U.S. patent application number 15/374944 was filed with the patent office on 2017-05-04 for method for decolorizing a denim fabric using ozone.
The applicant listed for this patent is Kevin Jin Youn. Invention is credited to Kevin Jin Youn.
Application Number | 20170121902 15/374944 |
Document ID | / |
Family ID | 50231704 |
Filed Date | 2017-05-04 |
United States Patent
Application |
20170121902 |
Kind Code |
A1 |
Youn; Kevin Jin |
May 4, 2017 |
Method for Decolorizing a Denim Fabric Using Ozone
Abstract
This invention relates to a method for decolorizing a dyed denim
fabric through a dry ozone process to obtain an aesthetically
pleasing decolorized look or fashionably faded look in the denim
fabric. The method comprises three dry ozone treatment processes
used alone or in combination thereof. The first dry ozone treatment
process includes wetting a denim textile product with water and
oxidizing it with ozone. The second dry ozone treatment process
includes spraying water to desired areas of the textile product and
oxidizing it with ozone. The third dry ozone treatment process
includes loading the denim textile product and wetted cotton fabric
scraps into a drum, and oxidizing them with ozone.
Inventors: |
Youn; Kevin Jin; (Paramount,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Youn; Kevin Jin |
Paramount |
CA |
US |
|
|
Family ID: |
50231704 |
Appl. No.: |
15/374944 |
Filed: |
December 9, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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13746144 |
Jan 21, 2013 |
9562318 |
|
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15374944 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06L 4/50 20170101; D06P
5/153 20130101; D06L 4/13 20170101; D06L 1/14 20130101; D06P 5/132
20130101 |
International
Class: |
D06L 4/50 20060101
D06L004/50; D06P 5/13 20060101 D06P005/13; D06L 1/14 20060101
D06L001/14 |
Claims
1. A Method for decolorizing a textile product, comprising: a dry
process for manually treating a textile product; a desize process
for removing starch from the textile product; spraying water to
desired areas of the textile, product; exposing the textile product
to ozone gas to decolorize the textile product; rinsing the textile
product; and drying the textile product.
2. The method for decolorizing a textile product of claim 1 wherein
the step of exposing the textile product to ozone gas comprises a
step of loading the textile product into a drum; a step of
supplying and stirring ozone gas inside the drum; and a step of
rotating the air-tight drum.
3. The method for decolorizing a textile product of claim 3 wherein
cotton fabric scraps are loaded into the drum, before the step of
supplying and stirring ozone gas inside the drum wherein the cotton
fabric scraps are wetted with water.
4. The method for decolorizing a textile product of claim 3 wherein
the cotton fabric scraps are about or smaller than 25 square
inches.
Description
CROSS-REFERENCE TO BELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Non-provisional
Application No. 13/746,144, filed Jan. 21, 2013, the entirety of
which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a method for decolorizing a
denim fabric using ozone. More particularly, this invention relates
to a method for decolorizing a dyed denim fabric through a dry
ozone process to obtain an aesthetically pleasing decolorized look
or fashionably faded look in the denim fabric.
BACKGROUND OF THE INVENTION
[0003] Denim fabric has been decolorized to produce an
aesthetically pleasing decolorized look or fashionably faded look.
Two major means used for such decolorization are stones and
bleaches. Stones such as pumice stones are used to create a used
and abused appearance in denim fabric through a physical washing of
the denim fabric with stones or rocks having an abrasive surface.
Alternatively, bleaches such as potassium permanganate., peroxide,
or hypochlorite are used with or without stones to decolorize or
discolorize the surface of denim fabric.
[0004] FIG. 1 shows a conventional fabric decolonization method
which comprises a dry process S110, a desize process S120, an
optional resin process S130, an abrasion process S140, a
decolorization process S150, a local decolonization process S160
and a finish process S170.
[0005] Dry process S110 is first performed on garments to achieve
used or worn out look, and the dry process includes hand sand,
whisker, grinding and laser operation. After the dry process S110,
the desize process S120 is conducted to remove starch from the raw
fabric. In this process S120, enzymes such as amylase enzyme,
lubricant and/or wetting may be applied to the fabric and then, the
fabric is rinsed. After the desize process S120, the resin process
S130 may or may not be performed. The resin process S130 is to
achieve three dimensional rigid look in the fabric and can be done
by the processes of resin dip or spray, dry and resin cure.
[0006] Then, the abrasion process S140 is conducted on the fabric
using stone, superstone (like sand), and/or neutral enzyme. Then,
the fabric is rinsed and dried. After the abrasion process S140,
the decolorization process S150 and the local decolorization
process S160 are conducted on the fabric. The decolorization
process S150 is performed on the overall areas of the garments
whereas the local decolorization process S160 is conducted on
desired areas of the garments. Bleach or potassium permanganate is
applied and then, the garments are neutralized using chemicals such
as sodium met a bisulfate.
[0007] Pumice stones are widely used for the abrasion process and
adding pumice stones gives the additional effect of a faded or worn
look, especially at the seam allowance or on stitches. The pumice
abrades the surface of the garments like sandpaper, removing some
dye particles from the surfaces of the yarn.
[0008] Bleaching gives garments a more used look and brighter
complexion and is usually carried out by strong oxidizing agents
such as potassium permanganate, hypochlorite, or peroxide.
Bleaching may be performed on the garments in overall or
selectively using a spray. Oxidation has to be followed by
neutralization because the remaining bleach will keep on damaging
the fabric.
[0009] Lastly, the finish process S170 is performed. Pocket white,
softener and/or tint may be applied to the garments. Laccase enzyme
may be used for a special effect and rewashing with bleach or
potassium permanganate followed by neutralization may be optionally
conducted.
[0010] While the denim, garments are decolorized, high quantities
of indigo dye are separated and they soil weft threads, inside
pockets as well as labels. To prevent this backstaining, pocket
white is used to separate indigo. Pocket white may be applied in
every treatment phase on the denim fabric. The application of
pocket white during stone washing or separate after-washing leads
to a reduction of the backstaining.
[0011] A number of problems have been presented by the use of
stones and/or bleaches. First, the use of stones creates a
considerable amount of damage to the denim products and the machine
used for the stone washing process and a lot of time and labor have
to be spent to remove stones and rocks in pockets, creases, and
interior folds of the garment and in the machine. Ail the suspended
solid of stone debris goes down to the wastewater and this makes it
more costly to dump the, wastewater to the sanitation system.
Furthermore, the stone abrasion process is not selective and
everything in the machines gets abraded whether it's a garment, a
metal button or a rivet on the garments. This significantly reduces
the quality of the garments.
[0012] Besides, use of bleach or potassium permanganate requires
the neutralization process because the remaining bleach or
oxidative will continue to damage the garments and affect the shade
and color of the garments, Additionally, the use of bleach or
potassium permanganate may cause environmental problems, by
increasing suspended solids and chemical oxygen demand in
wastewater as well as the volume of wastewater itself. These
increases will lead to increased time and cost to treat wastewater
because suspended solids in wastewater always have to be treated
and environmental regulations have put severe stress on the textile
industry to control pollution by wastewater treatment and disposing
of the used pumice stones.
[0013] For the case of decolorizing t-shirts, there are several
ways to dye t-shirts: direct dyeing, pigment dyeing, sulfur dyeing
and reactive dyeing. Reactive dyeing uses a chemical reaction to
dye a t-shirt. Stones or bleaches may be used to decolorize
t-shirts if they are dyed by direct dyeing or pigment dyeing. Even
if reactive dyeing produces vibrant colors of a t-shirt, there is
no conventional way to decolorize t-shirts with reactive
dyeing.
[0014] Accordingly, to solve the above problems, a need for a
method for decolorizing a dyed denim fabric through a dry ozone
process to obtain an aesthetically pleasing decolorized, look or
fashionably faded look in the denim fabric has been present for a
long time considering the expansive demands in the everyday life.
This invention is directed to solve these problems and satisfy the
long-felt need.
SUMMARY OF THE INVENTION
[0015] The present invention contrives to solve the disadvantages
of the prior art.
[0016] An object of the invention is to provide a method for
decolorizing a dyed denim fabric through a dry ozone process to
obtain an aesthetically pleasing decolorized look or fashionably
faded look in the denim fabric.
[0017] Another object of the invention is to provide three dry
ozone treatment processes used alone or In combination thereof for
decolorizing a dyed denim fabric to obtain an aesthetically
pleasing decolorized look or fashionably faded look in the denim
fabric. The three dry ozone treatment processes dispense with the
need to use stories and bleaches such as pumice stones or potassium
permanganate. Furthermore, pocket white does not have to be used,
either. With the three processes in use, stone washing, bleach
washing and bleach spraying processes are not necessary, but the
same or better decolorized look or faded look of garments can foe
achieved by using the processes.
[0018] The first dry ozone treatment process includes wetting a
denim textile product with water, removing excess water from the
water-soaked denim textile product, and exposing the denim textile
product to the ozone gas for decolorizing the textile product. The
second dry ozone treatment process includes spraying water to
desired areas of the denim textile product and exposing the denim
textile product to ozone gas to decolorize the textile product.
Lastly, the third dry ozone treatment process includes loading the
denim textile product and cotton fabric scraps into a drum wherein
the cotton fabric scraps are wetted with water, supplying and
stirring ozone gas inside the drum, and rotating the air-tight
drum. The three dry ozone treatment processes may be applied alone
or in any combination thereof.
[0019] Still another object of the invention is to provide the
three dry ozone treatment processes used alone or in combination
thereof for decolorizing a dyed t-shirts fabric to obtain an
aesthetically pleasing decolorized look, or fashionably faded look
in the t-shirts fabric. There was no conventional way to dye
t-shirts with reactive dying, but the three dry ozone treatment
processes can achieve aesthetic decolorization effects even for
t-shirts with reactive dying. Preferably, the third dry ozone
treatment process can achieve decolonization of t-shirts,
especially at the hems.
[0020] The advantages of the present invention are: (1) the dry
ozone treatment processes of this invention dispense with the; need
to use stones and bleaches such as pumice stones or potassium
permanganate, and thus they do not create damages to the garments
or machine, but improve the quality of the garments; (2) the dry
ozone treatment processes of this invention reduce fabric treatment
time and labor; (3) the dry ozone treatment processes of this
invention can create better and more varied aesthetically pleasing
decolorized looks or fashionably faded looks in the fabric; (4) the
dry ozone treatment processes of this invention reduce the amounts
of suspended solids and chemical oxygen demand in wastewater as
well as the volume of wastewater itself; (5) the dry ozone
treatment processes of this invention can achieve aesthetically
pleasing decolorized looks or fashionably faded looks in t-shirts
even with reactive dyeing; (6) the dry ozone treatment processes of
this invention use less energy, water, labor, and process time than
conventional, methods using stones or bleaches; (7) the dry ozone
treatment processes of this invention use less bleaches, harmful
chemicals or potassium permanganate; and (8) the water used for
ozone decolorization is much easier to recycle than waste water
from the conventional methods.
[0021] Although the present invention is briefly summarized, the
fuller understanding of the invention can be obtained by the
following drawings, detailed description and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] These and other features, aspects and advantages of the
present invention will become better understood with reference to
the accompanying drawings, wherein:
[0023] FIG. 1 is a flow chart showing a conventional fabric
decolorization method;
[0024] FIG. 2 is a flow chart showing the dry ozone treatment
method of the present invention;
[0025] FIG. 3 is a flow chart showing the conventional abrasion
process; and
[0026] FIG. 4 is a flow chart showing the ozone abrasion process of
the present invention.
DETAILED DESCRIPTION EMBODIMENTS OF THE INVENTION
[0027] FIG. 2 shows the dry ozone treatment method of the present
invention using the first dry ozone treatment process. Unlike the
conventional fabric decolorization method having three separate
processes of abrasion process S140, decolorization process S150 and
local decolorization process S160, the present method has only one
ozone treatment process S240. Furthermore, the finish process S250
has become a lot simpler. Especially, pocket White does not have to
be used in the method of this invention.
[0028] There are three dry ozone treatment processes for the ozone
decolorization process S240 of FIG. 2 and the three processes may
be used alone or in any combination thereof for decolorizing a dyed
fabric to obtain an aesthetically pleasing decolorized look or
fashionably faded look in the fabric.
[0029] The first dry ozone treatment process includes wetting a
textile product with water, removing excess water from the
water-soaked textile product, and exposing the textile product to
the ozone gas for decolorizing the textile product. The second dry
ozone treatment process includes spraying water to desired areas of
the textile product and exposing the textile product to ozone gas
to decolorize the textile product. Lastly, the third dry ozone
treatment process includes loading the textile product and cotton
fabric scraps into a drum wherein the cotton, fabric scraps are
wetted with water, supplying and stirring ozone gas inside the
drum, and rotating the air-tight drum. The three dry ozone
treatment processes may be applied alone or in any combination
thereof.
[0030] The three dry ozone treatment processes dispense with the
need to use stones and bleaches such as pumice stones or potassium
permanganate. With the three processes in use, stone washing,
bleach washing and bleach spraying processes are not necessary,
but, the same or better decolorized look or faded look of garments
can be achieved by using ozone gas. Furthermore, pocket white does
not have to be used either because there is less concern for
backstaining.
[0031] The first dry ozone treatment process includes wetting a
textile product with water and thus, the process is not selective.
Thus, just like bleach washing, the whole wetted textile product is
oxidized.
[0032] The second dry ozone treatment process includes spraying
water to desired areas of the textile product and thus, only those
desired areas are oxidized. This process can achieve the effect of
bleach spraying.
[0033] The third dry ozone treatment process includes adding wetted
cotton, fabric scraps to dry garments. While the scraps and
garments are rotated inside a drum, the scraps provide water to
random areas of the garments and the areas are oxidized. This
process can achieve the effect of stone washing.
[0034] Preferably, star fish patterns were achieved on the surface
of the textile product when all of the cotton fabric scraps is
about or smaller than 25 square inches, the weight ratio of the
cotton fabric scraps to water is about 1.0:0.5.about.1.5, and the
weight ratio of the textile product to the cotton fabric scraps is
about 1.0:0.2.about.1.0. The ozone treatment is performed for up to
one hour.
[0035] FIG. 3 shows a conventional abrasion process S140 and FIG. 4
shows the ozone abrasion process S340 of the present invention
which is one example of the third dry ozone treatment process. The
ozone abrasion process may be applied to a fabric, denim fabric or
t-shirts. If applied to t-shirts, stylish decoloration was achieved
even if the t-shirts were dyed with reactive dyeing.
[0036] The ozone decolorizing method of the present invention
comprises a dry process for manually treating a textile product; a
desize process for removing starch from the textile product; a step
of wetting the textile product with water and removing excess water
from the water-soaked textile product; a step of exposing the
textile product to ozone gas for decolorizing the textile product;
and a step of washing the textile product with water and
dehydrating the textile product. The step of exposing the textile
product to ozone gas may further comprise a step of loading the
textile product into a drum; a step of supplying and stirring ozone
gas inside the drum; and a step of rotating the air-tight drum.
[0037] Additionally, cotton fabric scraps may be loaded into the
drum before the step of supplying and stirring ozone gas inside the
drum wherein the cotton fabric scraps are wetted with water.
Preferably, all of the cotton fabric scraps may be about or smaller
than 25 square inches. The weight ratio of the cotton fabric scraps
to water may be about 1.0:0.5.about.1.5 and the weight ratio of the
textile product to the cotton fabric scraps may be about
1-0:0.2.about.1.0. Moreover, the ozone treatment may be performed
for up to one hour.
[0038] Besides, the textile product may be denim or t-shirts.
[0039] Another ozone decolorization method of the present invention
comprises a dry process for manually treating a textile product; a
desize process for removing starch from the textile product;
spraying water to desired areas of the textile product; exposing
the textile product to ozone gas to decolorize the textile product;
rinsing the textile product; and drying the textile product.
[0040] Before the step of supplying and stirring ozone gas inside
the drum, wetted cotton fabric scraps may be loaded into the
drum.
[0041] Still another ozone decolorization method of the present
invention comprises a step of loading the textile product and
cotton fabric scraps into a drum wherein the cotton fabric scraps
are wetted with water; a step of supplying and stirring ozone gas
inside the drum; a step of rotating the air-tight drum; and a step
of washing the textile product with water and dehydrating the
textile product. Here, if the textile product is t-shirts, the
desize process is not necessary.
[0042] While the invention has been shown and described with
reference to different embodiments thereof, it will be appreciated
by those skilled in the art that variations in form, detail,
compositions and operation may be made without departing from the
spirit and scope of the invention as defined by the accompanying
claims.
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