Environmentally friendly non-bleed polyester fabric and method of manufacturing the same

Abstract

A method of manufacturing a polyester fabric with inherent color, the method including: providing a polyester fiber with inherent color; spinning polyester yarn from the fiber with inherent color; knitting the colored polyester yarn into knitted fabric which can combine with other yarn according to a requirement; washing the colored polyester fabric and heat-setting the fabrics with add-on functional finish to the fabric. The providing of polyester fiber with inherent color may include: cleaning and drying polyester bottles; recycling polyester chips from clean bottles; mixing chips with pigment evenly and melting the chips with pigment; extruding the filament fiber with color; and drawing and cutting filament fiber into staple fiber. Further aspects of the present invention are directed to a colored polyester fabric and a method of manufacturing an article of clothing using a colored polyester fabric produced using the above-described method.

What is claimed is: 
     
         1 . A method of manufacturing a polyester knitted fabric with inherent color, the method comprising:
 providing a polyester fiber with inherent color;   spinning a colored polyester yarn from the polyester fiber with inherent color; and   knitting the colored polyester yarn into a colored polyester fabric.   
     
     
         2 . The method of  claim 1 , wherein providing the polyester fiber with inherent color comprises:
 providing polyester chips;   mixing the polyester chips with a pigment;   extruding a colored filament fiber from the polyester chips mixed with the pigment; and   cutting the filament fiber into a staple fiber.   
     
     
         3 . The method of  claim 2 , wherein mixing the polyester chips with the pigment comprises melting the polyester chips with pigment chips having a color. 
     
     
         4 . The method of  claim 3 , wherein the polyester chips are melted with the pigment chips at 260-285° C., and the colored filament fiber is then extruded at 270-285° C. 
     
     
         5 . The method of  claim 2 , wherein the polyester chips are obtained from recycled polyester bottles. 
     
     
         6 . The method of  claim 2 , wherein the filament fiber is cut to a size of 1.5D×38 mm. 
     
     
         7 . The method of  claim 1 , wherein spinning the colored polyester yarn comprises spinning the colored polyester yarn at a twist of greater than 800 tpm. 
     
     
         8 . The method of  claim 1 , further comprising:
 washing the colored polyester fabric for 15-20 minutes; and   heat-setting the colored polyester fabric by passing the colored polyester fabric through a stenter only one time at 190-195° C.   
     
     
         9 . The method of  claim 8 , wherein heat-setting the colored polyester fabric comprises adding at least one of a wicking agent, an anti-bacterial agent, and an anti-odor agent to the fabric. 
     
     
         10 . The method of  claim 1 , wherein finishing the colored polyester fabric includes washing and heat-setting the colored polyester fabric, and does not include any dyeing process to the colored polyester fabric having inherent color. 
     
     
         11 . The method of  claim 1 , wherein the colored polyester fabric has colorfastness to washing AATCC61-2A at grade 4.5 or greater. 
     
     
         12 . The method of  claim 1 , wherein knitting the colored polyester yarn into a knitted fabric comprises knitting the colored polyester yarn in combination with other yarns. 
     
     
         13 . A colored polyester fabric manufactured using the method of  claim 1 . 
     
     
         14 . A colored polyester fabric manufactured from polyester fiber with inherent color, wherein the colored polyester fabric has colorfastness to washing AATCC61-2A at grade 4.5 or greater. 
     
     
         15 . A method of manufacturing an article of clothing, the method comprising:
 providing a first polyester fiber with inherent color;   spinning a first colored polyester yarn from the first polyester fiber with inherent color;   knitting the first colored polyester yarn into a first colored polyester fabric;   cutting the first colored polyester fabric to have a desired shape and size; and   assembling the first colored polyester fabric into an article of clothing.   
     
     
         16 . The method of  claim 15 , wherein providing the first polyester fiber with inherent color comprises:
 providing polyester chips;   mixing the polyester chips with a pigment;   extruding a colored filament fiber from the polyester chips mixed with the pigment; and   cutting the filament fiber into a staple fiber.   
     
     
         17 . The method of  claim 16 , wherein the polyester chips are obtained from recycled polyester bottles. 
     
     
         18 . The method of  claim 15 , further comprising:
 washing the first colored polyester fabric for 15-20 minutes; and   heat-setting the first colored polyester fabric by passing the first colored polyester fabric through a stenter only one time at 190-195° C.   
     
     
         19 . The method of  claim 15 , wherein the first colored polyester fabric has colorfastness to washing AATCC61-2A at grade 4.5 or greater. 
     
     
         20 . The method of  claim 15 , further comprising:
 providing a second polyester fiber with inherent color;   spinning a second colored polyester yarn from the second polyester fiber with inherent color;   knitting the second colored polyester yarn into a second colored polyester fabric having a different structure than the first polyester fabric;   cutting the second colored polyester fabric to have a desired shape and size; and   assembling the second colored polyester fabric together with the first colored polyester fabric into the article of clothing.