FIBER PRODUCT PROVIDED WITH WATER REPELLANT COATING LAYER AND METHOD FOR MANUFACTURING THE FIBER PRODUCT

Abstract

A method for manufacturing the fiber product comprises: a washing step for inserting and washing a semi-manufactured fiber product comprising a fabric having natural fiber; a first drying step for dehydrating and then drying the washed semi-manufactured fiber product; a water repellant solution submerging step for submerging the dried semi-manufactured fiber product so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured product; a thermal setting step for fixing the water repellant solution to the threads; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable; and a product finishing step for dehydrating and drying the semi-manufactured fiber product and producing a finished product.

Description

FIELD OF TECHNOLOGY

The present invention relates to a fiber product provided with water repellant coating layer and a method for manufacturing the fiber product.

BACKGROUND OF THE INVENTION

There are very many kinds in natural fibers and synthetic fibers we encounter in our everyday lives. Each of the natural fibers and synthetic fibers has strong and weak properties and features.

For example, the natural fibers are better in absorption, insulation, and touch compared to the synthetic fibers so that they are sanitary and have good wearing sensation, and some of them have more strength than the synthetic fibers, strong against extended usage and repeated cleaning.

However, since the natural fibers have hydrophile property of absorbing water easily in spite of the above merits, fabric products made of natural fibers show shortcomings that they get soaked easily on rainy days, for an example. For instance, cloths with natural fibers get wet on rainy days, decreasing coziness of the cloths drastically.

Furthermore, in a case of jean made of denim, one of natural fibers, if wet, the indigo dye gets lost and may dye or migrate to other cloths or socks put on along by the user.

As described in the above, as long as they have the hydrophile property, the fabric product made of natural fibers get soaked and heavy easily, sticking to skin and decreasing the coziness of wearing, even making uncomfortable. These disadvantages get worse on hot and humid summer days.

Since the above dye-migration or decrease of coziness of wearing is a phenomenon caused by the fact that the natural fibers get soaked easily, the above inconveniences would not be there if they don't get soaked. However, since products made of fabric containing natural fibers cannot help but have hydrophile property and do not have any specific means to discharge water, on rainy or snowy days, for example, it is unavoidable to get wet and soaked easily and have a bad feeling thereof in cases of cloths.

In contrast, the above compound fibers have a little different properties from one another according to their kinds, but have merits that they are more solid in structures, better wear resistance, stronger against tension and abrasion, tougher, and harder to wrinkle than the natural fibers. Especially, due to their low hygroscopicity, water absorption, they don't get heavy, keeping to be light, even in a highly humid environment. As the fabric technology is developed recently, highly-functional compound fibers have been developed, which do not lose properties of waterproofing and wind-shielding.

Because of the above advantages of compound fabric products, especially outdoor cloths and various accessories have been made with the compound fibers as a main component. In the case of cloths, insulating materials such as cotton, wool, or duck down may be included inside for warming, the surface fabric are treated with fabric made of compound fibers.

FIG. 1 is a perspective view showing an outdoor jacket (11) according to an example of conventional compound fabric product.

As illustrated, the conventional outdoor jacket (11) is fabricated with compound fiber fabric (12) for surface fabric having properties of wind-shielding and waterproofing in order to protect the body from humidity as well as to keep it from getting heavy due to rain and wind. Inside the jacket (11) may be embedded various kinds of insulating material or other components.

The above compound fiber fabric (12) is obtained by sewing small patches of compound fiber fabric, each of which being cut in various shapes according to a design, and as illustrated, a plurality of sewing lines (13) on a surface of the jacket (11). The sewing lines (13) are unavoidable in sewing of the jacket (11).

And the above conventional jacket (11), even though the compound fiber fabric (12) has state-of-the-art function, cannot avoid water leaking problem along the sewing lines (13) interconnecting the compound fiber fabric (12). Along the sewing lines (13) are formed minute needle holes through which needle passed, and through the needle holes water can enter into the jacket (11).

FIG. 2 is a cross-sectional view showing the surface fabric (15) sewn to the lining (17) in order to describe problems of conventional compound fiber fabric.

Referring to the figure, the surface fabric (15) and the lining (17) are tied and fixed by top and bottom sewing threads (19a, 19b) inter-tangled with each other. The sewing threads (19a, 19b) meet each other in the needle hole (21), through which the needle of sewing machine passed, and entangled to interlock the surface fabric (15) and the lining (17).

Both of the above surface fabric (15) and lining (17) may be compound fiber fabric (12), or the surface fabric (15) only may be compound fiber fabric, and in any cases, many needle holes (21) can be formed through the surface fabric (15) and the lining (17).

Since the needle holes (21) maintain their opening by the sewing threads (19a, 19b), and especially the sewing threads (19a, 19b) work as a siphoning wick, eventually water falling on one surface of the sewing line (13) goes through the fabric through the needle holes (21), reaching the other side of the fabric.

Even though a jacket (11) is fabricated with compound fiber fabric having state-of-the-art properties, it must have sewing lines (13), and therefore it cannot provide any perfect waterproofing.

As the so-far best way to solve such problems, there is so-called seam sealing method for attaching seam tape on an inner surface of the sewing lines (13). The seam tape is a waterproofing film for fabric, which is high-frequency melt-and-attached (or heated-and-pressed) along the sewing lines (13), providing waterproofing to the sewing lines.

FIG. 3 is a perspective view showing how the seam tape (23) is attached to the sewing lines (13).

As shown, the seam tape (23) is attached along the sewing lines (13) formed in the compound fiber fabric (12). The seam tape (23) is pushed to contact the compound fiber fabric (12) while covering the sewing lines (13), blocking water so as not to pass the needle holes of the sewing lines (13).

But the above seam sealing method has disadvantages that when the fabric (12) is thin the shape of the seam tape (23) is shown outside as it is and the corresponding portions get stiff, damaging the quality as product. Also, as washing with water or dry cleaning are repeated, it may be detached from the fabric (12). The seam tape beginning to wear off from the fabric (12) may get rugged, forcing it detached completely as the process goes on.

Also, for example, when the sewing line (13) was curved, it was almost impossible to attach the band-type seam tape (23) perfectly along the curved sewing line, and since creases were unavoidably formed at one side in width direction of the seam tape (23), the corresponding portions of the fabric (12) got wrinkled, looking ugly, and the sealing was so compromised that it was difficult to provide a reliable sealing.

Additionally, since the seam sealing work needs expensive equipments and high-tech, the product cost is unavoidable.

DETAILED DESCRIPTION OF THE INVENTION

Problems to Solve

The present invention aims to solve the above problems, in which in a case of fabricating a product with fabric including natural fibers, it is to provide a fiber product provided with water repellant coating layer and method for manufacturing the fiber product, in which since it is not soaked and maintains a dry state always thanks to the water repellant property with air permeability, there is no dye migration, cozy and light, and a cloth made out of the fabric product is excellent to put on and provides insulation, and a compound fiber product maintains a perfect waterproofing even without seam sealing over the sewing lines keeping waterproofing property under any weather conditions and not getting wet so as to make the cloth cozy and good to put on, and there is no problems caused by seam tapes and it is easy to manufacture.

Solutions to Problems

In order to solve the above problems, a method for manufacturing a fiber product provided with water repellant coating layer comprises: a washing step for inserting and washing a semi-manufactured fiber product comprising a fabric having natural fiber; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is washed; a water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured product that has completed the water repellant solution submerging step; a thermal setting step for fixing the water repellant solution to the threads; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Also, in a case that the fiber product is made of denim colored by dye, the method for manufacturing a fiber product further comprises an aging step for applying a physical force to and aging-processing the semi-manufactured fiber product prior to the washing step.

Also, in order to solve the above problems, a method for manufacturing a fiber product provided with water repellant coating layer comprises: a washing step for inserting and washing a semi-manufactured fiber product comprising a fabric having natural fiber; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is washed by the washing step; a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step; a first thermal setting step for fixing the water repellant solution to the threads; a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the first thermal setting step and in a washed and dried state, so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step; a second thermal setting step for heating the semi-manufactured fiber product dried by the third drying step and fixing the water repellant solution to a first coating layer; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Also, in order to solve the above problems, a method for manufacturing a fiber product provided with water repellant coating layer comprises: a first drying step for dehydrating and then drying a semi-manufactured fiber product comprising a fabric having natural fiber and made from denim colored by dye; a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step; a first thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads; an aging step for applying a physical force to and aging-processing the semi-manufactured fiber product; a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the aging step; a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the third drying step so as to coat the water repellant solution on a first coating layer; a fourth drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step; a second thermal setting step for heating the semi-manufactured fiber product dried by the fourth drying step and fixing the water repellant solution to a first coating layer; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Also, in order to solve the above problems, a method for manufacturing a fiber product provided with water repellant coating layer comprises: an aging step for applying a physical force to and aging-processing a semi-manufactured fiber product comprising a fabric having natural fiber and made from denim colored by dye; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is from the aging step; a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution: a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step; a first thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads; a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first thermal setting step; a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the third drying step so as to coat the water repellant solution on a first coating layer; a fourth drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step; a second thermal setting step for heating the semi-manufactured fiber product dried by the fourth drying step and fixing the water repellant solution to a first coating layer; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Also, in order to solve the above problems, a fiber product according to the invention is manufactured by: a washing step for inserting and washing a semi-manufactured fiber product comprising a fabric having natural fiber; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is washed; a water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured product that has completed the water repellant solution submerging step; a thermal setting step for fixing the water repellant solution to the threads; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Additionally, in order to solve the above problems, a fiber product according to the invention is manufactured by: a washing step for inserting and washing a semi-manufactured fiber product comprising a fabric having natural fiber; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is washed by the washing step; a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step; a first thermal setting step for fixing the water repellant solution to the threads; a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the first thermal setting step and in a washed and dried state, so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step; a second thermal setting step for heating the semi-manufactured fiber product dried by the third drying step and fixing the water repellant solution to a first coating layer; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Also, the fabric in the semi-manufactured fiber product is one selected from the group consisting of cotton fabric, blended cotton fabric, and natural fiber fabric.

Additionally, the fiber product provided with water repellant coating layer comprises clothes, backpack, bag, hat, shoes, and gloves.

Also, a fiber product according to the invention, in order to solve the above problems, is manufactured by: an aging step for applying a physical force to and aging-processing the semi-manufactured fiber product prior to the washing step in a case that the fiber product is made of denim colored by dye; a washing step for inserting and washing a semi-manufactured fiber product comprising a fabric having natural fiber; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is washed; a water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured product that has completed the water repellant solution submerging step; a thermal setting step for fixing the water repellant solution to the threads; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Also, a fiber product according to the invention, in order to solve the above problems, is manufactured by: a first drying step for dehydrating and then drying a semi-manufactured fiber product comprising a fabric having natural fiber and made from denim colored by dye; a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step; a first thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads; an aging step for applying a physical force to and aging-processing the semi-manufactured fiber product; a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the aging step; a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the third drying step so as to coat the water repellant solution on a first coating layer; a fourth drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step; a second thermal setting step for heating the semi-manufactured fiber product dried by the fourth drying step and fixing the water repellant solution to a first coating layer; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Also, a fiber product according to the invention, in order to solve the above problems, is manufactured by: an aging step for applying a physical force to and aging-processing a semi-manufactured fiber product comprising a fabric having natural fiber and made from denim colored by dye; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is from the aging step; a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution; a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step; a first thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads; a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first thermal setting step; a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the third drying step so as to coat the water repellant solution on a first coating layer; a fourth drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step; a second thermal setting step for heating the semi-manufactured fiber product dried by the fourth drying step and fixing the water repellant solution to a first coating layer; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Additionally, the fiber product comprises jean clothing, hat, bag, and backpack that are colored by indigo-series of dye.

Also, a method for manufacturing a fiber product provided with water repellant coating layer, in order to solve the above problems, comprises: a bio-processing step for putting in an enzyme solution and washing a semi-manufactured fiber product comprising a fabric having natural fiber and manufactured by sewing; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is from the bio-processing step; a water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution and filling needle holes on sewing lines formed by the sewing; a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the water repellant solution submerging step; a thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

Also, the bio-processing step is performed in the enzyme solution at a temperature from about 50° C. to about 70° C. for a time period from about 20 minutes to about 100 minutes.

Also, the water repellant solution submerging step is performed in the water repellant solution at a temperature from about 40° C. to about 60° C. for a time period from about 30 minutes to about 1 hour.

Also, a fiber product according to the invention, in order to solve the above problems, is manufactured by: a bio-processing step for putting in an enzyme solution and washing a semi-manufactured fiber product comprising a fabric having natural fiber and manufactured by sewing; a first drying step for dehydrating and then drying the semi-manufactured fiber product that is from the bio-processing step; a water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution and filling needle holes on sewing lines formed by the sewing; a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the water repellant solution submerging step; a thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads; a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the thermal setting; and a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product, and the fiber product provided with water repellant coating layer comprises clothes, backpack, bag, hat, shoes, and gloves.

Advantages of the Invention

The fiber product provided with water repellant coating layer and method for manufacturing the fiber product according to the invention as described in the above, have advantages that since it is not soaked and maintains a dry state always thanks to the water repellant property with air permeability, there is no dye migration, cozy and light, and a cloth made out of the fabric product is excellent to put on and provides insulation, and a compound fiber product maintains a perfect waterproofing even without seam sealing over the sewing lines keeping waterproofing property under any weather conditions and not getting wet so as to make the cloth cozy and good to put on, and there is no problems caused by seam tapes and it is easy to manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing schematically an outdoor jacket according to an example of conventional compound fabric product.

FIGS. 2 and 3 are figures showing problems of conventional compound fiber fabric.

FIG. 4 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to a first embodiment of the invention.

FIG. 5 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to a second embodiment of the invention.

FIG. 6 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to a third embodiment of the invention.

FIG. 7 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to a fourth embodiment of the invention.

FIG. 8 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to a fifth embodiment of the invention.

FIG. 9 is a figure showing a lamination structure of coating layers in a fiber product manufactured according to the fourth embodiment.

FIG. 10 is a diagram showing a clothing as a fiber product manufactured by the first through fifth embodiments.

FIG. 11 is a diagram showing a backpack as a fiber product manufactured by the first through fifth embodiments.

FIG. 12 is a diagram showing a cap as a fiber product manufactured by the first through fifth embodiments.

FIG. 13 is a diagram showing a water repellant cotton shoes as a fiber product manufactured by the first through fifth embodiments.

FIG. 14 is a diagram showing a bag as a fiber product manufactured by the first through fifth embodiments.

FIG. 15 is a diagram showing a cotton gloves as a fiber product manufactured by the first through fifth embodiments.

FIG. 16 is a flowchart showing a method for manufacturing a fiber product provided with a water repellant coating layer according to the sixth embodiment of the invention.

FIG. 17 is an exploded cross-sectional view showing features of the fabric in the fiber product manufactured according to the method of FIG. 16.

FIG. 18 is a diagram showing a clothing among the fiber products manufactured according to the method of FIG. 16.

FIG. 19 is a diagram showing a tent manufactured according to the method of FIG. 16.

FIG. 20 is a diagram showing a backpack among various kinds of bags manufactured according to the method of FIG. 16.

FIG. 21 is a perspective view showing a glove manufactured according to the method of FIG. 16.

FIG. 22 is a perspective view showing a shoe manufactured according to the method of FIG. 16.

FIG. 23 is a perspective view showing a cap manufactured according to the method of FIG. 16.

DETAILED DESCRIPTION OF THE INVENTION

Below, various embodiments according to the invention are described in detail referring to the attached drawings.

Basically, the invention is to treat a half-manufactured fiber product made of fabric including natural fibers and a semi-manufactured fiber product made of compound fabric for waterproofing using a plurality of methods described below, to realize water repellant property in the semi-manufactured fiber product made of fabric including natural fibers, and to strengthen waterproofing capability as well as water repellant property.

Manufacturing methods for manufacturing fiber product provided with water repellant coating layer according to the first through fifth embodiments of the invention to be described below are about processes that treat a semi-manufactured fiber product made of fabric with natural fibers as main component for water repellant property in many ways and impart a water repellant property with air permeability.

Additionally, the fabric in the above comprises blended cotton fabric and regenerated fabric as well as cotton fabric, hemp cloth, woolen cloth. Also threads to be described in the first through fifth embodiments are natural threads. Also, the natural fibers include natural fibers in animal and plant natures. Further, if necessary, the fabric may be a fabric with elasticity.

Especially, the semi-manufactured fiber product is an intermediate product to be completed through a product finishing step.

That is, in a case of cloths (30 in FIG. 10), the semi-manufactured fiber product is one in a state before fixing attachments including various accessories or labels. Also, in cases of backpack (39 in FIG. 11) or bag (51 in FIG. 14), it is in a state before fixing any accessories or attachments such as various labels, snap buttons, or Velcro® tape.

Furthermore, in a case of cap (47 in FIG. 12), it is in a state before works on linings or inner seaming on inside of tongue, and in a case of water repellant cotton shoe (49 in FIG. 13), it is in a state before works for sole, string holes, labels, and other rubber attachments. Also, in a case of cotton glove (53 in FIG. 15), it is in a state before attaching inner lining for double waterproofing, attaching insulating material on inner side for insulation, attaching zippers, printing or embroidering for decoration, detaching stray threads, or ironing. The name of the cotton glove (29) is for an example, so it is not limited to one made of cotton, and it may be made of blended cotton fabrics.

FIG. 4 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to a first embodiment of the invention.

As illustrated, a method for manufacturing a fiber product according to the first embodiment starts with a semi-manufactured fiber product pre-cleaning step (100). The semi-manufactured fiber product pre-cleaning step (100) is a process of pre-cleaning the semi-manufactured fiber product (semi-manufactured fiber product made of cotton fabric, hemp cloth, woolen cloth, blended cotton fabric, etc. as a main component) in order to get rid of various impurities stuck to the fiber product. For example, wax or oil from weaving processes and the like is to be removed in this step.

After the semi-manufactured fiber product pre-cleaning step (100), a washing step (102) is performed. The washing step (102) is a step for softening the fabric of the semi-manufactured fiber product after the pre-cleaning, and is performed by putting the semi-manufactured fiber product in a washing device. Sometimes, the washing step (102) may be skipped.

If the washing step (102) is finished, the semi-manufactured fiber product is dehydrated through a dehydrating step (104) and then a first drying step (106) is performed. The first drying step (106) is a process of drying the semi-manufactured fiber product completely and preparing it for the next water repellant solution submerging step (108). A drying device used in the first drying step (106) may be a steam-drying device, for an example. However, other kinds of drying devices can be used.

The water repellant solution submerging step (108) is a process of submerging the dried semi-manufactured fiber product so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution. The threads are warps and wefts forming the semi-manufactured fiber product.

The concentration of the water repellant solution may depend on the kinds and thickness of the fabric of the semi-manufactured fiber product. Also, the submerging time in the water repellant solution may be about 30 minutes to about 2 hours. The submerging time may be adjusted according to additional conditions such as the concentration of the water repellant solution, added catalyst, and etc. Furthermore, the water repellant solution submerging step (108) may be performed repeatedly more than twice.

After the water repellant solution submerging step (108), a dehydrating step (110) is performed. The dehydrating step (110) is a process of taking out the semi-manufactured fiber product from a water repellant solution tank (not shown), putting it into a dehydrating device, and removing remnant water repellant solution that is not coated on the semi-manufactured fiber product.

Next, a second drying step (112) is performed. The second drying step (112) is a process of putting the semi-manufactured fiber product finished with the dehydrating step (110) in the drying device and drying it, especially incomplete drying instead of complete drying. The incomplete drying means a drying so that some moisture remains in the semi-manufactured fiber product. The dehydrating rate of the second drying step (112) may be 50% to 80%. The reason for the second drying step leaves some moisture in the semi-manufactured fiber product is to increase the efficiency of the following thermal setting step (114).

The thermal setting step (114) following the second drying step (112) is a process of fixing the water repellant solution coated on the fabric of the semi-manufactured fiber product in place, and performed at a temperature between 140° C. to 200° C. for a time period of 15 minutes to 90 minutes. In order to perform the thermal setting step, a well-known curing device (not shown) may be used. The curing device is a device for rotating a wire conveyor where the semi-manufactured fiber products are hooked and applying heat to the rotating semi-manufactured fiber product.

Since a clothing finished with the thermal setting step (114) is stiff, a pliability processing step (116) is performed. The pliability processing step (116) is a process for washing and making soft the semi-manufactured fiber product (finished with the thermal setting step) in a water added with softener.

If the pliability processing step (116) is finished, then a dehydrating step (118) in performed. The dehydrating step (118) is a step for squeezing water out of the softened semi-manufactured fiber product, and uses a well-known dehydrating device.

After the dehydrating step (118), a third drying step (120) is performed. The third drying step (120) is a process of drying the semi-manufactured fiber product completely using the drying device used in the first drying step (106).

If the semi-manufactured fiber product has been dried completely through the third drying step (120), a product finishing step (122) is performed. The product finishing step (122) is a process of rendering the semi-manufactured fiber product to a finished product.

The product finishing step (122) includes a series of processes for fixing accessory, label, or other decorations, for example, to the semi-manufactured fiber product finished with the third drying. According to the kinds of the semi-manufactured fiber product, the processes performed in the product finishing step (122) may be different.

Especially, in the case of the water repellant cotton shoe (49), the semi-manufactured fiber product corresponds to uppers, and the water repellant cotton shoe (25) is finished by fixing string holes and label to the uppers, the semi-manufactured fiber product, and fixing other decorations such as heel insert and sole.

Anyway, by the product finishing step (122), water repellant clothing (30), water repellant bag (45), water repellant cap (47), water repellant shoe (49), water repellant bag (51), water repellant cotton glove (59), etc. are finished.

FIG. 5 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to the second embodiment of the invention.

In the following description, each step numbered with same numbers as in the above are same as the steps described with respect to FIG. 5, and repetitions are omitted.

In the second embodiment, the fabric in the semi-manufactured fiber product for imparting water repellant property is a denim cloth colored with indigo-series dye. That is, the semi-manufactured fiber product used in the second embodiment include jean pants or jean skirt, jean jacket, jean shirts, etc., and all kinds of semi-manufactured fiber product with denim cloth as main components.

Referring to the drawing, the method for manufacturing fiber product provided with water repellant coating layer according to the second embodiment further comprises a semi-manufactured fiber product aging step (124) prior to the washing step (102). Also, the pre-cleaning step (100) in the first embodiment is omitted.

The semi-manufactured fiber product aging step (124) is a process for treating physico-chemically using specific procedures the semi-manufactured fiber product to be finished to jean pants, jean skirts, jean jacket, jean shirts, etc. and make it look worn and old. For example, parts of semi-manufactured fiber product are scraped off, wrinkled, bored, ripped, bleached, etc. using sand-blaster, sand paper, brush, etc.

Regardless of the specific procedures in the semi-manufactured fiber product aging step (124), the surface of the semi-manufactured fiber product finished with the semi-manufactured fiber product aging step (124) is destroyed, and the corresponding parts become ragged and rough.

If the semi-manufactured fiber product aging step (124) is finished, the fiber product such as water repellant clothing (30) is obtained by going through the washing step (102) and subsequent steps (described with FIG. 4 already) serially.

FIG. 6 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to the third embodiment of the invention. The overlapped description with the above is omitted.

As shown, a method for manufacturing fiber product provided with water repellant coating layer according to the third embodiment performs a first water repellant solution submerging step (140) after the pre-cleaning step (100), the washing step (102), the dehydrating step (104), and the first drying step (106).

The first water repellant solution submerging step (140) is equivalent to the first drying step (106) described with FIG. 4. That is, it is a process for submerging the semi-manufactured fiber product in a prepared water repellant solution so that the water repellant solution penetrates into the threads of the semi-manufactured fiber product and coats the surface of the threads. By the first water repellant solution submerging step (140), a first coating layer is formed on the surface of the threads.

Additionally, the concentration of the water repellant solution may depend on the kinds and thickness of the fabric forming the semi-manufactured fiber product, and the time of submerging may be about 30 minutes to 2 hours. The submerging time also may be depend on the concentration of water repellant solution or presence of any added catalyst.

After the first water repellant solution submerging step (140), a dehydrating step (142) is performed. The dehydrating step (142) is a process for putting the semi-manufactured fiber product finished with the first water repellant solution submerging step in a dehydrating device and getting rid of remnant water repellant solution that is not coated on the semi-manufactured fiber product.

Next, a second drying step (144) is performed. The second drying step (144) is a process for incomplete drying the semi-manufactured fiber product finished with the dehydrating step (142) using a drying device. The dehydration rate of the second drying step (144) is about 50% to 80%. The reason for making the second drying step incomplete leaving some moisture in the semi-manufactured fiber product is to increase the efficiency of a following first thermal setting step (146).

The first thermal setting step (146) is a process for fixing the water repellant solution coated on the fabric forming the semi-manufactured fiber product in place using a curing device, and it may be performed at a temperature of 140° C. to 200° C. for a time period of 15 minutes to 90 minutes.

After the above step, a washing step (148) and a dehydrating step (150) follow. The washing step (148) is a process for softening the semi-manufactured fiber product somewhat stiffened through the first thermal setting step (146), and the dehydrating step (150) is a process for dehydrating the semi-manufactured fiber product.

After the dehydrating step (150), a second water repellant solution submerging step (152) is performed. The second water repellant solution submerging step (152) is a process for submerging the semi-manufactured fiber product again in the water repellant solution and forming a second water repellant coating layer on the first water repellant coating layer. The conditions for the second water repellant solution submerging step (152) is same as those for the first water repellant solution submerging step (140).

After the second water repellant solution submerging step (152) is completed, a dehydrating step (154) is performed. The dehydrating step (154) is a process for dehydrating the remnant water repellant solution that is not coated on the fabric of the semi-manufactured fiber product.

If the remnant water repellant solution was dehydrated to a certain degree by the dehydrating step (154), a third drying step (156) is performed. The third drying step (156) is an incomplete drying. The dehydration rate of the third drying step (156) is about 50% to 80%. The third drying step (156) is performed in the curing device, too.

Following the third drying step (156), a second thermal setting step (158) is performed. The second thermal setting step (158) is a process for fixing the newly-coated second water repellant coating layer on the first water repellant coating layer completely. If the semi-manufactured fiber product is heated by the second thermal setting step (158), the second water repellant coating layer is integrated with the first water repellant coating layer almost completely through molecular combining.

Next, a pliability processing step (160) is performed. The pliability processing step (160) is a process for washing the semi-manufactured fiber product in a stiff condition in water with fabric softener and making it soft.

After the pliability processing step (160) is completed and then water is squeezed out through a dehydrating step (162), a fourth drying step (164) is performed. The fourth drying step (164) is a process for drying the semi-manufactured fiber product completely using the drying device used in the first drying step (106).

If the semi-manufactured fiber product is dried completely through the fourth drying step (164), a fiber product provided with water repellant coating layer is completed through a product finishing step (122). The finished product completed by the above step includes clothing, bag, cap, cotton shoe, cotton glove, etc.

FIG. 7 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to the fourth embodiment of the invention.

Referring to the figure, a method for manufacturing a fiber product provided with water repellant coating layer goes through the pre-cleaning step (100), the washing step (102), the dehydrating step (104), the first drying step (106), the first water repellant solution submerging step (140), the dehydrating step (142), the second drying step (144), and the first thermal setting step (146), and then the semi-manufactured fiber product aging step (124).

The semi-manufactured fiber product aging step (124), as described with FIG. 5, is an intentional process for treating physico-chemically using specific procedures the semi-manufactured fiber product and make it look worn and old. Regardless of the specific procedures in the semi-manufactured fiber product aging step (124), the surface of the semi-manufactured fiber product finished with the semi-manufactured fiber product aging step (124) is destroyed, and the corresponding parts become ragged and rough.

After the semi-manufactured fiber product aging step (124) is completed, the washing step (102) and the dehydrating step (150) follow. The washing step (148) includes a process for getting rid of sands or chemicals contaminated the semi-manufactured fiber product during the semi-manufactured fiber product aging step (124). Also, the dehydrating step (150) is a process for squeezing water out from the semi-manufactured fiber product finished with the drying step.

After the dehydrating step (150) is completed, the semi-manufactured fiber product is dried completely through a third drying step (151). The third drying step (151) may use the steam drying device described in the above.

If the semi-manufactured fiber product was dried completely through the third drying step (151), after a second water repellant solution submerging step (152) and a dehydrating step (154), a fourth drying step (166) follows. The fourth drying step (166) is an incomplete drying process, and performed in a similar way as the second drying step (144).

If the semi-manufactured fiber product is dried incompletely through the fourth drying step (166), after a second thermal setting step (158), a pliability processing step (160), and a dehydrating step (162), a fifth drying step (174) follows. The fifth drying step (174) is a process for drying completely the semi-manufactured fiber product after the dehydrating step (162) using a steam drying device.

After the fifth drying step (174) is completed, a finished product is obtained through the product finishing step (122).

FIG. 8 is a block diagram showing a method for manufacturing a fiber product provided with water repellant coating layer according to the fifth embodiment of the invention.

Referring to the figure, a method for manufacturing a fiber product provided with water repellant solution starts with the semi-manufactured fiber product aging step (124) as in the second embodiment.

That is, the method for manufacturing fiber product according to the fifth embodiment is proceeded by performing the semi-manufactured fiber product aging step (124), the washing step (102), the dehydrating step (104), the 106, the first water repellant solution submerging step (140), the dehydrating step (142), the second drying step (144), and the first thermal setting step (146) serially.

Also, after the first thermal setting step (146) is completed, the washing step (148), the dehydrating step (150), the third drying step (156), the second water repellant solution submerging step (152), the dehydrating step (154), fourth drying step (166), the second thermal setting step (158), the pliability processing step (160), the dehydrating step (162), and the fifth drying step (174), and then finally the product finishing step (122) to finish up.

Features of each step of the fifth embodiment described in the above are same as described in the above.

In the above steps, any conventional devices can be used for individual devices performing each step as long as they make the manufacturing procedure proceed through their operations.

FIG. 9 is an exploded cross-sectional view showing threads (41) and coating layers (43) enclosing the threads forming the fabric of the fiber product manufactured by the method of manufacturing fiber product according to the fourth embodiment.

Referring to the figure, a first coating layer is combined with the threads (41), and a second coating layer is laminated on the first coating layer.

The first coating layer is a coating layer formed during the first water repellant solution submerging step (140), and especially fixed in a state that a part of water repellant solution penetrates into the fiber structure of the threads (41). Furthermore, the external surface of the threads (41) is destroyed partially during the semi-manufactured fiber product aging step (124), having surface roughness above a predetermined degree.

The second coating layer is a water repellant coating layer formed by the second water repellant solution submerging step (152). The second coating layer is attached to the rough surface of the first coating layer, and fixed to the surface of the first coating layer (15a) through inter-molecular combining by the heat delivered during the second thermal setting step (158). The surface of the second coating layer maintain a smooth state because any physical shock is not applied after the thermal setting step.

FIG. 10 is a diagram showing a clothing (30) as a fiber product manufactured by the first through fifth embodiments. In the figure, there are examples of a pair of pants (31), top (33), skirt (35), and pancho (37) for the water repellant clothing (30).

As shown, the coating layer (43) is coated on the threads (41) of the water repellant fabric (39) forming the water repellant clothing (30). The fabric of the water repellant fabric (39) is a fabric containing natural fibers.

The coating layer (43) is what is formed through the water repellant solution submerging step described in the above, and provides perfect water repellant property to the water repellant clothing (30) by enclosing the threads while penetrating the threads (41) partially.

Especially as shown, since the coating layer (43) enclosing the threads (41) is not stuck with neighboring coating layer but stayed away from each other, providing air-permeability in-between. Therefore, moisture or heat generated by the wearer's skin can be discharged to outside through the air-venting holes, making it sanitary. So called moisture-permeability is possible.

The water repellant clothing (30) includes all kinds of clothes. For example, army uniforms, other various uniforms, mountain clothes, ski suits, golf suits, etc. may be included.

FIGS. 11 to 15 are perspective views showing a water repellant backpack (47), a water repellant cap (47), a water repellant cotton shoe (49), a water repellant bag (51), and a water repellant cotton glove (53), each of which being manufactured by the method according to the first to fifth embodiments.

As shown, the coating layer (43) is coated on the threads (41) of the water repellant fabric (39) forming the water repellant backpack (47), the water repellant cap (47), the water repellant cotton shoe (49), the water repellant bag (51), and the water repellant cotton glove (53). Like this, since the coating layer (43) is coated on the water repellant fabric (39) containing natural fibers or made of natural fibers only, even though it rains on them, raindrops do not stay on the surface of the water repellant backpack (47), the water repellant cap (47), the water repellant bag (51), or the water repellant cotton shoe (49), and flow away immediately, not wetting. Especially, the water repellant cotton glove (53) does not get wet but has insulation, which is very handy in skiing.

As a result, since the water repellant solution got rooted and fixed in the textile structures of the threads (41) forming the fabric in the fiber product provided with water repellant coating layer according to the first through fifth embodiments in the above, the combining of the water repellant coating layer to the threads (41) is sturdy and therefore the water repellant property is maintained as it was even for long-time usage, and therefore it does not get wet easily, keeping in a dry condition.

The following quality-inspection sheet attached below is a result of tests performed in the Korean Fiber Institute according to the Japanese quality criteria, showing water repellant capability of the water repellant fiber product according to the invention.

As shown in the above test result, each of cloth samples 1 and 2 is cut into three pieces, washed 20 times, and tested for degree of water repellant, showing that all the three pieces of the cloth sample 1 got level 3 (3 3 3), and that all the three pieces of the cloth sample 2 got level 2 (2 2 2). In water repellant test under the Japanese Test Criterion (JIS L 1092), which is stricter and tougher than Korean standard, level 4 is the highest level, and levels higher or equal to level 2 (levels 4, 3, 2) are considered to pass.

Especially, the present standard of Japanese water repellant test is to wash the sample five times and then test, but the water repellant fabric of the invention was washed 20 times, four times more than the above standard, and then tested. Getting level 3 or level 2 after 20 times of washing is an excellent result.

Additionally, the fact that all the three pieces got the same level means that the water repellant property of fabric is uniform. That is, it is not that some portions of the fabric have better water repellant property and other portions of the fabric have relatively worse water repellant property, but that all the portions of the fabric have an even water repellant property. This shows the evenness and repeatability of the effects of the method.

On the other hand, FIG. 16 is a flowchart showing a method for manufacturing a fiber product provided with a water repellant coating layer according to the sixth embodiment of the invention.

Basically, the method for manufacturing fiber product provided with water repellant coating layer according to the sixth embodiment relates to a procedures of treating with water repellant semi-manufactured fiber product having various kinds of compound fibers at least on outer surface (surface fabric), imparting water repellant property and making sewing lines waterproof. Clothes and other items (bag, backpack, shoe, glove, tent, etc.) finished by the above method have very reliable waterproofing ability.

Furthermore, the semi-manufactured fiber product is a material to work on in order to finish into a finished product through subsequent finishing step, and in the case of clothing, it is in a state that even if the zipper is installed already but other attachments such as various accessories or labels are not attached yet.

Also, if the finished product is a tent (69 in FIG. 19), attachments such as metal rings for queuing pole to tent cloth are not fixed, and in cases of backpack (71 in FIG. 20) or glove (73 in FIG. 21), it is in a state before all the accessories or attachments including various labels, snap buttons, Velcro® tape, etc. are attached. Further, the semi-manufactured fiber product to be finished to a shoe (75 in FIG. 22) is in a state before sole, string holes, label, and various other kinds of rubber attachments are added.

In any cases, as shown in FIG. 16, the method for manufacturing fiber product provided with water repellant coating layer according to the six embodiment starts with the pre-cleaning step (100). As described in the above, the pre-cleaning step (100) is a basic step, in which a prepared semi-manufactured fiber product is pre-cleaned, getting rid of impurities stuck to the semi-manufactured fiber product. For example, it gets rid of wax, oil, silicone, or oil stuff, other contaminants, or dust contaminated during dying process.

Next, a bio-processing step (180) follows. The bio-processing step (180) is a process for putting the semi-manufactured fiber product into an enzyme solution and washing. In the bio-processing step, the temperature may be maintained at about 50° C. to about 70° C., and the washing time may be about 20 minutes to 60 minutes. In cases, the washing time may be extended to about 100 minutes.

If the semi-manufactured fiber product is enzyme-washed by the bio-processing step (180), the surface of the compound fiber fabric forming the semi-manufactured fiber product becomes smooth and various chemicals, wax, resin, etc. as well as bubbles or lints that are left (even after the pre-cleaning step) are removed completely, so that fixing of water repellant solution to be described below is obtained much effectively and it is possible to obtain very reliable water repellant coating layers on both of inner and outer surfaces of the compound fiber fabric. The more solidly the coating layer (43) is maintained, the more complete and long-lasting the water repellant and waterproofing is obtained.

Also, thanks to the enzyme, the compound fiber fabric gets softer and its fibers become stronger, obtaining increased durability and added value. These increased durability and added value cannot be obtained with conventional chemical cleaning agent.

After the bio-processing step (180) is completed, the dehydrating step (104) is performed. The dehydrating step (104) is performed using a general type of dehydrating device, and in order to lower the load to the following first drying step (106) the dehydrating rate better be raised.

The first drying step (106) following the dehydrating step (104) is a process for drying the semi-manufactured fiber product completely and being prepared for the following water repellant solution submerging step (108). Types of drying to be applied to the first drying step (106) may include seam drying, hot air drying, natural drying, etc.

The following water repellant solution submerging step (108) is a process for submerging the semi-manufactured fiber product dried completely through the first drying step (106) in the prepared water repellant solution so that the water repellant solution penetrates into, and gets thermally set, and then coated on the threads of the compound fiber fabric, and at the same time especially fills up the needle holes (21) of the sewing lines (13). Additional detailed description on this will be given through FIG. 17 below. The threads means the warps and wefts forming the semi-manufactured fiber product.

The concentration of water repellant solution used in the water repellant solution submerging step (108) depends on the kinds or thickness of the compound fiber fabric (62). Also, the time of submerging in water repellant solution may be about 30 minutes to 2 hours. The time of submerging in water repellant solution may be varied according to the concentration of water repellant solution, added catalyst, etc., too. Furthermore, if necessary, the water repellant solution submerging step may be repeated more than twice in serial many times.

The dehydrating step (110) following the water repellant solution submerging step (108) in a process for taking out the submerged semi-manufactured fiber product from water repellant solution and removing remnant water repellant solution that is not coated on the semi-manufactured fiber product. The dehydrating types of the dehydrating step (110) also adopt conventional ones.

Next, the second drying step (112) is performed. The second drying step (112) is a process for drying the semi-manufactured fiber product finished with the dehydrating step (110) using separate drying devices, and especially drys the semi-manufactured fiber product incompletely rather than completely. The incomplete drying means one in which some moisture is left in the semi-manufactured fiber product. The dehydrating rate of the semi-manufactured fiber product through the second drying step (112) may be about 50% to 80%. By such an incomplete drying of the semi-manufactured fiber product, the efficiency of the following thermal setting step (114) can be raised.

The thermal setting step (114) following the second drying step (112) heats the semi-manufactured fiber product at a temperature of 140° C. to 200° C. for about 15 minutes to 90 minutes, so that the water repellant solution penetrated into and coated on the semi-manufactured fiber product gets fixed in place. As the semi-manufactured fiber product passes the curing device, the water repellant solution that was penetrated to, attached to, and coated on the threads of the compound fiber fabric (62) or filled in the needle holes (21) gets fixed in place.

For such a thermal setting, a curing device may be used. The curing device is a device for heating the semi-manufactured fiber product moved by a conveyor with heaters disposed around the conveyor. Of course, other types of heating means may be applied for the above thermal setting step.

Since the semi-manufactured fiber product is in a stiff state after the thermal setting step (114), in order to remove such a stiffness, the pliability processing step (116) is performed. The pliability processing step (116) is a process for washing the semi-manufactured fiber product in water with fabric softener added in advance and making it soft.

If the pliability processing step (116) is done, the dehydrating step (118) is performed. The dehydrating step (118) is a process for removing water from the softened semi-manufactured fiber product using a conventional dehydrating means.

After the dehydrating step (118), the third drying step (120) is performed. The third drying step (120) is a process for drying the semi-manufactured fiber product completely using the drying device used in the first drying step (106).

On the other hand, the steps from the water repellant solution submerging step (108) to the third drying step (120) can be repeated twice or more. That is, according to the kind and thickness or usage of finished product, or in order to further increase the water repellant and waterproofing capability, the above steps may be repeated.

Also, the water repellant solution submerging step (108), the thermal setting step (114), the pliability processing step (116), etc. can be performed individually a couple of times.

In any case, if the third drying step (120) is performed through the above steps, the semi-manufactured fiber product is done with treatment. The semi-manufactured fiber product finished with the third drying step (120) has the needle holes (21) blocked by water repellant solution and also both of inner and outer surfaces of the compound fiber fabric coated with water repellant solution, having perfect water repellant and waterproofing capability.

Next, the product finishing step (122) is performed for finishing the semi-manufactured fiber product into a finished product. The product finishing step (122) includes a series of processes for fixing attachments such as accessories, labels, or other decorations to the semi-manufactured fiber product finished with the third drying, ironing, and packing.

According to the kinds of the semi-manufactured fiber product, each process performed in the product finishing step (122) may be different naturally. For example, in the case of the shoe (75) shown in FIG. 22, the finishing step includes processes for fixing labels, sole, heel insert and the like to the surface fabric, the semi-manufactured fiber product.

FIG. 17 is an exploded cross-sectional view showing features of the fabric (62) in the fiber product manufactured according to the method of FIG. 16.

Referring to the figure, the needle holes (21 in FIG. 2) formed on the compound fiber fabric (62) are filled up with water repellant solution completely. The water repellant solution forms the coating layer (43), and in the water repellant solution submerging step (108), some of it penetrates into the needle holes (21) and fixed while filling up the needle holes, so that any water cannot pass through the needle holes.

FIG. 18 is a diagram showing a top (61) and a bottom (63) of a clothing among the fiber products manufactured according to the method of FIG. 16.

As shown, the coating layer (43) is formed on the surface of the threads (67) forming the compound fiber fabric (62) of the top (61) and the bottom (63). The coating layer (43) is water repellant solution penetrated into and fixed to the threads (67), and encloses completely and protects the threads (67).

In a case that the threads (67) itself forming the compound fiber fabric (62) is water-absorbing, the coating layer (43) has rain water not-absorbed into inside but just flow down, keeping the top and bottom (61, 63) dry.

Also, even when the threads (67) is hydrophobic, it makes rain water flow down quickly, providing more reliable waterproofing, and by enclosing the threads (67) and blocking its oxidation, it extends the life of the threads (67).

Especially, since the needle holes formed on the top (61) and the bottom (63) are also filled up by water repellant solution, there is no concern of water leak into the inside of the clothing even under harsh rain.

The reference numeral 65 indicates a moisture-passing gap. The moisture-passing gap (65) works as passage through which moisture or heat from the body is discharged.

FIG. 19 is a diagram showing a tent (69) manufactured according to the method of FIG. 16.

Referring to the figure, the coating layer (43) is laminated on the threads (67) of the compound fiber fabric (62) forming the tents (69). The coating layer (43) has water drops such as rain, dew, etc. not stay there but roll down immediately.

Furthermore, since the needle holes of the sewing lines (13) formed on the roof of the tents (69), as described in FIG. 17, are blocked by the coating layer (43), even though it rains harshly, for example, there is no peril of water leaking into the inside of the tents (69) through the needle holes.

FIGS. 20 through 23 are diagrams showing the backpack (71), the glove (73), the shoe (75), and the cap (77) among various kinds of fiber products manufactured according to the method of FIG. 16.

As shown, the coating layer (43) is laminated on the threads (67) of the compound fiber fabric (62) forming surface fabrics of the backpack (71), the glove (73), the shoe (75), and the cap (77). Since the coating layer (43) of water repellant solution is formed in the compound fiber fabric (62), even when it rains, the rain drops are reflected right away and flow down, keeping them dry all the time.

Also, since the needle holes of the sewing lines (13) is blocked completely by the water repellant solution, water is not leaked into the inside, resulting in an excellent waterproofing. The shoe (75) includes ugg boots or children's insulating boots that are popular nowadays.

In the case of the glove (73), since it does not get wet from snows during winter time, it is very convenient to use in skiing. Since the shoe (75) has waterproofing capability, water does not enter the inside (as if it is like boots) even when it rains or walks on snow. Also, since the cap (77) is free from moisture leaking-in, the user does not have to worry about spoiling hair style from water.

On the other hand, the test report attached below is one from a test in Korean Fiber Institute according to the Japanese Quality Criterion, which shows the water repellant capability of the compound fiber fabric forming the fiber product provided with water repellant coating layer according to the sixth embodiment.

As shown in the above test result, each of cloth samples 1 and 2 is cut into three pieces, and tested for degree of water repellant, showing that all the three pieces of the cloth sample 1 got level 3 (3 3 3), and that all the three pieces of the cloth sample 2 got level 3 (3 3 3).

As described previously, in water repellant test under the Japanese Test Criterion (JIS L 1092), which is stricter and tougher than Korean standard, level 4 is the highest level, and levels higher or equal to level 2 (levels 4, 3, 2) are considered to pass.

Additionally, the fact that all the three pieces got the same level means that the water repellant property of fabric is uniform. That is, it is not that some portions of the fabric have better water repellant property and other portions of the fabric have relatively worse water repellant property, but that all the portions of the fabric have an even water repellant property. This shows the evenness and repeatability of the effects of the method.

While the invention has been shown and described with reference to different embodiments thereof, it will be appreciated by those skilled in the art that variations in form, detail, compositions and operation may be made without departing from the spirit and scope of the invention as defined by the accompanying claims.

Claims

1. A method for manufacturing a fiber product comprising:

a washing step for inserting and washing a semi-manufactured fiber product comprising a fabric having natural fiber;

a first drying step for dehydrating and then drying the semi-manufactured fiber product that is washed;

a water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution;

a second drying step for dehydrating and then drying the semi-manufactured product that has completed the water repellant solution submerging step;

a thermal setting step for fixing the water repellant solution to the threads;

a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after thermal setting; and

a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

2. The method for manufacturing a fiber product of claim 1, further comprising an aging step for applying a physical force to and aging-processing the semi-manufactured fiber product prior to the washing step in a case that the fiber product is made of denim colored by dye.

3. A method for manufacturing a fiber product comprising:

a washing step for inserting and washing a semi-manufactured fiber product comprising a fabric having natural fiber;

a first drying step for dehydrating and then drying the semi-manufactured fiber product that is washed by the washing step;

a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution;

a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step;

a first thermal setting step for fixing the water repellant solution to the threads;

a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the first thermal setting step and in a washed and dried state, so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution;

a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step;

a second thermal setting step for heating the semi-manufactured fiber product dried by the third drying step and fixing the water repellant solution to a first coating layer;

a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and

a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

4. A method for manufacturing a fiber product comprising:

a first drying step for dehydrating and then drying a semi-manufactured fiber product comprising a fabric having natural fiber and made from denim colored by dye;

a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution;

a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step;

a first thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads;

an aging step for applying a physical force to and aging-processing the semi-manufactured fiber product;

a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the aging step;

a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the third drying step so as to coat the water repellant solution on a first coating layer;

a fourth drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step;

a second thermal setting step for heating the semi-manufactured fiber product dried by the fourth drying step and fixing the water repellant solution to a first coating layer;

a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and

a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

5. A method for manufacturing a fiber product comprising:

an aging step for applying a physical force to and aging-processing a semi-manufactured fiber product comprising a fabric having natural fiber and made from denim colored by dye;

a first drying step for dehydrating and then drying the semi-manufactured fiber product that is from the aging step;

a first water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution;

a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first water repellant solution submerging step;

a first thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads;

a third drying step for dehydrating and then drying the semi-manufactured fiber product that is from the first thermal setting step;

a second water repellant solution submerging step for submerging the semi-manufactured fiber product that is from the third drying step so as to coat the water repellant solution on a first coating layer;

a fourth drying step for dehydrating and then drying the semi-manufactured fiber product that is from the second water repellant solution submerging step;

a second thermal setting step for heating the semi-manufactured fiber product dried by the fourth drying step and fixing the water repellant solution to a first coating layer;

a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the second thermal setting; and

a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

6. The fiber product provided with water repellant coating layer manufactured by the method for manufacturing a fiber product of claim 3.

7. The fiber product provided with water repellant coating layer of claim 6, wherein the fabric in the semi-manufactured fiber product is one selected from the group consisting of cotton fabric, blended cotton fabric, and natural fiber fabric.

8. The fiber product provided with water repellant coating layer of claim 6, wherein the fiber product provided with water repellant coating layer comprises clothes, backpack, bag, hat, shoes, and gloves.

9. The fiber product provided with water repellant coating layer manufactured by the method for manufacturing a fiber product of claim 5.

10. The fiber product provided with water repellant coating layer of claim 9, wherein the fiber product provided with water repellant coating layer comprises jean clothing, hat, bag, and backpack.

11. A method for manufacturing a fiber product comprising:

a bio-processing step for putting in an enzyme solution and washing a semi-manufactured fiber product comprising a fabric having natural fiber and manufactured by sewing;

a first drying step for dehydrating and then drying the semi-manufactured fiber product that is from the bio-processing step;

a water repellant solution submerging step for submerging the semi-manufactured fiber product that is dried from the first drying step so that the water repellant solution penetrates the threads of the fabric and coats the surface of the threads with the water repellant solution and filling needle holes on sewing lines formed by the sewing;

a second drying step for dehydrating and then drying the semi-manufactured fiber product that is from the water repellant solution submerging step;

a thermal setting step for applying heat to the semi-manufactured fiber product that is from the second drying step and fixing the water repellant solution to the threads;

a pliability processing step for washing and rendering the semi-manufactured fiber product pliable after the thermal setting; and

a product finishing step for dehydrating and drying the semi-manufactured fiber product that is rendered pliable and producing a finished product.

12. The method for manufacturing a fiber product of claim 11, wherein the bio-processing step is performed in the enzyme solution at a temperature from about 50° C. to about 70° C. for a time period from about 20 minutes to about 100 minutes.

13. The method for manufacturing a fiber product of claim 11, wherein the water repellant solution submerging step is performed in the water repellant solution at a temperature from about 40° C. to about 60° C. for a time period from about 30 minutes to about 1 hour.

14. The fiber product provided with water repellant coating layer manufactured by the method for manufacturing a fiber product of claim 13.

15. The fiber product provided with water repellant coating layer of claim 14, wherein the fiber product provided with water repellant coating layer comprises clothes, backpack, bag, hat, shoes, and gloves.

16. The fiber product provided with water repellant coating layer manufactured by the method for manufacturing a fiber product of claim 1.

17. The fiber product provided with water repellant coating layer manufactured by the method for manufacturing a fiber product of claim 2.

18. The fiber product provided with water repellant coating layer manufactured by the method for manufacturing a fiber product of claim 4.

19. The fiber product provided with water repellant coating layer manufactured by the method for manufacturing a fiber product of claim 11.

20. The fiber product provided with water repellant coating layer manufactured by the method for manufacturing a fiber product of claim 12.