers from the nonwoven layer wherein having a generally vertical orientation, the array of garments comprising: a first garment formed from a first instance of a pattern piece taken from the nonwoven textile, the first non-linear entangled seam and the second non-linear entangled seam positioned at a first location on the first garment; and a second garment formed from a second instance of the pattern piece taken from the nonwoven textile, the first non-linear entangled seam and the second non-linear entangled seam positioned at a second location on the second garment, the second location different from the first location relative to the pattern piece.

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

Clause 103. The array of garments according to any of clauses 101 through 102, wherein the entanglement areas partially overlap each other.

Clause 104. The array of garments according to any of clauses 101 through 103, further comprising a third garment formed from a third instance of the pattern piece taken from the nonwoven textile, the first non-linear entangled seam and the second non-linear entangled seam positioned at a third location on the third garment, the third location different from one or more of the first location and the second location relative to the pattern piece.

Clause 105. The array of garments according to any of clauses 101 through 104, wherein the array of garments includes upper-body garments.

Clause 106. The array of garments according to any of clauses 101 through 104, wherein the array of garments includes lower-body garments.

Clause 107. A method of manufacturing an array of garments having a common finished form, the method comprising: obtaining a nonwoven textile having at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising entanglement areas extending from each other to form an apparent continuous non-linear entangled seam, wherein the entanglement areas comprise fibers having a generally vertical orientation; removing a first portion having a first pattern from the nonwoven textile, the first portion having the first non-linear entangled seam and the second non-linear entangled seam; using the first portion to form a first garment, the first non-linear entangled seam and the second non-linear entangled seam positioned at a first location on the first portion; removing a second portion having the first pattern from the nonwoven textile, the second portion having the first non-linear entangled seam and the second non-linear entangled seam; and using the second portion to form a second garment, the first non-linear entangled seam and the second non-linear entangled seam positioned at a second location on the second portion, the second location different from the first location.

Clause 108. The method of manufacturing the array of garments according to clause 107, wherein the first non-linear entangled seam and the second non-linear entangled seam each extend in a material flow direction.

Clause 109. The method of manufacturing the array of garments according to clause 108, wherein a distance between the first non-linear entangled seam and the second non-linear entangled seam varies along the material flow direction, wherein the distance between the first non-linear entangled seam and the second non-linear entangled seam is measured in a direction non-parallel to the material flow direction.

Clause 110. The method of manufacturing the array of garments according to any of clauses 107 through 109, wherein the first non-linear entangled seam and the second non-linear entangled seam include different visual arrangements of entangled seams.

Clause 111. The method of manufacturing the array of garments according to any of clauses 107 through 110, wherein the entanglement areas partially overlap each other.

Clause 112. The method of manufacturing the array of garments according to any of clauses 107 through 111, wherein the array of garments include upper-body garments.

Clause 113. The method of manufacturing the array of garments according to any of clauses 107 through 111, wherein the array of garments include lower-body garments.

Clause 114. An array of garments having a common finished form, the array of garments formed from a nonwoven textile having at least a first non-linear entangled seam and a second non-linear entangled seam, the first non-linear entangled seam and the second non-linear entangled seam each comprising entanglement areas extending from each other to form the respective first non-linear entangled seam and the second non-linear entangled seam, wherein at each of the entanglement areas, fibers forming the nonwoven textile have a generally vertical orientation, the array of garments comprising: a first garment formed from a first portion of the nonwoven textile having a first pattern, the first non-linear entangled seam and the second non-linear entangled seam positioned at a first location on the first portion of the first garment; and a second garment formed from a second portion of the nonwoven textile having the first pattern, the first non-linear entangled seam and the second non-linear entangled seam positioned at a second location on the second portion of the second garment, the second location different from the first location.

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

Clause 116. The array of garments according to clause 115, wherein a distance between the first non-linear entangled seam and the second non-linear entangled seam varies along the material flow direction, wherein the distance between the first non-linear entangled seam and the second non-linear entangled seam is measured in a direction non-parallel to the material flow direction.

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

Clause 118. The array of garments according to any of clauses 114 through 117, wherein the entanglement areas partially overlap each other.

Clause 119. The array of garments according to any of clauses 114 through 118, wherein the array of garments include upper-body garments.

Clause 120. The array of garments according to any of clauses 114 through 118, wherein the array of garments include lower-body garments.

Aspects of the present disclosure have been described with the intent to be illustrative rather than restrictive. Alternative aspects will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present disclosure.