The present invention relates to a multi-colored yarns and a fabric made of the multi-colored yarns.
Denim is a fabric in which the indigo dyed wrap threads are woven with white weft threads. Many techniques have been developed to color demin, for example, piece color coating, tainting/overdyeing and garment dye, etc. However, these coloring techniques cannot give natural and brilliant colors to denim. As a result, there is a need for a new technique for coloring denim which is also environmental friendly.
In the light of the foregoing background, it is an object of the present invention to provide an alternative and novel technique in coloring denim (also applies to other fabrics) while preserving the essence of denim.
Accordingly, the present invention, in one aspect, is a denim comprising:
In one embodiment, the plurality of dyes comprises a non-VAT dye and a non-sulfur dye; wherein the non-VAT and the non-sulfur dye are selected from the group consisting of reactive dye, direct dye, pigment dye, acid dye and disperse dye.
According to another aspect of the present invention, a method of preparing a dyed yarn is disclosed. The method comprises the steps of
Yet another aspect of dyed yarn of the present invention is a fabric obtained by a process comprising the step of
There are many advantages to the present invention. In particular, the present invention, the colored denim of the present invention is sharp, crisp and smooth and the color of the denim of the present invention is natural and brilliant. The denim using the coloring technique of this invention has higher quality (e.g. higher contrast, with washing effects, great hand feel, etc) as compared to denim prepared from conventional coloring techniques such as tainting and garment dyeing with. Further, this technique is environmentally friendly and safe with the use of less water and in absence of the use of resin. Application of this technique leads to more cost-efficient productivity, shorter lead time, and great savings in the overall garment process. Furthermore, the novelties of the present invention are listed as follow:
For a more complete understanding of the present invention, reference is made to the following detailed description and accompanying drawings, in which:
As used herein and in the claims, “comprising” means including the following elements but not excluding others.
Now referring to
In an exemplary embodiment, each of the wrap threads 20 further comprises a polymer type coating on the first yarn 22 configured to increase wet crock fastness.
In another embodiment, the plurality of dyes comprises a non-VAT dye and a non-sulfur dye; wherein the non-VAT and the non-sulfur dye are selected from the group consisting of reactive dye, direct dye, pigment dye, acid dye and disperse dye.
In yet another embodiment, the plurality of dyes further comprises a VAT dye and a sulfur dye such that the dye coating is a combination of the VAT dye, the sulfur dye, the non-VAT dye and the non-sulfur dye; wherein the VAT dye is indigo and forms the top most dye layer.
Accordingly to yet another aspect of the present invention, a method of preparing a dyed yarn comprises the steps of (a) continuously passing the yarn through a dyeing machine selected from a group consisting of slasher dyeing machine and rope dyeing machine; (b) dyeing the yarn with a dye coating comprising a plurality of different dyes forming a plurality of different dye layers in said dye coating in a single process/pass-through of the dyeing machine; wherein the plurality of dyes further comprises non-VAT dye, non-sulfur dye, sulfur dye and VAT dye such that the dye coating is a combination of the VAT dye, the sulfur dye, the non-VAT dye and the non-sulfur dye; wherein the top most dye layer of the dye coating is formed by a cover dye layer with a single color selected from a group consisting of the VAT dye, the sulfur dye, the non-VAT dye and the non-sulfur dye; and (c) performing a post-treatment step configured to remove at least a portion of the dye coating such that at least one the plurality of dyes in the dye coating at least partially reveals and partially cover another different dye immediately therebelow; and the bottom most dye only partially covers the first yarn, such that the dyes are not disposed on at least a portion of the first yarn, thereby showing the wrap thread with a plurality of colors.
In one embodiment, the continuously passing step further comprises the steps of (a) absorbing and fixing a polymer on the yarn; and (b) coating the polymer on the yarn. The polymer is selected from a group consisting of polyurethane, poly-acrylic, polyethylene, and silicone polymer. The post-treatment step is performed at a pre-fabrication stage or a fabric making stage or a garment making stage; and the post-treatment step is selected from a group consisting of bleaching, abrasion, oxidation and reduction.
In yet another aspect of the present invention, a dyed yarn obtained by a process comprising the steps of (a) continuously passing the yarn through a dyeing machine selected from a group consisting of slasher dyeing machine and rope dyeing machine; (b) dyeing the yarn with a dye coating comprising a plurality of different dyes forming a plurality of different dye layers in said dye coating in a single process/pass-through of the dyeing machine; wherein the plurality of dyes further comprises non-VAT dye, non-sulfur dye, sulfur dye and VAT dye such that the dye coating is a combination of the VAT dye, the sulfur dye, the non-VAT dye and the non-sulfur dye; wherein the top most dye layer of the dye coating is formed by a cover dye layer with a single color selected from a group consisting of the VAT dye, the sulfur dye, the non-VAT dye and the non-sulfur dye; and (c) performing a post-treatment step configured to remove at least a portion of the dye coating such that at least one the plurality of dyes in the dye coating at least partially reveals and partially cover another different dye immediately therebelow; and the bottom most dye only partially covers the first yarn, such that the dyes are not disposed on at least a portion of the first yarn, thereby showing the wrap thread with a plurality of colors.
In one embodiment, the continuously passing step further comprises the steps of (a) absorbing and fixing a polymer on the yarn; and (b) coating the polymer on the yarn. The polymer is selected from a group consisting of polyurethane, poly-acrylic, polyethylene, and silicone polymer. The post-treatment step is performed at a pre-fabrication stage or a fabric making stage or a garment making stage; and the post-treatment step is selected from a group consisting of bleaching, abrasion, oxidation and reduction.
In yet another aspect of the present invention, a fabric obtained by a process comprising the steps of weaving the dyed yarn obtained by a process comprising the steps of (i) continuously passing the yarn through a dyeing machine selected from a group consisting of slasher dyeing machine and rope dyeing machine; and (ii) dyeing the yarn with a dye coating comprising a plurality of different dyes forming a plurality of different dye layers in said dye coating in a single process/pass-through of the dyeing machine; wherein the plurality of dyes further comprises non-VAT dye, non-sulfur dye, sulfur dye and VAT dye such that the dye coating is a combination of the VAT dye, the sulfur dye, the non-VAT dye and the non-sulfur dye; wherein the top most dye layer of the dye coating is formed by a cover dye layer with a single color selected from a group consisting of the VAT dye, the sulfur dye, the non-VAT dye and the non-sulfur dye. And after the weaving step, performing a post-treatment step configured to remove at least a portion of each the dye coating such that at least one the plurality of dyes in the dye coating at least partially reveals and partially cover another different dye immediately therebelow; and the bottom most dye only partially covers the first yarn, such that the dyes are not disposed on at least a portion of the first yarn, thereby showing the wrap thread with a plurality of colors.
In one embodiment, the continuously passing step further comprises the steps of (a) absorbing and fixing a polymer on the yarn; and (b) coating the polymer on the yarn. The polymer is selected from a group consisting of polyurethane, poly-acrylic, polyethylene, and silicone polymer. The post-treatment step is performed at a fabric stage or a garment making stage; and the post-treatment step is selected from a group consisting of bleaching, abrasion, oxidation and reduction.
Further, continuous of yarn dyeing machine of non VAT/sulfur dyeing does not exist. Also, continuous of yarn dyeing machine of combination of VAT/sulfur dye and non VAT/sulfur dyeing does not exist.
The configuration of dyeing non VAT/sulfur dye yarn on continuous machines requires intermediate drying, intermediate heating, additional bath slots, additional heating sensors, specialized designed heated rollers.
By this invention, greige yarn or colored yarn can be the input of the dyeing system and the output will be a dyed yarn using non VAT/sulfur dye yarn.
In slash or rope dyeing, no machines uses intermediate heating.
Greige yarn or colored yarn can be the input of the continuous system. Once entered, the desired combination of dyes (non VAT/sulfur dye)/auxiliaries will be set into the water basins. Yarn will be passed through the basins by picking up non VAT/sulfur dye and its auxiliaries. Through the cycle of the machine with intermediate heating, drying and re-wetting, the non VAT/sulfur dye with its auxiliaries will be reacted/fixed onto the yarn. The output of the system will be colored yarn.
By creating a recombination of the mentioned process, the output can be colored yarn with different dye types, for example, indigo with reactive, indigo with direct, reactive with direct, pigment with reactive etc. The combination of such can also be created by replacing greige yarn with colored yarn in the input process, for example, the input is to be reactive dyed yarn and the output can be pigment yarn with reactive dyed yarn.
Combination dyeing of the mentioned process can be used on piece dyes to create combination of dyeing.
In another embodiment, the process of dyeing yarn using slasher dyeing machines, rope dyeing machines or other continuous dyeing machines use the following dye types:
The output fabrics consist of the following:
In yet another embodiment, the process of dyeing fabric using continuous dyeing machine (yarn dye or piece dye) uses the following dye type or combination thereof:
The output fabrics consist of the following:
The use of intermediate heating device in continuous yarn dyeing machines includes:
The present invention provides denim with different color layers while having white slubs. The colors on the denim of the present invention are natural and brilliant. Yet other advantages of the present invention are cheap, environment friendly, with high contrast and high color gradient. In addition, the present invention disposes a plurality of dyes on a yarn and allows each of the plurality of dyes to form a dye layers on the yarn, wherein the dye of the top most dye layer is indigo. Moreover, in one embodiment, wherein each dye layer only partially covers a layer immediately there-below and the bottom most dye layer only partially covers the yarn. Furthermore, the yarn is continuously dyed with non-VAT/non-sulfur dyes by a dyeing machine.
It will thus be seen that the objects set forth above, among those elucidated in, or made apparent from, the preceding description, are efficiently attained and, since certain changes may be made in the above construction and/or method without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawing figures shall be interpreted as illustrative only and not in a limiting sense.
The following claims should not be read as limited to the described order or elements unless stated to that effect. Therefore, all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
This application claims the priority of U.S. Provisional Application No. 61/820,716 filed May 8, 2013, the whole of which is hereby incorporated by reference herein.
Number | Date | Country | |
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61820716 | May 2013 | US |