Claims
- 1. A method of producing denim fabric that has an overall look and feel of a denim garment that has been laundered, comprising, in sequence, the steps of:
- (a) raising only the warp yarns of a piece of already woven denim fabric over substantially the entire surface of the fabric so that the warp crimp or loops are at the face of the fabric to a greater extent than loom state denim fabric, and
- (b) abrading only the tips of the raised crimp or loops to duplicate the surface abrasion of washing and tumble drying without making a napped or brushed type of face.
- 2. A method as recited in claim 1 wherein step (a) is practiced by: (i) partially removing weaving size and non-fibrous portions of fabric while protecting the physical look and characteristics of the fabric; (ii) closing up the fabric, allowing the dyed warp to shrink and come to the face of the fabric; (iii) removing any creasing in the fabric; (iv) softening and lubricating the fabric; and (v) shrinking and crimping the warp to further push the warp yarns to the face of the fabric and position them so that they can be rubbed and abraded.
- 3. A method as recited in claim 2 wherein step (i) is practiced by scouring and open-width washing of the fabric.
- 4. A method as recited in claim 3 wherein step (ii) is practiced by rope washing of the fabric.
- 5. A method as recited in claim 4 wherein step (iii) is practiced by drying the fabric under controlled tension.
- 6. A method as recited in claim 5 wherein step (iv) is practiced by treating the fabric with a finishing formula including wetting agent and a softener.
- 7. A method as recited in claim 6 wherein step (v) is practiced by compressively shrinking the fabric.
- 8. A method as recited in claim 7 comprising the further step of, prior to step (a), of lightly singeing the fabric to remove only long hair.
- 9. A method as recited in claim 8 comprising the further step, after step (b), of shrinking the fabric to stabilize the fabric to a 0-2 percent warp shrinkage range.
- 10. A method as recited in claim 9 wherein step (b) is practiced by sanding the tips of the warp crimp with a fine sandpaper in the range of about 50-100 grit.
- 11. A method as recited in claim 1 wherein step (b) is practiced by sanding the tips of the warp crimp with a fine sandpaper in the range of about 50-100 grit.
- 12. A method as recited in claim 1 comprising the further step of, prior to step (a), of lightly singeing the fabric to remove only long hair.
- 13. A method as recited in claim 1 comprising the further step, after step (b), of shrinking the fabric to stabilize the fabric to a 0-2 percent warp shrinkage range.
- 14. A method of producing denim fabric that has an overall look and feel of a denim garment that has been laundered, comprising raising only the warp yarn of said fabric and including the steps of:
- (a) removing the long hair, only, from the denim fabric;
- (b) partially removing the weaving size and non-fibrous portions while still protecting the physical look and characteristics of the fabric;
- (c) closing up the fabric, allowing the dyed warp to shrink and come to the face of the fabric;
- (d) removing any creasing in the fabric;
- (e) softening and lubricating the fabric;
- (f) shrinking and crimping the fabric to further push only the warp yarns to the face of the fabric and position them so that they can be rubbed and abraded to loosen the surface fibers;
- (g) rubbing and abrading the surface of substantially all of the warp yarns at the face of the fabric with an abrasive element; and
- (h) shrinking the fabric to stabilize it so that it has an appropriate warp shrinkage range.
- 15. A method as recited in claim 14 wherein step (b) is practiced by scouring the fabric, followed by open-width washing of the fabric.
- 16. A method as recited in claim 15 wherein the scouring is practiced utilizing a blend of phosphated esters with a concentration range of about 0.25-1.0 percent at a temperature within the range of about 140.degree. F.-200.degree. F.; and wherein said open-width washing is practiced by passing the fabric through between about 5-10 wash boxes at a speed within the range of about 30-80 yards per minute.
- 17. A method as recited in claim 15 wherein step (c) is practiced by subjecting the fabric to a first rope washing which completes the rinsing of detergent and size from the fabric while leaving an amount of starch and other non-fibrous material in the range of about 1.5-3.5 percent to ensure good hand development and thickness, by rope washing at 180.degree. F. for a period of about 15-25 minutes, and then subjecting the fabric to a second rope washing at about 140.degree. F. for a time period of about 15-25 minutes.
- 18. A method as recited in claim 17 wherein step (d) is practiced by drying the fabric under tension.
- 19. A method as recited in claim 18 wherein step (f) is practiced by compressively shrinking the fabric.
- 20. A method as recited in claim 19 wherein step (g) is practiced by sanding the tips of the warp crimp with a fine sandpaper in the range of about 50-100 grits, or the equivalent, in order to duplicate the surface abrasion of washing and tumble drying without making a napped or brushed type of finish or face.
- 21. A method as recited in claim 14 wherein step (g) is practiced by sanding the tips of the warp crimp with a fine sandpaper in the range of about 50-100 grits, or the equivalent, in order to duplicate the surface abrasion of washing and tumble drying without making a napped or brushed type of finish or face.
- 22. A method of producing denim fabric that has an overall look and feel of a denim garment that has been laundered, raising only the warp yarn of said fabric and including, comprising the steps of:
- (a) lightly singeing the fabric;
- (b) scouring the fabric
- (c) open-width washing the fabric;
- (d) rope washing the fabric;
- (e) drying the fabric under tension;
- (f) finishing the fabric;
- (g) sanforizing the fabric;
- (h) abrading substantially all of the tips of the warp crimp of the fabric without making a napped or brushed type finish or face; and
- (i) shrinking the fabric to stabilize it at no more than 3 percent.times.3 percent warp and filling shrinkage.
- 23. A method as recited in claim 22 wherein step (h) is practiced by sanding the tips of the warp crimp on a 9 roll T-Ralph sander with 6 rolls running at a speed of about 50 ydm, utilizing a fine sandpaper in the range of about 50-100 grit or the equivalent.
- 24. A method as recited in claim 23 wherein step (d) is practiced by a first rope washing at a relatively high temperature for a time of approximately 15-25 minutes, and a second rope washing at a lower temperature for a time of about 15-25 minutes so as to establish the proper crimp exchange between warp and filling, and starting crimping of the warp yarns to the face of the denim fabric.
- 25. A denim fabric, suitable for making into garments such as pants and jackets, and produced by raising only the warp yarn of said fabric and including practicing the following steps: (a) lightly singeing the fabric; (b) scouring the fabric; (c) open-width washing the fabric; (d) rope washing the fabric; (e) drying the fabric under tension; (f) finishing the fabric; (g) sanforizing the fabric; (h) abrading substantially all of the tips of the warp crimp of the fabric without making a napped or brushed type of finish or face; and (i) shrinking the fabric to stabilize it at no more than 3 percent.times.3 percent warp and filling shrinkage.
- 26. A denim fabric, suitable for making into garments such as pants and jackets, and produced by practicing the following steps:
- (a) raising the warp yarns of a piece of woven denim fabric relative to the weft yarns so that the warp crimp or loops are at the face of the fabric, and
- (b) abrading only the tips of the raised crimp or loops to duplicate the surface abrasion of washing and tumble drying without making a napped or brushed type of finish or face.
- 27. A method of producing denim fabric that has an overall look and feel of a denim garment that has been laundered, raising only the warp yarn of said fabric and including comprising the steps of:
- (a) scouring the fabric;
- (b) drying the fabric under tension;
- (c) finishing the fabric;
- (d) compressively shrinking the fabric;
- (e) abrading the tips of the warp crimp over substantially an entire face surface of the fabric without making a napped or brushed type finish; and
- (f) shrinking the fabric to stabilize it at no more than 3 percent.times.3 percent warp and filling shrinkage.
- 28. A method as recited in claim 27 wherein step (e) is practiced by sanding the tips of the warp crimp on a 9 roll sander with 6 rolls running at a speed of about 50 ydm, utilizing a fine sandpaper in the range of about 50-100 grit or the equivalent.
- 29. A method as recited in claim 28 wherein step (a) is practiced by a first washing at a relatively high temperature for a time of approximately 15-25 minutes, and a second washing at a lower temperature for a time of about 15-25 minutes so as to establish the proper crimp exchange between warp and filling, and starting crimping of the warp yarns to the face of the denim fabric.
- 30. A denim fabric, suitable for making into garments such as pants and jackets, comprising only and produced by practicing the following steps:
- (a) scouring the fabric;
- (b) drying the fabric under tension;
- (c) finishing the fabric;
- (d) compressively shrinking the fabric;
- (e) abrading the tips of the warp crimp over substantially an entire face surface of the fabric without making a napped or brushed type finish; and
- (f) shrinking the fabric to stabilize it at no more than 3 percent.times.3 percent warp and filling shrinkage.
Parent Case Info
This is a continuation of application Ser. No. 06/900,690, filed Aug. 27, 1986, now abandoned.
US Referenced Citations (1)
Number |
Name |
Date |
Kind |
4000342 |
Rochelle et al. |
Dec 1976 |
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Continuations (1)
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Number |
Date |
Country |
Parent |
900690 |
Aug 1986 |
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