Method for manufacturing a garment having a rigid front portion and a stretchable back portion

Abstract

A method for making jeans. A material is weaved for use as a front portion of the jeans. The warp portion of the weave is spun with a combination of open-end and ring spinning. The weft portion of the weave is spun with open-end spinning. The resulting weaved material is then sulfur dyed, singed and pre-shrunk to form the front portion. Another material is weaved for use as a back portion of the jeans using a fabric composition which is 79% cotton, 20% filament fiber polyester, 1% spandex. The warp portion of the weave is spun using a combination of open-end and ring spinning. The weft portion of the weave is made from the filament fiber polyester. The resulting fabric composition weaved material is then indigo dyed and singed and then pre-shrunk to form the back portion. The two portions are cut and sewed together to produce the jeans.

Description

BACKGROUND OF THE INVENTION[0001]Denim is a sturdy cotton warp-faced twill textile in which the weft passes under two or more warp threads. This twill weaving produces the familiar diagonal ribbing of the denim that distinguishes it from cotton duck.[0002]It is a characteristic of most indigo denim that only the warp threads are dyed, whereas the weft threads remain plain white. As a result of the warp-faced twill weaving, one side of the textile then shows the blue warp threads and the other side shows the white weft threads. This is why blue jeans are white on the inside. The indigo dyeing process, in which the core of the warp threads remains white, creates denim's fading characteristics, which are unique compared to other textiles.[0003]After being made into an article of clothing, as part of the manufacturing process, most denim articles are washed to make them softer and to reduce or eliminate shrinkage (which could cause the article to not fit properly after its owner washes ...

AI Technical Summary

Benefits of technology

[0007]In order to address the problem in the prior art, a specific blend of fibers and different size yarns is needed to overcome this problem, that is, jeans need to be manufactured using a using a rigid fabric front and a stretch fabric back while maintaining the same character and shrinkage factors for both. In this connection, according to the invention, a rigid fabric using 100% cotton yarn for the front is used to match the fabric used for the back of the jeans while maintaining the same character and shrinkage factors. The 100% cotton yarn is blended with a filament fiber polyester and a small amount of spandex all in the same size yarn to keep the shrinkage consistent between the front and the back. In this manner the front of the jeans can be stressed to provide a worn look while the back of the jeans made of the stretch material produces a tight, but comfortable fit without any puckering at the seams where the two materials are sewn together.

Problems solved by technology

In addition to being washed, “washed denim” is sometimes artificially distressed to produce a “worn” look.

However, the stretch yarn used does not destruct and provide the desired vintage, worn in look.

As a result, it has not been possible to produce jeans which paired the characteristics of being able to produce the worn look with a stretch, tight fitting jean.

Although combining a rigid jean material with a stretch jean material is not in and of itself a problem, manufacturers have determined that it is not possible to make such a combined product due to the different shrinkage factors of the two fabrics when combined in one garment.

The different shrinkage percentages results in puckering of the sides where the two different materials are attached which is not an acceptable result.