Subject of the Invention

The present invention relates to an aging method which is performed in order to provide the surface of the cotton denim which is used especially in jeans production with a worn appearance. The invention relates to an ecological method allowing for the denim fabric aging process without damaging to the environment and people by means of metal-derived steel particles, apart from known materials which has been used on the stone-washing benches.

Current Technical Field

Cotton fabric and its derivative textile products have become widespread increasingly and the demand for the products produced with these fabrics is increasing continuously. Accordingly, various machines or methods have been developed for the production of fashion industry products that are cultivated by this sector, the products made of denim, and other products such as jeans. Considering the state of the art, it is seen that the fabric is used by going through some processes and the clothes are subjected to various steps after sewing, during the production of such textile products. In said various steps, the processes of providing desired worn effect and creating waves on the fabric, etc. are named as stone-washing, washing or aging. This process is carried out by various methods and the result may not be the same for each process. Production benches having various sizes may be utilized for fabric aging by using the technologies such as chemical agents, abrasive glass particles like sand, silicone particles and laser.

The desired nostalgic (vintage) and old appearance is intended to be obtained by applying these processes on the clothes which were brought onto a pneumatic formwork or hanger, sewed and put into their final form. Decolorizing is enabled by spraying bleach-derivative chemicals (potassium permanganate) on the indigo fabric consisting of the knit yarn, in the methods which are performed by using chemical substances. Then, these clothing products need to be washed in order to be free of chemicals. This extra process leads to both water usage and contamination (then this water needs to be neutralized and left to the flow) and extra time and costs.

In the aging and wearing processes using other methods such as sand, glass, etc. usages, the multiple products are either put into a kier and the abrasive effect is used which occurs by rotating the kier or the materials in the kier or these particles are sprayed on the clothes separately by pressurized air and the clothes are enabled to be abraded by this effect. A washing (purification) process is necessary again due to the chemical effect that occurs upon such methods. In the methods described, washing creates an extra work load and increases production durations and process costs. Also, it is known that the gases such as Silicon and Silica which emerges in such methods negatively affect the health of humans and environment due to the poisonous effect contained by thereof.

In the state of the art, there are many patent and designs about jeans stone-washing. However, any similar patent has not been encountered which is obtained through metal-derived steel particles.

In the U.S. Patent No. US4951366, the process of aging through sand is mentioned which is the most common method used for the jeans aging process and this method is now considered to be unhealthy.

In the European Patent No. EP0275432A1 , a method is described in which aging process is enabled together with the rotating drum and sand and denim clothing which are located therein such that the parts desired to be abraded will be above. The particles used are sand or glass crystals and metal particles are also used.

In the German Patent No. DE3129699A1 , a method is described in which aging process is enabled together with the rotating drum and denim clothing which are located in a vertical vessel such that the parts desired to be abraded by means of the abrasives such as sand, etc. will be above. The particles used are sand or glass crystals and metal particles are also used.

In the U.S. Patent No. USRE356343E, the way a kind of abrasive stone-derivative used for jeans aging process is created by means of thermal and chemical processes and the way it will be used for the aging processes are described. It does not have any metal-derivative feature.

In the U.S. Patent No. US5480457A, a method for jeans aging process was addressed and this method comprises processes such as washing, etc. Aging process which is performed with metal-derivative steel particles was not mentioned in this patent.

In the German Patent No. DE3217188A1 , a method for the use of pumice stone-like abrasives in small masses was mentioned. The materials used are those other than synthetic and metal derivatives and those produced from granulated glass. Any abrasive particle such as steel, etc. was not mentioned also in this patent.

In above-mentioned patents, fabric aging methods and systems were mentioned, but any method was not mentioned for the use of metal-derived, sharpened steel particles in this process.

The Object and Description of the Invention

Aging process is aimed to be performed by introducing metal particles onto the surface of denim fabric through the method of the invention. Thus, it is intended to carry out aging process of denim fabric in an ecological manner, within fewer process steps and without leading to any health risk.

The method of the invention is currently used for performing aging process on the surface of the final form of the denim product produced in the entire textile industry, the final form being created after all design and processing stages. The product which was produced from denim fabric is formed in accordance with both fashion and the taste of the user and it allows for the sewed portions to have another appearance form.

One of the advantages of the method according to the invention is to provide facilities that it has more effective solution since the abrasive metal particles used are the particles whose ends are sharpened, having elliptical forms and those that are produced from steel (FeNi) and there is no need for using them with an intense mass since they have abrasive sharp surfaces. That is, the desired aging patterns may be obtained more efficiently according to the state of the art by means of said method. One of the advantages of the method according to the invention is that it does not create any health risk for the environment and the operator performing the work, because there is no stone usage and the wastes thereafter which is encountered in the state of the art, any chemical or exhaust gas (such as Silicon and Silica, etc.) since the materials used in the aging method are metal particles.

Another one of the advantages of the method according to the invention is that there is no need for further washing process because any chemicals are not contained. Therefore, there occurs no waste water in this process, also in terms of the environment; no harmful effect is created for the nature. Because there is no washing process performed for suppressing chemical wastes, no water is used and there is no need for neutralizing the water, the extra time spent for this issue and the economic losses are eliminated.

Another advantage of the method according to the invention is that abrasive metal particles used are steel and its derivative materials. These particles are stainless and durable, and they do not react with the applied fabric and it does not lead to decolorizing. Moreover, metal particles used are sharpened, and this process causes the effect on the denim to occur more rapidly and causes less material usage compared to the aging process performed with the other particle types. Therefore, it shortens the process in terms of the time.

Another advantage of the method according to the invention is that abrasive metal particles used may be used several times. Also, it minimizes or removes the problems of the production facilities carrying out this process such as waste material output and recurrent material supply.

Description of the Drawings

Figure 1 shows the process steps of the denim fabric aging method with the metal particles of the invention.

Figure 2 is the conceptual design image representatively illustrating the application of the method of the invention. Stage Names, Reference Numerals of the Sections and Parts to Serve for Describing the Invention

1 - Particle chamber

1 a- Chamber inlet

2- Sprayer

3- Metal particles

4- Denim fabric

5- Hanger clip

6- Particle collection unit

7- Particle return line

8- Particle throwing line

9- System

A - B: Entrance-exit direction of the metal particles from particle chamber X - Y: Spraying and falling-to-ground direction of the metal particles.

Stages of the method of the invention; - Putting metal particles into the aging machines (1 10)

- Stretching sewed denim product through the mechanism and locating sprayer with an incline of 30-150 degrees and with a distance of 1 -3 meters (120)

- Throwing metal particles onto the denim fabric with an incline of 30-150 degrees (130)

- Sending metal particles onto the desired denim surface by moving sprayer or denim fabric (140)

- Recollecting metal particles sprayed for reuses and repeating all the process (150) Detailed Description of the Invention

The invention is a system and method for conducting the process of aging and forming the clothes made of denim fabric used in the textile industry in a water- and energy- efficient manner which is ecological and not harmful to the human health. Main feature of the method of the invention is that the entire process is realized in a closed system and that this closed cycle system (9) comprises a particle chamber (1 ), a chamber inlet (1 a) enabling metal particles (3) to be introduced into said particle chamber (1 ), particle throwing line (8) enabling said metal particles (3) to be transmitted into the system and sprayer (2) enabling said metal particles (3) to be sprayed on onto the denim fabric (4), hanger clip (5) enabling stretching said denim fabric (4) and particle collection unit (6) enabling sprayed metal particles (3) to be recollected, and particle return line (7) providing the connection between said particle chamber and particle collection unit (6).

Main principle in the denim fabric aging method of the invention is to throw metal particles (3) with definite sizes and shapes for the aging process of the clothes produced from denim fabric (4) and such fabric onto the denim fabric (4), thereby abrading the surface of denim fabric (4). However, this method should not be conducted in a closed area and without contacting metal particles (3) with air, in order not to be harmful for human and environment health. The application of the method may be realized in a cabin-like environment, and also it is possible to be performed in large production facilities through the integrated or fully automatic control systems. The process will be enabled in accordance with the description presented below and the appended figures.

In denim aging method of the invention, metal particles (3) with a certain pressure and a certain distance are mainly thrown onto the product that is produced from the stretched denim fabric (4). In order to enable this throwing process, preferably clothes made of denim fabric (4), e.g. jeans are stretched by being attached by hanger clips (5) from the ends or by placing them vertically inside or by blowing through various mechanisms.

In the above-mentioned method, metal particles (3) are thrown onto the denim fabric (4) located on the arrangement with a distance of 30 cm to 200 cm. This process may be performed by throwing from below or from above while denim fabric (4) is located on the plane vertically, which will be carried out by stretching denim fabric (4) vertically as seen below in the system and by throwing metal particles (3) onto this fabric. In said system, the position of denim fabric (4) may be arranged with different degrees in order to age denim fabric (4) with desired patterns and manner. For example, while abrasion is enabled perpendicularly on denim fabric (4) in a degree of 90°, different abrasions may occur in acute angle and obtuse angle positions.

The metal particles (3) used in said system are iron and nickel alloy (steel), have sharpened ends, have geoidal or elliptical forms, designed so as to enable maximum abrasion on denim fabric (4), larger than 10 microns, durable, and have the feature to be reused for many times.

Denim fabric aging method with metal particles of the invention mainly consists of the following stages, considered as a whole process:

- Putting metal particles into the aging machines (1 10)

- Stretching sewed denim product through the mechanism and locating sprayer with an incline of 30-150 degrees and with a distance of 1 -3 meters (120)

- Throwing metal particles onto the denim fabric with an incline of 30-150 degrees (130)

- Sending metal particles onto the desired denim surface by moving sprayer or denim fabric (140)

- Recollecting metal particles sprayed for reuses and repeating all the process (150)

The steps of these stages are described below:

Putting metal particles into the aging machines (110): In denim fabric aging method with metal particles, iron and nickel alloy steel metal particles (3) to be used are produced with a geoidal or elliptical form. Said pointed form of the metal particles (3) created in a different production step is designed to provide maximum abrasion on the denim fabric (4) and the surfaces of the clothes produced from such fabric. Metal particles (3) supplied externally are introduced into the particle chamber (1 ) portion which is present in the machines in which aging process is carried out through the chamber inlet (1 a). Then, having passed through the throwing line (8), the contact of these metal particles (3) to be sprayed onto the denim fabric (4) with an angle of 30 degrees to 150 degrees, preferably in a parallel position to the gravity, by means of the sprayer (2), with the air or the operator was prevented by taking them into a closed cycle. Stretching sewed denim product through the mechanism and locating the sprayer with an incline of 30-150 degrees and with a distance of 1-3 meters (120):

In denim fabric aging method with metal particles, denim fabric (4) is vertically stretched by being attached to the hanger clips (5) from the ends thereof or by blowing such that the product will have the form to be worn, through a mechanism. In said position, metal particles (3) are thrown onto the denim fabric (4) with an angle of 30 degrees to 150 degrees by means of a sprayer (2). However, same process may also be performed so as to throw metal particles (3) from above or from below, while denim fabric (4) is located on the plane vertically.

Throwing metal particles onto the denim fabric with an incline of 30-150 degrees (130): In denim fabric aging method with metal particles, metal particles (3) located into the particle chamber (1 ) and being larger than 10 microns are sprayed onto the produced denim fabric (4) with a duration varying between 10 seconds and 60 seconds and with a pressure varying between 3 and 9 bar, through a sprayer (2). Desired aging and forming are provided on the denim fabric (4) by the help of the angle arranged upon this spraying.

Sending metal particles onto the desired denim surface by moving sprayer or denim fabric (140): In denim fabric aging method with metal particles, denim fabric (4) is vertically or horizontally stretched by being attached to the hanger clips (5) from the ends thereof or by blowing such that the product will have the form to be worn, through a mechanism. Thus, metal particles (3) are thrown onto the denim fabric (4) with an angle of 30 degrees to 150 degrees by means of a sprayer (2). In this stage, the hanger clip (5) where the denim fabric (4) is hanged or the sprayer (2) are moved according to the appearance to be determined by the operator or the patterns involved in the system previously. Thus, metal particles (3) hitting onto the determined areas provides the desired abrasion effect and the desired appearance on the denim fabric (4).

Recollecting metal particles sprayed for reuses and repeating all the process (150) In denim aging method with metal particles, metal particles (3) hitting on the denim fabric (4) by spraying fall onto the ground within the system again. Metal particles (3) are collected in the particle collection unit (6) by means of a vacuum force. These metal particles (3) collected are transferred into the particle chamber (1 ) portion where they are loaded first through the particle return line (7). Metal particles (3) are used continuously and the entire process is enabled to be maintained without any interruption, by means of this closed cycle. Abrasion times of these metal particles (3) used by carrying out a continuous cycle are very long, therefore they may be used for a long time without disrupting the cycle.

Also, they are used in the method and in the textile industry where the method is applied, in order to provide the effects on the denim fabric (4) and the clothes produced from this fabric type (to provide a vintage appearance) and to perform aging process. However, they may be used in said industries such as metal, glass and forestry products where other similar abrasive effect is required in the production.