An abrasive structure for stone washing garments in a wash medium and a method for abrading garments using that abrasive structure to achieve controlled abrasion of those garments are disclosed. The abrasive structure has a uniform abrasive surface which will not damage or excessively wear fabrics and garments being subjected to the stone washing method, which will not deteriorate during use, and which will provide uniformly stone washed garments having a consistent nap and a low level amount of textile wear. The abrasive structure is formed of a substantially form-retaining material having a resilient abrasive surface. For example, the abrasive structure may be formed of a block of form-retaining material substantially impervious to aqueous washing systems and a resilient layer of synthetic abrasive material substantially surrounding the block and affixed to the exterior surfaces of the block.
The invention relates to a process of premature wear of textile articles. It is characterized in that instead of using bodies 2 of material known for its abrasive power, the articles are agitated with the bodies 2, which over at least a thick peripheral layer if not in totality have a homogeneous structure of relatively flexible material, having a Shore hardness of between 50 and 70, and an index of compression of 55 to 80, and preferably 65 to 70.
Improved techniques are provided for giving new garments, such as jeans, a worn appearance by tumbling the garments with potassium permanganate impregnated pumice rock. Pumice rock is thoroughly and quickly impregnated with potassium permanganate solution by placing the rock in a sealed chamber, drawing a vacuum in the chamber, spraying a potassium permanganate solution into the chamber while allowing the vacuum to drop to a preselected level, then retrieving the impregnated rock from the chamber. The garments and impregnated rock are then tumbled in a perforated container. New garments are added with additional rock to replenish the reduced the reduced volume of the used rock, which need not be reimpregnated. A preferred stone-washed appearance may be obtained by the combined bleaching effect of the potassium permanganate and the abrasive action of the rock.
Improved methods and apparatus are provided for altering fabric finishes on a garment to give the garment a "lived-in" or worn appearance before the garment is actually worn by the user. According to the method of the present invention, a batch of garments is preferably stone-washed to generally fade and abrade the entire garment. The garment is then inflated by passing air through an inlet port in the garment and by substantially sealing one or more exit ports in the garment to create a greater than atmospheric pressure within the garment. The inflated garment is then sprayed with a low-strength bleaching solution on selected exterior portions to provide an additional fading or worn appearance on those portions of the garment. Thereafter, the garment is placed in a neutralizing liquid to chemically counteract the sprayed bleaching solution. A plurality of garments may be each suspended from a common air duct interconnected with a blower for providing air to inflate the garments. The garment is preferably rotatable with respect to the air duct so that the garment may be easily rotated by an operator to a selective position for the spraying operation.
The apparatus of the invention allows for efficient and safe decolorizing or dyeing of cloth articles using bleach or dye-impregnated stones or granules. The apparatus includes a cylindrical drum with longitudinal baffles along its inner surface. Liner sheets are attached to adjacent baffles, thereby lining the entire drum. The sheets flex inwardly due to gravity as the drum is rotated, thereby dislodging any residual materials layered thereon. The apparatus also provides for separation of treated articles from stones and re-impregnation of the stones with a bleaching agent or a dyestuff solution or dispersion.
Methods are provided for abrading dyed fabric to produce a stonewashed effect by tumbling the fabric with stones of a chemical composition that is soluble in wash or rinse liquid for the fabric, where the stones are of sufficient size and hardness to effect abrasion of the fabric without substantial mechanical disintegration of the stones and in a manner simulating the action of pumice stone. The chemical stonewashing composition may be a compacted powder, agglomerate, coagulate, or other integral mass or solid formed from an alkali or alkaline earth metal carbonate, bicarbonate, silicate, sulfate, borate, halide, hydroxide or hydrate or peroxyhydrate thereof, for example.
