Patent Description:
Traditional garments that include, for example, insulation zones and pile zones are generally formed using a panel-type, cut-and-sew construction where seams are used to affix the textiles that form the insulation zones with the textiles that form the pile zones. The seam lines may introduce areas of structural weakness, may be aesthetically undesirable, and/or may cause chaffing or discomfort for wearers.

<CIT> describes that a composite interlining fabric for garments comprises a close woven or non-woven fabric backing and a web of fibres, preferably wool, needled into the backing fabric from one side.

<CIT> describes that tufted carpets which are conformable and stretchable make use of a stretchable carpet backing formed from a composite fabric. The stretchable carpet backing fabric is formed of a stretchable elastic net and at least one nonwoven fibrous layer overlying the stretchable elastic net.

<CIT> describes that base fabric for use in producing a press felt on the batt-on-base type for a papermaking machine wherein a layer of multifilament tow is provided as an integral part of the base fabric and at that face thereof to which the batt is to be applied, as by needling.

The claimed invention provides a method of forming a textile as defined in claim <NUM>, and a garment as defined in claim <NUM>. Particular embodiments are defined in dependent claims <NUM>-<NUM> and <NUM>-<NUM>.

The subject matter of the present invention is described with specificity herein to meet statutory requirements. However, the description itself is not intended to limit the scope of this disclosure. Rather, the inventors have contemplated that the claimed subject matter might also be embodied in other ways, to include different steps or combinations of steps similar to the ones described in this document, in conjunction with other present or future technologies. Moreover, although the terms "step" and/or "block" might be used herein to connote different elements of methods employed, the terms should not be interpreted as implying any particular order among or between various steps herein disclosed unless and except when the order of individual steps is explicitly stated.

Traditional articles of apparel that have insulation zones and pile zones (i.e., fleece-like zones) are generally formed using a panel-type, cut-and-sew construction where textiles used to form the insulation zone are seamed to textiles used to form the pile zone. The resultant seams may introduce areas of structural weakness, may create an undesirable aesthetic, and/or may cause chaffing or discomfort to a wearer. As well, textiles used to form traditional pile zones may lack features that make the textiles suitable for use in adverse weather conditions such as rain, snow, and/or wind.

Aspects herein are directed to a textile, garments formed from the textile, and methods of manufacturing the textile, where the textile has an insulation zone and a pile zone that seamlessly extend from one another. As well, due to the construction of the pile zone, the pile zone includes features that make it more resistant to adverse weather conditions than typical pile textiles. In example aspects, the insulation zone includes a first woven layer, a second woven layer, and a nonwoven layer positioned in a space between the first woven layer and the second woven layer. In the insulation zone, the first woven layer, the second woven layer, and the nonwoven layer are unaffixed from each other such that the first woven layer, the second woven layer, and the nonwoven layer are separate and distinct layers. In addition to the spaces formed between the different layers which may be used to trap heated air, the nonwoven layer includes a large number of spaces between the fibers and filaments that form the nonwoven layer which further helps to trap heated air and insulate a wearer.

The pile zone includes the first woven layer, the second woven layer, and the nonwoven layer. In the pile zone, fibers/filaments from the nonwoven layer extend into and through the first woven layer and the second woven layer and are entangled with fibers, filaments, and/or yarns from both the first woven layer and the second woven layer through, for example, an entanglement process such as, for example, needlepunching. Because of the entanglement of the nonwoven fibers/filaments with the first woven layer and the second woven layer, the first and second woven layers are bound or secured to the nonwoven layer in the pile zone. The pile zone has a fleece-like texture due to the fibers/filaments from the nonwoven layer extending through the first woven layer and the second woven layer. Unlike typical pile textiles in which tufts or loops integrally extend from a base textile which may not exhibit weather-resistant properties, the pile zone contemplated herein may have weather-resistant properties due to the presence of the first woven layer and the second woven layer. For instance, in example aspects where the first woven layer and the second woven layer are tightly woven, the pile zone may exhibit wind-resistant properties. In additional example aspects where one or more of the first woven layer and the second woven layer are treated with a durable water repellant, the pile zone may be generally resistant to rain or precipitation.

Although the insulation zone and the pile zone are formed from the same materials, aspects herein contemplate having a varied aesthetic between the insulation zone and the pile zone based on, for example, the entanglement process. For example, the first and/or second woven layers may have a first visual property. The nonwoven layer may have a second visual property different from the first visual property. In this aspect, the insulation zone may primarily exhibit or display the first visual property associated with the first and/or second woven layer since the nonwoven layer is positioned between the first and second woven layers and may not be visible. The pile zone, due to the entanglement of the fibers and filaments of the nonwoven layer with the fibers, filaments, and yarns of the first and/or second woven layers may exhibit or display a different visual property that is intermediate between the first visual property and the second visual property. Using an example, the first and/or second woven layers may be white in color and the nonwoven layer may be grey in color. The insulation zone may primarily exhibit or display a white color, and the pile zone may have a heather grey and white appearance due to the mixture of the white yarns forming the first and/or second woven layers with the grey fibers/filaments forming the nonwoven layer.

As used herein, the term "garment" encompasses any number of products meant to be worn by a wearer including upper-body garments (e.g., shirts, jackets, hoodies, tank tops, pullovers), lower-body garments (e.g., pants, shorts, leggings), articles of footwear such as shoes or socks, articles of headwear (e.g., hats), gloves, sleeves (e.g., arm sleeves, calf sleeves), and the like. Positional terms used when describing the garment such as front, back, inner-facing surface, outer-facing surface, and the like are with respect to the garment being worn as intended with the wearer standing upright. As such, when the garment is in the form of an upper-body garment, the front of the upper-body garment is configured to cover, for instance, a front upper torso area and a front arm area (when the garment has sleeves), and the back of the upper-body garment is configured to cover a back upper torso area and a back arm area (when the garment has sleeves). When the garment is in the form of a lower-body garment, the front of the lower-body garment is configured to cover, for instance, a front lower torso area and a front leg area of the wearer, and the back of the lower-body garment is configured to cover a back lower torso area and a back leg area. Similarly, the inner-facing surface of the garment is configured to face inwardly (e.g., toward a body surface of a wearer), and the outer-facing surface of the garment is configured to face toward the external environment or away from the inner-facing surface of the garment. It is contemplated herein that, in some aspects, the inner-facing surface of the garment may comprise the innermost-facing surface of the garment. In some aspects, the outer-facing surface of the garment may comprise the outermost-facing surface of the garment.

The term "yarn" as used herein may mean an assemblage of fibers or filaments that are twisted or laid together so as to form a continuous strand. The term "yarn" may also encompass a single monofilament that forms a continuous strand. In example aspects, the first and second woven layers described herein may be formed from yarns and the fibers or filaments that form the yarns. The nonwoven layer described herein may be formed from fibers and/or filaments.

The term "woven layer" means a textile having a plurality of warp yarns and a plurality of weft yarns interwoven with the plurality of warp yarns, where the plurality of weft yarns extend generally orthogonal to the plurality of warp yarns. The term "nonwoven layer" as used herein refers to fibers or filaments that 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 textile includes a collection of fibers or filaments that are mechanically manipulated to form a mat-like material. Stated differently nonwoven textiles are directly made from fibers or filaments. The term "pile" or "pile zone" as used herein means a textile, including a composite textile, having a raised surface formed from upright loops or strands of fibers/filaments.

The term "seamlessly extend" means two areas or zones that extend from one another without seams. With respect to the present disclosure, the insulation zone and the pile zone seamlessly extend from one another such that one or more warp yarns and/or a weft yarns in the insulation zone continuously and without interruption extend into the pile zone.

The term "visual property" as used herein broadly means the visual impression created by a textile. This may be due to different characteristic of the yarns/fibers/filaments used to form the textile including differences in texture, denier, shine, color, and the like. With respect to the term "pattern," the term generally means a repeated decorative design. With respect to the term "color," the term generally relates to a color of a textile that may be afforded by dyes and/or colorants. Moreover, the term "color" when describing, for example, a textile means an observable color of yarns/fibers/filaments that form the textile. Such aspects contemplate that a color may be any color that may be afforded to yarns/fibers/filaments using dyes, pigments, and/or colorants that are known in the art. As such, yarns/fibers/filaments may be configured to have a color including, but not limited to red, orange, yellow, green, blue, indigo, violet, white, black, and shades thereof.

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

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

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

Unless otherwise noted, all measurements provided herein are measured at standard ambient temperature and pressure (<NUM> degrees Celsius or <NUM> and <NUM> bar).

<FIG> respectively depict a view of a first surface <NUM> and a second opposite surface <NUM> of an example textile <NUM>. The textile <NUM> includes an insulation zone <NUM> and a pile zone <NUM>. With respect to <FIG>, the first surface <NUM> of the insulation zone <NUM> is formed from a first woven layer <NUM>. The first woven layer <NUM>, in example aspects, may include nylon yarns, polyester yarns, a combination of nylon yarns and polyester yarns, and the like. When the textile <NUM> is incorporated into a garment, the first woven layer <NUM> of the insulation zone <NUM> may form an outermost-facing surface of the garment. In example aspects, the first woven layer <NUM> may be tightly woven such that the first woven layer <NUM> is generally resistant to wind penetration and/or rain penetration. Having a tightly woven first woven layer <NUM> also helps to maintain heated air in the space between the first woven layer <NUM> and the second woven layer. In further example aspects, the first woven layer <NUM> may be treated with a durable water repellant finish to enhance the water-resistant or repellant properties of the first woven layer <NUM>. The first woven layer <NUM> may have a visual property such as a color or a pattern.

The first surface <NUM> of the pile zone <NUM> is formed from the first woven layer <NUM> and fibers/filaments <NUM> of a nonwoven layer that is positioned between the first woven layer <NUM> and the second woven layer as discussed below. The fibers/filaments <NUM> of the nonwoven layer extend through the first surface <NUM> in the pile zone <NUM> such that the fibers/filaments <NUM> of the nonwoven layer extend outwardly (i.e., in a positive z-direction) from a surface plane of the first woven layer <NUM>. This configuration imparts a fleece-like texture to the pile zone <NUM>. Due to the presence of the first woven layer <NUM>, the pile zone <NUM> may also exhibit wind and rain resistant properties while providing a pleasing hand feel and a fleece-like aesthetic.

With respect to <FIG>, the second surface <NUM> of the insulation zone <NUM> is formed from a second woven layer <NUM>. The second woven layer <NUM>, in example aspects, may include nylon yarns, polyester yarns, a combination of nylon yarns and polyester yarns, and the like. When the textile <NUM> is incorporated into a garment, the second woven layer <NUM> of the insulation zone <NUM> may form an innermost-facing surface of the garment. Similar to the first woven layer <NUM>, the second woven layer <NUM> may be tightly woven such that heated air trapped in the space between the first woven layer <NUM> and the second woven layer <NUM> is generally retained in the space to help warm or insulate a wearer. The second woven layer <NUM> may also have a visual property such as a color or a pattern. The visual property of the second woven layer <NUM> may be the same or different from the visual property of the first woven layer <NUM>.

The second surface <NUM> of the pile zone <NUM> is formed from the second woven layer <NUM> and the fibers/filaments <NUM> of the nonwoven layer that is positioned between the first woven layer <NUM> and the second woven layer <NUM>. The fibers/filaments <NUM> of the nonwoven layer extend through the second surface <NUM> in the pile zone <NUM> such that the fibers/filaments <NUM> of the nonwoven layer extend outwardly (i.e., in a negative z-direction with respect to the fibers/filaments <NUM> extending through the first surface <NUM>) from a surface plane of the second woven layer <NUM> to impart a fleece-like texture to the second surface <NUM> of the pile zone <NUM>. As shown, the location of the pile zone <NUM> on the first surface <NUM> of the textile <NUM> corresponds to the location of the pile zone <NUM> on the second surface <NUM> of the textile <NUM>. Similarly, the location of the insulation zone <NUM> on the first surface <NUM> of the textile <NUM> corresponds to the location of the insulation zone <NUM> on the second surface <NUM> of the textile <NUM>. Stated differently the insulation zone <NUM> and the pile zone <NUM> are symmetrically located on the opposing surfaces <NUM> and <NUM> of the textile <NUM>.

<FIG> depicts a cross-section of the textile <NUM> taken through the insulation zone <NUM> and the pile zone <NUM>. As shown, the insulation zone <NUM> includes the first woven layer <NUM> and the second woven layer <NUM>. The first woven layer <NUM> includes a first surface <NUM> and a second surface <NUM> opposite the first surface <NUM>. In example aspects, the first surface <NUM> of the first woven layer <NUM> forms the first surface <NUM> of the insulation zone <NUM> of the textile <NUM>. The second woven layer <NUM> also includes a first surface <NUM> and a second surface <NUM> opposite the first surface <NUM>. In example aspects, the first surface <NUM> of the second woven layer <NUM> forms the second surface <NUM> of the insulation zone <NUM> of the textile <NUM>.

A nonwoven layer <NUM> having a first surface <NUM> and a second surface <NUM> opposite the first surface <NUM> is positioned in a space formed between the first woven layer <NUM> and the second woven layer <NUM>. More specifically, the first surface <NUM> of the nonwoven layer <NUM> is positioned adjacent to the second surface <NUM> of the first woven layer <NUM>, and the second surface <NUM> of the nonwoven layer <NUM> is positioned adjacent to the second surface <NUM> of the second woven layer <NUM>. As explained in additional detail below, the nonwoven layer <NUM> may include two or more nonwoven sheets that are entangled together. In example aspects, the fibers/filaments <NUM> of the nonwoven layer <NUM> may be formed from polyester fibers/filaments including recycled polyester fibers/filaments although other materials including natural materials are contemplated herein. In example aspects, the nonwoven layer <NUM> has a weight from about <NUM> grams per square meter (gsm) to about <NUM> gsm, from about <NUM> gsm to about <NUM> gsm, from about <NUM> gsm to about <NUM> gsm, or about <NUM> gsm. As used herein, the term "about" means within ± <NUM>% of an indicated value. The weight of the nonwoven layer <NUM> may be measured using, for example, ISO3801 testing standard.

In the insulation zone <NUM>, the first woven layer <NUM>, the nonwoven layer <NUM>, and the second woven layer <NUM> are separate and distinct from each other such that a space, or a potential space, is maintained between the second surface <NUM> of the first woven layer <NUM> and the first surface <NUM> of the nonwoven layer <NUM> and between the second surface <NUM> of the second woven layer <NUM> and the second surface <NUM> of the nonwoven layer <NUM>. Stated differently, in the insulation zone <NUM>, the first woven layer <NUM>, the nonwoven layer <NUM>, and the second woven layer <NUM> are not affixed to each other or are unaffixed from each other. In the insulation zone <NUM>, the spaces between the first woven layer <NUM>, the second woven layer <NUM>, and the nonwoven layer <NUM> trap heated air helping to insulate a wearer of a garment incorporating the textile <NUM>. Additionally, spaces between the fibers/filaments <NUM> that form the nonwoven layer <NUM> also help to trap heated air further increasing the insulation features of the insulation zone <NUM>.

The pile zone <NUM> of the textile <NUM> seamlessly extends from the insulation zone <NUM> as shown in <FIG>. Stated differently, one or more warp or weft yarns in the insulation zone <NUM> extend continuously and without interruption into the pile zone <NUM>. The pile zone <NUM> is created by an entanglement process whereby the fibers/filaments <NUM> of the nonwoven layer <NUM> are entangled with fibers, filaments, and/or yarns of the first woven layer <NUM> and the second woven layer <NUM>. In example aspects, the integrity of the first woven layer <NUM> and the second woven layer <NUM> remains generally intact in the pile zone <NUM>. For example, the warp and weft yarns that form the first woven layer <NUM> and the second woven layer <NUM> remain generally interwoven in the pile zone <NUM>.

As shown in <FIG>, the fibers/filaments <NUM> of the nonwoven layer <NUM> extend into the first woven layer <NUM>. In some example aspects, the fibers/filaments <NUM> of the nonwoven layer <NUM> extend through the first woven layer <NUM> (i.e., extend through the first surface <NUM> of the first woven layer <NUM>) such that the fibers/filaments <NUM> of the nonwoven layer <NUM> extend outwardly from the first surface <NUM> of the textile <NUM> in the pile zone <NUM>. Similarly, the fibers/filaments <NUM> of the nonwoven layer <NUM> extend into the second woven layer <NUM>. In some example aspects, the fibers/filaments <NUM> of the nonwoven layer <NUM> extend through the second woven layer <NUM> (i.e., extend through the first surface <NUM> of the second woven layer <NUM>) such that the fibers/filaments <NUM> of the nonwoven layer <NUM> extend outwardly from the second surface <NUM> of the textile <NUM> in the pile zone <NUM>. Due to the entanglement of the fibers/filaments <NUM> of the nonwoven layer <NUM> with the first woven layer <NUM> and the second woven layer <NUM> in the pile zone <NUM>, the first woven layer <NUM> and the second woven layer <NUM> are bound or secured to the nonwoven layer <NUM> in the pile zone <NUM>. The extension of the fibers/filaments <NUM> of the nonwoven layer <NUM> through the first woven layer <NUM> and the second woven layer <NUM> creates a pile or fleece-like texture on the first surface <NUM> and the second surface <NUM> of the textile <NUM> in the pile zone <NUM>. This, in turn, provides a good hand feel and a pleasing aesthetic. Moreover, because the first woven layer <NUM> and the second woven layer <NUM> are present in the pile zone <NUM>, the pile zone <NUM> also exhibits wind and/or rain resistant or repellant properties due to the tightly woven nature of the first woven layer <NUM> and/or the second woven layer <NUM>.

<FIG> illustrates a schematic of an example process <NUM> of forming the nonwoven layer <NUM>. At a step <NUM>, two or more nonwoven sheets are provided. The two or more nonwoven sheets may each be formed of a web of fibers that has undergone a carding and lapping process that generally aligns the fibers in one or more common directions that extend along an x, y plane and that achieves a desired basis weight. The web of fibers may also undergo a light needling process or mechanical entanglement process that entangles the fibers of the web to a degree such that the web of fibers forms a cohesive structure that can be manipulated (e.g., rolled on to a roller, un-rolled from the roller, stacked, and the like). The nonwoven sheets may also undergo one or more additional processing steps such as printing (digital printing, sublimation printing, ink jet printing, and the like). In example aspects, four nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> are provided. Each of the four nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> may have a basis weight from about <NUM> gsm to about <NUM> gsm, from about <NUM> gsm to about <NUM> gsm, from about <NUM> gsm to about <NUM> gsm, or about <NUM> gsm to achieve a desired basis weight for the nonwoven layer <NUM> of from about <NUM> gsm to about <NUM> gsm. The nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> may respectively have a visual property <NUM>, <NUM>, <NUM>, and <NUM> as indicated by the different shading patterns. The visual properties <NUM>, <NUM>, <NUM>, and <NUM> may be imparted through a printing process (digital printing, sublimation printing, ink jet printing, and the like). Additionally or alternatively, the visual properties <NUM>, <NUM>, <NUM>, and <NUM> may be imparted by using dope-dyed fibers/filaments to form the nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM>. Although the visual properties <NUM>, <NUM>, <NUM>, and <NUM> are shown as different, it is contemplated herein that two or more of the visual properties may be the same. The visual properties <NUM>, <NUM>, <NUM>, and <NUM> may include a color, a pattern, a combination of a color and a pattern, and the like.

At a step <NUM>, the nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> are positioned or layered on top of each other to form a layered construction. Dependent upon a desired visual property of the nonwoven layer <NUM>, the nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> may be arranged in a specific order although a random arrangement is also contemplated. At a step <NUM>, a first entanglement process <NUM> is executed from a first side or surface of the layered construction through a second side or surface of the layered construction. Additionally, a second entanglement process <NUM> is executed from the second side or surface of the layered construction through the first side or surface of the layered construction. The first and second entanglement processes <NUM> and <NUM> may comprise a mechanical process such as needlepunching or hydroentangling although other entanglement processes are contemplated herein. The first and second entanglement processes <NUM> and <NUM> causes the fibers/filaments from each of the nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> to become entangled thus affixing the nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> together into a cohesive single layer structure. In example aspects, to achieve a desired integrity or cohesiveness of the nonwoven layer <NUM>, the first and second entanglement processes <NUM> and <NUM> may be respectively executed a number of times such as two times up to seven times. In one example aspect, the first and second entanglement processes <NUM> and <NUM> may each be executed five times to achieve a desired cohesiveness while still having a desired loft of the nonwoven layer <NUM>.

Step <NUM> depicts the nonwoven layer <NUM> formed from the entanglement of the fibers/filaments of the nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM>. The nonwoven layer <NUM> is shown as a continuous sheet without holes or apertures. It is contemplated herein that the nonwoven layer <NUM> may include holes or apertures. The holes or apertures may be formed during the entanglement process or they may be formed in a post-processing step using, for example, die cutting, laser cutting, water jet cutting, and the like.

Because the fibers/filaments from each of the nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> are entangled with each other, the visual property of the nonwoven layer <NUM> represents a composite or mixture of the respective visual properties <NUM>, <NUM>, <NUM>, and <NUM> as indicated by the shading pattern in the step <NUM>. In example aspects, the amount of entanglement between the different nonwoven sheets <NUM>, <NUM>, <NUM>, and <NUM> influences the visual property of the resulting nonwoven layer <NUM>. Using an illustrative example, the visual properties <NUM> and <NUM> may comprise the color blue and the visual properties <NUM> and <NUM> may comprise the color yellow. When a greater number of the first and second entanglement processes <NUM> and <NUM> are executed, the visual property of the nonwoven layer <NUM> may comprise a generally green color due to a greater degree of entanglement of the blue and yellow fibers and filaments. When a lesser number of the first and second entanglement processes <NUM> and <NUM> are executed, the visual property of the nonwoven layer <NUM> may comprise a heather color with blue areas intermixed with yellow areas.

In one example aspect, one of the nonwoven sheets such as the nonwoven sheet <NUM> or the nonwoven sheet <NUM>, or an additional nonwoven sheet not shown may be added after the first and second entanglement processes <NUM> and <NUM> have been executed one or more times. By introducing a nonwoven sheet later in entanglement process, a visual property that is present on the introduced nonwoven sheet may be more distinct or less intermixed in the resulting nonwoven layer <NUM>. In an illustrative example, the nonwoven sheet <NUM> may be introduced after the first and second entanglement processes <NUM> and <NUM> have been executed, for instance, three times. The visual property <NUM> in this example may comprise a pattern such as diagonal stripes. The first and second entanglement processes <NUM> and <NUM> may be executed, for example, two more times to produce the nonwoven layer <NUM>. Because the nonwoven sheet <NUM> is subject to less entanglement than the remaining nonwoven sheets <NUM>, <NUM>, and <NUM>, the visual property <NUM> is more distinct than the visual properties <NUM>, <NUM>, and <NUM> in the resulting nonwoven layer <NUM>.

<FIG> depicts a schematic of an example process <NUM> for forming the textile <NUM>. At a step <NUM>, the first woven layer <NUM> and the nonwoven layer <NUM> are provided. The first woven layer <NUM> includes a visual property <NUM>, and the nonwoven layer <NUM> includes a visual property <NUM> as indicated by the shading patterns. In example aspects, the visual property <NUM> may be the same or different from the visual property <NUM>. The visual properties <NUM> and <NUM> may include a color, a pattern, a combination of a color and a pattern, and the like.

At a step <NUM>, the second surface <NUM> of the first woven layer <NUM> is positioned adjacent to the first surface <NUM> of the nonwoven layer <NUM> to form a layered construction. At a step <NUM>, a first entanglement process <NUM>, such as needlepunching, is executed on a first area of the layered construction to at least partially form the pile zone <NUM>. The first entanglement process <NUM> is executed in a direction from the nonwoven layer <NUM> toward the first woven layer <NUM> to entangle the fibers/filaments <NUM> from the nonwoven layer <NUM> with the fibers/filaments/yarns of the first woven layer <NUM>. In example aspects, the first entanglement process <NUM> may be executed one time, although it is contemplated herein that the first entanglement process <NUM> may be executed more than one time. Executing the first entanglement process <NUM> in the direction from the nonwoven layer <NUM> toward the first woven layer <NUM> effectively secures or affixes the layers <NUM> and <NUM> together in the pile zone <NUM> due to greater fiber/filament availability in the nonwoven layer <NUM>. In contrast, it has been found that executing an entanglement process in the direction from the first woven layer <NUM> toward the nonwoven layer <NUM> fails to secure the layers together because of less fiber/filament availability in the first woven layer <NUM>. For instance, when needlepunching is used as the entanglement process, the needlepunching creates holes in the first woven layer <NUM> but generally fails to entangle the fibers/filaments/yarns from the first woven layer <NUM> with the fibers/filaments <NUM> of the nonwoven layer <NUM>. It has also been found that needlepunching versus other mechanical entanglement processes such as hydroentangling, works better to secure the first woven layer <NUM> to the nonwoven layer <NUM>. This is likely because hydroentanglement fails to generate enough force to push the fibers/filaments <NUM> of the nonwoven layer <NUM> into and through the first woven layer <NUM>.

At a step <NUM>, the first woven layer <NUM> that is entangled with the nonwoven layer <NUM> in the pile zone <NUM> is depicted. As further shown, because the fibers/filaments <NUM> from the nonwoven layer <NUM> comprise a visual property <NUM> (e.g., a color), the visual property <NUM> is visible on the first surface <NUM> of the first woven layer <NUM> in the pile zone <NUM> due to the entanglement of the fibers/filaments <NUM> of the nonwoven layer <NUM> with the fibers/filaments/yarns of the first woven layer <NUM>. At the step <NUM>, the second woven layer <NUM> is provided. In example aspects, the second woven layer <NUM> comprises a visual property <NUM>. The visual property <NUM> may the same or different from the visual property <NUM> and/or the visual property <NUM>. Similar to the above, the visual property <NUM> may include a color, a pattern, a combination of a color and a pattern, and the like.

At a step <NUM>, the first surface <NUM> of the second woven layer <NUM> is positioned adjacent to the second surface <NUM> of the nonwoven layer <NUM> to form a layered construction. At a step <NUM>, a second entanglement process <NUM>, such as needlepunching, is executed on the area of the layered construction corresponding to the pile zone <NUM>. The second entanglement process <NUM> is executed in a direction from the first woven layer <NUM> toward the second woven layer <NUM> to entangle the fibers/filaments <NUM> of the nonwoven layer <NUM>, including the fibers/filaments <NUM> that are present within and on the first surface <NUM> of the first woven layer <NUM> with the fibers/filaments/yarns of the second woven layer <NUM>. In example aspects, the second entanglement process <NUM> may be executed one time, although it is contemplated herein that the second entanglement process <NUM> may be executed more than one time. Similar to the first entanglement process <NUM>, it has been found that needlepunching versus other mechanical entanglement processes such as hydroentangling, works better to secure the second woven layer <NUM> to the nonwoven layer <NUM> likely to the large amount of force able to be generated through the needlepunching process.

Step <NUM> depicts the first surface <NUM> and the second surface <NUM> of the textile <NUM>. With respect to the first surface <NUM>, and as noted above, the insulation zone <NUM> generally comprises the visual property <NUM> of the first woven layer <NUM>, and the pile zone <NUM> generally comprises an intermixing of the visual property <NUM> of the first woven layer <NUM> and the visual property <NUM> of the nonwoven layer <NUM>. With respect to the second surface <NUM> of the textile <NUM>, the insulation zone <NUM> generally comprises the visual property <NUM> of the second woven layer <NUM>, and the pile zone <NUM> generally comprises an intermixing of the visual property <NUM> of the nonwoven layer <NUM> and the visual property <NUM> of the second woven layer <NUM>. The depiction of the process <NUM> is illustrative only and it is contemplated herein that the visual properties may vary from those shown. For example, in some aspects, the first woven layer <NUM> and/or the second woven layer <NUM> may be translucent or partially translucent such that the visual property <NUM> of the nonwoven layer <NUM> is partially visible through the first woven layer <NUM> and/or the second woven layer <NUM> in the insulation zone <NUM> of the textile <NUM>. As well, the location, size, and shape of the insulation zone <NUM> and the pile zone <NUM> may vary from that shown.

The process <NUM> as described utilizes two woven layers such as the first woven layer <NUM> and the second woven layer <NUM> and a nonwoven layer, such as the nonwoven layer <NUM> to produce a textile that includes both insulation zones and pile zones in a seamless construction. The process <NUM> produces a varied aesthetic between the insulation zones and the pile zones on a particular surface of the textile, as well as a varied aesthetic on both the first surface and the second surface of the textile.

The textile <NUM> may be incorporated into a number of different garments. For example, <FIG> depicts an upper-body garment <NUM> formed from the textile <NUM>. The upper-body garment <NUM> is shown in the form of a vest having a torso portion <NUM>, a neck opening <NUM>, a waist opening <NUM>, a first arm opening <NUM>, and a second arm opening <NUM>. Although shown as a vest, it is contemplated herein that the upper-body garment <NUM> may be in the form of a jacket with sleeves, a pullover, a shirt, a hoodie, and the like.

The upper-body garment <NUM> includes an insulation zone <NUM> corresponding to the insulation zone <NUM> of the textile <NUM> and a pile zone <NUM> corresponding to the pile zone <NUM> of the textile <NUM>. The location of the insulation zone <NUM> and the pile zone <NUM> may be based on, for instance, heat maps of a human body. For example, the insulation zone <NUM> may be located on the upper-body garment <NUM> in areas corresponding to high heat loss of a wearer such as the upper front torso and the upper back torso, and the pile zone <NUM> may be located on the upper-body garment <NUM> in areas of less heat loss such as the lower front torso and the lower back torso. The size, shape, and number of the insulation zone <NUM> and the pile zone <NUM> on the upper-body garment <NUM> is illustrative only. In an example aspect, the upper-body garment <NUM> may include multiple insulation zones and multiple pile zones. Any and all aspects, and any variation thereof, are contemplated as being within aspects herein.

<FIG> depicts a lower-body garment <NUM> formed from the textile <NUM>. The lower-body garment <NUM> is in the form of a pant that has a torso portion <NUM> with a waist opening <NUM>, a first leg portion <NUM> with a first leg opening <NUM>, and a second leg portion <NUM> with a second leg opening <NUM>. Although shown as a pant, it is contemplated herein that the lower-body garment <NUM> may be in the form of a short, a tight, a capri, a unitard, and the like.

The lower-body garment <NUM> includes insulation zones <NUM> located on the torso portion <NUM> and a lower aspect of the first leg portion <NUM> and the second leg portion <NUM>. A pile zone <NUM> is located on an upper and mid aspect of the first leg portion <NUM> and the second leg portion <NUM>. The location of the insulation zones <NUM> and the pile zones <NUM> may be based on heat maps of a human body. The size, shape, and number of the insulation zones <NUM> and the pile zones <NUM> is illustrative.

Although not shown, it is contemplated that the textile <NUM> may be used to form additional articles such as hats, gloves, extremity sleeves, socks, uppers, and the like.

<FIG> is a flow diagram of an example method <NUM> of manufacturing a textile such as the textile <NUM>. At a step <NUM>, a nonwoven layer, such as the nonwoven layer <NUM> is positioned between a first woven layer, such as the first woven layer <NUM> and a second woven layer, such as the second woven layer <NUM> to form a layered construction. At a step <NUM>, fibers and filaments from the nonwoven layer are entangled with fibers, filaments and/or yarns from each of the first woven layer and the second woven layer in a first area of the layered construction to form a pile zone. It is contemplated herein that in a second area of the layered construction corresponding to an insulation zone, the entanglement process is not executed such that the first woven layer, the second woven layer, and the nonwoven layer comprise separate and distinct layers.

Aspects herein further contemplate that the nonwoven layer is formed by entangling fibers and filaments from two or more nonwoven sheets together as described with respect to the process <NUM>.

As illustrated in <FIG>, the step <NUM> may include positioning the first woven layer adjacent to a first surface of the nonwoven layer and executing a first entanglement process in a direction from the nonwoven layer toward the first woven layer. After the first entanglement process is completed, the second woven layer is positioned adjacent to a second opposite surface of the nonwoven layer. A second entanglement process is then executed in a direction from the first woven layer toward the second woven layer to finish forming the pile zone.

As described with respect to the processes <NUM> and <NUM>, the visual properties of the nonwoven sheets used to form the nonwoven layer may be selected to achieve a desired visual property for the nonwoven layer. In addition, the visual properties of the first woven layer and the second woven layer may be selected to achieve a desired visual property for the insulation zone(s) and the pile zone(s) on the first surface of the textile as well as a desired visual property for the insulation zone(s) and the pile zone(s) on the second opposite surface of the textile. The visual properties of the textile may also be adjusted based on the degree of entanglement of the nonwoven sheets used to form the nonwoven layer and the degree of entanglement of the nonwoven layer with each of the first woven layer and the second woven layer.

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 claims.

Claim 1:
A method of forming a textile (<NUM>) incorporated into a garment, comprising:
positioning a woven layer (<NUM>) and a nonwoven layer (<NUM>) to form a layered construction; and
executing a needlepunching process (<NUM>) on the layered construction one or more times to at least partially form a pile zone (<NUM>) and to entangle fibers/filaments (<NUM>) from the nonwoven layer (<NUM>) with fibers/filaments/yarns of the woven layer (<NUM>),
wherein the woven layer (<NUM>) includes a first visual property (<NUM>), wherein the nonwoven layer (<NUM>) includes a second visual property (<NUM>), and wherein the first visual property (<NUM>) is different from the second visual property (<NUM>), and
wherein the first and second visual properties (<NUM>, <NUM>) include a color, a pattern, or a combination of a color and a pattern.