Ring dyed materials and method of making the same

Abstract

A ring dyed textile product resulting from the treatment of yarn, fabric, or garments with a combination of a dye, engineered polymer, and heat. The resulting material can be engineered into fabric, garments, or other textile product. Subsequent abrasion of the article can produce apparel in a broad color range that has an aesthetic appearance similar to that of garments produced from indigo dyed yarn. Colorfastness performance including crocking, washfastness, and lightfastness are good to excellent for a broad color range.

What is claimed is: 
     
         1 . A ring dyed yarn comprising:
 a polymer-dye matrix positioned adjacent to an outer portion of the yarn, the polymer-dye matrix comprising a polymer layer and a reactive dye entrapped within the polymer layer.   
     
     
         2 . The ring dyed yarn of  claim 1 , wherein the polymer layer comprises at least one of a urethane based polymer and an acrylic polymer. 
     
     
         3 . The ring dyed yarn of  claim 2 , wherein the urethane based polymer has a glass transition temperature (Tg) of −65° C. to 70° C. 
     
     
         4 . The ring dyed yarn of  claim 1 , wherein the reactive dye comprises at least one of triazine derivatives, pyridimine derivatives, quinoxaline derivatives, and activated vinyl compounds. 
     
     
         5 . The ring dyed yarn of  claim 1 , wherein the yarn comprises at least one material selected from the group consisting of cotton, polyamide, wool, polyester, meta-aramids, polyproplylene, polyethylene, para-aramids, and modacrylics. 
     
     
         6 . The ring dyed yarn of  claim 1 , wherein an inner portion of the yarn is substantially free of the reactive dye. 
     
     
         7 . The ring dyed yarn of  claim 1 , wherein an inner portion of the yarn comprises a dye that is different from the reactive dye. 
     
     
         8 . A ring dyed fabric comprising:
 a polymer-dye matrix positioned adjacent to an outer portion of the fabric, the polymer-dye matrix comprising a polymer layer and a reactive dye entrapped within the polymer layer.   
     
     
         9 . The fabric of  claim 8 , wherein the fabric comprises at least one of a denim-like woven fabric construction, a non-woven fabric, and a knit fabric. 
     
     
         10 . The fabric of  claim 8 , wherein the fabric comprises at least one of cellulosic fibers and synthetic fibers. 
     
     
         11 . The fabric of  claim 8 , further comprising a flame retardant agent. 
     
     
         12 . The fabric of  claim 8 , wherein the polymer layer comprises a urethane based polymer having a glass transition temperature (Tg) from about −50° C. to about −20° C. 
     
     
         13 . The fabric of  claim 8 , wherein the percent solids on fabric ratio of polymer to reactive dye is at least 1:1. 
     
     
         14 . The fabric of  claim 8 , wherein the fabric has a dry crocking of greater than 3.5 and a wet crocking of greater than 2.5 in accordance with AATCC Test Method 8. 
     
     
         15 . The fabric of  claim 8 , wherein the fabric has a lightfastness of greater than 3.0 at 20 hours and a lightfastness of greater than 2.5 at 40 hours in accordance with AATCC Test Method 16A. 
     
     
         17 . The fabric of  claim 8 , wherein the fabric comprises an abraded fabric such that one or more surface areas of the fabric are substantially free of the polymer-dye matrix. 
     
     
         18 . The fabric of  claim 8 , wherein the fabric further comprises a post treatment additive comprising an emulsified wax. 
     
     
         19 . A ring dyed garment comprising:
 a fabric;   a polymer-dye matrix positioned adjacent to an outer portion of the fabric, the polymer-dye matrix comprising a polymer layer and a reactive dye entrapped within the polymer layer.   
     
     
         20 . A method of producing a ring dyed substrate, the method comprising:
 providing a substrate;   depositing a polymer-dye composition on at least a portion of the substrate, the polymer-dye composition comprising an aqueous mixture of one or more polymers and a reactive dye;   heating the treated substrate such that the polymer-dye composition moves to the surface of the substrate;   depositing an alkaline salt mixture on the substrate; and   forming a polymer-dye matrix positioned adjacent to an outer portion of the substrate in response to the alkaline salt mixture deposition, the polymer-dye matrix comprising a polymer layer and a reactive dye entrapped within the polymer layer.   
     
     
         21 . The method of  claim 20 , wherein the substrate comprises at least one of a yarn or fabric. 
     
     
         22 . The method of  claim 21 , wherein an inner portion of the yarn is substantially free of the reactive dye. 
     
     
         23 . The method of  claim 21 , further comprising:
 depositing a dye mixture comprising a second reactive dye on the yarn or fabric; and   producing a two-toned fabric as a result of the deposit, wherein an inner portion of the yarn comprises the second reactive dye and wherein the yarn is substantially free of the first reactive dye.   
     
     
         24 . The method of  claim 20 , wherein the substrate comprises a previously dyed substrate. 
     
     
         25 . The method of  claim 20 , wherein the substrate is subjected to at least one of desizing, scouring, bleaching, and mercerization prior to treatment. 
     
     
         26 . The method of  claim 20 , wherein the polymer is cured in response to the heating. 
     
     
         27 . The method of  claim 20 , further comprising:
 abrading at least a portion of the outer portion of the substrate to remove at least some of the polymer-dye matrix such that the substrate has first surface areas comprising fibers that comprise the reactive dye and second surface areas comprising fibers that do not include the reactive dye.   
     
     
         28 . The method of  claim 20 , further comprising:
 depositing a post treatment additive comprising an emulsified wax on at least a portion of the substrate.