US 20140013555A1 (19) United States (12) Patent Application Publication (10) Pub. No.: US 2014/0013555 A1 Xu (43) Pub. Date: Jan. 16, 2014

(54) METHOD OF MANUFACTURING VELVET (57) ABSTRACT PLUSH AND ARTICLE THEREOF (76) Inventor: Michael Xu, City of Industry, CA (U S) A method of manufacturing a velvet plush article includes the steps of: a greige cloth by interweaving face _ and backing yarns, Wherein the face yarns are selected from (21) Appl' NO" 13/507’616 single-ply bright trilobal yarns and tWo-ply yarns and the backing yarns are selected from FDY or DTY yam; pre (22) Filed; J u], 12, 2012 processing the greige cloth by brushing, ?rst setting, singeing and second setting the greige cloth sequentially; and/ or printing the greige cloth; and ?nishing the greige cloth by Publication Classi?cation softening, drying, brushing, stentering, heat-setting, singe ing, shearing and ?nal heat-setting the greige cloth. Accord (51) IIlt- Cl- ingly, a velvet plush article having superior smoothness and D06C 29/00 (2006-01) softness for providing a superior touch and feel comfort is (52) US. Cl. achieved. The velvet plush article may be a velvet plush throW USPC ...... 28/163 or blanket, or a velvet plush cloth for further processing. Patent Application Publication Jan. 16, 2014 Sheet 1 0f 4 US 2014/0013555 A1

FIG.1 Patent Application Publication Jan. 16, 2014 Sheet 2 0f 4 US 2014/0013555 A1

121 1211 N 10

1212 ‘ 122 'lllHHIHIHIIIIIHIVIIHH\IH1IHIIHIIHIHIHIHIIYIIHIHIIH\HIHHHHIlllilllllllllllll F|G.2 j\1221 IIHIHIHIIIIHIHIHIHIIImum||||||m||m|

,llllll Patent Application Publication Jan. 16, 2014 Sheet 3 0f 4 US 2014/0013555 A1

weaving a greige cloth synthetic materials such as polyester

V pre-processing the greige cloth

V Dyeing to provide a color 12 Printing to provide a pattern 16

a a l

_v_ . Final velvet plush article such Flnishlng as a throw or a blanket having at least one pile layer comprising a plurality of pile hair which is highly smooth and soft to provide a superior soft and smooth touch and feel effect

FIG. 3 Patent Application Publication Jan. 16, 2014 Sheet 4 0f 4 US 2014/0013555 A1

weaving a greige cloth by synthetic yarn materials interweaving face yarns and backing such as polyester yarns, wherein the face yarns are single-ply bright trilobal yarns or two- the Sing|e_p|y bright triloba' ply yarns and the backing yarns are yarns are yams with FDY or DTY Yams 75D/144F, 90D/144F, ' 1OOD/144F or 15OD/288F, the pre-processing by brushing, first two'ply yams are yams with setting, singeing and second setting 12°P/288F~3°°D/574F| the process sequentially backing yarns are FDY 68D 100D or DTY 100D-15OD yarn

V Dyeing: Bathing (i) brushing along a frontward & a backward and Rinsing direction; (ii) first setting under 130-120°C at 25m/min; (iii) singeing with sequential rolling: frontward, backward, backward, frontward, backward and backward direction; (iv) second setting under 170-180°C at 25m/min

,w Printing to provide a by softening, Pattern 16 drying, brushing, stentering, heat-setting, singeing, 8533225022: 22122;"), Final velvet plush article such as a throw or a blanket havlng at least one pile layer comprising a plurality of pile hair which is highly smooth and soft to provide a superior soft and smooth touch and feel effect FIG. 4 US 2014/0013555 A1 Jan. 16, 2014

METHOD OF MANUFACTURING VELVET [0014] According to the present invention, the foregoing PLUSH AND ARTICLE THEREOF and other objects and advantages are attained by a method of manufacturing a velvet plush article, comprising the steps of: BACKGROUND OF THE PRESENT INVENTION [0015] (a.1) Weaving a greige cloth by interWeaving face yarns and backing yarns, Wherein the face yarns are selected [0001] 1. Field of Invention from a group consisting of single-ply bright trilobal yarns [0002] The present invention relates to velvet plush, and With 75D/144F, 90D/144F, 100D/144F or 150D/288F and more particularly to a method of manufacturing velvet plush throW Which utiliZes synthetic ?ber to produce a particularly tWo-ply yarns With 120D/288F-300D/574F, Wherein the backing yarns are selected from FDY 68D-100D or DTY soft and smooth velvet plush throW. 100D-150D; [0003] 2. Description of Related Arts [0016] (b.1) pre-processing the greige cloth obtained from [0004] Velvet plush has a generally soft and smooth texture step (a) by brushing, ?rst setting, singeing and second setting and is a very popular materials used in . Recently, the greige cloth sequentially; velvet plush throW, blanket or the like is very popular in [0017] (c. 1) dyeing the greige cloth after step (b. 1) to form regular household use because its softness and smoothness a colored greige cloth; and provides a very great feel and touch sensation to a user. [0018] (e. 1) ?nishing the colored greige cloth by softening, HoWever, in order to manufacture a velvet plush throW, blan drying, brushing, stentering, heat-setting, singeing, shearing ket or the like With superior feel and touch sensation, the cost and ?nal heat-setting the colored greige cloth. of manufacture is very high. On the contrary, in order to manufacture a velvet plush throW and blanket With reasonable [0019] Altemately, after the step (b.1) or (c.l), the method manufacture cost, the quality of the velvet plush throW is loW. of manufacturing a velvet plush article further comprises the There is no Way to manufacture a high quality velvet plush steps of: throW With a cost-effective method. [0020] (d. 1) printing the greige cloth obtained from the step [0005] For example, silk is the traditional material Which (b.1) or printing the colored greige cloth obtained from the provides superior softness and smoothness. HoWever, silk is step (c.l) to form a printed greige cloth; and also a very expensive raW material and therefore it is not an [0021] (e. 1) ?nishing the colored greige cloth or the printed option When manufacturing cost is a concern. greige cloth by softening, drying, brushing, stentering, heat [0006] On the other hand, synthetic materials such as poly setting, singeing, shearing and ?nal heat-setting the colored ester and nylon are more reasonable in price. HoWever, the or printed greige cloth sequentially. quality of a velvet plush cloth made in polyester or nylon is [0022] Preferably, in step (a1), a ?rst and a second ?la relatively loW. ments are provided and a ratio of the ?rst ?lament to the second ?lament is 4: 1, Wherein the ?rst ?lament is a backing [0007] Conventional method for manufacturing a tufted surface involves needling and adding the tufted pile onto a ?lament. backing, Which is also incapable of providing a smooth and [0023] Preferably and in particular, in step (b1), the brush soft tufted surface of high quality With evenly distributed pile ing involves brushing along a frontWard direction as Well as layer. brushing at a backWard direction; the ?rst setting involves heat-setting at 130-1200 C. at a rolling speed of 25 m/min; the SUMMARY OF THE PRESENT INVENTION singeing involves a sequential rolling for six times at a front Ward, backWard, backWard, frontWard, backWard and back [0008] The invention is advantageous in that it provides a Ward directions; the second setting involves heat-setting at method of manufacturing velvet plush Which can utiliZe syn 170-1800 C. at a rolling speed of 25 m/min. thetic materials to produce a high quality velvet plush article. [0024] In particular, in the step (c.l), dyeing the greige [0009] Another advantage of the invention is to provide a cloth includes bathing in dye ?uid and rinsing by Water. method of manufacturing velvet plush Which can utiliZe syn Preferably, an additional dyeing time is required for bathing thetic materials to produce a velvet plush article having supe and a pH of the Water for rinsing is neutral or has a loWest rior smoothness and softness so as to provide a superior touch acidity for providing a smooth and bright surface. The addi and feel comfort. tional dyeing time for bathing is 20 minutes. [0010] Another advantage of the invention is to provide a [0025] In particular, in the step (d.1), printing includes the method of manufacturing velvet plush Which can utiliZe syn steps of brushing at a frontWard direction, setting at 150° C. at thetic materials to produce a velvet plush article through an a rolling speed of 25 m/min, and printing a preset pattern. automated process With loWered cost and higher quality. [0026] Preferably, in the step (e. 1), softening includes [0011] Another advantage of the invention is to provide a Washing to add acidity until the greige cloth is soft and then velvet plush article through a method of manufacture thereof neutraliZing the greige cloth until a pH of the greige cloth is so as to provide a velvet plush article having superior smooth neutral. It is Worth mentioning if the pH is smaller than 7, then ness and softness While providing ?exibilities in dyeing and hair loss Will occur. If the pH is greater than 7, the greige cloth printing. Will be hardened; drying includes drying under 190° C. at a [0012] Another advantage of the invention is to provide a rolling speed of 20 m/min With an upper drying channel velvet plush article through a method of manufacture thereof operated at 300rpm and a loWer drying channel operated at so as to provide a velvet plush article having superior smooth 1200 rpm; brushing includes brushing for tWo times; stenter ness and softness so as to provide a superior touch and feel ing includes stentering at a frontWard direction and a back comfort. Ward direction; [0013] Additional advantages and features of the invention [0027] heat-setting includes heat-setting under 1500 C. at a Will become apparent from the description Which folloWs, rolling speed of 25 m/min With soft air; singeing includes and may be realiZed by means of the instrumentalities and singeing at a frontWard direction and a backWard direction, combinations particular point out in the appended claims. and preferably includes singeing at a backWard, backWard, US 2014/0013555 A1 Jan. 16, 2014

frontward, frontward, backward, frontward, backward and on one of the top surface 1211 and the bottom surface 1212. frontward directions sequentially; shearing includes shearing Preferably, the velvet plush article 10, as shown in FIG. 2 of at a frontward, backward, backward, frontward, frontward, the drawings, is a velvet plush throw having two pile layers frontward, backward and backward directions sequentially 122 on the top surface 1211 and the bottom surface 1212 such that the ?nal direction of the hair at a frontward direction respectively and the pile hair 1221 is uni-directional in which and at a backward direction are the same; and ?nal heat a direction of the pile hair 1221 at a frontward direction is the setting includes heat-setting at 190° C. at a rolling speed of 30 same as a direction of the pile hair at a backward direction. m/min. The velvet plush article 10 is made in synthetic materials such [0028] In accordance with another aspect of the invention, as polyester and the two pile layers 122 on the top surface the present invention comprises a velvet plush article, com 1211 and the bottom surface 1212 provide a highly smooth prising: and soft touch and feel to a user. In addition, a color 14 and/or [0029] a ?at body having a middle layer de?ning a top a pattern 16 is preferably provided on one or both of the two surface and a bottom surface, and at least one pile layer pile layers 122 on the top surface 1211 and/or the bottom extended from the middle layer on one of the top surface and surface 1212 ofthe body 12 ofthe velvet plush article 10. It is the bottom surface, worth mentioning that the velvet plush article 10 can also be [0030] wherein the velvet plush article is made in synthetic a velvet plush blanket or simply a velvet plush sheet for materials such as polyester and the pile layer provides a further processing. highly smooth and soft touch and feel to a user. [0046] In particular, as shown in FIGS. 3 and 4 of the [0031] Preferably, a color and/ or a pattern is provided to the drawings, the method of manufacturing a velvet plush article ?at body of the velvet plush article. It is worth mentioning that comprises the steps of: the velvet plush article can also be a velvet plush blanket or [0047] (a.1) weaving a greige cloth by interweaving face simply a velvet plush sheet for further processing. yarns and backing yarns, wherein the face yarns are selected [0032] Still further objects and advantages will become from a group consisting of single-ply bright trilobal yarns apparent from a consideration of the ensuing description and with 75D/144F, 90D/144F, 100D/144F or 150D/288F and drawings. two-ply yarns with 120D/288F-300D/574F, wherein the [0033] These and other objectives, features, and advantages backing yarns are selected from FDY 68D-100D or DTY of the present invention will become apparent from the fol 100D-150D; lowing detailed description, the accompanying drawings, and [0048] (b.1) pre-processing the greige cloth obtained from the appended claims. step (a.1) by brushing, ?rst setting, singeing and second set ting the greige cloth sequentially; BRIEF DESCRIPTION OF THE DRAWINGS [0049] (c. 1) dyeing the greige cloth after step (b. 1) to form [0034] FIG. 1 is an illustration of a velvet plush article a colored greige cloth; and according to a preferred embodiment of the present invention. [0050] (e. 1) ?nishing the colored greige cloth by softening, [0035] FIG. 2 is a cross section illustration of a velvet plush drying, brushing, stentering, heat-setting, singeing, shearing article according to the above preferred embodiment of the and ?nal heat-setting the colored greige cloth. present invention. [0051] Altemately, after the step (b.1) or (c.1), the method [0036] FIG. 3 is an illustration of a method of manufactur of manufacturing a velvet plush article further comprises the ing velvet plush article according to the above preferred steps of: embodiment of the present invention. [0052] (d. 1) printing the greige cloth obtained from the step [0037] FIG. 4 is an illustration of a method of manufactur (b.1) or printing the colored greige cloth obtained from the ing velvet plush article according to the above preferred step (c.1) to form a printed greige cloth; and embodiment of the present invention. [0053] (e. 1) ?nishing the colored greige cloth or the printed greige cloth by softening, drying, brushing, stentering, heat DETAILED DESCRIPTION OF THE PREFERRED setting, singeing, shearing and ?nal heat-setting the colored EMBODIMENT or printed greige cloth sequentially. [0038] Referring to FIGS. 1 to 4 of the drawings, a method [0054] Preferably, in step (a1), a ?rst and a second ?la of manufacturing velvet plush article and a ?nal velvet plush ments are provided and a ratio of the ?rst ?lament to the article are illustrated. The method of manufacturing a velvet second ?lament is 4: 1, wherein the ?rst ?lament is a backing plush article comprises the steps of: ?lament. [0039] (a) weaving a greige cloth; [0055] Preferably and in particular, in step (b1), the brush [0040] (b) pre-processing the greige cloth from step (a); ing involves brushing along a frontward direction as well as [0041] (c) dyeing the greige cloth after step (b); brushing at a backward direction; the ?rst setting involves [0042] (d) printing the greige cloth after step (b) or (c); and heat-setting at 130-1200 C. at a rolling speed of 25 m/min; the [0043] (e) ?nishing process the greige cloth to form a ?nal singeing involves a sequential rolling for six times at a front velvet plush article. ward, backward, backward, frontward, backward and back [0044] It is worth mentioning that dyeing and printing are ward directions; the second setting involves heat-setting at optional steps as desired in order to create a particular color 170-1800 C. at a rolling speed of 25 m/min. and pattern onto the velvet plush article. [0056] In particular, in step (c.1), dyeing the greige cloth [0045] In particular, as shown in FIGS. 1 and 2 of the includes bathing in dye ?uid and rinsing by water. Preferably, drawings, the velvet plush article 10 has a ?at body 12 having an additional dyeing time is required for bathing and a pH of a middle layer 121 de?ning a top surface 1211 and a bottom the water for rinsing is neutral or has a lowest acidity for surface 1212, and at least one pile layer 122 comprising a providing a smooth and bright surface. The additional dyeing plurality of pile hair 1221 extended from the middle layer 121 time for bathing is 20 minutes. US 2014/0013555 A1 Jan. 16, 2014

[0057] In particular, in step (d. 1), printing includes the 6. A method of manufacturing a velvet plush article, com steps of brushing at a frontward direction, setting at 150° C. at prising the step of: a rolling speed of 25 m/min, and printing a preset pattern. (a. 1) weaving a greige cloth by interweaving face yarns and [0058] Preferably, in the step (e. 1), softening includes backing yarns, wherein the face yarns are single-ply washing to add acidity until the greige cloth is soft and then bright trilobal yarns or two-ply yarns and the backing neutralizing the greige cloth until a pH of the greige cloth is yarns are FDY or DTY yarns; neutral. It is worth mentioning if the pH is smaller than 7, then (b.1) pre-processing the greige cloth obtained from step hair loss will occur. If the pH is greater than 7, the greige cloth (a.1) by brushing, ?rst setting, singeing and second set will be hardened; drying includes drying under 190° C. at a ting process sequentially to obtain a pre-processed rolling speed of 20 m/min with an upper drying channel greige cloth; operated at 300 rpm and a lower drying channel operated at (c.1) dyeing the pre-processed greige cloth to form a col 1200 rpm; brushing includes brushing for two times; stenter ored greige cloth; and ing includes stentering at a frontward direction and a back (e.1) ?nishing by softening, drying, brushing, stentering, ward direction; heat-setting includes heat-setting under 1500 heat-setting, singeing, shearing and ?nal heat-setting C. at a rolling speed of 25 m/min with soft air; singeing process sequentially to form a ?nal velvet plush article, includes singeing at a frontward direction and a backward whereby the ?nal velvet plush article has a ?at body having direction, and preferably includes singeing at a backward, a middle layer and two pile layers de?ning a plurality of backward, frontward, frontward, backward, frontward, back pile hair, wherein the pile hair of the pile layers are ward and frontward directions sequentially; shearing uni-directional and is highly smooth and soft to provide includes shearing at a frontward, backward, backward, front a superior soft and smooth touch and feel effect. ward, frontward, frontward, backward and backward direc 7. The method, as recited in claim 6, after step (d. 1), further tions sequentially such that the ?nal direction of the hair at a comprising the step of: frontward direction and at a backward direction are the same; (d. 1) printing the colored greige cloth such that a pattern is and ?nal heat-setting includes heat-setting at 1900 C. at a provided onto the colored greige cloth. rolling speed of 30 m/min. 8. The method, as recited in claim 6, wherein in the step [0059] One skilled in the art will understand that the (a.1), the single-ply bright trilobal yarns are selected from a embodiment of the present invention as shown in the draw group of yarns with 75D/144F, 90D/144F, 100D/144F and ings and described above is exemplary only and not intended 150D/288F, the two-ply yarns are selected from a group of to be limiting. yarns with 120D/288F~300D/574F, and the backing yarns [0060] It will thus be seen that the objects of the present are yarns selected from FDY 68D-100D or DTY 100D-150D. invention have been fully and effectively accomplished. It 9. The method, as recited in claim 7, wherein in the step embodiments have been shown and described for the pur (a.1), the single-ply bright trilobal yarns are selected from a poses of illustrating the functional and structural principles of group of yarns with 75D/144F, 90D/144F, 100D/144F and the present invention and is subject to change without depar 150D/288F, the two-ply yarns are selected from a group of ture from such principles. Therefore, this invention includes yarns with 120D/288F-300D/574F, and the backing yarns are all modi?cations encompassed within the spirit and scope of yarns selected from FDY 68D-100D or DTY 100D-150D. the following claims. 10. The method, as recited in claim 8, wherein in the step What is claimed is: (a.1), the face yarn and the backing yarn has a ratio of 4:1 by 1. A method of manufacturing a velvet plush article, com weight. prising the step of: 11. The method, as recited in claim 9, wherein in the step (a) weaving a greige cloth by synthetic yarn materials; (a.1), the face yarn and the backing yarn has a ratio of 4:1 by (b) pre-processing the greige cloth; weight. (c) dyeing the greige cloth to form a colored greige cloth; 12. The method, as recited in claim 10, wherein in the step and (b1), the brushing process includes brushing along a front (e) ?nishing the colored greige cloth to form a ?nal velvet ward direction as well as brushing at a backward direction; plush article, the ?rst setting process includes heat-setting under 130-1200 whereby the ?nal velvet plush article has a ?at body having C. at a rolling speed of 25 m/min; the singeing process a middle layer and at least one pile layer de?ning a includes a sequential rolling for six times at a frontward, plurality of pile hair, wherein the pile hair of the pile backward, backward, frontward, backward and backward layer is uni-directional and is highly smooth and soft to directions respectively; and the second setting process provide a superior soft and smooth touch and feel effect. includes heat-setting under 170-1800 C. at a rolling speed of 2. The method, as recited in claim 1, wherein the synthetic 25 m/min. yarn materials are polyester and the velvet plush article is a 13. The method, as recited in claim 11, wherein in the step velvet plush throw. (b1), the brushing process includes brushing along a front 3. The method, as recited in claim 2, wherein the ?at body ward direction as well as brushing at a backward direction; of the ?nal velvet plush article has two pile layers on a top the ?rst setting process includes heat-setting under 130-1200 surface and a bottom surface of middle layer of the ?at body C. at a rolling speed of 25 m/min; the singeing process respectively. includes a sequential rolling for six times at a frontward, 4. The method, as recited in claim 1, after step (c), further backward, backward, frontward, backward and backward comprising a step (d): printing the colored greiged cloth such directions respectively; and the second setting process that a pattern is provided. includes heat-setting under 170-1800 C. at a rolling speed of 5. The method, as recited in claim 3, after step (c), further 25 m/min. comprising a step (d): printing the colored greiged cloth such 14. The method, as recited in claim 12, wherein in the step that a pattern is provided. (c. 1 ), further comprising the sub steps of: (c. 1 1) bathing in dye US 2014/0013555 A1 Jan. 16, 2014

?uid and (c. 12) rinsing by water, wherein a pH of the water for tion of the pile hair at a frontward direction and at a backward rinsing is neutral or has an acidity which is the lowest for direction are the same; and the ?nal heat-setting process providing a smooth and bright surfacing effect to the greige includes heat-setting under 1900 C. at a rolling speed of 30 cloth. m/min. 15. The method, as recited in claim 13, wherein in the step (c. 1), further comprising the substeps of: (c.1 1) bathing in dye 17. The method, as recited in claim 16, wherein in the step ?uid and (c. 12) rinsing by water, wherein a pH of the water for (e.1), the softening process includes washing to add acidity rinsing is neutral or has an acidity which is the lowest for until the greige cloth is soft and then neutraliZing the greige providing a smooth and bright surfacing effect to the greige cloth until a pH of the greige cloth is neutral; the drying cloth. process includes drying under 1900 C. at a rolling speed of 20 16. The method, as recited in claim 14, wherein in the step m/min with an upper drying channel operated at 300rpm and (e.1), the softening process includes washing to add acidity a lower drying channel operated at 1200 rpm; the brushing until the greige cloth is soft and then neutraliZing the greige process includes brushing for two times; the stentering pro cloth until a pH of the greige cloth is neutral; the drying cess includes sequentially stentering at a frontward direction process includes drying under 1900 C. at a rolling speed of 20 and a backward directions respectively; the heat-setting pro m/ min with an upper drying channel operated at 300rpm and cess includes heat-setting under 1500 C. at a rolling speed of a lower drying channel operated at 1200 rpm; the brushing 25 m/min; the singeing process includes sequential singeing process includes brushing for two times; the stentering pro at a backward, backward, frontward, frontward, backward, cess includes sequentially stentering at a frontward direction frontward, backward and frontward directions respectively; and a backward directions respectively; the heat-setting pro the shearing process includes shearing at a frontward, back cess includes heat-setting under 1500 C. at a rolling speed of ward, backward, frontward, frontward, frontward, backward 25 m/min; the singeing process includes sequential singeing and backward directions sequentially such that the ?nal direc at a backward, backward, frontward, frontward, backward, tion of the pile hair at a frontward direction and at a backward frontward, backward and frontward directions respectively; direction are the same; and the ?nal heat-setting process the shearing process includes shearing at a frontward, back includes heat-setting under 1900 C. at a rolling speed of 30 ward, backward, frontward, frontward, frontward, backward m/min. and backward directions sequentially such that the ?nal direc