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.

Claims

1. A Method for decolorizing a textile product, comprising: a dry process for manually treating a textile product; a desize process 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 decoorizing the textile product; and step of washing the textile product with water and dehydrating the textile Product, wherein the step of exposing the textile product to ozone gas comprises: a step of loading the textile product and cotton fabric scraps into an air-tight drum wherein the cotton fabric scraps are wetted with water; a step of supplying and stirring ozone gas inside the drum; and a step of rotating the air-tight drum so that the cotton fabric scraps can provide water to various parts of the textile product and that the ozone as decolorizes the textile product.

2. The method for decolorizing a textile product of claim 1, wherein the cotton fabric scraps are about or smaller than 25 square inches.

3. The method for decolorizing a textile product of claim 1, wherein the weight ratio of the cotton fabric scraps to water is about 1.0:0.1.5 and the weight ratio of the textile product to the cotton fabric scraps is about 1.0:0.21.0.

4. The method for decolorizing a textile product of claim 1, wherein the ozone treatment is performed for up to one hour.

5. The method for decolorizing a textile product of claim 1 wherein the method for decolorizing a textile product does not use bleach to oxidize the textile product.

6. The method for decolorizing a textile product of claim 1 wherein the method for decolorizing a textile product does not use KMnO.sub.4.

7. The method for decolorizing a textile plroduct of claim 1 wherein the method for decolorizing a textile product does not use pocket white.

8. The method for decolorizing a textile product of claim 1 Wherein the textile product is denim.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other features, aspects and advantages of the present invention will become better understood with reference to the accompanying drawings, wherein:

(2) FIG. 1 is a flow chart showing a conventional fabric decolorization method;

(3) FIG. 2 is a flow chart showing the dry ozone treatment method of the present invention;

(4) FIG. 3 is a flow chart showing the conventional abrasion process; and

(5) FIG. 4 is a flow chart showing the ozone abrasion process of the present invention.

DETAILED DESCRIPTION EMBODIMENTS OF THE INVENTION

(6) 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.

(7) 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.

(8) 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.

(9) 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.

(10) 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.

(11) 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.

(12) 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.

(13) 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 1.0:0.51.5, and the weight ratio of the textile product to the cotton fabric scraps is about 1.0:0.21.0. The ozone treatment is performed for up to one hour.

(14) 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.

(15) 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.

(16) 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 1.0:0.51.5 and the weight ratio of the textile product to the cotton fabric scraps may be about 1.0:0.21.0. Moreover, the ozone treatment may be performed for up to one hour.

(17) Besides, the textile product may be denim or t-shirts.

(18) 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.

(19) Before the step of supplying and stirring ozone gas inside the drum, wetted cotton fabric scraps may be loaded into the drum.

(20) 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.

(21) 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.