Composite nonwoven textile having increased pilling resistance through use thermal bonding

Abstract

Aspects herein are directed to a composite nonwoven textile suitable for use in apparel and other articles that are resistant to pilling. The composite nonwoven textile may be finished by one or more of applying a chemical binder to a first face of the composite nonwoven textile and forming thermal bonding sites. The chemical binder and the thermal bonding sites help to secure fiber terminal ends and minimize the formation of pills.

What is claimed is: 
     
         1 . A composite nonwoven textile having a first face and an opposite second face, the composite nonwoven textile comprising:
 a first entangled web of fibers that forms, at least in part, the first face;   a second entangled web of fibers that forms, at least in part, the second face;   an elastomeric layer positioned between the first entangled web of fibers and the second entangled web of fibers, wherein at least some of the fibers of the first entangled web of fibers extend through the elastomeric layer and are entangled with fibers of the second entangled web of fibers; and   a plurality of discrete thermal bonding sites, each of the plurality of discrete thermal bonding sites including a thermal bond structure that is located between the first face and the second face, wherein fibers from the first entangled web of fibers extend from each of the thermal bond structures.   
     
     
         2 . The composite nonwoven textile of  claim 1 , wherein each of the thermal bond structures is offset relative to the first face in a direction extending toward the second face, and wherein each of the thermal bond structures is offset relative to the second face in a direction extending toward the first face. 
     
     
         3 . The composite nonwoven textile of  claim 1 , wherein a first average depth of the offset relative to the first face is different than a second average depth of the offset relative to the second face. 
     
     
         4 . The composite nonwoven textile of  claim 1 , wherein each of the thermal bond structures includes fibers from at least the first entangled web of fibers in a film form. 
     
     
         5 . The composite nonwoven textile of  claim 1 , wherein each of the thermal bond structures includes one or more of fibers from the second entangled web of fibers in a film form and a portion of the elastomeric layer in a film form. 
     
     
         6 . The composite nonwoven textile of  claim 1 , wherein a distance between adjacent discrete thermal bonding sites is less than a length of a fiber in at least the first entangled web of fibers. 
     
     
         7 . A nonwoven article of apparel having an outer-facing surface and an opposite inner-facing surface, the nonwoven article of apparel comprising:
 a first entangled web of fibers forming, at least in part, the outer-facing surface;   a second entangled web of fibers that forms, at least in part, the inner-facing surface;   an elastomeric layer positioned between the first entangled web of fibers and the second entangled web of fibers, wherein at least some of the fibers of the first entangled web of fibers extend through the elastomeric layer and are entangled with at least some of the fibers of the second entangled web of fibers; and   a first plurality of discrete thermal bonding sites positioned at first locations on the nonwoven article of apparel, each of the first plurality of discrete thermal bonding sites including a first thermal bond structure that is offset relative to the outer-facing surface in a direction extending toward the inner-facing surface, each of the first thermal bond structures including fibers from the first entangled web of fibers in a film form.   
     
     
         8 . The nonwoven article of apparel of  claim 7 , wherein the outer-facing surface further comprises a second plurality of discrete thermal bonding sites positioned at second locations on the nonwoven article of apparel, the second locations different from the first locations. 
     
     
         9 . The nonwoven article of apparel of  claim 8 , wherein a density of the first plurality of discrete thermal bonding sites is different from a density of the second plurality of discrete thermal bonding sites. 
     
     
         10 . The nonwoven article of apparel of  claim 8 , wherein a first average depth of the offset of the first thermal bond structures relative to the outer-facing surface is different than a second average depth of offset of the first thermal bond structures relative to the inner-facing surface. 
     
     
         11 . The nonwoven article of apparel of  claim 8 , wherein fibers from the first entangled web of fibers extend from each of the first thermal bond structures. 
     
     
         12 . The nonwoven article of apparel of  claim 8 , wherein each of the first thermal bond structures includes one or more of fibers from the second entangled web of fibers in a film form and a portion of the elastomeric layer in a film form. 
     
     
         13 . The nonwoven article of apparel of  claim 8 , wherein a distance between adjacent discrete thermal bonding sites of the first plurality of discrete thermal bonding sites is less than a length of a fiber in at least the first entangled web of fibers. 
     
     
         14 . A method of finishing a composite nonwoven textile comprising a first entangled web of fibers that forms, at least in part, a first face of the composite nonwoven textile, a second entangled web of fibers that forms, at least in part, an opposite second face of the composite nonwoven textile, and an elastomeric layer positioned between the first entangled web of fibers and the second entangled web of fibers, wherein at least some of the fibers from the first entangled web of fibers extend through the elastomeric layer and are entangled with fibers of the second entangled web of fibers, the method comprising:
 forming a plurality of discrete thermal bonding sites in a first predetermined pattern, each of the plurality of discrete thermal bonding sites including a thermal bond structure that is offset relative to the first face in a direction extending toward the second face, each of the thermal bond structures including fibers from at least the first entangled web of fibers in a film form.   
     
     
         15 . The method of finishing the composite nonwoven textile of  claim 14 , wherein the plurality of discrete thermal bonding sites are formed using an ultrasonic bonding system comprising an impression roller and an ultrasonic horn. 
     
     
         16 . The method of finishing the composite nonwoven textile of  claim 15 , wherein the composite nonwoven textile is positioned in the ultrasonic bonding system such that the first face of the composite nonwoven textile is in contact with the impression roller and the second face of the composite nonwoven textile is in contact with the ultrasonic horn. 
     
     
         17 . The method of finishing the composite nonwoven textile of  claim 15 , wherein the composite nonwoven textile is positioned in the ultrasonic bonding system such that the second face of the composite nonwoven textile is in contact with the impression roller and the first face of the composite nonwoven textile is in contact with the ultrasonic horn. 
     
     
         18 . The method of finishing the composite nonwoven textile of  claim 14 , wherein fibers from the first entangled web of fibers extend from each of the thermal bond structures. 
     
     
         19 . The method of finishing the composite nonwoven textile of  claim 14 , wherein each of the thermal bond structures is offset relative to the second face in a direction extending toward the first face. 
     
     
         20 . The method of finishing the composite nonwoven textile of  claim 19 , wherein a first average depth of the offset relative to the first face is different than a second average depth of the offset relative to the second face.