Velvet Plush Manufacturing Using Sequential Singeing and Heat-Setting
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Solution Overview
Problem
There is no practical cost-effective method for manufacturing high-quality velvet plush articles, as traditional methods using expensive silk materials result in high production costs, while synthetic materials like polyester and nylon produce low-quality velvet plush with uneven pile layers.
Innovation Solution
A method involving brushing and singeing greige cloth made from synthetic materials, followed by specific yarn weaving, dyeing, printing, and finishing processes to create a velvet plush article with a smooth and soft texture, using a 4:1 ratio of face to backing yarns and sequential heat-setting and singeing steps to achieve a high-quality, cost-effective product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If expensive silk materials are used to manufacture velvet plush articles, then the smoothness and softness quality is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive silk materials with inexpensive synthetic materials (polyester, nylon) that can achieve similar velvet plush effects through chemical treatment. The synthetic fibers are treated with oxidizing agents to create a fuzzy, soft surface that mimics silk's luxurious feel without the high cost
Solution Approach 2:
The patent changes the chemical and physical parameters of synthetic materials through sequential treatments (brushing, singeing, oxidizing, softening) to transform their surface properties. This converts ordinary synthetic fibers into materials with silk-like smoothness and softness, resolving the contradiction between material cost and quality
2Quantity of substance
If synthetic materials like polyester and nylon are used to reduce manufacturing costs, then the manufacturing cost decreases, but the quality of velvet plush article becomes low with uneven pile layers
Solution Approach 1:
The patent applies preliminary actions to synthetic materials before final velvet plush formation. Sequential treatments including brushing, singeing, oxidizing, and softening are performed in advance to prepare the synthetic fibers, ensuring uniform pile layers and high quality surface appearance before the material is used
Solution Approach 2:
The patent replaces traditional mechanical needling methods with chemical treatment processes. Instead of mechanically creating pile structures, the invention uses chemical oxidizing agents and surface treatments to achieve uniform, high-quality velvet plush surfaces from synthetic materials
3Ease of manufacture
If traditional needling methods are used to add tufted pile onto backing, then the manufacturing process is simple, but the resulting surface is uneven and lacks smoothness
Solution Approach 1:
The patent replaces mechanical needling systems with chemical treatment processes. oxidizing agents and surface chemistry methods are used to create uniform pile structures and smooth surfaces, eliminating the unevenness inherent in mechanical needling while maintaining process efficiency
Solution Approach 2:
The patent changes the fundamental approach from mechanical pile formation to chemical surface modification. By controlling chemical parameters (oxidizing agent concentration, treatment time, temperature), the process achieves superior surface smoothness and uniform pile distribution compared to traditional mechanical methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces a high-quality velvet plush article with a smooth and soft touch using synthetic materials, reducing production costs and allowing for optional dyeing and printing, while maintaining superior smoothness and softness.
Implementation Method 1
singeing the brushed greige cloth by passing it across a plurality of hot singe rollers
Implementation Method 2
brushing a greige cloth comprising synthetic materials
Data Source
AI summary
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.