Methods for processing denim

Abstract

Methods for processing denim are provided. An initial fabric is abraded by passing the initial fabric through an abrader at a first predetermined speed, thereby obtaining a pre-washed fabric with an abraded texture. The abrader comprises one or more sanding boards, where each respective sanding board has a respective diamond surface that contacts the initial fabric while spinning about a respective axis at the respective center of the respective sanding board during the abrading. The pre-washed fabric is then washed with an ozone composition, thereby obtaining an ozone washed fabric.

1 . A method for processing denim comprising:
 abrading an initial fabric by passing the initial fabric through an abrader at a first predetermined speed in a first direction, wherein the abrader comprises one or more sanding boards, wherein each respective sanding board in the one or more sanding boards has a respective surface that contacts the initial fabric while spinning about a respective axis at the respective center of the respective board during the abrading, thereby obtaining a pre-washed fabric with an abraded texture; and   washing the pre-washed fabric with an ozone composition, thereby obtaining an ozone washed fabric.   
     
     
         2 . The method of  claim 1 , the method further comprising:
 using the ozone washed fabric to produce an article of clothing.   
     
     
         3 . The method of  claim 1 , wherein the ozone washed fabric is denim. 
     
     
         4 . The method of  claim 1 , the method further comprising, prior to the abrading:
 dyeing a yarn comprising a plurality of textile fibers with a blue dye by coating a surface of the yarn with the blue dye; and   weaving the yarn to form the initial fabric.   
     
     
         5 . The method of  claim 4 , wherein the blue dye is an indigo dye or a sulphur dye. 
     
     
         6 . (canceled) 
     
     
         7 . The method of  claim 4 , wherein the plurality of textile fibers comprises cotton fibers. 
     
     
         8 . (canceled) 
     
     
         9 . (canceled) 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . The method of  claim 4 , wherein the plurality of textile fibers is round, dog bone shaped, trilobal, multilobal, serrated, band, triangular, oval, or hollow shaped. 
     
     
         15 . The method of  claim 4 , wherein the plurality of textile fibers is blended fibers. 
     
     
         16 . The method of  claim 4 , wherein the plurality of textile fibers is cotton blended with lycra, polyester, lyocell, wool, flax, or hemp. 
     
     
         17 . The method of  claim 4 , wherein the plurality of textile fibers comprises  Gossypium hirsutum  cotton,  Gossypium barbadense  cotton,  Gossypium arboreum  cotton, or  Gossypium herbaceum  cotton. 
     
     
         18 . The method of  claim 4 , wherein the plurality of textile fibers have a length in the range of 10-65 mm, a fitness in the range of 1.2-2.8 dtex, a dry tenacity in the range of 1.9-3.1 cN/dtex, a dry breaking extension in the range of 7 percent to 10 percent, a moisture regain of about 8.5 percent, and/or a density of 1.5 to 1.54 g/cm 3 . 
     
     
         19 . (canceled) 
     
     
         20 . The method of  claim 4 , wherein the yarn is a denim warp yarn having a count of between Ne 4.0 and Ne 12.5. 
     
     
         21 . The method of  claim 4 , wherein the yarn is a denim warp yarn having a count of between Ne 12.5 and Ne 30.0. 
     
     
         22 . (canceled) 
     
     
         23 . The method of  claim 4 , where the yarn is a blend of X percent cotton and Y percent elastane, wherein X and Y sum to 100 percent and X is in the range of 50 percent to 99 percent. 
     
     
         24 . The method of  claim 4 , where the yarn is a blend of X percent cotton, Y percent elastane, and Z percent Lycra, wherein X, Y, and Z sum to 100 percent and X is in the range of 50 percent to 94 percent. 
     
     
         25 . The method of  claim 4 , where the yarn is a blend of X percent cotton, Y percent polyester, and Z percent Lycra, wherein X, Y, and Z sum to 100 percent and X is in the range of 50 percent to 94 percent. 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . (canceled) 
     
     
         29 . (canceled) 
     
     
         30 . The method of  claim 1 , wherein each respective surface of each sanding board in the one or more sanding boards spins about the respective axis of the respective board at the center of the respective board at a rate of between 1000 revolutions per minute and 3000 revolutions per minute. 
     
     
         31 . The method of  claim 1 , wherein each respective sanding board in the one or more sanding boards is tubular and has a diameter of between 2 inches and 20 inches. 
     
     
         32 . The method of  claim 1 , wherein the first predetermined speed is between 5 meters per minute and 100 meters per minute. 
     
     
         33 . (canceled) 
     
     
         34 . The method of  claim 1 , wherein each respective surface of each sanding board in the one or more sanding board is electroplated diamond have a specified Grit, wherein the specified Grit is between Grit 150 and Grit 2400. 
     
     
         35 . (canceled) 
     
     
         36 . The method of  claim 1 , wherein the one or more sanding boards comprises between 2 and 10 sanding boards. 
     
     
         37 . The method of  claim 1 , wherein the abrading and washing cause the pre-washed fabric to exhibit a predetermined amount of color fade relative to the initial fabric. 
     
     
         38 . The method of  claim 37 , wherein the predetermined amount of color fade causes the ozone washed fabric to have a CIELab L* value that is between 8 and 49, a CIELab a* value that is between −1.4 and 3.5, and a CIELab b* value that is between −10.50 and −1.20. 
     
     
         39 . The method of  claim 2 , wherein the article of clothing is a pair of denim jeans. 
     
     
         40 . (canceled) 
     
     
         41 . The method of  claim 1 , wherein the ozone composition is between 5 g/Nm 3  ozone and 100 g/Nm 3  ozone. 
     
     
         42 . The method of  claim 1 , wherein the ozone washed fabric has a width of between 40 centimeters and 400 centimeters and a length of at least 50 meters. 
     
     
         43 . (canceled) 
     
     
         44 . (canceled) 
     
     
         45 . (canceled) 
     
     
         46 . The method of  claim 2 , wherein using the ozone washed fabric to produce the article of clothing comprises cutting, making, and trimming with the ozone washed fabric to form the article of clothing. 
     
     
         47 . The method of  claim 2 , the method further comprising:
 agitation washing the article of clothing, and   drying the article of clothing.   
     
     
         48 . The method of  claim 47 , the method further comprising patterning the article of clothing with a laser to produce one or more laser designs within the article of clothing. 
     
     
         49 . (canceled) 
     
     
         50 . (canceled) 
     
     
         51 . (canceled) 
     
     
         52 . The method of  claim 1 , wherein
 the one or more sanding boards is a plurality of slat rollers, cylinder rollers, or a combination thereof,   each roller in the plurality of slat rollers, cylinder rollers, or combination thereof, spins clockwise or counterclockwise with respect to the first direction, independent of a spin of all other sanding boards in the plurality of slat rollers, cylinder rollers, or a combination thereof; and   the abrader further comprises a plurality of contact rolls that push the fabric against the plurality of slat rollers at a predetermined pressure, wherein the predetermined pressure is between 5 and 60 Kg/cm.   
     
     
         53 . (canceled)