Abstract: The invention generally relates to fabric dyeing, such as fabric dyeing using indigo or sulphur dyes. A process is provided which provides a dyed yarn having reduced dye penetration and a white core. The process involves modification of existing sulfur dye ranges to more efficiently and in an environmentally improved method produce dyed fabrics. The modification involves one or more of i) using of a barrier compound to subsequent dye applications; ii) performing a scouring stage without a caustic agent; iii) bypassing scouring and/or scour rising; iv) using sodium bicarbonate to control the pH of dye tanks; v) reducing the dye concentration and increasing the number of dye vats; and vi) adding a sizing stage to the dye range. The invention also is directed to yarns dyed on dye ranges through use of the process, and fabrics formed from the dyed yarns.

Abstract: The present invention generally relates to sulfur dyeing of fabrics. In particular, a process is provided which provides a sulfur dyed yarn having reduced dye penetration and a white core. The process involves modification of existing sulfur dye ranges in order to more efficiently and in an environmentally improved method produce dyed fabrics. The process involves modifying the immersion time, temperature, pH, and/or dye oxidation of existing sulfur dye ranges. The resulting yarns may then be woven into fabrics used to produce garments.

Abstract: The present invention relates to yarn dyeing, such as denim dyeing. A process provides a dyed yarn having reduced dye penetration and a white core at lower cost. The improved process for yarn dyeing is referred to herein as the CleanKore technology. The CleanKore technology improves one or more steps in dye ranges to achieve dyeing of the yarn while retaining a white core at the center of the yarn. When viewing a cross-section of a yarn, the peripheral portion is dyed while the center remains white (not dyed). The CleanKore technology modifies the scouring stage (or phase), the scour rinsing stage, the dyeing stage, and/or the dye rinsing phase of existing dye ranges. The modifications may be applied individually or any combinations thereof to the existing dye range.

Abstract: A method is provided of generating a pattern image used to form a pattern on a surface of a fabric using laser irradiation. A plurality of parameters associated with laser irradiation units are input into a user interface. The parameters include an area parameter, a laser irradiation unit density parameter, optionally a discontinuity parameter, and a dye removal parameter. A plurality of laser irradiation units arranged in a pattern area of a user interface based on computer processing of the inputted plurality of parameters is received for viewing at the user interface. The laser irradiation units collectively establish the pattern image for viewing by the user.

Abstract: Ring dyeing of yarn with indigo dye to produce an improved white core, An outer surface of the yarn is scoured prior to applying the indigo dye, and then applying the indigo dye is applied. Scouring parameters of the dyeing are used to limit a penetration of the indigo into the white core, so that the white core has mostly sections of white yarn, and the yarn has indigo dye on the outer surface, said parameters comprising limiting scouring parameters to at least 10% below current parameters used to scour the yarn.

Abstract: A method of scribing abrasion aesthetics, patterns, images, serial numbers, ply markings and/or other information, such as sizing or care information, on fabric such as denim, before or during the fabric cutting process is provided. The method comprises loading the panel abrasion software, pattern marker software, and fabric scribing software; placing the fabric on a flat surface under at least one laser; laser scribing ply numbers, serial labels, fabric markers, and panel abrasions on the fabric; cutting the fabric into fabric lengths; spreading the pre-abraded and pre-marked fabric lengths on top of each other to create multiple plies in precise alignment; cutting shaped panels along the lines of the pattern marker with a conventional knife, laser, or other appropriate cutting tool; and stacking the abraded, labeled and shaped panels robotically or manually for sewing.

Abstract: A method is provided of generating a pattern image used to form a pattern on a surface of a fabric using laser irradiation. A plurality of parameters associated with laser irradiation units are input into a user interface. The parameters include an area parameter, a laser irradiation unit density parameter, optionally a discontinuity parameter, and a dye removal parameter. A plurality of laser irradiation units arranged in a pattern area of a user interface based on computer processing of the inputted plurality of parameters is received for viewing at the user interface. The laser irradiation units collectively establish the pattern image for viewing by the user.

Abstract: A method of scribing a graphic on a material is provided, in which laser output is applied to the material. The laser output is moved relative to the material at a high speed greater than 10 m per second, and at a high power greater than 500 W, to scribe a graphic on a surface of the material. Also provided is a system for scribing a graphic on a material. The method and system of the invention are especially useful in the scribing of building materials.

Abstract: A method of scribing abrasion aesthetics, patterns, images, serial numbers, ply markings and/or other information, such as sizing or care information, on fabric such as denim, before or during the fabric cutting process is provided. The method comprises loading the panel abrasion software, pattern marker software, and fabric scribing software; placing the fabric on a flat surface under at least one laser; laser scribing ply numbers, serial labels, fabric markers, and panel abrasions on the fabric; cutting the fabric into fabric lengths; spreading the pre-abraded and pre-marked fabric lengths on top of each other to create multiple plies in precise alignment; cutting shaped panels along the lines of the pattern marker with a conventional knife, laser, or other appropriate cutting tool; and stacking the abraded, labeled and shaped panels robotically or manually for sewing.

Abstract: A method of scribing abrasion aesthetics, patterns, images, serial numbers, ply markings and/or other information, such as sizing or care information, on fabric such as denim, before or during the fabric cutting process is provided. The method comprises loading the panel abrasion software, pattern marker software, and fabric scribing software; placing the fabric on a flat surface under at least one laser; laser scribing ply numbers, serial labels, fabric markers, and panel abrasions on the fabric; cutting the fabric into fabric lengths; spreading the pre-abraded and pre-marked fabric lengths on top of each other to create multiple plies in precise alignment; cutting shaped panels along the lines of the pattern marker with a conventional knife, laser, or other appropriate cutting tool; and stacking the abraded, labeled and shaped panels robotically or manually for sewing.

Abstract: A method is provided of generating a pattern image used to form a pattern on a surface of a fabric using laser irradiation. A plurality of parameters associated with laser irradiation units are input into a user interface. The parameters include an area parameter, a laser irradiation unit density parameter, optionally a discontinuity parameter, and a dye removal parameter. A plurality of laser irradiation units arranged in a pattern area of a user interface based on computer processing of the inputted plurality of parameters is received for viewing at the user interface. The laser irradiation units collectively establish the pattern image for viewing by the user.

Abstract: A method of scribing a graphic on a material is provided, in which laser output is applied to the material. The laser output is moved relative to the material at a high speed greater than 10 m per second, and at a high power greater than 500 W, to scribe a graphic on a surface of the material. Also provided is a system for scribing a graphic on a material. The method and system of the invention are especially useful in the scribing of building materials.

Abstract: A method of scribing a graphic on a material is provided, in which laser output is applied to the material. The laser output is moved relative to the material at a high speed greater than 10 m per second, and at a high power greater than 500 W, to scribe a graphic on a surface of the material. Also provided is a system for scribing a graphic on a material. The method and system of the invention are especially useful in the scribing of building materials.

Abstract: A method of scribing a graphic on a material is provided, in which laser output is applied to the material. The laser output is moved relative to the material at a high speed greater than 10 m per second, and at a high power greater than 500 W, to scribe a graphic on a surface of the material. Also provided is a system for scribing a graphic on a material. The method and system of the invention are especially useful in the scribing of building materials.

Abstract: A method is provided of generating a pattern image used to form a pattern on a surface of a fabric using laser irradiation. A plurality of parameters associated with laser irradiation units are input into a user interface. The parameters include an area parameter, a laser irradiation unit density parameter, optionally a discontinuity parameter, and a dye removal parameter. A plurality of laser irradiation units arranged in a pattern area of a user interface based on computer processing of the inputted plurality of parameters is received for viewing at the user interface. The laser irradiation units collectively establish the pattern image for viewing by the user.

Abstract: A method of scribing a graphic on a material is provided, in which laser output is applied to the material. The laser output is moved relative to the material at a high speed greater than 10 m per second, and at a high power greater than 500 W, to scribe a graphic on a surface of the material. Also provided is a system for scribing a graphic on a material. The method and system of the invention are especially useful in the scribing of building materials.

Abstract: A method of scribing abrasion aesthetics, patterns, images, serial numbers, ply markings and/or other information, such as sizing or care information, on fabric such as denim, before or during the fabric cutting process is provided. The method comprises loading the panel abrasion software, pattern marker software, and fabric scribing software; placing the fabric on a flat surface under at least one laser; laser scribing ply numbers, serial labels, fabric markers, and panel abrasions on the fabric; cutting the fabric into fabric lengths; spreading the pre-abraded and pre-marked fabric lengths on top of each other to create multiple plies in precise alignment; cutting shaped panels along the lines of the pattern marker with a conventional knife, laser, or other appropriate cutting tool; and stacking the abraded, labeled and shaped panels robotically or manually for sewing.

Abstract: The present invention provides systems and methods for imparting designs and/or patterns on fabric by laser etching the fabric at an energy density of about 0.0398 to about 31.85 watts-sec/mm3. The resulting fabric contains designs and/or patterns thereon and has great feel or hand.

Abstract: The present invention generally relates to a surface treatment of fabric with a laser and, more specifically, to a system and method for generating a pattern used to process a surface of a fabric through laser irradiation and the fabric resulting from such treatment. The present invention provides small laser spot sizes while operating a laser at large field size by 1) using a laser system with post-objective scanning architecture; 2) using multiple lasers across the width of a fabric roll; and/or 3) increasing the size and weight of the laser scanning mirrors. The spot size normally associated with a smaller laser field size (e.g. 500 mm) may be achieved with a laser having a larger field size (e.g. 950 mm or greater) by practicing the teachings of this invention.

Abstract: A method of surface marking an article, especially a building product, is provided. One described method includes the steps of laser marking a first graphic design element on a surface of an article and ink-jet printing a second graphic design element in registry with the first graphic design element on the surface of the article to create a high quality overall graphic design. Also provided are articles made according to this method, and systems for carrying out the method.