Washed down fabric articles and process for making same

Abstract

A washed down fabric article and a process for treating a fabric article for producing the washed or faded effect is disclosed. The process may include fixing a dye onto the fabric article, discharging a portion of the dye with non-abrasive tumbling elements that includes a bleaching agent. The process further comprises neutralizing the bleaching agent with a neutralizer, and stabilizing the final color of the fabric article.

What is claimed is: 
     
         1 . A washed down fabric article, comprising:
 a panel defining an outer edge and being formed from a textile fabric that includes at least cellulosic fibers and a dye component fixed to the cellulosic fibers, the dye component including a modified reactive dye, the panel including a first area having a first color and a plurality of dye discharge areas, each dye discharge areas including discharged dye components, such that the dye discharges areas has a second color that is different than the first color so as to create a washed down effect.   
     
     
         2 . The washed down fabric article of  claim 1 , wherein the panel has a face and a back, wherein the discharged dye areas are disposed along at least one of the face and the back. 
     
     
         3 . The washed down fabric article of  claim 1 , wherein at least one of the discharge areas are disposed along the outer edge of the panel. 
     
     
         4 . The washed down fabric article as claimed in  claim 1 , wherein the textile fabric is a yarn dyed fabric. 
     
     
         5 . The washed down fabric article of  claim 1 , wherein the modified reactive dye includes a chromophore that breaks via oxidation. 
     
     
         6 . The washed down fabric article of  claim 1 , wherein the cellulosic fibers include cotton fibers. 
     
     
         7 . The washed down fabric article of  claim 1 , wherein the textile fabric is a woven fabric, non-woven fabric or a knit fabric. 
     
     
         8 . The washed down fabric article of  claim 6 , wherein the textile fabric is a woven fabric. 
     
     
         9 . The washed down fabric article of  claim 6 , wherein the woven fabric is a plain weave, a satin weave, a basket weave, a rib weave, a twill weave, oxford weave, or a terry woven fabric 
     
     
         10 . The washed down fabric article of  claim 1 , wherein the textile fabric is a terry fabric. 
     
     
         11 . The washed down fabric article of  claim 9 , wherein the terry fabric is a woven terry fabric or a knitted terry fabric. 
     
     
         12 . The washed down fabric article of  claim 9 , wherein terry fabric includes a plurality of piles, each pile having a tip and a base, wherein the tip of the piles define at least one of the plurality of discharged dye areas. 
     
     
         13 . The washed down fabric article as claimed in  claim 1 , includes one of rug, bath mat, towel, wash cloth, bath robe, blanket, and shower curtain. 
     
     
         14 . A process for treating a fabric article, the process comprising:
 placing a fabric article into a tumbling chamber, the fabric article including a dye component fixed thereto; and   tumbling the dyed fabric article in the tumbling chamber with a plurality of non-abrasive tumbling elements and alkaline agent, the plurality of non-abrasive tumbling elements and the alkaline agent repeatedly strike the fabric article to selectively discharge a portion of the dye from the fabric article to create a washed down effect on the fabric article.   
     
     
         15 . The process according to  claim 14 , wherein the dye component is a modified reactive dye. 
     
     
         16 . The process according to  claim 14 , wherein the modified reactive dye includes a chromophore that breaks via oxidation during the tumbling step. 
     
     
         17 . The process according to  claim 14 , wherein the non-abrasive tumbling elements include expanded polystyrene impregnated with the bleaching agent. 
     
     
         18 . The process according to  claim 15 , wherein the bleaching agent is a chlorine based or a non-chorine based bleaching agent. 
     
     
         19 . The process according to  claim 14 , wherein the plurality of non-abrasive tumbling elements have a cross-sectional dimension in a range from 2.0 mm to 20.0 mm. 
     
     
         20 . The process according to  claim 14 , further comprising the step of washing the fabric in at least one wash cycle after the tumbling step. 
     
     
         21 . The process according to  claim 20 , wherein the at least one wash cycle comprising the step of neutralizing the bleaching agent with a neutralizer. 
     
     
         22 . The process according to  claim 21 , wherein the neutralizer is at least one of a detergent, oxalic acid, and sodium metabisulphite, and an anti-chlorine agent. 
     
     
         23 . The process according to  claim 21 , further comprising the step of applying a composition to the fabric article in the at least one wash cycle, the composition including at least one of a softener and a wicking agent. 
     
     
         24 . The process according to  claim 14 , further comprising the step of combining the plurality of non-abrasive tumbling elements and the bleaching agent prior to the step of placing the fabric article in the tumbling chamber. 
     
     
         25 . A process for treating a fabric article, the process comprising the steps of:
 fixing a modified reactive dye onto fibers of the fabric article;   tumbling the fabric article in the tumbling chamber with a plurality of non-abrasive tumbling elements and alkaline agent, the non-abrasive tumbling elements including a bleaching agent, wherein the plurality of non-abrasive tumbling elements and alkaline agent repeatedly strike the fabric article to selectively discharge a portion of the modified reactive dye from the fabric article so as to define discharge dye portions;   washing the fabric article in a composition including water and a neutralizer in at least one wash cycle so as to neutralize the bleaching agent; and   stabilizing the modified reactive dye that remains on the fabric article with a soaping agent.   
     
     
         26 . The process according to  claim 25 , wherein the modified reactive dye includes a chromophore, wherein the tumbling step oxidizes the chromophore via at least the bleaching agent and the alkaline agent. 
     
     
         27 . The process according to  claim 25 , wherein the non-abrasive tumbling elements include expanded polystyrene impregnated with a bleaching agent. 
     
     
         28 . The process according to  claim 25 , wherein the bleaching agent is a chlorine based agent or a non-chlorine based agent. 
     
     
         29 . The process according to  claim 25 , wherein the tumbling elements have a cross-sectional dimension in a range from 2.0 mm to 20.0 mm. 
     
     
         30 . The process according to  claim 25 , wherein the neutralizer is at least one of a detergent, oxalic acid, and sodium metabisulphite, and an anti-chlorine agent. 
     
     
         31 . The process according to  claim 25 , further comprising the step of applying a composition to the fabric article in the at least one wash cycle, the composition including at least one of a softener and a wicking agent.