JP-7856281-B2 - Denim product manufacturing methods

JP7856281B2JP 7856281 B2JP7856281 B2JP 7856281B2JP-7856281-B2

Inventors

岡本恭平
前田進悟
田代雄久

Assignees

豊和株式会社

Dates

Publication Date: 20260511
Application Date: 20211011

Claims (4)

A method for manufacturing denim products with a distressed finish, A first step involves stirring a denim product with one or more abrasives selected from the group consisting of pumice, whetstones, and artificial abrasives, and a liquid containing water, to fade the denim product overall and to reproduce the fading caused by friction at least at one of the edges of the fabric constituting the denim product and the seams of the fabric constituting the denim product. A second step involves irradiating a dried denim product with a laser beam to reproduce fading caused by friction in one or more areas selected from the group consisting of whiskers appearing on the wearer's thighs or knees, whiskers appearing behind the wearer's knees, faded areas on the front pockets, extensive faded areas appearing from the wearer's knees to thighs, extensive faded areas appearing on the wearer's buttocks, faded areas on the yoke located between the waist and back, faded areas at the hem, faded areas on the wearer's elbows, extensive faded areas appearing on the wearer's forearms, whiskers appearing on the wearer's forearms, faded areas appearing on the cuffs, and faded areas appearing on the wearer's back. The process includes a third step of wetting the denim product and then exposing the wet denim product to ozone gas to cause the denim product to fade overall. The first step includes a step of removing starch from the denim product as a pretreatment, The first and second steps are performed before the third step. The third step is performed after the first and second steps, and the first and second steps are performed in any order, in a method for manufacturing distressed denim products.
The method for manufacturing a denim product according to claim 1, wherein in the first step, the denim product, the abrasive, and the liquid are stirred for 150 to 300 minutes.
When reproducing fading caused by friction in one or more areas selected from the group consisting of whiskers appearing on the wearer's thighs or knees, whiskers appearing behind the wearer's knees, faded areas on the pockets of the front body, extensive faded areas appearing from the wearer's knees to the thighs, extensive faded areas appearing on the wearer's buttocks, faded areas on the yoke located between the waist and the back body, faded areas at the hem, faded areas on the wearer's elbows, extensive faded areas appearing on the wearer's forearms, whiskers appearing on the wearer's forearms, faded areas appearing on the cuffs, and faded areas appearing on the wearer's back, A method for manufacturing a distressed denim product according to claim 1 or 2, wherein the method does not involve partial fading by an abrasive material and a washing step to remove abrasive debris.
A method for manufacturing a distressed denim product according to any one of claims 1 to 3, wherein, in order to fade the denim product overall, a bleaching process using a bleaching agent and a washing process to remove the bleaching agent are not performed.

Description

This invention relates to a method for manufacturing denim products with a distressed finish. Denim products such as denim pants, denim jackets, and denim shirts are made from fabric using yarn with a white core and an indigo dye on the outside. In denim products, areas frequently exposed to friction are more prone to fading than areas less exposed to friction. Therefore, in denim products, areas frequently exposed to friction tend to become whiter, while areas less exposed to friction tend to retain the indigo dye color. In denim products, repeated wear and washing expose the fabric to friction, creating a gradient of light and dark tones, resulting in the distinctive texture characteristic of denim. Denim products have the characteristic of changing appearance with use, as described above. Users widely appreciate denim products that replicate the appearance changes that occur with use, even when they are brand new and unused. Patent Document 1 discloses a method for imparting a worn look to denim fabric by performing the following steps in the order described: irradiating denim fabric with a laser beam; exposing the laser-irradiated denim fabric to ozone gas under dry conditions; spraying water onto the ozone-exposed denim fabric; stirring the water-sprayed denim fabric with Scotch-Brite and artificial stone; drying the stirred denim fabric; drying the dried denim fabric by bringing it into contact with ozone gas; and softening the denim fabric that has been in contact with ozone gas. Japanese Patent Publication No. 2019-81993 This is a front view showing the areas to be faded in the first or second step of the denim pants manufacturing process.This is a rear view of the denim pants, showing the areas to be faded in the first or second step of the manufacturing process.This is a front view of a denim jacket, showing the areas to be faded in the first or second step of the manufacturing process.This is a rear view of the denim jacket, showing the areas to be faded in the first or second step of the manufacturing process.This table shows the procedure, working time, and amount of water used for the manufacturing method of denim products according to Example 1.This table shows the procedure, working time, and amount of water used for the manufacturing method of the denim product according to Comparative Example 1. The following describes preferred embodiments of the method for manufacturing denim products according to the present invention. This invention relates to a method for manufacturing distressed denim products. The manufacturing method comprises the following three steps: a first step, a second step, and a third step. The first, second, and third steps may be performed in any order; the order is not particularly limited. The denim products mentioned above can be anything made by sewing denim fabric, such as denim clothing. Examples of denim clothing include denim pants, denim jackets, denim shirts, denim vests, denim overalls, denim jumpsuits, or denim skirts. In the first step, the denim product, one or more abrasive materials selected from the group consisting of pumice, whetstones, and artificial abrasives, and a liquid containing water are stirred together to fade the denim product as a whole, thereby reproducing the fading caused by friction at least at either the edges 31 of the fabric constituting the denim product or the seams 32 of the fabric constituting the denim product, as shown in Figures 1 to 4. The edges 31 of the fabric constituting the denim product include, as shown in Figures 1 to 4, the edges of the hem, pocket openings, fly, waistband, belt loops, collar, collar openings, pocket flaps, placket, waistband adjusters, pleats, or tucks. Thus, the edges of the fabric constituting the denim product include the fabric itself or any protruding parts of the fabric's edges. The seams 32 of the fabric that make up the denim product include the seams between the front and back panels, the selvage formed by folding the edges of the front and back panels inward, the seams between the pockets and the body, the seams between the left and right panels, the seams between the yoke and the waist, the seams between the yoke and the back panel, the seams between the cuff and the sleeve, the seams between the body and the sleeve, the seams between the waist and the body, the seams between the front shoulder yoke and the front panel, the seams between the back shoulder yoke and the back panel, and the seams between the front and back shoulder yokes. Thus, the seams of the fabric that make up the denim product include the seams of each individual fabric that makes up the denim product. In the first step, during the stirring process, the abrasive comes into contact with the edges and seams of the denim fabric, causing discoloration and damage through friction. Simultaneously, the abrasive comes into contact with the entire denim product, causing it to discolor. The indigo dye leaches into the water-conta