U.S. patent application number 12/771100 was filed with the patent office on 2011-11-03 for manufacturing methods for indigo fleck fancy yarn and indigo fleck fancy fabric.
This patent application is currently assigned to RUENTEX INDUSTRIES LIMITED. Invention is credited to Chih-Chang Hsu, Shih-Ching Hung.
Application Number | 20110265440 12/771100 |
Document ID | / |
Family ID | 44857148 |
Filed Date | 2011-11-03 |
United States Patent
Application |
20110265440 |
Kind Code |
A1 |
Hsu; Chih-Chang ; et
al. |
November 3, 2011 |
Manufacturing Methods for Indigo Fleck Fancy Yarn and Indigo Fleck
Fancy Fabric
Abstract
Manufacturing methods for an indigo fleck fancy yarn and for an
indigo fleck fancy fabric are provided. The indigo fleck fancy yarn
manufacturing method includes providing an original indigo yarn,
oxidizing the original indigo yarn, reducing the oxidized indigo
yarn, soap washing the reduced indigo yarn, and drying the soap
washed indigo yarn to form an indigo fleck fancy yarn. The indigo
fleck fancy yarn is an indigo yarn having irregular white area. The
indigo fleck fancy fabric manufacturing method includes providing a
plurality of indigo fleck fancy yarns made by the above indigo
fleck fancy yarn manufacturing method, and using the indigo fleck
fancy yarn to make an indigo fleck fancy fabric.
Inventors: |
Hsu; Chih-Chang; (Taipei,
TW) ; Hung; Shih-Ching; (Taipei, TW) |
Assignee: |
RUENTEX INDUSTRIES LIMITED
Taipei
TW
|
Family ID: |
44857148 |
Appl. No.: |
12/771100 |
Filed: |
April 30, 2010 |
Current U.S.
Class: |
57/362 |
Current CPC
Class: |
D06P 5/134 20130101;
D06P 5/155 20130101; D06P 5/153 20130101; D06P 5/132 20130101; D06P
1/228 20130101; D06P 5/02 20130101; D06P 5/13 20130101; D06B
11/0096 20130101; D06P 5/15 20130101; D06P 1/0096 20130101; D02G
3/346 20130101 |
Class at
Publication: |
57/362 |
International
Class: |
D02G 3/02 20060101
D02G003/02 |
Claims
1. An indigo fleck fancy yarn manufacturing method, includes:
providing an original indigo yarn; oxidizing the original indigo
yarn; reducing the oxidized indigo yarn; soap washing the reduced
indigo yarn; and drying the soap washed indigo yarn to form an
indigo fleck fancy yarn, wherein the indigo fleck fancy yarn is an
indigo yarn having irregular white area.
2. The indigo fleck fancy yarn manufacturing method of claim 1,
wherein the oxidizing step includes using potassium permanganate or
sodium hypochlorite as an oxidant.
3. The indigo fleck fancy yarn manufacturing method of claim 1,
wherein the oxidizing step includes immersing the original indigo
yarn in a 0.3-10.0 wt % oxidant solution at 15-55.degree. C. for
0.5-10 seconds.
4. The indigo fleck fancy yarn manufacturing method of claim 1,
wherein the reducing step includes using hydrogen peroxide or
oxalic acid as a reductant.
5. The indigo fleck fancy yarn manufacturing method of claim 1,
wherein the reducing step includes immersing the oxidized indigo
yarn in a 0.5-10.0 wt %, pH 4.0-5.0 oxidant solution at
15-55.degree. C. for 1-30 minutes.
6. The indigo fleck fancy yarn manufacturing method of claim 1,
wherein the soap washing step includes using non-ionic surfactant
or anion surfactant as a soap washing agent.
7. The indigo fleck fancy yarn manufacturing method of claim 1,
wherein the soap washing step includes immersing the reduced indigo
yarn in a 0.5-2.0 wt % soap washing agent solution at 50-85.degree.
C. for 1-30 minutes.
8. An indigo fleck fancy fabric manufacturing method, includes:
providing an indigo fleck fancy yarn made by the following steps:
providing an original indigo yarn; oxidizing the original indigo
yarn; reducing the oxidized indigo yarn; soap washing the reduced
indigo yarn; and drying the soap washed indigo yarn to form the
indigo fleck fancy yarn, wherein the indigo fleck fancy yarn is an
indigo yarn having irregular white area; and using the indigo fleck
fancy yarn to make an indigo fleck fancy fabric.
9. The indigo fleck fancy fabric manufacturing method of claim 8,
further comprising providing a yarn for weaving into the indigo
fleck fancy fabric with the indigo fleck fancy yarn.
10. The indigo fleck fancy fabric manufacturing method of claim 8,
wherein the oxidizing step for making the indigo fleck fancy yarn
includes immersing the original indigo yarn in a 0.3-10.0 wt %
oxidant solution at 15-55.degree. C. for 0.5-10 seconds.
11. The indigo fleck fancy fabric manufacturing method of claim 8,
wherein the reducing step for making the indigo fleck fancy yarn
includes immersing the oxidized indigo yarn in a 0.5-10.0 wt %, pH
4.0-5.0 oxidant solution at 15-55.degree. C. for 1-30 minutes.
12. The indigo fleck fancy fabric manufacturing method of claim 8,
wherein the soap washing step for making the indigo fleck fancy
yarn includes immersing the reduced indigo yarn in a 0.5-2.0 wt %
soap washing agent solution at 50-85.degree. C. for 1-30 minutes.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to a yarn manufacturing
method. More particularly, this invention relates to an indigo
fleck fancy yarn manufacturing method.
[0003] 2. Description of the Prior Art
[0004] The indigo fleck fancy yarn or fabric is a yarn or fabric
produced with some deliberate discontinuity introduced into the
color with the intention of producing an enhanced aesthetic
impression. For example, the indigo fleck fancy yarn and an Indigo
fleck fancy fabric having a "washed look" are very popular due to
the special visual effect.
[0005] Conventional technique for producing the indigo fleck fancy
yarn is to spin blue fibers with white fibers, wherein blue fibers
of different hue must be prepared in advance and the spinning ratio
between the blue fiber and the white fiber must be controlled based
on the desired color effect.
[0006] Similarly, in order to impart the "washed look" to the
fabric, a conventional technique is to bleach a blue fabric, which
has generally been dyed with indigo, together with stones or
enzyme. The process of beaching together with stones or enzyme
usually results in a significant demand of time, manpower,
chemicals, and/or water. Moreover, by means of this conventional
method, the "washed look" is generally applied to the whole fabric
instead of a specified area. Moreover, U.S. Pat. No. 6,308,506
provides a method for producing denim fabric having a "washed" or
heather look/effect. In this method, the indigo dyed yarn is dried
and then cut up into individual fibers with appropriate length.
These fibers are blended with other fibers to produce a blended
composite. The blended composite is then carded, spun into yarn,
and woven into denim fabric having a washed look, or a heather
effect, which then can be made into any suitable article. However,
the manufacturing process of the method is relatively
complicated.
[0007] Therefore, a new process to produce the indigo fleck fancy
yarn or fabric in a more efficient way is needed.
SUMMARY OF THE INVENTION
[0008] It is an object of the present invention to provide an
indigo fleck fancy yarn manufacturing method to produce indigo
fleck fancy yarns having irregular white fleck.
[0009] It is another object of the present invention to provide an
indigo fleck fancy fabric manufacturing method to produce an indigo
fleck fancy fabric with deliberate white fleck design more
efficiently.
[0010] The indigo fleck fancy yarn manufacturing method includes
providing an original indigo yarn, oxidizing the original indigo
yarn, reducing the oxidized indigo yarn, soap washing the reduced
indigo yarn, and drying the soap washed indigo yarn to form an
indigo fleck fancy yarn. The indigo fleck fancy yarn is an indigo
yarn having irregular white area to constitute the indigo
fleck.
[0011] The oxidizing step includes using potassium permanganate or
sodium hypochlorite as an oxidant. The oxidizing step includes
immersing the original indigo yarn in a 0.3-10.0 wt % oxidant
solution at 15-55.degree. C. for 0.5-10 seconds. The reducing step
includes using hydrogen peroxide or oxalic acid as a reductant. The
reducing step includes immersing the oxidized indigo yarn in a
0.5-10.0 wt %, pH 4.0-5.0 oxidant solution at 15-55.degree. C. for
1-30 minutes. The soap washing step includes using non-ionic
surfactant or anion surfactant as a soap washing agent. The soap
washing step includes immersing the reduced indigo yarn in a
0.5-2.0 wt % soap washing agent solution at 50-85.degree. C. for
1-30 minutes.
[0012] The indigo fleck fancy fabric manufacturing method includes
providing a plurality of indigo fleck fancy yarns made by the above
indigo fleck fancy yarn manufacturing method, and weaving the
indigo fleck fancy yarn to form the indigo fleck fancy fabric.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a flow chart of an embodiment of the indigo fleck
fancy yarn manufacturing method; and
[0014] FIG. 2 is a flow chart of another embodiment of the indigo
fleck fancy fabric manufacturing method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] As shown in FIG. 1, the indigo fleck fancy yarn
manufacturing method includes the following steps.
[0016] Step 1010, a step of providing an original indigo yarn is
performed. The original indigo yarn can include natural fibers and
synthetic fibers which have been dyed with indigo. In a preferred
embodiment, the indigo dyed natural fibers and synthetic fibers are
commercially available. In other embodiment, however, uncolored
natural fibers and synthetic fibers are prepared and then dyed into
indigo color with indigo dyes. The natural fiber can be selected
from a group consisting of cotton fiber, wool fiber, linen fiber,
jute fiber, ramie fiber, shengma fiber, hemp fiber, and a
combination thereof. The synthetic fiber can selected from a group
consisting of polyethylene terephthalate fiber, polyamide 6 fiber,
polyamide 66 fiber, Nylon 6 fiber, Nylon 66 fiber, polypropylene
fiber, polyolefin fiber, and a combination thereof.
[0017] After the original indigo yarn is provided or prepared. Step
1030, a step of oxidizing the original indigo yarn is performed.
The oxidizing step includes using potassium permanganate or sodium
hypochlorite as an oxidant. The oxidizing step is preferably
performed by immersing the original indigo yarn in a 0.3-10.0 wt %
oxidant solution at 15-55.degree. C. for 0.5-10 seconds. In a
preferred embodiment, the color of the oxidized indigo yarn is blue
in green after being dried. However, in other embodiments, the
color of the oxidized indigo yarn can be yellow in green, brown in
green, or blue in brown after being dried.
[0018] Step 1050, a step of reducing the oxidized indigo yarn is
performed. The reducing step can include using hydrogen peroxide or
oxalic acid as a reductant. The reducing step is preferably
performed by immersing the oxidized indigo yarn in a 0.5-10.0 wt %,
pH 4.0-5.0 oxidant solution at 15-55.degree. C. for 1-30
minutes.
[0019] Step 1070, a step of soap washing the reduced indigo yarn is
performed. The soap washing step can include using non-ionic
surfactant or anion surfactant as a soap washing agent. The soap
washing step is preferably performed by immersing the reduced
indigo yarn in a 0.5-2.0 wt % soap washing agent solution at
50-85.degree. C. for 1-30 minutes.
[0020] Step 1090, a step of drying the soap washed indigo yarn is
performed to form the indigo fleck fancy yarn, wherein the indigo
fleck fancy yarn is an indigo yarn having irregular white area. In
a preferred embodiment, the soap washed indigo yarn can be first
dewatered by a dewaterer and then dried with hot wind. In other
embodiments, however, the soap washed indigo yarn can be dried by
exposing the soap washed indigo yarn in infrared rays or by baking
the soap washed indigo yarn in an oven.
[0021] Compared to the conventional technique in which the indigo
fleck fancy yarn is made by spinning blue fibers with white fibers,
the method of present invention produces the indigo fleck fancy
yarn having irregular white area directly from the indigo yarn.
Therefore, the processes of preparing blue fibers of different hue
and spinning the blue fibers and white fibers are eliminated, and
the manufacturing efficiency of the indigo fleck fancy yarn
manufacturing method is accordingly improved.
[0022] As shown in FIG. 2, the indigo fleck fancy fabric
manufacturing method includes the following steps.
[0023] Step 2010, a step of providing an indigo fleck fancy yarn
produced by the above indigo fleck fancy yarn manufacturing method
is performed. Step 2030, a step of using the indigo fleck fancy
yarn to produce an indigo fleck fancy fabric is performed. That is,
after an original indigo yarn is processed by the above indigo
fleck fancy yarn manufacturing method, including oxidizing,
reducing, soap-washing, and drying, the original indigo yarn is
introduced with discontinuity in color to serve as the indigo fleck
fancy yarn in manufacturing the fancy fabric.
[0024] More particularly, the conventional technique for producing
the Indigo fleck fancy fabric is to bleach a blue fabric together
with stones or enzyme, which usually results in a significant
demand of time, manpower, chemicals, and/or water, and the "washed
look" is generally applied to the entire fabric instead of a
specified area. In contrast, since in the indigo fleck fancy fabric
manufacturing method of the present invention the indigo fleck
fancy fabric is made by using the indigo fleck fancy yarn having
irregular white area, the indigo fleck fancy fabric exhibits the
"washed look" inherently. Therefore, the manufacturing cost can be
reduced.
[0025] Moreover, in a preferred embodiment, the indigo fleck fancy
fabric manufacturing method further includes step 2050, wherein a
step of providing a yarn for weaving into the indigo fleck fancy
fabric with the indigo fleck fancy yarn is performed.
[0026] In other words, since the indigo fleck fancy fabric is made
by weaving a yarn with the indigo fleck fancy yarn, the indigo
fleck fancy fabric can exhibit the "washed" look/effect at a
specified area. More particularly, ordinary yarns can be woven
first and then the indigo fleck fancy yarn is introduced when an
area exhibiting the "washed look" is desired is woven. Therefore,
the "washed look" can be preformed at a specified area and the
design of the fabric can have more variety.
[0027] Although the preferred embodiments of the present invention
have been described herein, the above description is merely
illustrative. Further modification of the invention herein
disclosed will occur to those skilled in the respective arts and
all such modifications are deemed to be within the scope of the
invention as defined by the appended claims.
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