Patent Grant
7628822
The present application incorporates by reference U.S. patent application Ser. No. 10/337,896, now U.S. Pat. No. 6,774,098, filed Oct. 10, 2002, entitled “Methods For Removing Stains From Fabrics Using Tetrapotassium EDTA,” which claims priority to U.S. Provisional Application Ser. No. 60/423,978, filed Nov. 6, 2002, entitled “A Subclass of Aqueous, Hard Surface Cleaners Used in A New and Unobvious Soft Surface Cleaning Application.” The present application also incorporates by reference U.S. patent application Ser. No. 10/612,016, filed Jul. 3, 2003, and U.S. patent application Ser. No. 10/373,787, filed Feb. 27, 2003, both of which are entitled “Methods and Equipment for Removing Stains from Fabrics.”
This invention relates to a fabric having a pattern of fades and a methodology for their creation. The fades are made by exposing selected areas of the fabric to a hypochlorite salt-containing composition.
Fades on garments and other apparel are popular among all age groups, both female and male. Due to its popularity to the consumers, jean manufacturers have developed various methods to produce fades on jeans or denims to achieve a faded look. One method employs washing denims with a cellulase enzyme to release the denim's color, which produces light or white areas and lightens the dark areas (see U.S. Pat. Nos. 4,832,864, 4,912,056, 5,006,126 and 5,122,159). However, the use of enzymes to create a faded appearance can also at the same time be used to desize or shrink a fabric or garment. Thus, extra care and precision are needed if one were to employ an enzymatic approach.
Another method, as disclosed in U.S. Pat. No. 4,740,213, uses pumice stones impregnated with fluid having powerful bleaching properties to create a random faded effect on the fabric when the stones and fabric are tossed together, such as in a dryer or other tumbling apparatus. However, this process, commonly known as “stone-washing,” produces uneven faded patches that vary in color shades and intensity, which, due to the random admixture, spread out in a non-uniform manner over the entire fabric being treated. These whole-fabric techniques do not permit treating specific areas of the fabric individually. Moreover, the use of strong bleaching agents is inherently harmful to the fabric.
Another technique to produce fades on fabric employs lasers. A laser method to mark and fade textiles, as disclosed in U.S. Pat. No. 5,567,207, involves exposing a textile or fabric to laser radiation of sufficient intensity. Such exposure photo-decomposes the coloring agent within the material without causing damage to the underlying textile or fabric. The pre-dyed material is scanned by a laser beam to produce uniform fading and patterns of photo-bleached marks on the textile material. Despite the possibility of great precision and potential for print-like art quality, this method is more expensive, time-consuming, and generally unavailable to consumers.
Unlike the above-mentioned methods, the present invention is simple, safe and readily available to consumers. The present invention can be done at home and allows the end users to selectively choose an area of the fabric where he or she wants to impart a customized and desired faded appearance, with a hand-art quality, either uniformly or non-uniformly. Additionally, there is a need for fabric having a pattern of fades thereon that can be customized by the consumers in a cost-effective manner and is a product of the consumers' artistic creation.
The present invention is directed to a fabric that comprises a pattern of fades produced by a method that includes (i) contacting a hypochlorite salt-containing composition on at least one portion of the fabric, wherein the hypochlorite salt-containing composition comprises an alkali metal hydroxide and a hypochlorite salt, and (ii) inactivating or removing the hypochlorite salt-containing composition from said at least one portion of the fabric to obtain a desired pattern of fades on the fabric. In one embodiment, the application of the hypochlorite salt-containing composition is performed at room temperature and the removal or inactivation of the hypochlorite salt-containing composition is achieved by a cold water wash.
In another embodiment, the hypochlorite salt-containing composition comprises an alkali metal hydroxide and a hypochlorite salt. In a preferred embodiment, the alkali metal hydroxide is sodium hydroxide and the hypochlorite salt is sodium hypochlorite. The weight concentration ratio of sodium hydroxide over sodium hypochlorite is no less than 1:12.5. In another embodiment, the weight concentration ratio of sodium hydroxide over sodium hypochlorite ranges from about 1:5 to about 5:1. In yet another embodiment, the weight concentration ratio of sodium hypochlorite over sodium hydroxide is about 2:1. In a further embodiment, the pH of the hypochlorite salt-containing composition is at least 11.8. It can also be, for example, at least 12, 12.5, or 13.
In yet another embodiment, the hypochlorite salt containing composition includes at least 0.2, 0.3, 0.5, 1, 2, 3 or higher weight percent of sodium hydroxide. In a non-limiting example, the concentration of sodium hydroxide ranges from 0.5-5.5 weight percent.
In a further embodiment, the hypochlorite salt is sodium hypochlorite whose concentration ranges from 0.1-11.0 weight percent or 1.0-2.5 weight percent. In a non-limiting example, the hypochlorite salt containing composition contains about 2.5% weight percent of sodium hypochlorite and 0.5. to 1.25 weight percent of sodium hydroxide. In another embodiment, the hypochlorite salt containing composition includes about 6 weight percent of sodium hypochlorite and 1.2 to 3 weight percent of sodium hydroxide. In yet another embodiment, the hypochlorite salt containing composition contains about 8 weight percent of sodium hypochlorite and 1.2 to 4 weight percent of sodium hydroxide. In still another embodiment, the hypochlorite salt containing composition includes about 11 weight percent of sodium hypochlorite and up to 5.5 weight percent of sodium hydroxide.
The hypochlorite salt-containing composition can be applied for successive intervals to produce successive faded hues. It can be applied as a liquid or a gel. In addition, it can be applied by means of a gel stick, microspray jet, fabric dye brush or any other appropriate applicators for generating artwork on a canvass. The duration of the application may depend on the formation of faded hues, as pre-determined by the end user. In a non-limiting example, the duration of application ranges from at least 1 minute to 30 minutes.
The hypochlorite salt-containing composition can be employed in various concentrations on a given fabric. The duration of application to achieve the formation of a variety of faded hues on a fabric can be standardized, such as in a commercial usage of the present invention. Instead of multiple, time-spaced passes over the fabric applying the full strength composition, one application from multiple sources of varying concentrations to achieve the desired variegated effect can be put down, thereby minimizing handling of the fabric and simplifying the production process. At the end of a predetermined treatment time, the treated fabric can be inactivated, such as by cold water immersion.
In one embodiment, the formation of the fades pattern on the fabric is dyed with another color or left as the fabric base color. It can be formed by means of free hand, template guide or machine operation. A preferred fabric is cotton and preferred garments are denim jeans or trousers.
In another embodiment, a method and a kit for the production of fabric having a pattern of fades are also provided in the present invention.
In a further embodiment, a device to manufacture the fabric having a pattern of fades is also contemplated. The device of the present invention includes a surface where the fabric is placed upon and at least one dispenser disposed adjacent to the surface. To produce a pattern of fades on the fabric, at least one dispenser relatively moves to the fabric and applies the hypochlorite salt-containing composition to the fabric. In addition, at least one dispenser may include a plurality of dispensers that relatively moves to the fabric and applies a hypochlorite salt-containing composition to the fabric. The device may further include at least one template that is placed atop the fabric. The hypochlorite salt-containing composition is applied through the template to form the pattern of fades on the fabric. The device may still further include a vat that is adjacent to the surface. After being in contact with the hypochlorite salt-containing composition, the treated fabric is inactivated, such as by cold water immersion in the vat.
Other features, objects, and advantages of the present invention are apparent in the detailed description that follows. It should be understood, however, that the detailed description, while indicating embodiments of the present invention, is given by way of illustration only, not limitation. Various changes and modifications within the scope of the invention will become apparent to those skilled in the art from the detailed description.
The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawings (
The present invention is based on the surprising discovery that a hypochlorite salt-containing composition, which contains a metallic salt of hypochlorous acid and an appropriate amount of alkali metal, can not only be used as a cleaning composition but can also be used to non-destructively and conveniently create a pattern of fades on a fabric. The fades are formed by the application of the hypochlorite salt-containing composition on one or more selected portion(s) of the fabric. The fades action can be stopped by removal, dilution, or otherwise inactivation of the hypochlorite salt-containing composition when a desired fades formation is produced.
Without limiting the present invention to any particular mechanism, Applicant has found that alkali metal hydroxide (such as sodium hydroxide) adds significantly to the cleaning power of sodium hypochlorite to remove stains, such as menstrual fluid or underarm perspiration stains, from clothes and other soft fabric articles, while significantly increasing the compatibility of sodium hypochlorite with soft fabric, such as cotton fabric, thereby preventing sodium hypochlorite from damaging the fabric. The discovery of the hypochlorite salt-containing composition as an effective cleaning composition is disclosed in co-pending U.S. patent application Ser. Nos. 10/373,787 and 10/612,016, incorporated by reference herein.
The metallic salt of hypochlorous acid preferably is sodium hypochlorite. The alkali metal hydroxide preferably is sodium hydroxide. It should, of course, be understood that other hypochlorous salts and/or alkali metal hydroxides can also be used in the present invention.
Sodium hypochlorite (NaOCl) dissolves in water to sodium and hypochlorite ions. The hypochlorite ion is a strong oxidant which can react with numerous materials. The stability of the sodium hypochlorite composition is affected by the pH of the composition. It has been reported that sodium hypochlorite is the most stable when the pH of the composition is between 11 to 13. Such a high pH can be created by adding excess alkali metal hydroxide, such as sodium hydroxide, to the sodium hypochlorite composition. Thus, the pH of the hypochlorite salt-containing composition preferably is at least about 11.8. For instance, the pH of the hypochlorite salt-containing composition can be at least 12, 12.5 or 13. In one embodiment, the pH of the hypochlorite salt-containing composition is about 13.
The decomposition rate of the hypochlorite ion increases when the pH of the composition falls below 11. This is because of the rapid acid-catalyzed decomposition pathway of the hypochlorite ion. The rate of decomposition also increases when the pH of the composition is over 13. This is due to the increase in the ionic strength of the composition caused by the increased level of excess alkali metal hydroxide added to the composition. The present invention finds, however, that even with a high ionic strength, the sodium hypochlorite/sodium hydroxide composition is effective in imparting a faded appearance on the fabric without any significant damaging effects. In addition, Applicant has found that addition of appropriate amounts of alkali metal hydroxide to a hypochlorite composition retards the damaging effect of the hypochlorite composition on soft fabric (such as cotton fabric).
The concentration of sodium hypochlorite in the hypochlorite salt-containing composition of the present invention is preferably at least 0.1% by weight, based on the total weight of the hypochlorite salt-containing composition. For instance, the concentration of sodium hypochlorite can be at least 0.5, 1, 2, 3, 4, 5, 6, 7 or 8% by weight. In one embodiment, the concentration of sodium hypochlorite ranges from 0.1 to 11% by weight. In another embodiment, the concentration of sodium hypochlorite is about 0.5 to 5% by weight. In yet another embodiment, the concentration of sodium hypochlorite is about 1 to 2.5% by weight. In still another embodiment, the concentration of sodium hypochlorite is about 1.5 to 2% by weight.
The concentration of sodium hydroxide in the hypochlorite salt-containing composition preferably is at least 0.2% by weight, based on the total weight of the hypochlorite salt-containing composition. For instance, the concentration of sodium hydroxide can be at least about 0.3, 0.4, 0.5, 1, 1.5, 2, 2.5, 3, 4 or 5% by weight. In one embodiment, the concentration of sodium hydroxide ranges from about 0.5 to about 5.5% by weight. In another embodiment, the concentration of sodium hydroxide ranges from about 1 to 2% by weight. It is generally known that an appropriate amount of alkali metal hydroxide (such as sodium hydroxide) increases the stability of sodium hypochlorite in the hypochlorite salt-containing composition.
Applicant has discovered that the weight concentration ratio of sodium hydroxide over sodium hypochlorite may vary substantially without affecting the ability of the hypochlorite salt-containing composition to form pattern of fades on fabrics. Preferably, the weight concentration ratio of sodium hydroxide over sodium hypochlorite is no less than 1:12.5. For instance, the weight concentration ratio of sodium hydroxide over sodium hypochlorite can be no less than 1:10, 1:5, 1:2.5 or 1:1.
In one embodiment, the weight concentration ratio of sodium hydroxide over sodium hypochlorite can range from about 1:5 to about 5:1. In another embodiment, the weight concentration ratio of sodium hydroxide over sodium hypochlorite is about 1:3 to about 1:1. For instance, the weight concentration ratio of sodium hydroxide over sodium hypochlorite can be about 1:2.
In another embodiment, the hypochlorite salt-containing composition includes about 6 weight percent of sodium hypochlorite and 1.2 to 3 weight percent of sodium hydroxide. In another embodiment, the hypochlorite salt-containing composition includes about 2.5 weight percent of sodium hypochlorite and 0.5 to 1.25 weight percent of sodium hydroxide. In still another embodiment, the hypochlorite salt containing composition contains about 8 weight percent of sodium hypochlorite and 1.2 to 4 weight percent of sodium hydroxide. In yet another embodiment, the hypochlorite salt containing composition includes about 11 weight percent of sodium hypochlorite and up to 5.5 weight percent of sodium hydroxide.
Other ingredients or additives can be added in the hypochlorite salt-containing composition. These ingredients or additives include, for example, chelating agents, phosphorous-containing salts, surfactants, or abrasive agents. These ingredients or additives, however, are not necessary for the fading formation function of the hypochlorite salt-containing composition. In one embodiment, the hypochlorite salt-containing composition is substantially free of chelating agents, phosphorous-containing salts, surfactants, and abrasive agents.
The hypochlorite salt-containing composition can be applied for successive intervals to produce successive hues of fades. In one embodiment, the application of the hypochlorite salt-containing composition is performed at room temperature (e.g., 68-72° F. or 21-23° C.) and the inactivation process can be achieved by a cold water wash.
The composition of the present invention can be applied on the fabric as a liquid or gel by means of a fabric dye brush, gel stick, spray jet, e.g., microspray jet, or any other appropriate applicators for generating artwork on a canvass. In a non-limiting example, the duration of the application ranges from at least 1 min-30 min. In another example, an application time of less than 15 minutes produces partially bleached-out (dark) fades while an application time of approximately 30 minutes produces totally bleached-out (white) fades. In another embodiment, the faded pattern is dyed with another color or left as the fabric base color, typically white.
The fabric patterns formed by the hypochlorite salt-containing composition can be applied onto the fabric in a uniform and non-uniform faded manner to achieve a variety of effects. For example, contacting the fabric at certain duration with the hypochlorite salt-containing composition in a non-uniform manner produces an uneven faded appearance. Also, one can spot treat the pockets or certain sections of the denim jeans with the hypochlorite salt-containing composition at a certain time frame, while leaving the remainder of the fabric untreated, to produce an overall uneven or targeted faded look. Alternatively, one can evenly expose the entire fabric to a hypochlorite salt-containing composition to create a homogeneous faded appearance over the entire fabric.
In another embodiment, the present invention includes a method to produce a fabric having a pattern of faded hues. This method includes, for example, the steps of (i) contacting a hypochlorite salt-containing composition on at least one portion of the fabric, wherein the hypochlorite salt-containing composition comprises an alkali metal hydroxide. and a hypochlorite salt, and (ii) inactivating or removing the hypochlorite salt-containing composition from at least one portion of the fabric to obtain a desired pattern of fades on the fabric. The step of contacting the fabric with the hypochlorite salt-containing composition is performed at either a fixed concentration or varying concentrations of the hypochlorite salt-containing composition. The present invention can also further comprise contacting the fabric with the hypochlorite salt-containing composition by means of free hand, a template guide or machine operation.
The hypochlorite salt-containing composition of the present invention is available to consumers as a kit. The kit preferably includes a container of the hypochlorite salt-containing composition (e.g., in a spray bottle, gel stick, spray jet, e.g., a microspray jet, or any other appropriate applicators for generating artwork on a canvass), a flat fabric dye brush made of synthetic fiber, a labeled container box and an instruction sheet.
Sodium hypochlorite and sodium hydroxide can be separately stored prior to use. For instance, they can be stored in two separate compartments of a common container. The first compartment encloses a sodium hypochlorite composition, which preferably has a pH of between 11 and 13. The second compartment encloses a concentrated sodium hydroxide composition. The two compositions are mixed together upon use. An exemplary device suitable for this purpose is illustrated in U.S. Pat. No. 6,398,077, which is incorporated herein by reference. The two compositions may also, of course, be stored separately and mixed together in one of the containers or admixed into a third container.
In a further embodiment, the present invention contemplates a device for producing a pattern of fades on the fabric. The device comprises a surface where the fabric rests upon and at least one dispenser disposed adjacent to the surface. To form the pattern of fades according to the present invention, at least one dispenser relatively moves to the fabric and applies the hypochlorite salt-containing composition to the fabric. It should be understood that a plurality of dispensers that relatively moves to the fabric may be employed to apply a hypochlorite salt-containing composition to the fabric. The device may further include at least one template that is placed atop the fabric. The hypochlorite salt-containing composition is applied through the template to form the pattern of fades on the fabric. The device may still further include a vat that is adjacent to the surface. After being in contact with the hypochlorite salt-containing composition, the treated fabric is inactivated, such as by cold water immersion in the vat.
Fabrics suitable for the present invention can be made of a variety of materials, such as cotton, cotton/polyester, corduroy, rayon, canvas, linen, nylon, acrylic, flax, hemp, jute, ramie, polyester, polyamide, acrylic, polyvinyl chloride and polyolefin. A preferred fabric is cotton. In addition, the fabric can be a garment or other apparel, carpet, tote bags, curtains, towels, bed clothing, indoor or outdoor protective covers or various wall-covering fabrics to name but a few of the potential fabrics. The garment or apparel items can be a dress, work wear, coveralls, denim or jeans, jacket, pants, gloves, undergarments, socks, hats, skirts, aprons, head coverings, and T-shirts. A preferred garment or apparel is a denim or jeans.
The gradation of hues or fades is best illustrated with respect to
As indicated in
With reference to
In one embodiment of the present invention, a consumer can purchase a kit containing the aforedescribed hypochlorite salt-containing composition along with instructions for use. Templates of patterns may also be purchased or constructed by the user. It should be understood that the user may employ the instant invention in a wide variety of artistic expression, creating patterns on fabrics of all types. As discussed, the principles of the present invention can be employed on apparel or any other fabric to create patterns, messages or other expression thereon. Designs can include purely ornamental works of expression as well as practical uses, e.g., camouflage or other functional usages. Indeed, the full measure of consumer use of the instant invention is subject only to the imagination of the user, and the instant invention provides the means for this new form of expression.
In another aspect of the present invention, the fabric or apparel items can be treated in a commercial fashion, such as on an assembly line or in an automated factory. Patterns can be coded into a program and the hypochlorite salt-containing composition can be directed on the subject fabric, e.g., sprayed or otherwise applied. As discussed, a uniform strength composition can be applied in a time-delayed fashion through multiple applications at staggered times, thereby obtaining varied hues, as noted above and as discussed in more detail hereinbelow. Another approach is a single application of the composition from multiple sources and in varying strengths to the entire fabric to achieve the desired pattern, and immerse the entire fabric at the end, thereby simplifying the process for throughput, as also discussed hereinbelow. It should be understood that various percentages of the composition can be formulated, each having a particular strength to fade the fabric over a common fixed time. Additionally, it should be understood that commercial manufacturing techniques could employ multiple treatments, differing compositional strengths and timed applications in a variety of ways to achieve a desired pattern, and deactivation can also be performed by a single or multiple partial or full immersions of the treated fabric.
For example, in
With reference now to
Patterns can be created on the fabric being treated using a template, designated by the reference numeral 660 in
As shown in
It should also be understood that a plurality of fabrics 650 can be processed simultaneously, e.g., transversely in parallel across the conveyor 630 or having multiple longitudinal staging areas under the dispenser 610, where multiple identical operations proceed simultaneously or substantially simultaneously, handling a batch of fabrics 650 at once.
With reference again to
It should, of course, be understood that a computer software program coded to implement the aforementioned applications can be operated by a controller computer that is coupled to the device 600. The computer software program would allow the user to perform the aforementioned techniques and coordinate the various steps, e.g., setting the appropriate template 660 in place prior to application of the composition thereon, and then advancing the process accordingly. As discussed hereinabove, different design patterns to be applied to the fabric 650, as illustrated in
It should be understood that the above-described embodiments and the following examples are given by way of illustration, not limitation. Various changes and modifications within the scope of the present invention will become apparent to those skilled in the art from the present description.
A flat dye brush (approximately 0.125×0.375×0.375 in) was used to apply the bleach in broad strokes and to make fine lines. The brush was dipped in a hypochlorite salt-containing composition, shaken to remove excess liquid and then applied to the fabric. Excessive liquid may diffuse into the adjoining areas of the pattern and may cause the loss of detail. On the other hand, insufficient liquid may require additional passes of the brush over the same area. Applications to a test fabric can be tried first to develop speed and skill. A template may be used as a guide for the application. After each section of artwork is completed, the template may be removed temporarily, if desired, to observe how the art is developing—being careful, of course, to replace the pattern exactly in the original location before continuing and be mindful of the treatment time.
Examples of the representative artwork are shown in
It should be understood that the above steps for forming the fade artwork or other fade pattern employ a uniform concentration of the hypochlorite salt containing composition that is applied at offset time intervals and inactivated by water immersion. Steps for forming the same fade artwork shown in
It should be understood that the number of discrete nozzles and the percentage strength compositions are variable and dependent upon the fade effect desired. For example, to minimize the entire processing time of a particular fabric, more powerful strength compositions may be employed to shorten the treatment time. Conversely, finer fade artwork or fade effects may be obtained using weaker concentrations, which would be useful on delicate fabrics. The techniques of the present invention may be employed in a variety of ways to achieve the creative results envisioned by the artists.
If desired, the artist can apply another color dye of choice to bleached-out or other sections of the artwork, such as a flower blossom. For example, in
It should be understood that many modifications and variations of the present inventions are possible in light of the above teachings. While the invention has been described in its preferred embodiments, it is understood that the invention shall not be limited by thus description alone but in combination with the appended claims.
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