Ring dyed polymer treated materials and method of making same

Abstract

Products and methods for ring dyeing a yarn and/or surface dyeing a fabric are provided. The product and method discloses the application of a dye binding composition including a urethane based polymer to a textile yarn, fabric, or garment. The dye binding composition is engineered so that the composition is positioned on or near the surface of the yarn, producing a ring dyed material. The dye binding composition can be colored with selective dyes that bind to the composition but generally do not have affinity for textile substrate. Garments created using this fabric can be abraded to remove surface polymer and color in different locations of the garment, creating an antiqued appearing garment. Dyes of different classifications can be used to produce novel performance and coloration effects in textile materials and garments. This process has been demonstrated on yarn (for a denim-like appearance), knitted and woven fabrics, and garments.

What is claimed is: 
     
         1 ) A dye binding composition for a ring dyed material, the composition comprising a urethane based polymer having a solids percentage in the composition of between 0.5% and 50% by weight. 
     
     
         2 ) The dye binding composition for the ring dyed material of  claim 1 , wherein the solids percentage in the composition is between 2.0% and 12.0%. 
     
     
         3 ) The dye binding composition for the ring dyed material of  claim 1 , the composition further comprising a cationic material. 
     
     
         4 ) The dye binding composition for the ring dyed material of  claim 4 , wherein the cationic material is selected from the group consisting of guanidine and urethane. 
     
     
         5 ) The dye binding composition for the ring dyed material of  claim 1 , the composition further comprising a UV inhibitor. 
     
     
         6 ) The dye binding composition for the ring dyed material of  claim 1 , wherein the urethane based polymer is a polyurethane dispersion. 
     
     
         7 ) A ring dyed yarn comprising:
 at least one fiber; and   a dye binding composition for a ring dyed material, the composition comprising a urethane based polymer having a solids percentage in the composition of between 0.5% and 50% by weight.   
     
     
         8 ) The ring dyed yarn of  claim 7 , further comprising at least one dye configured to selectively dye the dye binding composition positioned on at least a portion of the surface of the fiber. 
     
     
         9 ) The ring dyed yarn of  claim 7 , wherein at least some of the dye binding composition is positioned on at least a portion of the surface of the fibers 
     
     
         10 ) The ring dyed yarn of  claim 7 , wherein the fiber is selected from the group consisting of cotton, wool, silk, hemp, flax, polyester, rayon, acetate, nylons, spandex, olefins, polyethylene, polyethylene, and polypropylene. 
     
     
         11 ) A fabric comprising:
 fibers;   a dye binding composition for a ring dyed material, the composition comprising a urethane based polymer having a solids percentage in the composition of between 0.5% and 50% by weight, wherein at least some of the dye binding composition is positioned on at least a portion of the surface of the fibers; and   at least one dye configured to selectively color the dye binding composition positioned on at least a portion of the surface of the fibers.   
     
     
         12 ) The fabric of  claim 11 , wherein the dye bind composition further comprises a cationic material selected from the group consisting of guanidine and urethane. 
     
     
         13 ) The fabric of  claim 11 , wherein the at least one dye does not directly dye the fibers. 
     
     
         14 ) The fabric of  claim 11 , wherein the fabric comprises denim. 
     
     
         15 ) The fabric of  claim 11 , wherein the fibers comprise at least one of cotton fibers and synthetic fibers. 
     
     
         16 ) A garment comprising:
 fabric comprising fibers;   a dye binding composition for a ring dyed material, the composition comprising a urethane based polymer having a solids percentage in the composition of between 0.5% and 50% by weight, wherein at least some of the dye binding composition is positioned on at least a portion of the surface of the fibers; and   at least one dye configured to selectively dye the dye binding composition positioned on at least a portion of the surface of the fibers.   
     
     
         17 ) The garment of  claim 16 , wherein the garment comprises a first surface area comprising the dye binding composition that has been dyed with the at least one dye and a second surface area that is free of the dye binding composition. 
     
     
         18 ) A method of producing ring dyed or surface dyed fiber, yarn, fabric, or garment, the method comprising:
 applying a dye binding composition for a ring dyed material to at least one of the fiber, yarn, fabric, or garment, the composition comprising a urethane based polymer having a solids percentage in the composition of between 0.5% and 50% by weight;   heating the fiber, yarn, fabric, or garment to cause the dye binding composition to mobilize to a surface of the fiber, yarn, fabric, or garment; and   applying at least one selective dye to the at least one of the fiber, yarn, fabric, or garment, wherein the selective dye is selective for the dye binding composition.   
     
     
         19 ) The method of  claim 18 , wherein the dye binding composition and the selective dye are applied simultaneously. 
     
     
         20 ) The method of  claim 18 , wherein the dye binding composition and the selective dye are applied sequentially. 
     
     
         21 ) The method of  claim 18 , further comprising:
 abrading at least a portion of the surface of the garment to remove at least some of the dye binding composition that has been dyed with the at least one dye such that the garment has first areas comprising fibers that comprise the dye binding composition that has been dyed with the at least one dye and second areas comprising fibers that do not include the dye binding composition.   
     
     
         22 ) The method of  claim 21 , wherein the abrading is performed based on at least one of:
 sanding;   application of diatomaceous earth; and   application of pumice stones to the garment.   
     
     
         23 ) The method of  claim 18 , wherein the heating the dye binding composition is performed using at least one of a curing oven, steam cans, and hot flue. 
     
     
         24 ) The method of  claim 18 , wherein the selective dye is applied using at least one of thermosol dyeing on a continuous dye range or tenter frame, pad steaming on a continuous pad/steam range or flash ageing machine, jet dyeing, jigger dyeing, beam dyeing, pad/dry/thermosol dyeing, and printing.