WO2000044529A1 - Composite fabric finishing media, method of fabricating and method of using - Google Patents

Composite fabric finishing media, method of fabricating and method of using Download PDF

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Publication number
WO2000044529A1
WO2000044529A1 PCT/US1999/002048 US9902048W WO0044529A1 WO 2000044529 A1 WO2000044529 A1 WO 2000044529A1 US 9902048 W US9902048 W US 9902048W WO 0044529 A1 WO0044529 A1 WO 0044529A1
Authority
WO
WIPO (PCT)
Prior art keywords
surface layer
abrasive
composite fabric
finishing media
pockets
Prior art date
Application number
PCT/US1999/002048
Other languages
French (fr)
Inventor
Kingsford Kwok
Original Assignee
Ron Steven, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ron Steven, Inc. filed Critical Ron Steven, Inc.
Priority to AU23513/99A priority Critical patent/AU2351399A/en
Priority to PCT/US1999/002048 priority patent/WO2000044529A1/en
Publication of WO2000044529A1 publication Critical patent/WO2000044529A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
    • B24B1/007—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes abrasive treatment to obtain an aged or worn-out appearance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B31/00—Machines or devices designed for polishing or abrading surfaces on work by means of tumbling apparatus or other apparatus in which the work and/or the abrasive material is loose; Accessories therefor
    • B24B31/12—Accessories; Protective equipment or safety devices; Installations for exhaustion of dust or for sound absorption specially adapted for machines covered by group B24B31/00
    • B24B31/14—Abrading-bodies specially designed for tumbling apparatus, e.g. abrading-balls
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B11/00—Treatment of selected parts of textile materials, e.g. partial dyeing
    • D06B11/0093—Treatments carried out during or after a regular application of treating materials, in order to get differentiated effects on the textile material
    • D06B11/0096—Treatments carried out during or after a regular application of treating materials, in order to get differentiated effects on the textile material to get a faded look
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06P—DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM
    • D06P5/00—Other features in dyeing or printing textiles, or dyeing leather, furs, or solid macromolecular substances in any form
    • D06P5/13—Fugitive dyeing or stripping dyes
    • D06P5/137—Fugitive dyeing or stripping dyes with other compounds

Definitions

  • This invention relates to softening and preferential fading of fabric. More particularly this invention relates to abrasive bodies that are used in washing fabric to produce this softening and preferential fading effect.
  • the process of softening and preferentially fading fabric is commonly known as "stone washing.”
  • Stone washed fabrics have been popular for clothing for a number of years.
  • fabric or items of clothing are washed in a special tumbling chamber with a number of abrasive bodies.
  • Softeners and bleach are sometimes also added.
  • the chamber is opened and the fabric separated from the water and abrasive bodies.
  • the fabric has been preferentially faded and has been softened.
  • the typical abrasive media that is used for stone washing is "lava rock.” This is an irregularly shaped, naturally occurring rock froth. It is produced when lava containing large quantities of gas cools and solidifies to produce a rock full of holes and sometimes trapped gas. Lava is chiefly magnesium silicate. The rock froth is lightweight and sometimes called pumice. As this media is used it becomes smaller and an abrasive powder is produced. Smaller media is less effective in producing the desired effect on the fabric. Furthermore, the abrasive powder is a hazardous waste and must be disposed of in accordance with governing regulations. This adds to the expense of the process. Several inventors have tried to improve on or overcome the shortcomings of the "lava rock" media. US Patent No.
  • 4,750,227 discloses stone washing structures comprising a block of impervious material, such as polypropylene, covered with a layer of resilient synthetic abrasive, such as a non-woven fabric.
  • the fabric may be impregnated with an abrasive such as silicon carbide.
  • US Patent No.4,954,138 discloses artificial stones made of inorganic filler, abrasive and bonding material.
  • Abrasives used include walnut shells, clay, sand and pearlite.
  • US Patent No.5,298,027 discloses bleaching jeans by tumbling them with foamed glass-ceramics.
  • An example formulation for such materials includes volcanic ash, silica, clay and silicon carbide, processed and sintered.
  • US Patents No. 5,326,382 and 5,359,745 disclose methods of making synthetic glass stones from glass and a foaming agent.
  • US Patent No. 5,538,515 discloses a method of randomly fading fabric including a hammering body which may be made of plastic or metal and has protrusions on its surface.
  • This invention is a composite fabric finishing media, a method of fabricating the media and a method of using this media.
  • the media has several embodiments which are related to each other.
  • the primary embodiment is a body which has a thick surface layer, a plurality of pockets protruding into this surface layer and a plurality of spines projecting from this surface layer.
  • the body is spherical however it could be made cubical; elliptical; as a cylinder with a rectangular, square, or circular cross section; or any convenient shape.
  • the body is hollow. Then it can be evacuated or filled with a material designed to adjust the density of the body. Bodies that are evacuated or filled with various fluids constitute further embodiments of this invention.
  • the final embodiment constitutes any one of the bodies described above with an abrasive coating distributed over the plurality of spines and pockets.
  • the abrasive coating contains silicon carbide or aluminum oxide.
  • the preferred method of fabricating the bodies described above is to fabricate two concave half-bodies with pockets and spines and assembling these half-bodies to form a complete body. This creates a hollow body.
  • the preferred fabricating method is injection molding. Consequently, each half body is fabricated simultaneously with its pockets and spines. In order to meet the requirements of the injection molding process, it is preferable for the spines and pockets to be parallel to the central, radial axis of the body.
  • the preferred method of stone washing fabric utilizing the above described embodiments is to charge a suitable tumbling machine with fabric, water and several of each of the above described media.
  • a suitable tumbling machine with fabric, water and several of each of the above described media.
  • suitable enzymes, detergents and softeners can be added to the tumbling chamber. During tumbling some of the abrasive particles are worn off the coating. After the stone washing process is finished, the fabric, media and abrasive particles are separated from the waste water. The abrasive particles can be recycled into abrasive coating and thus reused.
  • the bodies described above must be made of a material resistant to the solutions created in the tumbling machine.
  • a variety of plastics, such as acrylonitrile/butadiene/styrene (ABS) and polycarbonate are eminently suitable.
  • the above described media can produce the desired softness and preferential fading in fabric via the stone washing process.
  • the media is suitable for use in industrial and family washing machines and experience has shown that it can be used for several hundred washing cycles.
  • the abrasive embodiment of above described media is recyclable.
  • Figure 1 is an exterior view of the first hemisphere of the preferred embodiment of this invention.
  • Figure 2 is a simplified cross section of Figure 1 along the lines 2-2.
  • Figure 3 is an interior view of the first hemisphere of the preferred embodiment of this invention.
  • Figure 4 is an exterior view of the second hemisphere of the preferred embodiment of this invention.
  • Figure 5 is a simplified cross section of Figure 4 along the lines 5-5
  • Figure 6 is an interior view of the second hemisphere of the preferred embodiment of this invention.
  • Figure 7 is a three dimensional view of the spherical body of this invention.
  • Figure 8 is a three dimensional view of the body of Figure 7 coated with an abrasive coating.
  • Figure 9 is a three dimensional view of the body of Figure 8 after it has been through many stone washing cycles.
  • Figures 1 , 2 and 3 illustrate the first hemisphere 10 of this invention.
  • the first hemisphere 10 is concave and fairly thick. Typically the hemisphere 10 has a radius R of about 21 mm and a thickness T of about 7 mm.
  • the spines 14 are cylindrical, project from about 5 to 10 mm above the surface and and are about 3 mm in diameter.
  • An annular ring 26 and two diametrically opposed pins 30 protrude from the mating surface 34.
  • the ring 26 projects about .5 mm and is about 36 mm in diameter.
  • the pins 30 are about 1.5 mm in diameter and project about 3 mm from the mating surface 34.
  • a number of tabs 38 about 3 mm square and 1.5 thick project from the circumference C of the hemisphere at the mating surface 34.
  • a tapered bore 38 of maximum diameter about 3 mm, passes through the entire surface layer 22 of this hemisphere 10 at its apex.
  • FIGS 4, 5 and 6 illustrate the second hemisphere 42 of this invention.
  • the second hemisphere 42 is concave and fairly thick. Typically the hemisphere has a radius R of about 21 mm and a thickness T of about 7 mm.
  • the spines 14 are cylindrical, project from about 5 to 10 mm above the surface and and are about 3 mm in diameter.
  • sockets 46 protrude into the surface layer at the mating surface 34.
  • the sockets 46 are about 1.5 mm in diameter and protrude about 3 mm in from the mating surface 34. These sockets 46 are designed to mate with the pins 30 on the first hemisphere 10.
  • the second hemisphere 42 is identical to the first hemisphere 10 with the exception that there is no ring 26, no tapered bore 38 and the pins 30 are replaced by mating sockets 46.
  • the hemispheres 10, 42 described above are preferably made of plastic by injection molding. Preferred plastics are ABS and polycarbonate.
  • the spines 14 and pockets 18 In order to meet the requirements of the injection molding process, it is preferable for the spines 14 and pockets 18 to be parallel to the central, radial axis A of the body. However, if another fabrication process is used, the spines 14 and pockets 18 can project and protrude at any angle, e.g. they may project and protrude radially.
  • Figure 7 shows a three dimensional view of the primary three embodiments 50, 51 and 52 of this invention.
  • first hemisphere 10 and one second hemisphere 42 are mated together, using the pins 30 and sockets 46 to ensure proper alignment.
  • the hemispheres 10, 42 are permanently joined by any convenient process such as thermal welding, ultrasonic welding and adhesive bonding. Typically, during joining, pressure is applied, which flattens the ring 26 to provide an unbreakable joint.
  • the tapered bore 38 is then plugged by inserting and fastening in place a tapered plug 54. Again the plug 54 may be inserted by welding or bonding.
  • the sphere 50 may be filled with a fluid, such as water or brine, or evacuated.
  • a fluid such as water or brine
  • the purpose of filling is to adjust the weight and thus the density of the sphere 50.
  • unfilled media are designated 50
  • filled media are designated 51
  • evacuated media are designated 52.
  • Figure 8 shows a three dimensional view of the abrasive coated embodiments 50c, 51c and 52c of this invention. Note that the "c" suffix has been added to the reference numerals to denote the relationship between the coated 50c, 51c, 52c and uncoated 50, 51 , 52 media.
  • any one of the spheres 50, 51 , 52 are coated with an abrasive coating 58.
  • the coating 58 preferably contains silicon carbide or aluminum oxide particles and a binder.
  • the binder is a melamine modified, phenolic resin and the coating 58 is air dried.
  • the preferred method of stone washing fabric utilizing the above described embodiments 50, 51 , 52, 50c, 51c, 52c is to charge a suitable tumbling machine with fabric, water and several of each of the above described media 50, 51 , 52, 50c, 51 c, 52c - in other words, several coated media 50c, 51 c of low density, several coated media 51 c of a higher density, several un-coated media 50, 51 of low density and several un-coated media 51 of a higher density.
  • suitable enzymes, detergents and softeners can be added to the tumbling chamber.
  • Typical commercially available tumbling machines can hold 50, 100, 200 and 500 lbs.
  • the ratio of fabric to water ranges from 1 :5 to 1 :10.
  • Each load may typically require 5 coated media 50c, 51c and 15-20 non-coated media 50, 51.
  • the media 50, 51 , 50c, 51c of different densities tend to rotate at different levels in the tumbling machine thus creating more interesting patterns in the fabric.
  • the highest density media 51 , 51 c will rotate at the bottom of the machine while the lowest density media 50, 51 , 50c, 51 c will rotate at the bottom.
  • Figure 9 shows a three dimensional view of an abrasive media 50c, 51c, 52c that has been through a number of stone washing cycles. After the stone washing process is finished, the fabric, media 50, 51 , 50c, 51c and abrasive particles are separated from the waste water. The abrasive particles can be recycled into abrasive coating 58 and thus reused.
  • one or two evacuated media 52, 52care introduced into the tumbling machine as each load of fabric is being stone washed. Under washing action, the evacuated media 52, 52c will crack before the other media 50, 51 , 50c, 51c. Thus, the appearance of cracking in the evacuated media 52, 52c at the end of a washing cycle can be used as a signal to replace all the other media 50, 51 , 50c, 51c in the load.
  • the preferred embodiments 50, 51 , 52, 50c, 51c, 52c of this invention are hollow and circular with spines 14 and pockets 18 that project parallel to the central, radial axis A of the media 50, 51 , 52, 50c, 51c, 52c.
  • the spines 14 and pockets 18 are of circular cross- section.
  • the media 50, 51 , 52, 50c, 51c, 52c could be made solid, of different shapes and with spines 14 and pockets 18 that are not parallel and do not have circular cross-sections.

Abstract

A hollow body (10) has a surface layer (22), a plurality of pockets (18) protruding into a plurality of spines (14) projecting from the surface layer (22). The body (10) may be filled with a material and coated with an abrasive. The body (10) is fabricated by making two concave half-bodies and assembling them to form a complete body (10). The body (10) is used to stone wash fabric by charging a tumbling machine with fabric, water and several of the bodies (10).

Description

Composite Fabric Finishing Media. Method of Fabricating and Method of Using
Technical Field
This invention relates to softening and preferential fading of fabric. More particularly this invention relates to abrasive bodies that are used in washing fabric to produce this softening and preferential fading effect. The process of softening and preferentially fading fabric is commonly known as "stone washing."
Background Art
Stone washed fabrics have been popular for clothing for a number of years. In the typical process, fabric or items of clothing are washed in a special tumbling chamber with a number of abrasive bodies. Softeners and bleach are sometimes also added. After a period of time, the chamber is opened and the fabric separated from the water and abrasive bodies. As a result of this process, the fabric has been preferentially faded and has been softened.
The typical abrasive media that is used for stone washing is "lava rock." This is an irregularly shaped, naturally occurring rock froth. It is produced when lava containing large quantities of gas cools and solidifies to produce a rock full of holes and sometimes trapped gas. Lava is chiefly magnesium silicate. The rock froth is lightweight and sometimes called pumice. As this media is used it becomes smaller and an abrasive powder is produced. Smaller media is less effective in producing the desired effect on the fabric. Furthermore, the abrasive powder is a hazardous waste and must be disposed of in accordance with governing regulations. This adds to the expense of the process. Several inventors have tried to improve on or overcome the shortcomings of the "lava rock" media. US Patent No. 4,750,227 discloses stone washing structures comprising a block of impervious material, such as polypropylene, covered with a layer of resilient synthetic abrasive, such as a non-woven fabric. The fabric may be impregnated with an abrasive such as silicon carbide.
US Patent No.4,954,138 discloses artificial stones made of inorganic filler, abrasive and bonding material. Abrasives used include walnut shells, clay, sand and pearlite.
US Patent No.5,298,027 discloses bleaching jeans by tumbling them with foamed glass-ceramics. An example formulation for such materials includes volcanic ash, silica, clay and silicon carbide, processed and sintered.
US Patents No. 5,326,382 and 5,359,745 disclose methods of making synthetic glass stones from glass and a foaming agent.
US Patent No. 5,538,515 discloses a method of randomly fading fabric including a hammering body which may be made of plastic or metal and has protrusions on its surface.
The problem with all these media is that they produce blotchy fading patterns and a by-product which is not recyclable.
Development of a media which can produce the desired softness and preferential fading in the stone washing process and is recyclable represents a great improvement in the field of fabric finishing and satisfies a long felt need of the fabric finisher. Disclosure of Invention
This invention is a composite fabric finishing media, a method of fabricating the media and a method of using this media. The media has several embodiments which are related to each other. The primary embodiment is a body which has a thick surface layer, a plurality of pockets protruding into this surface layer and a plurality of spines projecting from this surface layer. Preferably the body is spherical however it could be made cubical; elliptical; as a cylinder with a rectangular, square, or circular cross section; or any convenient shape.
Preferably the body is hollow. Then it can be evacuated or filled with a material designed to adjust the density of the body. Bodies that are evacuated or filled with various fluids constitute further embodiments of this invention.
The final embodiment constitutes any one of the bodies described above with an abrasive coating distributed over the plurality of spines and pockets. Preferably, the abrasive coating contains silicon carbide or aluminum oxide.
The preferred method of fabricating the bodies described above is to fabricate two concave half-bodies with pockets and spines and assembling these half-bodies to form a complete body. This creates a hollow body. Preferably, the preferred fabricating method is injection molding. Consequently, each half body is fabricated simultaneously with its pockets and spines. In order to meet the requirements of the injection molding process, it is preferable for the spines and pockets to be parallel to the central, radial axis of the body.
The preferred method of stone washing fabric utilizing the above described embodiments is to charge a suitable tumbling machine with fabric, water and several of each of the above described media. In other words, several coated media of one density, several coated media of another density, several un-coated media of one density and several un-coated media of another density. If desired, suitable enzymes, detergents and softeners can be added to the tumbling chamber. During tumbling some of the abrasive particles are worn off the coating. After the stone washing process is finished, the fabric, media and abrasive particles are separated from the waste water. The abrasive particles can be recycled into abrasive coating and thus reused.
The bodies described above must be made of a material resistant to the solutions created in the tumbling machine. A variety of plastics, such as acrylonitrile/butadiene/styrene (ABS) and polycarbonate are eminently suitable.
It will be appreciated that the above described media can produce the desired softness and preferential fading in fabric via the stone washing process. The media is suitable for use in industrial and family washing machines and experience has shown that it can be used for several hundred washing cycles. At the same time, the abrasive embodiment of above described media is recyclable.
An appreciation of the other aims and objectives of the present invention and a more complete and comprehensive understanding of it may be achieved by referring to the accompanying drawings and studying the following description of the best mode of carrying out the invention.
Brief Description of Drawings
Figure 1 is an exterior view of the first hemisphere of the preferred embodiment of this invention. Figure 2 is a simplified cross section of Figure 1 along the lines 2-2.
Figure 3 is an interior view of the first hemisphere of the preferred embodiment of this invention.
Figure 4 is an exterior view of the second hemisphere of the preferred embodiment of this invention.
Figure 5 is a simplified cross section of Figure 4 along the lines 5-5
Figure 6 is an interior view of the second hemisphere of the preferred embodiment of this invention.
Figure 7 is a three dimensional view of the spherical body of this invention.
Figure 8 is a three dimensional view of the body of Figure 7 coated with an abrasive coating.
Figure 9 is a three dimensional view of the body of Figure 8 after it has been through many stone washing cycles.
Best Mode for Carrying Out Invention
Figures 1 , 2 and 3 illustrate the first hemisphere 10 of this invention. The first hemisphere 10 is concave and fairly thick. Typically the hemisphere 10 has a radius R of about 21 mm and a thickness T of about 7 mm. On its outer surface 12 there are a number of spine-like projections 14. The spines 14 are cylindrical, project from about 5 to 10 mm above the surface and and are about 3 mm in diameter. A number of cylindrical pockets 18, of about 3 mm diameter and 5 mm depth, protrude into the surface layer 22. An annular ring 26 and two diametrically opposed pins 30 protrude from the mating surface 34. The ring 26 projects about .5 mm and is about 36 mm in diameter. The pins 30 are about 1.5 mm in diameter and project about 3 mm from the mating surface 34.
A number of tabs 38, about 3 mm square and 1.5 thick project from the circumference C of the hemisphere at the mating surface 34. A tapered bore 38, of maximum diameter about 3 mm, passes through the entire surface layer 22 of this hemisphere 10 at its apex.
Figures 4, 5 and 6 illustrate the second hemisphere 42 of this invention. The second hemisphere 42 is concave and fairly thick. Typically the hemisphere has a radius R of about 21 mm and a thickness T of about 7 mm. On its outer surface 12 there are a number of spine-like projections 14. The spines 14 are cylindrical, project from about 5 to 10 mm above the surface and and are about 3 mm in diameter. A number of cylindrical pockets 18, of about 3 mm diameter and 5 mm depth, protrude into the surface layer 22.
Two diametrically opposed sockets 46 protrude into the surface layer at the mating surface 34. The sockets 46 are about 1.5 mm in diameter and protrude about 3 mm in from the mating surface 34. These sockets 46 are designed to mate with the pins 30 on the first hemisphere 10.
A number of tabs 38, about 3 mm square and 1.5 thick project from the circumference C of the hemisphere 42 at the mating surface 34. In other words, the second hemisphere 42 is identical to the first hemisphere 10 with the exception that there is no ring 26, no tapered bore 38 and the pins 30 are replaced by mating sockets 46. The hemispheres 10, 42 described above are preferably made of plastic by injection molding. Preferred plastics are ABS and polycarbonate. In order to meet the requirements of the injection molding process, it is preferable for the spines 14 and pockets 18 to be parallel to the central, radial axis A of the body. However, if another fabrication process is used, the spines 14 and pockets 18 can project and protrude at any angle, e.g. they may project and protrude radially.
Figure 7 shows a three dimensional view of the primary three embodiments 50, 51 and 52 of this invention. To make these embodiment 50, 51 , 52 one first hemisphere 10 and one second hemisphere 42 are mated together, using the pins 30 and sockets 46 to ensure proper alignment. The hemispheres 10, 42 are permanently joined by any convenient process such as thermal welding, ultrasonic welding and adhesive bonding. Typically, during joining, pressure is applied, which flattens the ring 26 to provide an unbreakable joint.
The tapered bore 38 is then plugged by inserting and fastening in place a tapered plug 54. Again the plug 54 may be inserted by welding or bonding.
If desired, before the plug 54 is inserted, the sphere 50 may be filled with a fluid, such as water or brine, or evacuated. The purpose of filling is to adjust the weight and thus the density of the sphere 50. For purposes of this application, unfilled media are designated 50, filled media are designated 51 and evacuated media are designated 52.
Figure 8 shows a three dimensional view of the abrasive coated embodiments 50c, 51c and 52c of this invention. Note that the "c" suffix has been added to the reference numerals to denote the relationship between the coated 50c, 51c, 52c and uncoated 50, 51 , 52 media. To make these embodiments 50c, 51c, 52c, any one of the spheres 50, 51 , 52 are coated with an abrasive coating 58. The coating 58 preferably contains silicon carbide or aluminum oxide particles and a binder. Preferably, the binder is a melamine modified, phenolic resin and the coating 58 is air dried.
The preferred method of stone washing fabric utilizing the above described embodiments 50, 51 , 52, 50c, 51c, 52c, is to charge a suitable tumbling machine with fabric, water and several of each of the above described media 50, 51 , 52, 50c, 51 c, 52c - in other words, several coated media 50c, 51 c of low density, several coated media 51 c of a higher density, several un-coated media 50, 51 of low density and several un-coated media 51 of a higher density. If desired, suitable enzymes, detergents and softeners can be added to the tumbling chamber. Typical commercially available tumbling machines can hold 50, 100, 200 and 500 lbs. The ratio of fabric to water ranges from 1 :5 to 1 :10. Each load may typically require 5 coated media 50c, 51c and 15-20 non-coated media 50, 51. The media 50, 51 , 50c, 51c of different densities tend to rotate at different levels in the tumbling machine thus creating more interesting patterns in the fabric. In other words, the highest density media 51 , 51 c will rotate at the bottom of the machine while the lowest density media 50, 51 , 50c, 51 c will rotate at the bottom.
During tumbling some of the abrasive particles are worn off the coating 58. Figure 9 shows a three dimensional view of an abrasive media 50c, 51c, 52c that has been through a number of stone washing cycles. After the stone washing process is finished, the fabric, media 50, 51 , 50c, 51c and abrasive particles are separated from the waste water. The abrasive particles can be recycled into abrasive coating 58 and thus reused.
For testing purposes, one or two evacuated media 52, 52care introduced into the tumbling machine as each load of fabric is being stone washed. Under washing action, the evacuated media 52, 52c will crack before the other media 50, 51 , 50c, 51c. Thus, the appearance of cracking in the evacuated media 52, 52c at the end of a washing cycle can be used as a signal to replace all the other media 50, 51 , 50c, 51c in the load.
The preferred embodiments 50, 51 , 52, 50c, 51c, 52c of this invention are hollow and circular with spines 14 and pockets 18 that project parallel to the central, radial axis A of the media 50, 51 , 52, 50c, 51c, 52c. Preferably, also, the spines 14 and pockets 18 are of circular cross- section. However, it will be obvious to those familiar with the art to which this invention pertains that the media 50, 51 , 52, 50c, 51c, 52c could be made solid, of different shapes and with spines 14 and pockets 18 that are not parallel and do not have circular cross-sections.
A composite fabric finishing media, a method of fabricating this media and a method of using it has been described with reference to particular embodiments 50, 51 , 52, 50c, 51 c, 52c. However, it should be obvious to those skilled in the art to which this invention pertains that other modifications and enhancements can be made without departing from the spirit and scope of the claims that follow.

Claims

Claims
1. A composite fabric finishing media comprising: a body means for providing a substrate; said body means having a thick surface layer and a plurality of pockets protruding into said surface layer; and b a plurality of spine means projecting from said surface layer for retaining a coating.
2. A composite fabric finishing media as claimed in claim 1 in which said body means is hollow.
3. A composite fabric finishing media as claimed in claim 2 in which said body means is filled with a material designed to adjust the density of said body means.
4. A composite fabric finishing media as claimed in claim 2 in which said body means is evacuated.
5. A composite fabric finishing media as claimed in claim 1 , 2, 3 or 4 further comprising a coating means distributed over said plurality of spine means and plurality of pockets for abrading said fabric.
6. A composite fabric finishing media as claimed in claim 5 in which said abrasive coating means contains an abrasive selected from the group consisting of silicon carbide and aluminum oxide.
7. A composite fabric finishing media as claimed in claim 1 , 2, 3 or 4 in which said body means is spherical.
8. A composite fabric finishing media comprising: a a body having a thick surface layer and a plurality of pockets protruding into said surface layer; and b a plurality of spines projecting from said surface layer.
9. A composite fabric finishing media as claimed in claim 8 in which said body is hollow.
10. A composite fabric finishing media as claimed in claim 9 in which said body is filled with a material designed to adjust the density of said body.
11. A composite fabric finishing media as claimed in claim 9 in which said body is evacuated.
12. A composite fabric finishing media as claimed in claim 8, 9, 10 or 11 further comprising an abrasive coating distributed over said plurality of spines and plurality of pockets.
13. A composite fabric finishing media as claimed in claim 12 in which said abrasive coating contains an abrasive selected from the group consisting of silicon carbide and aluminum oxide.
14. A composite fabric finishing media as claimed in claim 8, 9, 10, or 11 in which said body is spherical.
15. A method of fabricating a composite fabric finishing media comprising the steps of: a fabricating a body having a thick surface layer; b fabricating a plurality of pockets protruding into said surface layer; and c fabricating a plurality of spines projecting from said surface layer.
16. A method of fabricating a composite fabric finishing media as claimed in claim 15 in which said steps are accomplished by fabricating two concave half-bodies with said pockets and spines and assembling said half-bodies to form said body, whereby said body is hollow.
17. A method of fabricating a composite fabric finishing media as claimed in claim 16 in which each half-body is fabricated simultaneously with its pockets and spines.
18. A method of fabricating a composite fabric finishing media as claimed in claim 16 further comprising the step of filling said body with a material designed to adjust the density of said body.
19. A composite fabric finishing media as claimed in claim 16 in which said body is evacuated.
20. A method of fabricating a composite fabric finishing media as claimed in claim 15, 16, 17, 18 or 19 further comprising the steps of: a providing an abrasive filled coating; b distributing said coating over said plurality of spines and plurality of pockets; and c curing said coating.
1. A method of stone washing fabric comprising the steps of: a providing a first body having a thick surface layer, a plurality of pockets protruding into said surface layer and a plurality of spines projecting from said surface layer; b providing a second body having a thick surface layer, a plurality of pockets protruding into said surface layer and a plurality of spines projecting from said surface layer; said second body having a density different from that of said first body; c providing a third body having a thick surface layer, a plurality of pockets protruding into said surface layer and a plurality of spines projecting from said surface layer; said third body being hollow; said hollow being evacuated; d providing a first abrasive body having a thick surface layer, a plurality of pockets protruding into said surface layer, a plurality of spines projecting from said surface layer and an abrasive filled coating distributed over said plurality of spines and plurality of pockets; e providing a second abrasive body having a thick surface layer, a plurality of pockets protruding into said surface layer, a plurality of spines projecting from said surface layer and an abrasive filled coating distributed over said plurality of spines and plurality of pockets; said second abrasive body having a density different from that of said first abrasive body; f providing a third abrasive body having a thick surface layer, a plurality of pockets protruding into said surface layer and a plurality of spines projecting from said surface layer; said third abrasive body being hollow; said hollow being evacuated; g charging a tumbling chamber with said fabric, water, at least one first body, at least one second body, at least one third body at least one first abrasive body, at least one second abrasive body and at least one third abrasive body; h tumbling the fabric and said bodies in said chamber so as to produce a desired stone washing effect; i separating the waste water from the fabric and said bodies; and j separating said abrasive from the waste water for reuse.
22. A method of stone washing fabric as claimed in claim 21 further comprising the step of adding enzyme, detergent and softener to said tumbling chamber.
23. A method of stone washing fabric as claimed in claim 21 or 22 further comprising the step of fabricating said bodies of a material resistant to the solution created.
PCT/US1999/002048 1999-01-27 1999-01-27 Composite fabric finishing media, method of fabricating and method of using WO2000044529A1 (en)

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AU23513/99A AU2351399A (en) 1999-01-27 1999-01-27 Composite fabric finishing media, method of fabricating and method of using
PCT/US1999/002048 WO2000044529A1 (en) 1999-01-27 1999-01-27 Composite fabric finishing media, method of fabricating and method of using

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PCT/US1999/002048 WO2000044529A1 (en) 1999-01-27 1999-01-27 Composite fabric finishing media, method of fabricating and method of using

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110497308A (en) * 2018-05-16 2019-11-26 吉林博仁科技有限责任公司 A kind of light decorations abrasive material of sensor connector

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US591225A (en) * 1897-10-05 Tumbling-star
US2947124A (en) * 1959-09-08 1960-08-02 Bendix Aviat Corp Process for tumble finishing
US2978850A (en) * 1958-05-01 1961-04-11 Dixon Sintaloy Inc Tumble finishing process
US4750227A (en) * 1986-10-28 1988-06-14 Dexter Chemical Corporation Abrasive structures and methods for abrading fabrics
US4954138A (en) * 1988-11-07 1990-09-04 Norton Company Stone to finish stone washed jeans
US5298027A (en) * 1987-03-13 1994-03-29 Inax Corporation Methods of bleaching jeans
US5326382A (en) * 1992-05-27 1994-07-05 Oat Henry C Synthetic abrasive stones and method for making same
US5538515A (en) * 1994-03-22 1996-07-23 Sentani Trading Ltd. Method for making a randomly faded fabric
US5653625A (en) * 1996-06-04 1997-08-05 Pierce; John Star shot wave tumbler systems

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US591225A (en) * 1897-10-05 Tumbling-star
US2978850A (en) * 1958-05-01 1961-04-11 Dixon Sintaloy Inc Tumble finishing process
US2947124A (en) * 1959-09-08 1960-08-02 Bendix Aviat Corp Process for tumble finishing
US4750227A (en) * 1986-10-28 1988-06-14 Dexter Chemical Corporation Abrasive structures and methods for abrading fabrics
US5298027A (en) * 1987-03-13 1994-03-29 Inax Corporation Methods of bleaching jeans
US4954138A (en) * 1988-11-07 1990-09-04 Norton Company Stone to finish stone washed jeans
US5326382A (en) * 1992-05-27 1994-07-05 Oat Henry C Synthetic abrasive stones and method for making same
US5359745A (en) * 1992-05-27 1994-11-01 Oat Henry C Method of stone washing fabric with a synthetic abrasive stone
US5538515A (en) * 1994-03-22 1996-07-23 Sentani Trading Ltd. Method for making a randomly faded fabric
US5653625A (en) * 1996-06-04 1997-08-05 Pierce; John Star shot wave tumbler systems

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110497308A (en) * 2018-05-16 2019-11-26 吉林博仁科技有限责任公司 A kind of light decorations abrasive material of sensor connector

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