Garment and manufacturing method

Abstract

Garment and manufacturing method, describes a one size garment (1) for different sizes of women or men, made of a fabric comprising at least a natural non-elastic fibre material, a first synthetic fibre material and a second elastic synthetic fibre material, these synthetic fibres being covered by polyurethane and polyethylene, having chain stitch seams (3) using 100% polyester thread (4) in which are also stretchy, which join together the different pieces (2) to form the garment; and in that said garment (1) has a distressed look in certain areas of the material. The manufacture thereof comprises making, by hand or machine, using round point needles and a subsequent wash process in two phases, in which an emulsion to protect the elastic fibres is added.

Claims

1. A manufacturing method for a garment, comprising the step of: cutting different pieces of a fabric of the garment, comprising in said fabric at least a natural non-elastic fibre material, a first synthetic fibre material and a second elastic synthetic fibre material, being the fibres of the synthetic fibre materials twisted together, sewing said different pieces between them using round point needles for a chain-stitch seam and 100% polyester thread to form the garment, washing the garment, and adding components during the washing step, for protecting the synthetic fibres of the garment, wherein the washing step comprises at least the following steps: removing all the oils, waxes and grease that may eventually have been incorporated during the prior process, rinsing to improve the cleanliness of the raw material, enzymatic washing adding enzymes to the process to provide a surface shine and distressed look to the garment, rinsing again to improve the cleanliness of the material, drying the garment, and applying a solution of K2MnO4 (potassium permanganate).

2. The manufacturing method, according to claim 1, wherein the components are polyurethane and polyethylene.

3. The manufacturing method, according to claim 2, wherein the polyethylene addition is in the range of 2 g/l and 7 g/l in respect of the litres of water in the washing step.

4. The manufacturing method, according to claim 2, wherein the polyurethane addition is in the range of 1% and 5% in respect of the total weight of the garments in the washing step.

5. The manufacturing method, according to claim 1, wherein the added components comprise of polyurethane and polyethylene and the addition is made before the drying step.

6. The manufacturing method, according to claim 5, wherein the polyethylene addition is in the range of 2 g/l and 7 g/l in respect of the litres of water in the washing step.

7. The manufacturing method, according to claim 5, wherein the garment comprises trousers.

8. The manufacturing method, according to claim 1, wherein the polyurethane addition is in the range of 1% and 5% in respect of the total weight of the garments in the washing step and the polyethylene addition is in the range of 2 g/l and 7 g/l in respect of the litres of water in the washing step.

9. The manufacturing method, according to claim 1 wherein the garment comprises trousers.

10. A manufacturing method for a garment, comprising the step of: cutting different pieces of a fabric of the garment, comprising in said fabric at least a natural non-elastic fibre material, a first synthetic fibre material and a second elastic synthetic fibre material, being the fibres of the synthetic fibre materials twisted together, sewing said different pieces between them using round point needles for a chain-stitch seam and 100% polyester thread to form the garment, washing the garment, and adding components during a first washing phase of the washing step, for protecting the synthetic fibres of the garment, wherein the added components comprise polyurethane in the range of 1% and 5% in respect of the total weight of the garments in the washing step, and wherein the washing step comprises a second washing phase, after the first washing phase, with the following steps: bathing the garment for neutralising the K2MnO4, rinsing the garment, and drying the garment.

11. The manufacturing method, according to claim 10 wherein the added components comprise polyurethane and polyethylene and the addition is made before the drying step of the second washing phase.

12. The manufacturing method, according to claim 11, wherein the polyethylene addition is in the range of 2 g/l and 7 g/l in respect of the litres of water in the washing step.

13. The manufacturing method, according to claim 11, wherein the garment comprises trousers.

14. The manufacturing method, according to claim 10, wherein the addition of polyurethane is made before the drying step of the second washing phase.

15. The manufacturing method, according to claim 14, wherein the garment comprises trousers.

16. The manufacturing method, according to claim 10, wherein the garment comprises trousers.

Description

DESCRIPTION OF THE DRAWINGS

(1) With the aim of facilitating a better understanding of the features of the invention, a set of drawings is attached to the present specification as an integral part thereof, in which, by way of non-limiting examples, the following figures are included:

(2) FIGS. 1 and 2 show respective schematic representations, in front and back elevation, respectively, of an exemplary embodiment of a garment according to the present invention, specifically a distressed look pair of stretchy denim trousers wherein the general configuration thereof may be observed.

(3) FIG. 3 shows a detailed view of a portion of the inner part of the trousers, according to the invention, wherein the chain stitch used to make them and the position on the inner part of the loops of said stitch may be observed.

(4) FIG. 4 shows a representation of the chain stitch with which the parts of the pair of trousers object of the invention are sewn.

(5) FIG. 5 illustrates the synthetic fibres, non-elastic and elastic, being twisted together and covered by a protective component.

PREFERRED EMBODIMENT OF THE INVENTION

(6) In light of the aforementioned figures and in accordance with the reference numbers included therein, a preferred, but non-limiting embodiment of a garment object of the present invention is hereby described. The embodiment described herein will refer to a pair of trousers although it can be applied to other garments or clothing.

(7) The fabric of the garment comprises at least a natural non-elastic fibre material, a first synthetic non-elastic fibre material, and a second elastic synthetic fibre material. Further, as illustrated in FIG. 5, the synthetic fibres, non-elastic 6 and elastic 7, are twisted together and are covered by protective components 5, preferably by polyurethane and polyethylene. The polyurethane contributes to eliminate the static charges, avoiding the separation of the synthetic, non-elastic and elastic, fibres, while the polyethylene helps soften and reduces to a minimum the wrinkles of the fibres. It should be understood as covered by the protective components, when referred to the synthetic fibres, that the same are completely coated, encapsulated, enclosed or encircled by said protective components. Further, all the extension of the synthetic non-elastic fibres 6 and synthetic elastic fibres 7 twisted together is covered by the protective components 5.

(8) Therefore, as can be seen in the figures, the pair of trousers (1) is made of pieces (2) of denim fabric, consisting of a very stretchy material, which comprises in the range of 65.4% and 65.6% in weight of cotton as a natural non-elastic fibre material, in the range of 30% and 32% in weight of texturized polyester, as a first synthetic non-elastic fibre material 6, and in the range of 3.4% and 3.6% in weight of elastane, preferably Lycra®, as a second synthetic elastic fibre material 7, being the first synthetic non elastic fibre and the second synthetic elastic fibre twisted together within the fabric as illustrated in FIG. 5. The different pieces of the fabric are joined together with all the seams (3) that are also very stretchy, made of 100% polyester thread (4) with chain stitch, as FIG. 4) shows, which consists of thread (4) interconnecting in groups that form interlinked loops (4a). Said seams are placed on the inner part of the trousers (FIG. 3).

(9) Round point needles are used to make the chain stitch seams (3), which are preferably made by machine. Preferably, 5 stitches per cm are applied to assure that the seams stretch.

(10) Once manufactured, the pair of trousers is subjected to a washing treatment, comprising a step to protect the texturized polyester and elastane fibres within the fabric and further, as the trousers are made of a denim fabric, the washing process is used too to give the trousers a distressed look in certain areas of the material. Said washing process is divided in two washing phases, and using washing machines.

(11) The first washing phase comprises a first step where all the oils, waxes and grease that may eventually have been incorporated during the prior stitching and weaving process are removed from the fabric that constitutes the material from which the trousers are made. This step time is about 10 minutes at a temperature of 45° C., wherein the trousers are submerged in a bath at a ratio of 1:10 (ratio between the weight of the trousers and the quantity of water) to which enzymes (amylase) are applied with a specific combination of two dispersing agents, preferably Indisan iv and Rialdet tr, to remove and prevent the re-deposition of any of the hydrolysed colouring. Other dispersing agents with similar properties could also be used. A smooth mechanical action to move it is applied.

(12) After, the trousers are subjected to a rinsing step.

(13) Right after, another step consisting of an enzymatic wash for 5 minutes, in a bath at 45° C., to which latest generation enzymes (cellulase) are added at a ratio of 1:6 (ratio between the weight of the trousers and the quantity of water) is applied. This step provides a surface shine to the fabric. Alongside the enzyme, a specific combination of two dispersing agents is once again added, in order to remove and prevent the hydrolysed colouring from being deposited again, and therefore providing extra cleanliness to the fabric and to the accessories that make up the trousers. It is also subjected to a gentle mechanical action.

(14) Further, another step is rinsing again to improve the cleanliness of the fabric, after which the trousers are taken out of the washing machine and carefully centrifuged to extract part of the water incorporated in the previous process.

(15) Next, the trousers are dried at a low temperature until they reach a humidity point in the range of 5% and 10%.

(16) To finish this first phase of the washing process, a solution of K2MnO4 (potassium permanganate) is applied preferably by a manual spraying process, on certain parts of the trousers, such as knees, waist, pockets or back causing the typical distress of “vintage look” jeans. This operation is carried out carefully, using mannequins with pressure sensors that cut the pressurised air inlet for the optimal implementation of the operation, and thus preventing the seams and/or the material from getting damaged.

(17) After this first washing phase and some quality controls, the trousers are subjected to a second washing phase.

(18) The second washing phase comprises, as a first step, neutralising the K2MnO4 previously applied. During this process, the trousers are submerged in a bath at 45° C. for 10 minutes, wherein sodium metabisulfite is added, at a ratio of 1:10, alongside yet another specific combination of two dispersing agents, preferably the same as before, which remove and prevent any hydrolysed colouring from re-depositing. This provides extra cleanliness for the raw material and accessories that make up the trousers. A gentle mechanical action is applied during this bath.

(19) After another rinsing step, the trousers are subjected to a final softening, where the pair of trousers are once again submerged in a bath at 40° C. for 5 minutes, and wherein a quantity of emulsion of polyurethane and a quantity of polyethylene is added, at a ratio of 1:10 (ratio between total weight of the trousers and quantity of water in the washing machine), giving the trousers a good surface feel and at the same time, preventing the fibres that comprise the material structure from moving, thus removing static charges. The quantity of polyurethane applied is in the range of 1% and 5%, of the total weight of the trousers in the washing machine, of polyurethane, and in the range of 2 g/l and 7 g/l, of the total litres of water in the washing machine, of polyethylene. Preferably, the quantity of polyurethane is in the range of 2% and 3% and the quantity of polyethylene is in the range of 3 g/l and 5 g/l. The polyurethane should preferably be “Evo Fin Ash”, or similar products, and the polyethylene preferably is Denimcol Soft Pen, or similar products.

(20) After the washing process and specially after the treatment for applying the polyurethane and polyethylene to protect the texturized polyester and elastane fibres, twisted together, within the fabric, the composition of the trousers or garment is slightly different to the one of the starting fabric due to the introduction of the polyurethane and polyethylene in said fabric to the cover the synthetic fibres. The new composition of the garment will further comprise in the range of 0.1% and 0.3% in weight of polyurethane and in the range of 0.1% and 0.3% in weight of polyethylene.

(21) The final result is trousers or garments where its width can double up, allowing one size trousers or garment for women, men or kids to fit all sizes of women, men or kids respectively.

(22) As an example, the size range of an ordinary pair of women's trousers is 25, 26, 27, 28, 29, 30, 31, 32, 33 while a pair of trousers according to the present invention, covers all the seven sizes. This means that one size trousers according to the present application can be worn by women of all different sizes.