Patent 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.

<CIT> describes a method of manufacturing a vented insulated garment using sections of non-woven polymer material and garments produced therefrom. The method generally comprises positioning a section of non-woven polymer material between two textile layers, and bonding the textile layers together at areas adjacent to the section of non-woven polymer material to form seams. The seams may be optionally perforated.

The present invention relates to an entanglement system as defined in claim <NUM>, a method of manufacturing a nonwoven textile as defined in claim <NUM>, a garment as defined in claim <NUM>, a nonwoven textile as defined in claim <NUM>, and a method of manufacturing an array of garments as defined in claim <NUM>. Particular embodiments are defined in the dependent claims.

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 or disclosed 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.

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 (M<NUM> * K/W). Unless otherwise noted, all measurements provided herein are measured at standard ambient temperature and pressure (<NUM> degrees Celsius or <NUM> and <NUM> bar) with the nonwoven textile in a resting (un-stretched) state.

<FIG> depicts a first surface <NUM> of a composite nonwoven textile <NUM> where the first surface <NUM> is formed of a first nonwoven layer <NUM>. In example aspects, the first nonwoven layer <NUM> may 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 layer <NUM> is formed from entangled fibers as indicated by reference numeral <NUM>. When the composite nonwoven textile <NUM> is incorporated into a garment, the first surface <NUM> may be positioned as an inner-facing surface or an innermost-facing surface of the garment. Alternatively, the first surface <NUM> may be positioned as an outer-facing surface or an outermost-facing surface of the garment.

The composite nonwoven textile <NUM> also includes a second layer <NUM> which will be described in greater detail with respect to <FIG>. A fill material <NUM> is positioned between the first nonwoven layer <NUM> and the second layer <NUM>. The fill material <NUM> may 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 in <FIG>, the composite nonwoven textile <NUM> may include a plurality of non-linear entangled seams <NUM> that extend in a material flow direction <NUM> of the composite nonwoven textile <NUM>. The entangled seams <NUM> represent areas where fibers from the different layers are entangled with each other. In one example aspect, the entangled seams <NUM> represent areas where fibers from the first nonwoven layer <NUM> extend through the fill material <NUM> and into the second layer <NUM>. Regions <NUM> of the composite nonwoven textile <NUM> that are located between the entangled seams <NUM> represent regions where the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> are substantially unentangled such that the different layers are not secured or affixed or are lightly secured or affixed to one another at the regions <NUM>. As shown, the regions <NUM> have more loft or a greater thickness than the entangled seams <NUM> and may help to store and retain heat when the composite nonwoven textile <NUM> is incorporated into a garment. In turn, the entangled seams <NUM> may help to prevent shifting or drift of the fill material <NUM> when a garment incorporating the composite nonwoven textile <NUM> is worn.

With respect to at least entangled seam 118a, a distance between the entangled seam 118a and a linear first edge <NUM> of the composite nonwoven textile <NUM> varies along the material flow direction <NUM> of the composite nonwoven textile <NUM>. For example, a first distance <NUM> between the entangled seam 118a and the first edge <NUM> may be less than a second distance <NUM> between the entangled seam 118a and the first edge <NUM>. This also holds true for the other entangled seams <NUM> shown in <FIG>. As depicted, the entangled seams <NUM> may include linear segments that extend from each other, curves, and combinations of the above. The depiction of the shape of the individual entangled seams <NUM>, the number of entangled seams <NUM>, the spacing between adjacent entangled seams <NUM>, and the overall visual arrangement of the entangled seams <NUM> is illustrative and it is contemplated herein that the entangled seams <NUM> may include other non-linear shapes, a different number of entangled seams <NUM>, different spacing, and a different overall visual arrangement of the entangled seams <NUM>.

<FIG> illustrates an opposite second surface <NUM> of the composite nonwoven textile <NUM> where the second surface <NUM> is formed by the second layer <NUM>. In one example aspect as shown in <FIG>, the second layer <NUM> may include a woven layer as indicated by the example interlaced warp and weft yarns <NUM>. In this example, when the composite nonwoven textile <NUM> is incorporated into a garment, the second layer <NUM> may 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 textile <NUM>. The non-linear entangled seams <NUM> are shown extending through the composite nonwoven textile <NUM> such that they are present on the second surface <NUM> of the textile <NUM>.

<FIG> illustrates a second example where the second layer <NUM> is formed from a nonwoven material such as a spunbond or spunlace material. Entangled fibers forming the second layer <NUM> are indicated by reference numeral <NUM>. The non-linear entangled seams <NUM> extend through the composite nonwoven textile <NUM> such that they are present on the second surface <NUM> of the textile <NUM> in <FIG>.

<FIG> depicts a cross-section of the composite nonwoven textile <NUM> taken at cut line <NUM>-<NUM> of <FIG>. The first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> are indicated where the fill material <NUM> is positioned between the first nonwoven layer <NUM> and the second layer <NUM>. At the regions <NUM>, each of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> are substantially unentangled such that the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> remain generally separate and distinct layers having a combined thickness <NUM> as measured from the first surface <NUM> to the second surface <NUM>.

The fibers <NUM> from the first nonwoven layer <NUM> are shown extending through the fill material <NUM> and the second layer <NUM> at the entangled seams <NUM> such that the entangled seams <NUM> secure the different layers together at the seam areas. In one example aspect, the fibers <NUM> may extend through the second layer <NUM> such that they extend away from the second surface <NUM> of the composite nonwoven textile <NUM> as shown in <FIG>. In this example, the fibers <NUM> may be left unmodified such that the second surface <NUM> presents a fuzzy surface at the entangled seams <NUM>. In another example, the fibers <NUM> may be removed, compressed, or melted. For example, a calendaring process may be used to compress the fibers <NUM> such that they do not extend from the second surface <NUM>. In another example, the fill material <NUM> may include low-melt fibers, and any low-melt fibers extending from the second surface <NUM> may be removed by the application of heat. Additionally, a shaving process could be used to remove the fibers <NUM> if desired. In another example aspect, the fibers <NUM> may extend into the second layer <NUM> but not extend through the second layer <NUM> such that the fibers <NUM> are generally not present on the second surface <NUM> of the composite nonwoven textile <NUM>.

The entangled seams have a thickness <NUM> that is less than the thickness <NUM> at the regions <NUM>. In one example aspect, the thickness <NUM> may be from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, or about <NUM>. As used herein, the term "about" means within ± <NUM>% of an indicated value. In example aspects, the thickness <NUM> may be from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, from about <NUM> to about <NUM>, or about <NUM>. As such, in example aspects, the thickness <NUM> of the entangled seams <NUM> may be from about <NUM>% to about <NUM>% of the thickness <NUM> of the regions <NUM>.

<FIG> illustrates an enlarged view of one of the entangled seams <NUM> of the composite nonwoven textile <NUM> as viewed form the first surface <NUM> of the composite nonwoven textile <NUM>. A view of the entangled seam <NUM> from the second surface <NUM> would be similar. <FIG> illustrates a first example way that the entangled seam <NUM> may be formed. In example aspects, the entangled seam <NUM> may be formed from discrete entanglement areas <NUM> that partially overlap each other at overlap areas <NUM>. Each of the discrete entanglement areas <NUM> has an entanglement footprint. For instance, the entanglement footprint of the entanglement areas <NUM> is 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 areas <NUM>. As shown, the entanglement areas <NUM> extend from each other in a non-linear manner to form an apparent continuous non-linear entangled seam.

The individual dots within the entanglement areas <NUM> represent entanglement points <NUM> where either an entanglement needle or a fluid jet engages with the composite nonwoven textile <NUM> to entangle fibers. The number of the entanglement points <NUM> per cm<NUM> may 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 seams <NUM> compared to a lesser stitch density since a greater stitch density generally means a greater degree of fiber entanglement.

The overlap areas <NUM> represent 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 points <NUM> within the overlap areas <NUM> is greater than the number and/or density of the entanglement points <NUM> at remaining portions of the entanglement areas <NUM>. Stated differently, the stitch density of the overlap areas <NUM> is greater than the stitch density at remaining portions of the entanglement areas <NUM>. A result of this is that the overlap areas <NUM> may have a reduced thickness as compared to remaining portions of the entanglement areas <NUM>.

<FIG> illustrates a second example way that the entangled seam <NUM> may be formed. In this aspect, the entanglement areas <NUM> extend from one another in a non-linear manner to form an apparent continuous entangled seam. The entanglement areas <NUM>, however, do not partially overlap each other as in <FIG>. Instead, the entanglement areas <NUM> may be positioned directly adjacent to each other such that an entanglement point <NUM> of a first entanglement area <NUM> may share a common border with an entanglement point <NUM> of an adjacent second entanglement area <NUM>. With respect to the non-linear entangled seams <NUM>, the entangled seams <NUM> may include the configuration shown in <FIG>, the configuration shown in <FIG>, or a combination of the configurations shown in <FIG>. It is also contemplated herein that the entanglement areas <NUM> may be spaced apart from one another to form a discontinuous non-linear entangled seam.

<FIG> is a schematic depiction of a side view of an example entanglement system <NUM>. The depiction of the different components of the entanglement system <NUM> is illustrative only and does not represent the actual configuration or structure of the components. The entanglement system <NUM> includes a conveyance system <NUM> having a surface <NUM> adapted to advance a stacked configuration of, for example, the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> in a material flow direction as indicated by arrows <NUM>. As described further with respects to <FIG>, in another aspect, the conveyance system <NUM> may advance a single nonwoven layer, such as the first nonwoven layer <NUM> in the material flow direction <NUM>. The conveyance system <NUM> may include conveyance systems known in the art such as rollers, belts, and the like. The advancement of the conveyance system <NUM> may, in example aspects, include stationary phases or positions and movement phases in the material flow direction <NUM>. 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 system <NUM> further includes a number of entanglement stations such as entanglement stations <NUM>, <NUM>, and <NUM>. 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 in <FIG>. The entanglement stations <NUM>, <NUM>, and <NUM> are aligned serially along the conveyance system <NUM> in the material flow direction <NUM>. In example aspects, including a greater number of entanglement stations in the entanglement system <NUM> creates 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 system <NUM> creates 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 system <NUM> may be customized to achieve a desired repeat length of the visual arrangement of non-linear entangled seams.

The components associated with the different entanglement stations <NUM>, <NUM>, and <NUM> may be substantially similar and, as such, the components associated with the entanglement station <NUM> will be described herein with the understanding that the description of the components also applies to the entanglement stations <NUM> and <NUM>. The entanglement station <NUM> includes a carriage <NUM> slidably coupled to, for example, a mount <NUM>. The carriage <NUM> is adapted to move in directions non-parallel to the material flow direction <NUM>. Alternatively, the carriage <NUM> may not be used when the conveyance system <NUM> is adapted to move in directions non-parallel to the material flow direction <NUM>. In example aspects, the carriage <NUM> and/or the conveyance system <NUM> are adapted to move in directions perpendicular to the material flow direction <NUM> toward both a first side edge and an opposite second side edge of the conveyance system <NUM> (i.e., in a positive and negative y-direction).

The entanglement station <NUM> further includes an actuator <NUM> coupled to the carriage <NUM>. In one example aspect and as shown in <FIG>, the actuator <NUM> is adapted to move in a direction perpendicular to a plane of conveyance of the surface <NUM> of the conveyance system <NUM> as indicated by arrow <NUM>. 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 surface <NUM> of the conveyance system <NUM>. In still other example aspects, and as described in relation to <FIG>, the actuator <NUM> may remain stationary and the actuator may actuate entanglement heads to emit jets of fluid. An entanglement head <NUM> is coupled to the actuator <NUM> and may be indirectly coupled to the carriage <NUM> by way of the actuator <NUM>. In the example shown in <FIG>, the entanglement head <NUM> may include one or more entanglement needles <NUM> that extend toward the surface <NUM> of the conveyance system <NUM>. Although only one entanglement needle <NUM> is depicted, it is contemplated herein that the entanglement head <NUM> may include multiple entanglement needles as further described with respect to <FIG>.

<FIG> depicts a front view of the entanglement station <NUM> depicting the mount <NUM>, the carriage <NUM>, the actuator <NUM>, the entanglement head <NUM>, and the entanglement needle <NUM>. Arrow <NUM> represents a first direction of movement of the carriage <NUM> and/or conveyance system <NUM> in the direction non-parallel to the material flow direction <NUM>, and arrow <NUM> represents an opposite second direction of movement of the carriage <NUM> and/or conveyance system <NUM> in the direction non-parallel to the material flow direction <NUM>. In example aspects, the first and second directions <NUM> and <NUM> are perpendicular to the material flow direction <NUM>.

The front view of the entanglement station <NUM> depicts three entanglement heads 532a, 532b, and 532c spaced generally evenly apart where the three entanglement heads 532a, 532b, and 532c are 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 heads 532a, 532b, and 532c or fewer than the three entanglement heads 532a, 532b, and 532c. As well, the spacing between the entanglement heads 532a, 532b, and 532c may vary such that a spacing between a first and second entanglement head <NUM> of the entanglement heads 532a, 532b, and 532c may be greater than a spacing between the second and a third entanglement head <NUM> of the entanglement heads 532a, 532b, and 532c. As explained with respect to <FIG>, the entanglement heads 532a, 532b, and 532c may have different dimensions, a different structured arrangement of entanglement needles and/or orifices, and the like.

<FIG> depicts a front view of an alternative entanglement station <NUM> that may be part of an entanglement system such as the entanglement system <NUM> that is adapted to hydroentangle layers to create a composite structure instead of needlepunching the layers to create a composite structure. As such the entanglement station <NUM> may be representative of multiple hydroentanglement stations that are part of the entanglement system <NUM>.

The entanglement station <NUM> also includes a mount <NUM> to which a carriage <NUM> is slidably coupled, an actuator <NUM> coupled to the carriage <NUM>, and an entanglement head <NUM> coupled to the actuator <NUM>. The carriage <NUM> and/or conveyance system <NUM> is adapted to move in a first direction non-parallel to the material flow direction <NUM> as indicated by arrow <NUM> and in an opposite second direction <NUM> non-parallel to the material flow direction <NUM>. In example aspects, the directions <NUM> and <NUM> are perpendicular to the material flow direction <NUM>. In example aspects, the actuator <NUM> may not move in the direction <NUM> perpendicular to the plane of conveyance of the surface <NUM>. Instead, in example aspects, the actuator <NUM> is adapted to actuate the entanglement head <NUM> to emit one or more pressurized jets of fluid <NUM> that extend toward the surface <NUM> of the conveyance system <NUM>. With respect to this aspect, it is contemplated herein that the conveyance system <NUM> may intermittently advance as described above where the jets of fluid <NUM> are emitted when the conveyance system <NUM> is in a stationary phase. Alternatively, the conveyance system <NUM> may be continually advanced and the jets of fluid <NUM> may be continually emitted from the entanglement head <NUM>. Similar to the entanglement station <NUM>, the number of entanglement heads <NUM> may be different from that shown, the spacing between entanglement heads <NUM> may vary from that shown, and the entanglement heads <NUM> may have different dimensions, a different structured arrangement of orifices, and the like.

<FIG> depicts the second entanglement station <NUM> where the second entanglement station <NUM> includes the same components as the entanglement station <NUM> (e.g., mount <NUM>, carriage <NUM>, actuator <NUM>, and entanglement head <NUM>). Two entanglement heads 532d and 532e are depicted for the second entanglement station <NUM>. In example aspects, the entanglement heads 532d and 532e may be positioned such that they do not align in the material flow direction <NUM> with the entanglement heads 532a, 532b, and 532c. The result of this is that the entanglement heads 532d and 532e are adapted to engage with the composite nonwoven textile at different locations in a direction non-parallel to the material flow direction <NUM> as compared to the entanglement heads 532a, 532b, and 532c. Stated differently, the entanglement heads 532d and 532e are 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 heads 532a, 532b, and 532c. For instance, the entanglement head 532a may be offset from a first edge <NUM> of the surface <NUM> of the conveyance system <NUM> in a direction perpendicular to the material flow direction <NUM> by a first distance <NUM>, and the entanglement head 532d may be offset from the first edge <NUM> of the surface <NUM> of the conveyance system <NUM> in the direction perpendicular to the material flow direction <NUM> by a second distance <NUM> where the second distance <NUM> is greater than the first distance <NUM>. As such, a spacing arrangement between the entanglement heads 532d and 532e differs from a spacing arrangement between the entanglement heads 532a, 532b, and 532c. As shown, the entanglement station <NUM> includes a different number of entanglement heads <NUM> than the number of entanglement heads <NUM> at the entanglement station <NUM>. It is contemplated herein that the entanglement station <NUM> may include fewer entanglement heads than shown or a greater number of entanglement heads than shown. The dimensions of the entanglement heads 532e and 532d may be the same or different from the dimensions of the entanglement heads 532a, 532b, and 532c. Additionally, the entanglement footprint produced by the entanglement heads 532e and 532d may be the same or different from the entanglement footprint produced by the entanglement heads 532a, 532b, and 532c.

<FIG> depicts the third entanglement station <NUM> where the third entanglement station <NUM> includes the same components as the entanglement stations <NUM> and <NUM>. Two entanglement heads 532f and <NUM> are depicted for the third entanglement station <NUM>. In example aspects, the entanglement heads 532f and <NUM> may be positioned such that they do not align in the material flow direction <NUM> with the entanglement heads 532a, 532b, 532c, 532d, and 532e. Thus, the entanglement heads 532f and <NUM> are 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 heads 532a, 532b, 532c, 532d, and 532e. Stated differently, the entanglement heads 532f and <NUM> may be offset from the first edge <NUM> of the surface <NUM> of the conveyance system <NUM> by distances that are different than the distances of offset for the entanglement heads 532a, 532b, 532c, 532d, and 532e. The entanglement station <NUM> may include a different number of entanglement heads <NUM> than that shown. The entanglement heads 532f and <NUM> may also be spaced differently from that shown. The dimensions of the entanglement heads 532f and <NUM> may be the same or different from the dimensions of the entanglement heads 532a, 532b, 532c, 532d, and 532e. In addition, the entanglement footprint produced by the entanglement heads 532f and <NUM> may be the same or different from the entanglement footprint produced by the entanglement heads 532a, 532b, 532c, 532d, and 532e.

Although the entanglement system <NUM> is depicted as including multiple entanglement stations positioned serially along the conveyance system <NUM> in the material flow direction <NUM>, it is also contemplated herein that the entanglement system <NUM> may include one entanglement station such as the entanglement station <NUM>. In this aspect, the stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> may be passed through the entanglement station <NUM> multiple times to form the resulting composite nonwoven textile <NUM>. In this aspect, the positioning of the entanglement heads 532a, 532b, and 532c may be adjusted between each pass such that different areas of the stacked configuration are engaged by the entanglement heads 532a, 532b, and 532c during each pass. As well, different entanglement heads may be added, existing entanglement heads may be removed, and the like. The movement of the carriage <NUM> may also be adjusted during each pass such that the entanglement heads 532a, 532b, and 532c engage with different portions of the stacked configuration.

The illustrative entanglement system <NUM> shown in <FIG> and described further with respect to <FIG> may produce a complex visual arrangement of non-linear entangled seams that extend in the material flow direction <NUM>. The components and movements of the entanglement system <NUM> may be adjusted to create non-linear entangled seams that are spaced closely together or are spaced further apart. Additionally, the system <NUM> may 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 to <FIG>, this creates a differential thickness of a resulting composite nonwoven textile in the first and second directions <NUM> and <NUM> non-parallel or perpendicular to the material flow direction <NUM> (i.e., along a cross-section of the resulting composite nonwoven textile).

<FIG> depict bottom up views of two example entanglement heads <NUM> and <NUM> respectively. The entanglement heads <NUM> and <NUM> may be any of the entanglement heads described in relation to the entanglement system <NUM> or the entanglement station <NUM>. With respect to the entanglement head <NUM>, it includes a structured arrangement of entanglement needles <NUM> or, alternatively, orifices <NUM> adapted to emit jets of fluid. The entanglement head <NUM> has an example circular shape such that the entanglement needles <NUM> or orifices <NUM> are adapted to form a circular entanglement footprint on a composite nonwoven textile. The entanglement head <NUM> has a dimension <NUM> in the material flow direction and a dimension <NUM> in the first and second directions <NUM> and <NUM> non-parallel or perpendicular to the material flow direction <NUM>. Because the entanglement head <NUM> has a circular shape, the dimensions <NUM> and <NUM> are equivalent to the diameter of the entanglement head <NUM> and are equal.

The entanglement head <NUM> also includes a structured arrangement of entanglement needles <NUM> or, alternatively, orifices <NUM> adapted to emit jets of water. The entanglement head <NUM> has an example rectangular shape such that the entanglement needles <NUM> or orifices <NUM> are adapted to form a rectangular entanglement footprint on a composite nonwoven textile. The entanglement head <NUM> has a dimension <NUM> in the material flow direction <NUM> and a dimension <NUM> in the first and second directions <NUM> and <NUM> non-parallel or perpendicular to the material flow direction <NUM>.

In example aspects, the distance of advancement of the conveyance system <NUM> in the material flow direction <NUM> during the movement phases of the entanglement system <NUM> may be less than or equal to the dimensions <NUM> and <NUM> of the respective entanglement heads <NUM> and <NUM>. This ensures that the entanglement areas produced by the entanglement heads <NUM> and <NUM> are directly adjacent to each other and/or overlap to form an apparent continuous non-linear entangled seam. Further, the movement of the carriage <NUM> and/or conveyance system <NUM> in the first and second directions <NUM> and <NUM> non-parallel or perpendicular to the material flow direction <NUM> may be less than or equal to the dimensions <NUM> and <NUM> of the respective entanglement heads <NUM> and <NUM>. This further ensures that the entanglement areas produced by the entanglement heads <NUM> and <NUM> are 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 heads <NUM> and <NUM> is illustrative and it is contemplated herein that the entanglement heads may have other shapes such as oval, square, triangular, and the like.

<FIG> and <FIG> respectively schematically depict processes for manufacturing a composite nonwoven textile having non-linear entangled seams such as the composite nonwoven textile <NUM>. <FIG> depicts a process that uses entanglement needles and may be carried out at any of the entanglement stations <NUM>, <NUM>, or <NUM>. <FIG> depicts a process that uses hydroentanglement and may be carried out at, for instance, the entanglement station <NUM>. With respect to both <FIG> and <FIG>, a coordinate system is provided indicating an x direction, a y direction and a z direction.

Referring to <FIG>, at a step <NUM>, a stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> is positioned on the surface <NUM> of the conveyance system <NUM> such that the second layer <NUM> is positioned against the surface <NUM> and the first nonwoven layer <NUM> is spaced apart from the surface <NUM> by the fill material <NUM>. The conveyance system <NUM> and the stacked configuration are in a first stationary phase or position such that the conveyance system <NUM> is not advancing in the material flow direction <NUM> (i.e., the positive x-direction). During the first stationary phase, the actuator <NUM> moves in the direction <NUM> perpendicular to the plane of conveyance of the surface <NUM> (i.e., a negative z-direction) such that the entanglement head <NUM> is lowered causing the entanglement needle <NUM>, and indirectly the entanglement head <NUM>, to engage with the stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM>. Alternatively, the actuator <NUM> may actuate the entanglement head <NUM> and/or the entanglement needle <NUM> such that the entanglement needle <NUM> moves downward to engage with the stacked configuration. The engagement drives fibers from the first nonwoven layer through the fill material <NUM> and into (or through) the second layer <NUM> creating a first entanglement area <NUM> as shown in step <NUM>. The first entanglement area <NUM> may have an entanglement footprint corresponding to the shape of the structured arrangement of the entanglement needles <NUM> on the entanglement head <NUM>.

At a step <NUM>, the entanglement needle <NUM> disengages from the stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM>, and the conveyance system <NUM> advances the stacked configuration in the material flow direction <NUM> by a distance <NUM>. In example aspects, the distance <NUM> may be equal to or less than the dimension of the entanglement head <NUM> in the material flow direction <NUM>. At the step <NUM>, the carriage <NUM> moves a first distance in the first direction <NUM> non-parallel to the material flow direction <NUM> (i.e., a negative y-direction) where the first distance may be equal to or less than the dimension of the entanglement head <NUM> in the first direction <NUM> non-parallel to the material flow direction <NUM>. The movement of the carriage <NUM> may occur simultaneously with the movement of the conveyance system <NUM> in the material flow direction <NUM> or it may occur after the movement of the conveyance system <NUM> in the material flow direction <NUM> (i.e., when the conveyance system <NUM> is in a second stationary phase). Alternatively, or in addition to, the conveyance system <NUM> may move the first distance in the first direction <NUM> non-parallel to the material flow direction <NUM>.

At a step <NUM>, the conveyance system <NUM> and the stacked configuration are in a second stationary phase or position such that the conveyance system <NUM> is not advancing in the material flow direction <NUM>. The second stationary phase or position is advanced from the first stationary phase or position in the material flow direction <NUM>. During the second stationary phase, the actuator <NUM> again moves in the direction <NUM> perpendicular to the plane of conveyance of the surface <NUM> such that the entanglement head <NUM> is lowered causing the entanglement needle <NUM> to engage with the stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM>. Because of the movement of the carriage <NUM> and/or conveyance system <NUM>, the engagement of the entanglement needle <NUM> with the stacked configuration occurs at a location offset from the first entanglement area <NUM> in the first direction <NUM> non-parallel to the material flow direction <NUM>. The second engagement again drives fibers from the first nonwoven layer <NUM> through the fill material <NUM> and into (or through) the second layer <NUM> creating a second entanglement area <NUM> as shown in step <NUM> to create an apparent continuous non-linear entangled seam <NUM> in the composite nonwoven textile <NUM>. The second entanglement area <NUM> may have an entanglement footprint corresponding to the shape of the structured arrangement of the entanglement needles <NUM> on the entanglement head <NUM>. As shown at <NUM>, the second entanglement area <NUM> partially overlaps the first entanglement area <NUM>. This is illustrative, and it is contemplated herein that the second entanglement area <NUM> may not partially overlap the first entanglement area <NUM>.

The process depicted in <FIG> may include a plurality of stationary phases or positions that are advanced from each other in the material flow direction during which the entanglement needle <NUM> engages with the stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> to form entanglement areas that extend from one another. As well, the process depicted in <FIG> may include a plurality of movement phases during which the conveyance system <NUM> advances the stacked configuration in the material flow direction <NUM> a distance that is less than or equal to the dimension of the entanglement head <NUM> in the material flow direction <NUM> such that the resulting entanglement areas partially overlap or directly extend from one another. Moreover, the carriage <NUM> and/or the conveyance system <NUM> may execute multiple movements in the first direction <NUM> non-parallel to the material flow direction <NUM> and in the opposite second direction <NUM> (i.e., the positive y-direction). The distance of movement of the carriage <NUM> and/or conveyance system <NUM> in the first direction <NUM> and the opposite second direction <NUM> may be less than or equal to the dimension of the entanglement head <NUM> in the first direction <NUM> or the opposite second direction <NUM> such that the resulting entanglement areas partially overlap or directly extend from one another.

The process schematically depicted in <FIG> is similar to that shown in <FIG> but utilizes hydroentanglement to create non-linear entangled seams. At a step <NUM>, a stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> is positioned on the surface <NUM> of the conveyance system <NUM> such that the second layer <NUM> is positioned against the surface <NUM> and the first nonwoven layer <NUM> is spaced apart from the surface <NUM> by the fill material <NUM>. In one example aspect, the conveyance system <NUM> and the stacked configuration are in a first stationary phase or position such that the conveyance system <NUM> is not advancing in the material flow direction <NUM>. During the first stationary phase, the actuator <NUM> actuates the entanglement head <NUM> to emit one or more pressurized jets of fluid <NUM> in a direction toward the surface <NUM> of the conveyance system <NUM> to form a first entanglement area <NUM> as shown in step <NUM>. In example aspects, the actuator <NUM> may not move in a direction perpendicular to the plane of conveyance of the surface <NUM> during the first stationary phase though it is contemplated herein that the actuator <NUM> may move in the direction perpendicular to the plane of conveyance of the surface <NUM> in order to position the jets of fluid <NUM> closer to the first nonwoven layer <NUM>. In another example aspect, the conveyance system <NUM> may continually advance in the material flow direction <NUM> while the actuator <NUM> continually actuates the entanglement head <NUM> to emit the one or more pressurized jets of fluid <NUM>. The jets of fluid <NUM> drive fibers from the first nonwoven layer <NUM> through the fill material <NUM> and into (or through) the second layer <NUM> creating the first entanglement area <NUM>. The first entanglement area <NUM> may have an entanglement footprint corresponding to the shape of the structured arrangement of the orifices on the entanglement head <NUM>.

At a step <NUM>, the conveyance system <NUM> advances the stacked configuration in the material flow direction <NUM> by a distance <NUM>. In example aspects, the distance <NUM> may be equal to or less than the dimension of the entanglement head <NUM> in the material flow direction <NUM>. At the step <NUM>, the carriage <NUM> and/or the conveyance system <NUM> moves a first distance in the first direction <NUM> non-parallel to the material flow direction <NUM> where the first distance may be equal to or less than the dimension of the entanglement head <NUM> in the direction non-parallel to the material flow direction <NUM>. The movement of the carriage <NUM> and/or conveyance system <NUM> may occur simultaneously with the movement of the conveyance system <NUM> in the material flow direction <NUM> or it may occur after the movement of the conveyance system <NUM> in the material flow direction <NUM> (i.e., when the conveyance system <NUM> is in a second stationary phase or position that is advanced from the first stationary phase or position in the material flow direction).

At a step <NUM>, the conveyance system <NUM> and the stacked configuration are in a second stationary phase or position, the actuator <NUM> again actuates the entanglement head <NUM> to emit the jets of fluid <NUM> such that the jets of fluid <NUM> engage with the stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM>. Because of the movement of the carriage <NUM>, the engagement of the jets of fluid <NUM> with the stacked configuration occurs at a location offset from the first entanglement area <NUM> in the direction <NUM> non-parallel to the material flow direction <NUM>. The second engagement again drives fibers from the first nonwoven layer <NUM> through the fill material <NUM> and into (or through) the second layer <NUM> creating a second entanglement area <NUM> as shown in step <NUM> to create an apparent continuous non-linear entangled seam <NUM> in the composite nonwoven textile <NUM> that extends in the material flow direction <NUM>. As shown at <NUM>, the second entanglement area <NUM> partially overlaps the first entanglement area <NUM>. This is illustrative, and it is contemplated herein that the second entanglement area <NUM> may not partially overlap the first entanglement area <NUM>.

The process depicted in <FIG> may include a plurality of stationary phases or positions during which the jets of fluid <NUM> engage with the stacked configuration of the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> to form entanglement areas that extend from one another. As well, the process depicted in <FIG> may execute a plurality of movement phases during which the conveyance system <NUM> advances the textile in the material flow direction <NUM> a distance that is less than or equal to the dimension of the entanglement head <NUM> in the material flow direction <NUM> such that the resulting entanglement areas partially overlap or directly extend from one another. Moreover, the carriage <NUM> and/or the conveyance system <NUM> may execute multiple movements in the first direction <NUM> non-parallel to the material flow direction <NUM> and in the opposite second direction <NUM>. The distance of movement of the carriage <NUM> and/or conveyance system <NUM> in the first direction <NUM> and the opposite second direction <NUM> may be less than or equal to the dimension of the entanglement head <NUM> in the first direction <NUM> or the opposite second direction <NUM> such 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 system <NUM>, may create a composite nonwoven textile, such as the composite nonwoven textile <NUM> that 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> schematically 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 step <NUM>, the composite nonwoven textile <NUM> is provided or obtained. The composite nonwoven textile <NUM>, in this example, includes a first non-linear entangled seam <NUM> and a second non-linear entangled seam <NUM> both extending in the material flow direction <NUM> of the composite nonwoven textile <NUM>. In example aspects, a distance between the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> varies along the material flow direction <NUM>. For example, the first non-linear entangled seam <NUM> may be spaced apart from the second non-linear entangled seam by a first distance <NUM> at a first location <NUM> on the composite nonwoven textile <NUM>. At a second location <NUM> on the composite nonwoven textile <NUM>, the first non-linear entangled seam <NUM> may be spaced apart from the second non-linear entangled seam <NUM> by a second distance <NUM>, where the second distance <NUM> is greater than the first distance <NUM>.

At the step <NUM>, a first instance of a pattern <NUM> is removed, excised, and/or cut from the composite nonwoven textile <NUM> where the pattern <NUM> corresponds to a left sleeve for an upper-body garment. Stated differently, at the step <NUM>, a first portion <NUM> is removed from the composite nonwoven textile <NUM>, where the first portion <NUM> has a shape corresponding to the pattern <NUM>. The pattern <NUM> is illustrative only, and it is contemplated herein that the pattern <NUM> may correspond to any portion of an upper-body garment, a lower-body garment, a shoe upper, an article of headwear, and the like.

Step <NUM> illustrates the first portion <NUM> having the pattern <NUM> after it has been removed from the composite nonwoven textile <NUM>. As shown, the first portion <NUM> includes the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> where the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> are positioned at a first location on the first portion <NUM> and/or pattern <NUM> as indicated generally by the reference numeral <NUM>. At a step <NUM>, the first portion <NUM> is incorporated into a first garment <NUM>. As shown in <FIG>, the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> present a first visual arrangement of non-linear entangled seams on the first garment <NUM> as generally referenced by the numeral <NUM>.

At a step <NUM>, a second instance of the pattern <NUM> is removed, excised, and/or cut from the composite nonwoven textile <NUM>. The second instance of the pattern <NUM> includes the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM>. Stated differently, at the step <NUM>, a second portion <NUM> is removed from the composite nonwoven textile <NUM> where the second portion <NUM> has a shape corresponding to the pattern <NUM>. Step <NUM> illustrates the second portion <NUM> having the pattern <NUM> after it has been removed from the composite nonwoven textile <NUM>. As shown, the second portion <NUM> includes the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM>, where the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> are positioned at a second location on the second portion <NUM> and/or pattern <NUM> as indicated generally by the reference numeral <NUM>. At a step <NUM>, the second portion <NUM> is incorporated into a second garment <NUM> where the second garment <NUM> has the same finished form as the first garment <NUM>. As shown in <FIG>, the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> present a second visual arrangement of non-linear entangled seams on the second garment <NUM> as generally referenced by the numeral <NUM> where the second visual arrangement of non-linear entangled seams <NUM> is a different visual arrangement than the first visual arrangement of non-linear entangled seams <NUM>.

The process depicted in <FIG> may be repeated any number of times along the material flow direction <NUM> of the composite nonwoven textile <NUM> to form an array of garments having the first non-linear entangled seam <NUM> and the second non-linear entangled seams <NUM> positioned at different locations on the pattern <NUM> and presenting different visual arrangements of the first and second non-linear entangled seams <NUM> and <NUM>. Although <FIG> only depicts the pattern <NUM> being applied to the composite nonwoven textile <NUM>, it is contemplated herein that additional pattern pieces may be applied to the composite nonwoven textile <NUM> such that a resulting garment may be formed from the additional pattern pieces applied to the composite nonwoven textile <NUM>. 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 in <FIG> may 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 in <FIG> may be shredded and subsequently formed into, for example one or more of the first nonwoven layer <NUM>, the second layer <NUM>, or the fill material <NUM>. This is possible due to the materials forming the composite nonwoven textile <NUM> being of the same polymer class in example aspects (e.g., recycled polyester). Further, because the composite nonwoven textile <NUM> is 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.

<FIG> and <FIG> further illustrate garments produced from the process shown in <FIG>. <FIG> illustrates a front view of an array of upper-body garments in the form of a sleeveless top including a first upper-body garment <NUM> and a second upper-body garment <NUM> having 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 garment <NUM> includes a neck opening <NUM>, a waist opening <NUM>, a first sleeve opening <NUM>, and a second sleeve opening <NUM>. Similarly, the second upper-body garment <NUM> includes a neck opening <NUM>, a waist opening <NUM>, a first sleeve opening <NUM>, and a second sleeve opening <NUM>. Further, although the non-linear entangled seams are shown extending in a horizontal orientation (in a direction extending, for example, from the first sleeve opening <NUM>/<NUM> to the second sleeve opening <NUM>/<NUM>) 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 opening <NUM>/<NUM> to the waist opening <NUM>/<NUM>).

As depicted, at least a front panel <NUM> of the first upper-body garment <NUM> and a front panel <NUM> of the second upper-body garment <NUM> may be formed from the same pattern piece applied to the composite nonwoven textile <NUM>. The front panel <NUM> of the first upper-body garment <NUM> includes a first non-linear entangled seam <NUM> and a second non-linear entangled seam <NUM> positioned at a first location <NUM> on the first upper-body garment <NUM>. In example aspects, the first location <NUM> may correspond to a first distance <NUM> as measured at a front vertical midline of the first upper-body garment <NUM> for each of the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> relative to the waist opening <NUM> of the first upper-body garment <NUM>. The first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> present a first visual arrangement of entangled seams on the first upper-body garment <NUM>.

The front panel <NUM> of the second upper-body garment <NUM> further includes the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> positioned at a second location <NUM> on the second upper-body garment <NUM> where the second location <NUM> is different from the first location <NUM>. For example, the second location <NUM> may correspond to a second distance <NUM> as measured at a front vertical midline of the second upper-body garment <NUM> for each of the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> relative to the waist opening <NUM> of the second upper-body garment <NUM> where the second distance <NUM> for each of the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> is different from the first distance <NUM>. The first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> present a second visual arrangement of entangled seams on the second upper-body garment <NUM>.

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 garment <NUM> and the second upper-body garment <NUM>. The additional upper-body garments in the array may present a different visual arrangement of the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM>. Stated differently, the first non-linear entangled seam <NUM> and the second non-linear entangled <NUM> may 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> illustrates a front view of an array of lower-body garments in the form of a short including a first lower-body garment <NUM> and a second lower-body garment <NUM> having 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 garment <NUM> includes a waist opening <NUM>, a first leg opening 1316a, and a second leg opening 1316b. Similarly, the second lower-body garment <NUM> includes a waist opening <NUM>, a first leg opening 1324a, and a second leg opening 1324b. 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 panel <NUM> of the first lower-body garment <NUM> and a front panel <NUM> of the second lower-body garment <NUM> may be formed from the same pattern piece applied to the composite nonwoven textile <NUM>. The front panel <NUM> of the first lower-body garment <NUM> includes a first non-linear entangled seam <NUM> and a second non-linear entangled seam <NUM> positioned at a first location <NUM> on the first lower-body garment <NUM>. In example aspects, the first location <NUM> may correspond to a first distance <NUM> as measured at a front vertical midline of the first lower-body garment <NUM> for each of the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> relative to the waist opening <NUM> of the first lower-body garment <NUM>. The first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> present a first visual arrangement of entangled seams on the first lower-body garment <NUM>.

The front panel <NUM> of the second lower-body garment <NUM> further includes the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> positioned at a second location <NUM> on the second lower-body garment <NUM> where the second location <NUM> is different from the first location <NUM>. For example, the second location <NUM> may correspond to a second distance <NUM> as measured at a front vertical midline of the second lower-body garment <NUM> for each of the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> relative to the waist opening <NUM> of the second lower-body garment <NUM> where the second distance <NUM> for each of the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> is different from the first distance <NUM>. The first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> present a second visual arrangement of entangled seams on the second lower-body garment <NUM>.

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 garment <NUM> and the second lower-body garment <NUM>. The additional lower-body garments in the array may present a different visual arrangement of the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM>. Stated differently, the first non-linear entangled seam <NUM> and the second non-linear entangled seam <NUM> may 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 of <FIG> and <FIG> include 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 system <NUM> may 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 direction <NUM>. 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> depicts a second example composite nonwoven textile <NUM> formed from, for example, the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM>. The composite nonwoven textile <NUM> may be formed according to the methods and systems described herein including the entanglement system <NUM>. The composite nonwoven textile <NUM> includes non-linear entangled seams 1410a, 1410b, 1410c, and 1410d extending in the material flow direction <NUM>. As shown, the non-linear entangled seams 1410a and 1410b intersect or cross-over each other at intersection point <NUM>, and the non-linear entangled seams 1410c and 1410d intersect or cross-over each other at intersection points <NUM> and <NUM>. The intersection points <NUM>, <NUM>, and <NUM> represent areas where an entanglement head engages with the composite nonwoven textile <NUM> at least two times. As such, the intersection points <NUM>, <NUM>, and <NUM> have a greater stitch density than remaining portions of the non-linear entangled seams 1410a, 1410b, 1410c, and 1410d. The greater stitch density at the intersection points <NUM>, <NUM>, and <NUM> causes a further reduced thickness compared to remaining portions of the non-linear entangled seams 1410a, 1410b, 1410c, and 1410d and compared to regions <NUM> that extend between the non-linear entangled seams 1410a, 1410b, 1410c, and 1410d.

This is shown in <FIG> which is a cross-section of the composite nonwoven textile <NUM> taken at cut line <NUM>-<NUM>. The regions <NUM> have a thickness <NUM> as measured from a first surface <NUM> formed by the first nonwoven layer <NUM> to an opposite second surface <NUM> formed by the second layer <NUM>. The intersection point <NUM> has a thickness <NUM> as measured from the first surface <NUM> to the opposite second surface <NUM>, and the non-linear entangled seams 1410c and 1410d have a thickness <NUM> as measured from the first surface <NUM> to the opposite second surface <NUM>. In example aspects, the thickness <NUM> is greater than the thickness <NUM>, which is greater than the thickness <NUM>. The ability to create a varied thickness of the composite nonwoven textile <NUM> in 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 textile <NUM>. The insulation zones may have an increased thickness (e.g., more loft) and may correspond to the regions <NUM>. The low-insulation zones may correspond to areas that include multiple intersection points such as the intersection points <NUM>, <NUM>, and <NUM>.

<FIG> depicts a back view of an example upper-body garment <NUM> having a torso portion <NUM> where the torso portion <NUM> includes a neck opening <NUM> and a waist opening <NUM>. The upper-body garment <NUM> further includes an optional first sleeve <NUM> and an optional second sleeve <NUM>. Although shown as a top having long sleeves, it is contemplated herein that the upper-body garment <NUM> may be in the form of a vest, a pullover, a hoodie, a jacket, and the like.

The upper-body garment includes a low-insulation zone <NUM> located at a central back region of the torso portion <NUM> and high-insulation zones <NUM> located on either side of the low-insulation zone <NUM>. The location of the low-insulation zone <NUM> and the high-insulation zones <NUM> may 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 zone <NUM> includes a plurality of non-linear entangled seams 1624a, 1624b, 1624c, and 1624d extending in the material flow direction <NUM>. As depicted, the non-linear entangled seams 1624a, 1624b, 1624c, and 1624d are generally spaced close together and include multiple intersection points as they extend from the neck opening <NUM> to the waist opening <NUM> of the upper-body garment <NUM>. This results in an overall increased stitch density in the low-insulation zone <NUM> and an overall reduced thickness compared to other portions of the upper-body garment <NUM>. By contrast, the high-insulation zones <NUM> include non-linear entangled seams 1626a, 1626b, 1626c, and 1626d. The non-linear entangled seams 1626a, 1626b, 1626c, and 1626d are generally spaced further apart compared to the non-linear entangled seams 1624a, 1624b, 1624c, and 1624d, and the non-linear entangled seams 1626a, 1626b, 1626c, and 1626d do not intersect each other. As such, the high-insulation zones <NUM> have an overall reduced stitch density and an overall increased thickness than the low-insulation zone <NUM>. Stated differently, the high-insulation zones <NUM> may include a greater surface area occupied by regions 1628a, 1628b, 1628c, and 1628d where the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM> are substantially unentangled as compared to the low-insulation zone <NUM>. The greater thickness and loft of the regions 1628a, 1628b, 1628c, and 1628d help to trap and store heat.

The visual arrangement of the non-linear entangled seams in <FIG> is 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 garment <NUM> may include non-linear entangled seams at different locations on the upper-body garment than those shown. The depiction of the upper-body garment <NUM> in <FIG> is 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 regions 1628a, 1628b, 1628c, and 1628d occupying an overall greater surface area of the upper-body garment <NUM>), 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> depicts an example composite nonwoven textile <NUM> formed from the first nonwoven layer <NUM>, the second layer <NUM>, and the fill material <NUM>. In example aspects, the composite nonwoven textile <NUM> includes non-linear entangled seams 1710a, 1710b, and 1710c. The non-linear entangled seam 1710a is similar to other non-linear entangled seams discussed herein with respect to, for instance, the composite nonwoven textile <NUM> and the composite nonwoven textile <NUM>. The non-linear entangled seams 1710b and 1710c include discontinuous non-linear entangled seams. For example, the non-linear entangled seam 1710b includes a discontinuous segment <NUM> in which no entangled seam is formed. The non-linear entangled seam 1710c includes multiple discontinuous segments such as a discontinuous segment <NUM> and a discontinuous segment <NUM>. Further, the non-linear entangled seam 1710c includes an entangled seam portion <NUM> that 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 seam 1710c by a discontinuous segment <NUM> and a discontinuous segment <NUM>.

The discontinuous segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may be formed using the entanglement system <NUM> and the methods described herein. For example, with respect to the discontinuous segment <NUM>, it may be formed by not actuating the entanglement head <NUM> forming the non-linear entangled seam 1710b during one or more stationary phases such that the entanglement needle(s) <NUM> and/or orifice(s) associated with the entanglement head <NUM> does not come into contact with the composite nonwoven textile <NUM>. The length of the discontinuous segments <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> may be adjusted as desired by varying the number of stationary phases in which the entanglement head <NUM> is not actuated.

In example aspects, when the entanglement head <NUM> is subsequently actuated and as shown with respect to the non-linear entangled seam 1710b, the carriage <NUM> and/or conveyance system <NUM> may be positioned to align in the material flow direction <NUM> with a last entanglement area <NUM> formed before the discontinuous segment <NUM> is generated such that a next entanglement area <NUM> is aligned in the material flow direction <NUM> with the last entanglement area <NUM>. Alternatively, and as shown with respect to the discontinuous segment <NUM> of the non-linear entangled seam <NUM>, when the entanglement head <NUM> is actuated after the discontinuous segment <NUM> is formed, the carriage <NUM> and/or conveyance system <NUM> may be positioned to be offset in the first direction <NUM> from a last entanglement area <NUM> formed before the discontinuous segment <NUM> is generated such that a next entanglement area <NUM> is offset in the first direction <NUM> from the last entanglement area <NUM>. It is also contemplated herein that the carriage <NUM> and/or conveyance system <NUM> may be positioned to be offset in the second direction <NUM> such that a subsequent entanglement area is offset in the second direction <NUM> from a previous entanglement area as shown with respect to the discontinuous segment <NUM>.

With respect to the entangled seam portion <NUM>, in example aspects, the entangled seam portion <NUM> may be formed by actuating the entanglement head <NUM> at least one time after the discontinuous segment <NUM> is generated and before the discontinuous segment <NUM> is generated. The length of the entangled seam portion <NUM> may be adjusted based on the number of times the entanglement head <NUM> is actuated after the discontinuous segment <NUM> is formed and before the discontinuous segment <NUM> is formed. For example, actuating the entanglement head <NUM> one or two times may produce a point of entanglement while actuating the entanglement head <NUM> between 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 textile <NUM> is desired. For example, when the composite nonwoven textile <NUM> is 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> depicts an example nonwoven textile <NUM> having entangled seams <NUM> and <NUM>, and <FIG> depicts a cross-section of the nonwoven textile <NUM>. The nonwoven textile <NUM> may 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.

Claim 1:
An entanglement system (<NUM>) for forming at least one non-linear entangled seam (<NUM>) on a composite nonwoven textile (<NUM>), the entanglement system (<NUM>) comprising: a first entanglement station comprising: a conveyance system (<NUM>) having a surface adapted to advance the composite nonwoven textile (<NUM>) in a material flow direction (<NUM>); a first actuator adapted to actuate a first entanglement head (532a, 532b, 532c) coupled to the first actuator; and a first carriage coupled to the first entanglement head (532a, 532b, 532c), the first carriage adapted to move in a first direction non-parallel to the material flow direction (<NUM>).