Denim Fabric Including Recycled Material

Abstract

Denim fabric, suitable for use as apparel, and garments made therefrom, wherein the denim fabric is made from at least about 50 wt % fibers produced from post-consumer recycled polyester and recycled cotton. In particular, warp yarns are made of recycled cotton and the other cotton, and the filling yarns are made of the post-consumer recycled polyester and spandex material. The warp yarn may be plied with like reclaimed warp yarn, and/or with virgin fiber warp yarn. The warp and filling yarns are combined to make the denim fabric. The denim fabric produced has strength and related properties sufficient for consumer use. The fabric or garment may also be subjected to washing, handwork, and/or other finishing effects that would change the look and feel of the fabric or add special characteristics.

What is claimed is: 
     
         1 . A denim fabric comprising:
 a) from about 25 wt % to about 40 wt % based on the denim fabric of post-consumer recycled polyester,   b) from about 25 wt % to about 40 wt % based on the denim fabric of recycled cotton,   c) from about 25 wt % to about 40 wt % based on the denim fabric of other cotton, and   d) up to about 3 wt % based on the denim fabric of spandex.   
     
     
         2 . The denim fabric of  claim 1  comprising about 30% to about 35 wt % based on the denim fabric of post-consumer recycled polyester. 
     
     
         3 . The denim fabric of  claim 1  comprising about 30 wt % to about 35 wt % based on the denim fabric of recycled cotton. 
     
     
         4 . The denim fabric of  claim 1  comprising about 30 wt % to about 35 wt % based on the denim fabric of other cotton. 
     
     
         5 . The denim fabric of  claim 1  wherein the post-consumer polyester is a filament or staple fiber derived from plastic soda or water containers. 
     
     
         6 . The denim fabric of  claim 1  wherein the recycled cotton of b) is pre-consumer cotton waste. 
     
     
         7 . The denim fabric of  claim 1  wherein the recycled cotton of b) is pre-consumer denim waste. 
     
     
         8 . A process to make the denim fabric comprising the steps of:
 a) preparing a mixture of recycled cotton and other cotton into a warp yarn;   b) mixing the warp yarn with dyes and chemicals;   c) preparing a mixture of recycled polyester and spandex into a filling yarn; and   d) preparing the denim yarn from the warp yarn of (b) and the filling yarn of (c).   
     
     
         9 . A process as recited in  claim 8  wherein step (a) is practiced so as to produce denim fibers with an average length of about 0.6 inches, so that the denim fabric has denim waste fibers with an average length of about 0.6 inches. 
     
     
         10 . A process as recited in  claim 8  wherein step (a) includes collecting waste fiber and waste yarn. 
     
     
         11 . A process as recited in  claim 8  wherein step (a) includes collecting pre-consumer waste fiber and waste yarn. 
     
     
         12 . A process as recited in  claim 8  wherein step (a) includes collecting pre-consumer fabric waste. 
     
     
         13 . A process as recited in  claim 8  wherein step (a) includes collecting post consumer denim waste. 
     
     
         14 . A denim garment produced from denim fabric, the denim fabric comprising:
 a) from about 25 wt % to about 40 wt % based on the denim fabric of post-consumer recycled polyester,   b) from about 25 wt % to about 40 wt % based on the denim fabric of recycled cotton,   c) from about 25 wt % to about 40 wt % based on the denim fabric of other cotton, and   d) up to about 3% based on the denim fabric of spandex.   
     
     
         15 . A process for dyeing warp yarn of a denim fabric comprising the steps of:
 a) dyeing the warp yarn with minimum overflow as compared to traditional denim dyeing methods;   b) introducing said warp yarn to an aqueous solution comprising sulfur dye;   c) recovering the aqueous solution bath comprising sulfur dye in the form of recovered sulfur dye bath; and   d) re-using the recovered sulfur dye bath in dyeing of other fabrics.