Method of manufacturing eco-friendly jeans clothing using waste fabric

Abstract

The present invention relates to a method for manufacturing eco-friendly jeans using waste fabric, comprising: a recycled yarn manufacturing step for manufacturing recycled yarn using waste denim fabric; a recycled yarn dyeing step for dyeing the recycled yarn manufactured through the recycled yarn manufacturing step; a fabric manufacturing step for manufacturing a fabric using the recycled yarn dyed through the recycled yarn dyeing step; a fabric processing step for manufacturing a jeans product by processing the fabric manufactured through the fabric manufacturing step; a product washing step for washing the jeans product manufactured through the fabric processing step; a product coating step for coating the jeans product that has undergone the product washing step using a coating agent; and a product finishing step for completing a final jeans product by post-processing the jeans product coated through the product coating step.

Description

Technology Field

[0001] The present invention relates to a method for manufacturing eco-friendly jeans using waste fabric, and more specifically, to a method for manufacturing eco-friendly jeans using waste fabric that can prevent resource waste and produce jeans made of eco-friendly materials by using recycled fabric manufactured from waste denim fabric. Background Technology

[0002] The clothing industry produces products using various fabrics and materials; in particular, denim is widely used in clothing items such as jeans due to its durability and unique colors. However, the amount of waste fabric generated during the production and consumption of denim products is continuously increasing, intensifying environmental pollution issues and the difficulties in waste disposal.

[0003] Waste denim fabric is typically disposed of by incineration or landfill, but these methods not only result in a waste of resources but also cause environmental problems such as air and soil pollution. In particular, the manufacturing process of denim fabric uses large amounts of water and chemicals, and residual chemicals released during disposal can have a negative impact on the environment.

[0004] Recently, efforts have been made to manufacture new products by recycling waste denim fabric. For instance, technologies are being developed to process waste fabric into fibers, which are then produced into recycled yarn or fabric to manufacture items such as clothing and bags. While these technologies are garnering attention for their contribution to resource circulation and environmental protection, recycled fibers often suffer from quality degradation issues. In particular, there are limitations where the strength of the yarn decreases during the fiberization process, resulting in product durability and quality that are inferior to those of conventional fabrics. Furthermore, existing recycling technologies face difficulties in producing high-quality, eco-friendly products due to insufficient variety in color and texture, as well as a lack of improvements in functionality. Prior art literature

[0005] Republic of Korea Registered Patent No. 10-2105818 The problem to be solved

[0006] The objective of the present invention is to solve the aforementioned conventional problems by providing a method for manufacturing eco-friendly jeans using waste fabric, which prevents resource waste by using recycled fabric manufactured from waste denim fabric and enables the production of jeans made of an eco-friendly material. means of solving the problem

[0007] The above objective is achieved by a method for manufacturing eco-friendly jeans using waste fabric according to the present invention, comprising: a recycled yarn manufacturing step for manufacturing recycled yarn using waste denim fabric; a recycled yarn dyeing step for dyeing the recycled yarn manufactured through the recycled yarn manufacturing step; a fabric manufacturing step for manufacturing a fabric using the recycled yarn dyed through the recycled yarn dyeing step; a fabric processing step for manufacturing jeans products by processing the fabric manufactured through the fabric manufacturing step; a product washing step for washing the jeans products manufactured through the fabric processing step; a product coating step for coating the jeans products that have undergone the product washing step using a coating agent; and a product finishing step for completing the final jeans products by post-processing the jeans products coated through the product coating step.

[0008] In addition, the above-mentioned recycled yarn manufacturing step is to manufacture the recycled yarn by spinning a fiber mixture in which waste denim fibers extracted from the waste denim fabric, cotton fibers, polyester fibers, and plant fibers are mixed, wherein the plant fibers may include banaba fibers and green tea fibers.

[0009] In addition, the above-mentioned recycled yarn manufacturing step can be produced by spinning a fiber mixture comprising 50 to 60 parts by weight of cotton fiber, 40 to 50 parts by weight of polyester fiber, 10 to 20 parts by weight of banaba fiber, and 10 to 20 parts by weight of green tea fiber, based on 100 parts by weight of waste denim fiber.

[0010] In addition, the above product washing step can perform ozone washing treatment on the jeans product manufactured through the above fabric processing step.

[0011] In addition, the product washing step may perform ozone washing treatment on the jeans product manufactured through the fabric processing step. Furthermore, the product coating step may coat the jeans product using a polyurethane coating agent containing polyol, isocyanate, silicone powder, and natural oil components, wherein the natural oil may include rosemary essential oil and almond oil. Effects of the invention

[0012] According to the present invention, by using recycled fabric produced by utilizing waste denim fabric, waste of resources can be prevented, and there is an effect of being able to manufacture jeans made of environmentally friendly material.

[0013] In addition, by manufacturing recycled yarn by mixing plant fibers, it is possible to produce recycled yarn with improved quality and functionality, such as durability, texture, and moisture absorption.

[0014] In addition, applying an eco-friendly washing process has the effect of minimizing environmental pollution caused by washing.

[0015] Meanwhile, the effects of the present invention are not limited to those mentioned above, and various effects may be included within the scope obvious to a person skilled in the art from the contents described below. Brief explanation of the drawing

[0016] FIG. 1 is a flowchart of a method for manufacturing eco-friendly jeans using waste fabric according to one embodiment of the present invention. Specific details for implementing the invention

[0017] Hereinafter, some embodiments of the present invention will be described in detail with reference to the exemplary drawings. It should be noted that in assigning reference numerals to the components of each drawing, the same components are given the same reference numeral whenever possible, even if they are shown in different drawings.

[0018] In addition, when describing embodiments of the present invention, if it is determined that a detailed description of related known configurations or functions would hinder understanding of the embodiments of the present invention, such detailed description is omitted.

[0019] In addition, terms such as first, second, A, B, (a), (b), etc., may be used when describing the components of the embodiments of the present invention. These terms are used merely to distinguish the components from other components, and the essence, order, or sequence of the components is not limited by these terms.

[0021] Now, with reference to the attached drawings, a method (S100) for manufacturing eco-friendly jeans using waste fabric according to one embodiment of the present invention will be described in detail.

[0022] FIG. 1 is a flowchart (S100) of a method for manufacturing eco-friendly jeans using waste fabric according to one embodiment of the present invention.

[0023] As illustrated in FIG. 1, an eco-friendly denim garment manufacturing method using waste fabric according to one embodiment of the present invention (hereinafter, manufacturing method) (S100) may include a recycled yarn manufacturing step (S110), a recycled yarn dyeing step (S120), a fabric manufacturing step (S130), a fabric processing step (S140), a product washing step (S150), a product coating step (S160), and / or a product finishing step (S170).

[0024] First, the recycled yarn manufacturing step (S110) is a step of manufacturing recycled yarn using waste fabric.

[0025] In the recycled yarn manufacturing stage (S110), recycled yarn is produced by recycling waste fabric to manufacture new fabric. In other words, recycled yarn refers to yarn made by recycling waste fabric. Here, the waste fabric used to manufacture recycled yarn may be waste denim fabric, and the recycled yarn produced using it may be recycled denim yarn. Denim fabric is a sturdy and highly durable fabric, primarily used in the manufacture of clothing such as jeans.

[0026] In the recycled yarn manufacturing stage (S110), a series of processes may be carried out, including a pretreatment step of washing the collected waste fabric, a step of crushing the pretreated waste fabric to produce fiber cotton, and spinning the produced fiber cotton to produce recycled yarn.

[0027] Meanwhile, while manufacturing recycled yarn by recycling waste denim fabric offers the advantage of reducing environmental pollution and preventing resource waste through waste recycling, it may lead to a decline in strength and quality due to fiber damage during the fiberization process. To address this issue, recycled yarn can be manufactured by spinning a fiber mixture containing additional fibers alongside waste denim fibers; the specific details are as follows.

[0028] The fibers used in the manufacture of recycled yarn can primarily include waste denim fibers, cotton fibers, and polyester fibers. Waste denim fibers serve as the primary raw material for recycled yarn, providing basic structure and durability while preserving the unique texture of denim. Cotton fibers enhance fiber strength and softness to improve the quality of the recycled yarn, and their excellent moisture absorption can improve wearing comfort. Polyester fibers reinforce strength and elasticity, complementing the fiber's durability and flexibility.

[0029] In the regenerated yarn manufacturing step (S110) of the present invention, in addition to the basic fibers mentioned above, plant fibers such as Banaba fiber and Green Tea fiber may be additionally included during the regenerated yarn manufacturing process. Banaba fiber is a natural plant fiber composed mainly of plant cellulose extracted from Banaba leaves, and is characterized by relatively long fiber length, high strength, lightness, and good breathability. Green Tea fiber is a plant fiber manufactured using residues extracted from green tea leaves, and can provide antibacterial and deodorizing effects, as well as a soft texture.

[0030] Specifically, recycled yarn can be manufactured by spinning a fiber mixture comprising 50 to 60 parts by weight of cotton fiber, 40 to 50 parts by weight of polyester fiber, 10 to 20 parts by weight of banaba fiber, and 10 to 20 parts by weight of green tea fiber, based on 100 parts by weight of waste denim fiber.

[0031] Meanwhile, the fiber mixture mixed in the above mixing ratio may additionally include morning glory fibers and coffee grounds fibers to improve the color and texture of the recycled yarn.

[0032] Morning glory fiber is manufactured by extracting fibers from morning glory flowers. Its excellent breathability and moisture absorption improve wearing comfort, while its resistance to friction and abrasion enhances durability. In particular, morning glory fiber offers beige, light green, and light brown tones, enabling the realization of natural colors. Morning glory fiber can be produced by soaking morning glory stems in water to soften them, then separating the fibers by scraping or compressing the softened stems. Coffee grounds fiber is manufactured by processing coffee grounds into fine particles and mixing them with polyester. It features deodorizing effects, excellent moisture absorption, and quick-drying properties that facilitate sweat wicking and drying. Furthermore, when blended with polyester, it is characterized by superior durability and elasticity. Additionally, coffee grounds fiber offers a cooling effect and UV protection, and notably, it can produce natural brown tones. By adding these morning glory fibers and coffee grounds fibers to the above fiber mixture, not only can the functionality of the recycled yarn be improved, but the unique color of the recycled yarn can also be enhanced.

[0033] Specifically, based on 100 parts by weight of the fiber mixture, 3 to 5 parts by weight of morning glory fiber and 5 to 7 parts by weight of coffee grounds fiber may be added.

[0034] According to the above-described recycled yarn manufacturing step (S110), eco-friendly recycled yarn can be manufactured by recycling waste denim fabric, and through the addition of plant fibers, it is possible to manufacture recycled yarn with enhanced color as well as improved functionality such as durability and comfort.

[0035] Next, the regenerated yarn dyeing step (S120) is a step of dyeing the regenerated yarn produced through the regenerated yarn manufacturing step (S110).

[0036] The recycled yarn dyeing step (S120) is a step in which the recycled yarn produced through the recycled yarn manufacturing step (S110) is dyed using a dye. The recycled yarn produced through the recycled yarn manufacturing step (S110) can be washed and then immersed in a dye solution to be dyed. At this time, the dye may be a natural indigo dye, and accordingly, the recycled yarn can be dyed blue, which is suitable for manufacturing jeans. Conventional known methods may be applied without limitation to the recycled yarn dyeing step (S120).

[0037] Next, the fabric manufacturing step (S130) is a step of manufacturing a fabric using the recycled yarn dyed through the recycled yarn dyeing step (S120).

[0038] In the fabric manufacturing stage (S130), the fabric can be manufactured by weaving the dyed recycled yarn as the warp and weft through a loom, and twill weaving can be performed for the weaving of denim.

[0039] Specifically, the warp threads are threads arranged vertically on a loom to form the main color of the fabric, and the weft threads are threads that cross the warp threads horizontally and play an auxiliary role to the warp threads. Here, recycled yarn dyed with indigo dye through a recycled yarn dyeing step (S120) may be used for the warp threads, and recycled yarn not dyed with indigo dye may be used for the weft threads. In this case, the warp threads may be configured to utilize recycled yarn dyed with a dye made from a fiber mixture that does not contain morning glory fibers and coffee grounds fibers, and the weft threads may be configured to utilize recycled yarn made from a fiber mixture that contains morning glory fibers and coffee grounds fibers but is not dyed with a dye, thereby enabling a unique color contrast effect to be achieved in the fabric.

[0040] Next, the fabric processing step (S140) is a step of manufacturing jeans products by processing the fabric produced through the fabric manufacturing step (S130).

[0041] In the fabric processing step (S140), the fabric is cut to separate the fabric into parts such as the front panel, back panel, waistband, and pockets, and a series of processing steps are performed, such as combining them and sewing them into a jeans shape, to create a jeans-shaped product.

[0042] Next, the product washing step (S150) is a step of washing the jeans product manufactured through the fabric processing step (S140).

[0043] Washing refers to the process of treating textiles or clothing products using physical, chemical, or biological methods to improve color, texture, and comfort. It is an essential process for enhancing the design completeness of clothing, providing a soft feel, and giving it a unique appearance. Washing methods include stone washing (physical washing using natural stones), acid washing and bleaching washing (using chemicals), and biological washing (using enzymes); however, these methods present issues such as environmental burdens resulting from the use of water and chemicals.

[0044] Recognizing these problems, eco-friendly washing methods such as laser washing and ozone washing have been developed. In the product washing step (S150) of the present invention, the manufactured jeans product is treated with ozone washing to prevent environmental pollution. In ozone washing, the jeans product is placed in a rotary washing drum or a stationary chamber, and ozone gas is injected. The ozone oxidizes the dye to lighten the color and produce a natural bleaching effect. After washing, the ozone is converted back into oxygen, making it harmless to the environment. The oxidation intensity can be controlled by appropriately controlling the concentration and time of the ozone, and the washing is completed through neutralization treatment, rinsing, drying, etc.

[0045] According to the product washing step (S150) described above, the color and texture of the jeans product can be improved, and the environmental impact can be minimized.

[0046] Meanwhile, products that have undergone a washing step may experience a problem where the durability of the fabric is reduced due to the oxidation process of ozone washing. In particular, in the case of fabrics recycled using recycled yarn derived from waste fabrics as in the present invention, a significant reduction in durability may occur. Therefore, to solve this problem, the manufacturing method (S100) according to one embodiment of the present invention may additionally include a product coating step (S160).

[0047] The product coating step (S160) is a step of coating the jeans product using a coating agent. More specifically, the product coating step (S160) may include a pre-coating step and a post-coating step. Basically, the product coating step (S160) refers to a post-coating step performed after the product washing step (S150), and if necessary, a pre-coating step may be additionally performed to manufacture a higher quality jeans product. The product coating step (S160) may be performed by immersing the jeans product in the coating agent.

[0048] The pre-coating step is a step in which the jeans product is coated using the first coating agent prior to the product washing step (S150). In the pre-coating step, a coating is applied to protect the fibers from damage during the ozone washing process and to strengthen the fibers.

[0049] The first coating agent used in the pre-coating step may be a polyurethane coating agent. Polyurethane coating agents are composed of polyurethane produced by the chemical reaction of polyols and isocyanates, and due to their excellent durability and flexibility, they can be used for coating textile products such as jeans.

[0050] Specifically, the first coating agent is preferably composed of 40 to 50 parts by weight of isocyanate and 20 to 30 parts by weight of solvent per 100 parts by weight of polyol. Meanwhile, if the coating of the first coating agent is excessive, contact between the fiber and ozone is blocked, which may limit the effect of ozone washing; therefore, it is desirable to increase the proportion of the solvent to control the concentration and to apply a thin coating, for example, the coating may be formed with a thickness of 1 to 5 μm. In this case, the solvent may be acetone, methyl ethyl ketone (MEK), toluene, or N-methyl-2-pyrrolidone.

[0051] According to the aforementioned pre-coating step, the pre-coating forms a protective film on the surface of the fiber, thereby minimizing fiber damage that may occur during ozone washing.

[0052] The post-coating step is a step of coating a denim product that has undergone the product washing step (S150) using a second coating agent. In the post-coating step, a coating is performed to further improve the functionality of the fibers, such as restoring fibers damaged after ozone washing and improving the touch.

[0053] The second coating agent used in the post-coating step may be a polyurethane coating agent containing natural oil components. The second coating agent is basically a polyurethane coating agent with polyol and isocyanate as main components, similar to the first coating agent, but may additionally include silicone powder, rosemary essential oil, and almond oil. Silicone powder can enhance water resistance and stain resistance, rosemary essential oil can provide antioxidant and antibacterial effects, and almond oil can improve texture and wearability by providing a soft touch and gloss.

[0054] It is desirable that the second coating agent lowers the ratio of isocyanate content compared to the first coating agent to prevent a decrease in the flexibility of the fiber due to high rigidity, and increases the coating effect by lowering the content of the solvent to increase the concentration. Specifically, the second coating agent is preferably composed of 30 to 40 parts by weight of isocyanate, 10 to 20 parts by weight of solvent, 5 to 10 parts by weight of silicone powder, 3 to 5 parts by weight of rosemary essential oil, and 5 to 10 parts by weight of almond oil, based on 100 parts by weight of polyol.

[0055] According to the aforementioned post-coating step, it is possible to improve the quality of jeans products by restoring fibers weakened after morning washing to strengthen durability, and by providing water repellency, stain resistance, improved fiber texture, and antioxidant and antibacterial effects.

[0056] Next, the product completion stage (S170) is a stage in which the coated jeans product is post-processed to complete the final jeans product.

[0057] In the product completion stage (S170), post-processing steps such as heat treatment and drying to stabilize the coated jeans product obtained through the product coating stage (S160), washing, labeling, and packaging are performed to complete the final jeans product.

[0058] According to a manufacturing method (S100) according to an embodiment of the present invention comprising the above-described recycled yarn manufacturing step (S110), recycled yarn dyeing step (S120), fabric manufacturing step (S130), fabric processing step (S140), product washing step (S150), product coating step (S160) and / or product finishing step (S170), by using recycled fabric manufactured using waste denim fabric, waste of resources can be prevented and the effect of manufacturing jeans clothing made of environmentally friendly material is achieved.

[0059] In addition, by manufacturing recycled yarn by mixing plant fibers, it is possible to produce recycled yarn with improved quality and functionality, such as durability, texture, and moisture absorption.

[0060] In addition, applying an eco-friendly washing process has the effect of minimizing environmental pollution caused by washing.

[0062] Although all components constituting an embodiment of the present invention have been described above as being combined or operating in combination, the present invention is not necessarily limited to such an embodiment. That is, within the scope of the purpose of the present invention, all components may be selectively combined in one or more ways to operate.

[0063] Furthermore, terms such as “include,” “compose,” or “have,” as described above, mean that the relevant component may be inherent unless specifically stated otherwise; therefore, they should be interpreted as allowing for the inclusion of additional components rather than excluding them. All terms, including technical or scientific terms, have the same meaning as generally understood by those skilled in the art to which the present invention pertains, unless otherwise defined. Commonly used terms, such as those defined in advance, should be interpreted in accordance with their meaning in the context of the relevant technology and, unless explicitly defined in the present invention, should not be interpreted in an ideal or overly formal sense.

[0064] Furthermore, the above description is merely an illustrative explanation of the technical concept of the present invention, and those skilled in the art to which the present invention pertains will be able to make various modifications and variations within the scope of the essential characteristics of the present invention.

[0065] Accordingly, the embodiments disclosed in this invention are intended to illustrate, not limit, the technical concept of the invention, and the scope of the technical concept of the invention is not limited by these embodiments. The scope of protection of this invention shall be interpreted by the claims below, and all technical concepts within an equivalent scope shall be interpreted as being included within the scope of rights of this invention. Explanation of the symbols

[0066] S100: Method for manufacturing eco-friendly jeans using waste fabric according to one embodiment of the present invention S110: Recycled yarn manufacturing stage S120: Regeneration dyeing step S130: Fabric manufacturing stage S140: Fabric processing stage S150: Product washing stage S160: Product coating step S170: Product completion stage

Claims

Claim 1 A recycled yarn manufacturing step for manufacturing recycled yarn using waste denim fabric; a recycled yarn dyeing step for dyeing the recycled yarn manufactured through the recycled yarn manufacturing step; a fabric manufacturing step for manufacturing a fabric using the recycled yarn dyed through the recycled yarn dyeing step; a fabric processing step for manufacturing a jeans product by processing the fabric manufactured through the fabric manufacturing step; a pre-coating step for coating the jeans product manufactured through the fabric processing step using a first coating agent; a product washing step for washing the jeans product that has undergone the pre-coating step; and a post-coating step for coating the jeans product that has undergone the product washing step using a second coating agent.The method includes a product completion step in which the jeans product that has undergone the post-coating step described above is post-treated to complete the final jeans product, wherein the recycled yarn manufacturing step comprises manufacturing the recycled yarn by spinning a fiber mixture comprising waste denim fibers extracted from the waste denim fabric, cotton fibers, polyester fibers, and plant fibers, wherein the plant fibers include banaba fibers, green tea fibers, morning glory fibers, and coffee grounds fibers, wherein the recycled yarn manufacturing step comprises manufacturing a first fiber mixture by mixing 50 to 60 parts by weight of cotton fibers, 40 to 50 parts by weight of polyester fibers, 10 to 20 parts by weight of banaba fibers, and 10 to 20 parts by weight of green tea fibers based on 100 parts by weight of waste denim fibers, manufacturing a second fiber mixture by additionally mixing 3 to 5 parts by weight of morning glory fibers and 5 to 7 parts by weight of coffee grounds fibers based on 100 parts by weight of the first fiber mixture, and then manufacturing the recycled yarn by spinning the second fiber mixture, wherein the first coating agent is a polyol A method for manufacturing eco-friendly jeans using waste fabric, characterized in that the second coating agent is a polyurethane coating agent comprising 40 to 50 parts by weight of isocyanate and 20 to 30 parts by weight of solvent based on 100 parts by weight, and the second coating agent is a polyurethane coating agent comprising 30 to 40 parts by weight of isocyanate, 10 to 20 parts by weight of solvent, 5 to 10 parts by weight of silicone powder, 3 to 5 parts by weight of rosemary essential oil, and 5 to 10 parts by weight of almond oil based on 100 parts by weight of polyol. Claim 2 delete Claim 3 delete Claim 4 A method for manufacturing eco-friendly jeans using waste fabric according to claim 1, wherein the product washing step is characterized by ozone washing treatment of the jeans product manufactured through the fabric processing step. Claim 5 delete

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