Waterless dyeing method and yarn produced by waterless dyeing

Abstract

A polymer phase colored performance fabric is disclosed, which is formed of a fabric of a solution dyed yarn woven with an elastic yarn, the fabric comprising at least 60% by volume of the solution dyed yarn. The solution dyed yarn is formed of a synthetic substance in a polymer phase that is combined with a colored dye, the combination producing a polymer phase colorant comprising a masterbatch of colored chips, a portion of which is heated to a liquid polymer colorant. The liquid polymer colorant is extruded to form a thread-shaped colored fiber of the synthetic substance, which is then cooled to form the solution dyed yarn.

1 . A method of producing a polymer phase colored performance fabric, the method comprising:
 combining a synthetic substance in a polymer phase with a colored dye, the combining to produce a polymer phase colorant comprising a masterbatch of colored chips;   heating at least a portion of the masterbatch of colored chips to melt the portion of the masterbatch to a liquid polymer colorant;   extruding the liquid polymer colorant to form a thread-shaped colored fiber of the synthetic substance;   cooling the thread-shaped colored fiber of the synthetic substance to form a solution dyed yarn; and   weaving the solution dyed yarn with an elastic yarn to produce the polymer phase colored performance fabric, the polymer phase colored performance fabric being formed of at least 60% by volume of the solution dyed yarn.   
     
     
         2 . The method in accordance with  claim 1 , wherein the weight of the polymer phase colored performance fabric is between 15 and 70 denier. 
     
     
         3 . The method in accordance with  claim 1 , wherein combining the insoluble dye with the synthetic substance in the polymer phase further comprises includes enabling the insoluble dye to molecularly bond with the synthetic substance in the polymer phase. 
     
     
         4 . The method in accordance with  claim 1 , wherein the synthetic substance in the polymer phase is polyethylene terephthalate, and wherein the masterbatch of colored chips includes colored polyethylene terephthalate. 
     
     
         5 . The method in accordance with  claim 1 , wherein the colored dye is soluble, and wherein the masterbatch of colored chips is insoluble. 
     
     
         6 . A method of producing a polymer phase colored performance fabric, the method comprising:
 combining a synthetic substance in a polymer phase with a colored dye, the combining to produce a polymer phase colorant   forming the polymer phase colorant into a masterbatch of colored chips;   heating at least a portion of the masterbatch of colored chips to melt the portion of the masterbatch to a liquid polymer colorant;   extruding the liquid polymer colorant to form a thread-shaped colored fiber of the synthetic substance;   cooling the thread-shaped colored fiber of the synthetic substance to form a solution dyed yarn; and   weaving the solution dyed yarn with an elastic yarn to produce the polymer phase colored performance fabric, the polymer phase colored performance fabric being formed of at least 60% by volume of the solution dyed yarn.   
     
     
         7 . The method in accordance with  claim 6 , wherein the weight of the polymer phase colored performance fabric is between 15 and 70 denier. 
     
     
         8 . The method in accordance with  claim 6 , wherein combining the insoluble dye with the synthetic substance in the polymer phase further comprises includes enabling the insoluble dye to molecularly bond with the synthetic substance in the polymer phase. 
     
     
         9 . The method in accordance with  claim 6 , wherein the synthetic substance in the polymer phase is polyethylene terephthalate, and wherein the masterbatch of colored chips includes colored polyethylene terephthalate. 
     
     
         10 . The method in accordance with  claim 6 , wherein the colored dye is soluble, and wherein the masterbatch of colored chips is insoluble. 
     
     
         11 . A polymer phase colored performance fabric comprising:
 a fabric of a solution dyed yarn woven with an elastic yarn, the fabric comprising at least 60% by volume of the solution dyed yarn, the solution dyed yarn being formed of a synthetic substance in a polymer phase that is combined with a colored dye, the combination producing a polymer phase colorant comprising a masterbatch of colored chips, a portion of which is heated to a liquid polymer colorant, which is extruded to form a thread-shaped colored fiber of the synthetic substance, which is cooled to form the solution dyed yarn.   
     
     
         12 . The polymer phase colored performance fabric in accordance with  claim 11 , wherein the fabric has a weight of between 15 and 70 denier. 
     
     
         13 . The polymer phase colored performance fabric in accordance with  claim 12 , wherein the fabric has a weight of between 30 and 50 denier. 
     
     
         14 . The polymer phase colored performance fabric in accordance with  claim 11 , wherein the elastic yarn is formed of elastane. 
     
     
         15 . The polymer phase colored performance fabric in accordance with  claim 11 , wherein the synthetic substance in the polymer phase is polyethylene terephthalate.