Method of manufacturing velvet plush and article thereof

Abstract

A method of manufacturing a velvet plush article includes the steps of: weaving a greige cloth by interweaving face yarns and backing yarns, wherein the face yarns are selected from single-ply bright trilobal yarns and two-ply yarns and the backing yarns are selected from FDY or DTY yarn: pre-processing the greige cloth by brushing, first setting, singeing and second setting the greige cloth sequentially; dyeing and/or printing the greige cloth; and finishing the greige cloth by softening, drying, brushing, sentering, heat-setting, singeing, shearing and final heat-setting the greige cloth. Accordingly, a velvet plush article having a superior smoothness and softness for providing a superior touch and feel comfort is achieved. The velvet plush article may be a velvet plush throw or blanket, or a velvet plush cloth for further processing.

What is claimed is: 
     
       1. A method of manufacturing a velvet plush article, comprising the steps of:
 weaving a greige cloth by interweaving face yarns and backing yarns, said face yarns comprising single-ply trilobal yarns or two-ply yarns and said backing yarns comprising fully drawn yarns or draw-textured yarns; 
 pre-processing by sequentially brushing, first setting, singeing and second setting said greige cloth; 
 dyeing the pre-processed greige cloth to form a colored cloth; and 
 finishing by sequentially softening, drying, brushing, stentering, first heat-setting, singeing, shearing and final heat-setting said colored greige cloth to form a finished velvet plush article having a flat body including a middle layer and two pile layers, each said pile layer having pile hair that is uni-directional, smooth and soft. 
 
     
     
       2. The method of  claim 1  further comprising the steps of:
 printing a pattern on said colored cloth, and 
 performing said finishing step on the printed colored cloth. 
 
     
     
       3. The method of  claim 1  wherein
 said single-ply trilobal yarns are selected from the group of yarns having linear mass densities of 75D/144F, 90D/144F, 100D/144F and 150D/288F, 
 the two-ply yarns are selected from the group of yarns having linear mass densities of 120D/288F or 300D/574F, and 
 the backing yarns are yarns selected from fully drawn yarns having a weight of approximately 68D-100D or draw textured yarns having a weight of approximately, 100D-150D. 
 
     
     
       4. The method of  claim 2  wherein
 said single-ply trilobal yarns are selected from the group of yarns having linear mass densities of 75D/144F, 90D/144F, 120D/288F and 300D/574F 100D/144F and 150D/288F, and 
 the backing yarns are yarns selected from fully drawn yarns having a weight of approximately 68D-100D or draw textured yarns having a weight of approximately 100D-150D. 
 
     
     
       5. The method of  claim 3  wherein said face yarns and said backing yarns have a ratio of 4:1 by weight. 
     
     
       6. The method of  claim 4  wherein said face yarns and said backing yarns have a ratio of 4:1 by weight. 
     
     
       7. The method of  claim 5  wherein:
 said brushing during pre-processing includes brushing in a frontward direction and brushing in a backward direction opposite of said frontward direction; 
 said first setting process includes heat-setting between approximately 120-130° C. at a rolling speed of 25 m/min; 
 said singeing process during pre-processing includes passing said greige cloth across hot singe rollers in frontward, backward, backward, frontward, backward and backward directions, sequentially; and 
 said second setting process includes heat-setting between approximately 170-180° C. at a rolling speed of 25 m/min. 
 
     
     
       8. The method of  claim 6  wherein:
 said brushing during pre-processing includes brushing in a frontward direction and brushing in a backward direction opposite of said frontward direction; 
 said first setting process includes heat-setting between approximately 120-130° C. at a rolling speed of 25 m/min; 
 said singeing process during pre-processing includes passing said greige cloth across hot singe rollers in frontward, backward, backward, frontward, backward and backward directions, sequentially; and 
 said second setting process includes heat-setting between approximately 170-180° C. at a rolling speed of 25 m/min. 
 
     
     
       9. The method of  claim 7  wherein said dyeing comprises the substeps of:
 bathing in dye fluid, and 
 rinsing with water having a neutral pH or a low acidity that will result in the dyed greige cloth having a smooth and bright surface. 
 
     
     
       10. The method of  claim 8  wherein said dyeing comprises the substeps of:
 bathing in dye fluid, and 
 rinsing with water having a neutral pH or a low acidity that will result in the dyed greige cloth having a smooth and bright surface. 
 
     
     
       11. The method of  claim 10  wherein
 the softening process includes:
 washing to add acidity until the greige cloth is soft, and 
 neutralizing the pH of the acidified greige cloth; 
 
 the drying process includes drying at approximately 190° C. at a rolling speed of 20 m/min with an upper drying channel operated at 300 rpm and a lower drying channel operated at 1200 rpm; 
 the brushing process during finishing includes two brushing cycles; 
 the stentering process includes stentering in a frontward direction and in a backward direction, sequentially; 
 the first heat-setting process includes heat-setting at approximately under 150° C. at a rolling speed of 25 m/min; 
 the singeing process during finishing includes passing said greige cloth across hot singeing rollers in backward, backward, frontward, frontward, backward, frontward, backward and frontward directions, sequentially; 
 the shearing process includes shearing in frontward, backward, backward, frontward, frontward, frontward, backward and backward directions, sequentially, such that the final orientation of the pile hair is the same when approaching the cloth from both frontward and backward directions; and 
 the final heat-setting process includes heat-setting at approximately 190° C. at a rolling speed of 30 m/min. 
 
     
     
       12. The method of  claim 9  wherein
 the softening process includes:
 washing to add acidity until the greige cloth is soft, and 
 neutralizing the pH of the acidified greige cloth; 
 
 the drying process includes drying at approximately 190° C. at a rolling speed of 20 m/min with an upper drying channel operated at 300 rpm and a lower drying channel operated at 1200 rpm; 
 the brushing process during finishing includes two brushing cycles; 
 the stentering process includes stentering in a frontward direction and in a backward direction, sequentially; 
 the heat-setting process includes heat-setting at approximately under 150° C. at a rolling speed of 25 m/min; 
 the singeing process during finishing includes passing said greige cloth across hot singeing rollers in backward, backward, frontward, frontward, backward, frontward, backward and frontward directions, sequentially; 
 the shearing process includes shearing in frontward, backward, backward, frontward, frontward, frontward, backward and backward directions, sequentially, such that the final orientation of the pile hair is the same when approaching the cloth in both frontward and backward directions; and 
 the final heat-setting process includes heat-setting at approximately 190° C. at a rolling speed of 30 m/min. 
 
     
     
       13. A method of manufacturing a velvet plush article, comprising the steps of:
 weaving a greige cloth by interweaving face yarns and backing yarns, said face yarns comprising single-ply trilobal yarns or two-ply yarns and said backing yarns comprising fully drawn yarns or draw-textured yarns; 
 pre-processing by sequentially brushing, first setting, singeing and second setting said greige cloth; 
 dyeing the pre-processed greige cloth to form a colored cloth; and 
 finishing by sequentially softening, drying, brushing, first heat-setting, singeing, shearing and final heat-setting said colored greige cloth to form a finished velvet plush article having pile hair that is uni-directional, smooth and soft. 
 
     
     
       14. The method of  claim 13  further comprising the process of stentering between said brushing and said heat-setting processes in said finishing step, said velvet plush article having a flat body including a middle layer and two pile layers, each pile layer having pile hair that is uni-directional, smooth and soft. 
     
     
       15. The method of  claim 13  further comprising the step of printing on said colored cloth. 
     
     
       16. The method of  claim 13  wherein
 said single-ply trilobal yarns are selected from the group of yarns having linear mass densities of 75D/144F, 90D/144F, 120D/288F and 300D/574F 100D/144F and 150D/288F, and 
 said backing yarns are yarns selected from fully drawn yarns having a weight of approximately 68D-100D or draw textured yarns having a weight of approximately 100D-150D. 
 
     
     
       17. The method of  claim 13  wherein said face yarns and said backing yarns have a ratio of 4:1 by weight. 
     
     
       18. The method of  claim 13  wherein
 said brushing process during pre-processing includes brushing in a frontward direction and brushing in a backward direction; 
 said first setting process includes heat-setting between approximately 120-130° C. at a rolling speed of 25 m/min; 
 said singeing process during pre-processing includes passing the greige cloth across hot singe rollers in frontward, backward, backward, frontward, backward and backward directions, sequentially; and 
 said second setting process includes heat-setting between approximately 170-180° C. at a rolling speed of 25 m/min. 
 
     
     
       19. The method of  claim 13  wherein said dyeing step comprises the substeps of:
 bathing said pre-processed greige cloth in a dye solution fluid, and 
 neutralizing the pH or lowering the acidity of said greige cloth to give the dyed greige cloth a smooth and bright surface. 
 
     
     
       20. The method of  claim 13  wherein
 the softening process includes:
 washing to add acidity until the greige cloth is soft, and 
 neutralizing the pH of the acidified greige cloth; 
 
 the drying process includes drying at approximately 190° C. at a rolling speed of 20 m/min with an upper drying channel operated at 300 rpm and a lower drying channel operated at 1200 rpm; 
 the first heat-setting process includes heat-setting at approximately under 150° C. at a rolling speed of 25 m/min; 
 the singeing process during finishing includes passing said greige cloth across hot singeing rollers in backward, backward, frontward, frontward, backward, frontward, backward and frontward directions, sequentially; 
 the shearing process includes shearing in frontward, backward, backward, frontward, frontward, frontward, backward and backward directions, sequentially, such that the final orientation of the pile hair is the same when approaching the cloth in both frontward and backward directions; and 
 the final heat-setting process includes heat-setting at approximately 190° C. at a rolling speed of 30 m/min.