US4863775A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Garment wash finish for denim
Assignee: Burlington Industries Inc
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Filing: 1988-11-07
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Granted: 1989-09-05
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Expires: 2008-11-07
Abstract
Abstract It is possible to produce denim fabric suitable for manufacture into garments that have the look and feel of washed and tumble dried garments, practiced in a relatively simple and quick manner. Denim fabric is treated to raise the warp yarns so that the warp yarns are adjacent the face of the fabric and positioned so that they can be rubbed and abraded to loosen the surface fibers; and then effecting abrading and rubbing of the tips of the warp crimp so as to duplicate the surface abrasion of washing and tumble drying without making a napped or brushed type finish or face. The abrading action may be practiced by sanding utilizing a fine sandpaper in the range of about 50-100 grit, employing a 9-roll T-Ralph sander with 2 to 6 rolls running at a speed of about 50 ydm. The fabric is lightly singed prior to the raising action, and the raising is accomplished by scouring with a blend of phosphated esters; open-width washing through about 5-10 wash boxes at speeds of about 30-80 yards per minute; effecting first and second rope washings of about 15-25 minutes each, the first at about 180° F. and the second at about 140° F.; drying under tension; finishing utilizing wetters and softeners; and Sanforizing® (compressively shrinking). After the abrading step, the fabric is shrunk to stabilize it to a 0-2 percent warp shrinkage range.
Inventors
- 👤 Robert D. Jacobs
- 👤 Edward J. Davis
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 20:01
CPC Classifications
D; D06; D06C; D06C27/00; D06C13/00; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23929; Y10T428/23936; Y10T428/2395
Claims Analysis
Total Claims: 37
Claim 1
Independent Claim
103 words
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.
Claim 2
Independent Claim
103 words
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.
Claim 3
Dependent Claim
95 words
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.
Claim 4
Dependent Claim
20 words
A method as recited in claim 2 wherein step (i) is practiced by scouring and open-width washing of the fabric.
Claim 5
Dependent Claim
18 words
A method as recited in claim 3 wherein step (ii) is practiced by rope washing of the fabric.
Claim 6
Dependent Claim
19 words
A method as recited in claim 4 wherein step (iii) is practiced by drying the fabric under controlled tension.
Claim 7
Dependent Claim
26 words
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.
Claim 8
Dependent Claim
17 words
A method as recited in claim 6 wherein step (v) is practiced by compressively shrinking the fabric.
Claim 9
Dependent Claim
26 words
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.
Claim 10
Dependent Claim
29 words
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.
Claim 11
Dependent Claim
31 words
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.
Claim 12
Dependent Claim
31 words
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.
Claim 13
Dependent Claim
26 words
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.
Claim 14
Dependent Claim
29 words
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.
Claim 15
Independent Claim
172 words
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.
Claim 16
Independent Claim
172 words
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.
Claim 17
Dependent Claim
23 words
A method as recited in claim 14 wherein step (b) is practiced by scouring the fabric, followed by open-width washing of the fabric.
Claim 18
Dependent Claim
66 words
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° F.-200° 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.
Claim 19
Dependent Claim
91 words
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° F. for a period of about 15-25 minutes, and then subjecting the fabric to a second rope washing at about 140° F. for a time period of about 15-25 minutes.
Claim 20
Dependent Claim
18 words
A method as recited in claim 17 wherein step (d) is practiced by drying the fabric under tension.
Claim 21
Dependent Claim
17 words
A method as recited in claim 18 wherein step (f) is practiced by compressively shrinking the fabric.
Claim 22
Dependent Claim
57 words
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.
Claim 23
Dependent Claim
57 words
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.
Claim 24
Independent Claim
111 words
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×3 percent warp and filling shrinkage.
Claim 25
Independent Claim
111 words
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×3 percent warp and filling shrinkage.
Claim 26
Dependent Claim
51 words
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.
Claim 27
Dependent Claim
71 words
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.
Claim 28
Dependent Claim
107 words
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×3 percent warp and filling shrinkage.
Claim 29
Dependent Claim
107 words
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×3 percent warp and filling shrinkage.
Claim 30
Dependent Claim
84 words
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.
Claim 31
Dependent Claim
84 words
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.
Claim 32
Independent Claim
98 words
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×3 percent warp and filling shrinkage.
Claim 33
Independent Claim
98 words
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×3 percent warp and filling shrinkage.
Claim 34
Dependent Claim
50 words
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.
Claim 35
Dependent Claim
69 words
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.
Claim 36
Dependent Claim
85 words
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×3 percent warp and filling shrinkage.
Claim 37
Dependent Claim
85 words
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×3 percent warp and filling shrinkage.
References Cited (Backward Citations)
US4000342A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-09-04 | 1993-03-06 | 1993-09-05 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-09-04 | 1997-03-06 | 1997-09-05 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-09-04 | 2001-03-06 | 2001-09-05 | $7700.00 | Window Closed / Lapsed |