U.S. patent application number 10/458896 was filed with the patent office on 2004-02-19 for floor covering from synthetic twisted yarns.
This patent application is currently assigned to Sun Isle Casual Furniture, LLC. Invention is credited to Schwartz, Larry.
Application Number | 20040031534 10/458896 |
Document ID | / |
Family ID | 46150338 |
Filed Date | 2004-02-19 |
United States Patent
Application |
20040031534 |
Kind Code |
A1 |
Schwartz, Larry |
February 19, 2004 |
Floor covering from synthetic twisted yarns
Abstract
A woven article of furniture in the nature a floor covering is
formed from a weave of woven polymer yarns which include twisted
yarns for the weft and/or warp yarns. The floor covering is heat
set to provide dimensional stability during the intended use of the
floor covering.
Inventors: |
Schwartz, Larry; (Franklin
Lakes, NJ) |
Correspondence
Address: |
LERNER, DAVID, LITTENBERG,
KRUMHOLZ & MENTLIK
600 SOUTH AVENUE WEST
WESTFIELD
NJ
07090
US
|
Assignee: |
Sun Isle Casual Furniture,
LLC
Franklin Lakes
NJ
|
Family ID: |
46150338 |
Appl. No.: |
10/458896 |
Filed: |
June 11, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10458896 |
Jun 11, 2003 |
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10158629 |
May 30, 2002 |
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10458896 |
Jun 11, 2003 |
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10290638 |
Nov 8, 2002 |
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10290638 |
Nov 8, 2002 |
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10123943 |
Apr 17, 2002 |
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10123943 |
Apr 17, 2002 |
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10073634 |
Feb 11, 2002 |
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10073634 |
Feb 11, 2002 |
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10062905 |
Jan 31, 2002 |
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6625970 |
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60336819 |
Dec 5, 2001 |
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Current U.S.
Class: |
139/169 |
Current CPC
Class: |
A47C 5/02 20130101; D03D
29/00 20130101; D10B 2331/02 20130101; D02G 3/28 20130101; D03D
15/292 20210101; D03D 15/587 20210101; D02G 3/24 20130101; D03D
15/283 20210101; D10B 2503/04 20130101; D10B 2505/08 20130101; A47C
7/02 20130101; D03D 1/0029 20130101; D10B 2101/20 20130101; D03D
1/00 20130101; D03D 15/49 20210101; D10B 2401/08 20130101; D03D
15/30 20210101; D10B 2321/041 20130101; D10B 2331/04 20130101 |
Class at
Publication: |
139/169 |
International
Class: |
D03D 049/40 |
Claims
1. A woven floor covering comprising a plurality of warp yarns of
polymer material each having an outer surface, a plurality of weft
yarns of polymer material each having an outer surface, at least
one of said warp yarns or at least one of said weft yarns
comprising first and second strands of polymer material twisted
together over their length, said plurality of warp yarns and said
plurality of weft yarns being woven together to form a weave
therefrom, wherein said plurality of weft yarns and said plurality
of warp yarns are at least partially adhered to each other along a
portion of their outer surfaces.
2. The floor covering of claim 1, wherein each of said plurality of
warp yarns comprise first and second strands of polymer material
twisted together over their length.
3. The floor covering of claim 1, wherein each of said plurality of
weft yarns comprise first and second strands of polymer material
twisted together over their length.
4. The floor covering of claim 1, wherein each of said plurality of
warp yarns comprise first and second strands of polymer material
twisted together over their length and said plurality of weft yarns
comprise third and fourth strands of polymer material twisted
together over their length.
5. The floor covering of claim 4, wherein said first and second
strands are adhered to each other and said third and fourth strands
are adhered to each other.
6. The floor covering of claim 4, wherein at least one of said
first, second, third and fourth strands differ from the other of
said strands in at least one of size, shape, surface configuration,
coloration and surface appearance.
7. The floor covering of claim 4, wherein said first and second
strands are at least partially adhered to each other over their
length along a portion of their outer surfaces and said third and
fourth strands are at least partially adhered to each other over
their length along a portion of their outer surfaces.
8. The floor covering of claim 4, wherein each of said first,
second, third and fourth strands have a deformed outer surface.
9. The floor covering of claim 4, wherein each of said first,
second, third and fourth strands have a non-uniform cross-section
over their length.
10. The floor covering of claim 1, wherein said weave has a
plurality of openings formed between said plurality of weft yarns
and said plurality of warp yarns, said openings being of sufficient
size to allow the passage of water therethrough.
11. The floor covering of claim 1, wherein said weave is devoid of
a backing member, whereby said weave is reversible.
12. The floor covering of claim 1, wherein said plurality of weft
yarns and said plurality of warp yarns are uninterruptedly adhered
to each other over their entire length.
13. A woven floor covering comprising a plurality of warp yarns
each including a first and second strand of polymer material
twisted together, said first and second strands each having a
deformed outer surface, and a plurality of weft yarns each
including a third and fourth strand of polymer material twisted
together, said third and fourth strands each having a deformed
outer surface, said plurality of warp yarns and said plurality of
weft yarns woven together to form a weave devoid of a backing
member, wherein said plurality of weft yarns and said plurality of
warp yarns are at least partially adhered to each other over their
length along a portion of their outer surfaces, said weave having a
plurality of openings formed between said plurality of weft yarns
and said plurality of warp yarns of sufficient size to allow the
passage of water therethrough.
14. The floor covering of claim 13, wherein said first and second
strands are adhered to each other and said third and fourth strands
are adhered to each other.
15. The floor covering of claim 13, wherein at least one of said
first, second, third and fourth strands differ from the other of
said strands in at least one of size, shape, surface configuration,
coloration and surface appearance.
16. The floor covering of claim 13, wherein each of said first,
second, third and fourth strands have a non-uniform cross-section
over their length.
17. The floor covering of claim 13, wherein said plurality of weft
yarns and said plurality of warp yarns are uninterruptedly adhered
to each other over their entire length.
18. A method of making a woven floor covering, said method
comprising weaving a plurality of weft yarns of polymer material
and a plurality of warp yarns of polymer material to form a weave,
at least one of said weft yarns or at least one of said warp yarns
comprising first and second strands of polymer material twisted
together over their length, and heating said weave to a sufficient
temperature wherein said plurality of weft yarns and said plurality
of warp yarns are at least partially adhered to each other over
their length.
19. The method of claim 18, at least partially adhering said first
and second strands to each other over their length during said
heating.
20. The method of claim 18, further including adhering said first
and second strands to each other over their entire length at their
outer surfaces during said heating.
21. The method of claim 18, wherein each of said plurality of warp
yarns comprise first and second strands of polymer material twisted
together over their length and said plurality of weft yarns
comprise third and fourth strands of polymer material twisted
together over their length.
22. The method of claim 21, wherein said first and second strands
are at least partially adhered to each other over their length
during said heating and wherein said third and fourth strands are
at least partially adhered to each other over their length during
said heating.
23. The method of claim 22, wherein said first, second, third and
fourth strands are adhered contemporaneously with adhering said
plurality of weft yarns and said plurality of warp yarns during
said heating.
24. The method of claim 21, wherein at least one of said first,
second, third and fourth strands differ from the other of said
strands in at least one of size, shape, surface configuration,
coloration and surface appearance.
25. The method of claim 21, wherein each of said first, second,
third and fourth strands have a deformed outer surface.
26. The method of claim 21, wherein each of said first, second,
third and fourth strands have a non-uniform cross-section over
their length.
27. The method of claim 18, wherein said temperature is below the
melting temperature of said polymer material.
28. The method of claim 18, wherein said weave is heated in an
environment having a temperature of 200-375.degree. F.
29. The method of claim 18, further including forming a plurality
of openings between said plurality of weft yarns and said plurality
of warp yarns, said openings being of sufficient size to allow
passage of water therethrough.
30. The method of claim 21, wherein said first and second strands
are adhered together and said third and fourth strands are adhered
together by heating said strands prior to said weaving of said
plurality of weft yarns and said plurality of warp yarns.
31. A method of making a woven floor covering, said method
comprising forming a plurality of weft yarns by twisting together
first and second strands of polymer material each having a deformed
outer surface and a non-uniform cross-section over their entire
length, forming a plurality of warp yarns by twisting together
third and fourth strands of polymer material each having a deformed
outer surface and a non-uniform cross-section over their length,
weaving said plurality of weft and said plurality of warp yarns to
form a weave therefrom, and heating said weave to a sufficient
temperature wherein said plurality of weft yarns and said plurality
of warp yarns are at least partially adhered to each other over
their length.
32. The method of claim 31, wherein said first and second strands
and said third and fourth strands are at least partially adhered
contemporaneously with said plurality of weft yarns and said
plurality of warp yarns during said heating.
33. The method of claim 31, wherein said weave is heated in an
environment having a temperature of 200-375.degree. F.
34. The method of claim 31, wherein said first and second strands
are at least partially adhered together and said third and fourth
strands are at least partially adhered together by heating said
strand prior to said weaving of said plurality of said weft yarns
and said warp yarns.
35. The method of claim 31, wherein at least one of said first,
second third and fourth strands differ from the other of said
strands in at least one of size, shape, surface configuration,
coloration and surface appearance.
36. The method of claim 31, further including forming a plurality
of openings between said plurality of weft yarns and said plurality
of warp yarns, said openings being of sufficient size to allow the
passage of water therethrough.
37. The method of claim 31, further including attaching a binding
material around the periphery of said weave.
38. The method of claim 31, wherein said heating is sufficient to
cause said plurality of weft yarns and said plurality of warp yarns
to integrally adhere to each other.
39. A floor covering made in accordance with the method of claim
18.
40. A floor covering made in accordance with the method of claim
31.
41. A woven floor covering comprising a plurality of yarns of
polymer material each having an outer surface, at least one of said
yarns comprising first and second strands of polymer material
twisted together, said plurality of yarns being woven together to
form a weave therefrom, wherein said plurality of yarns are adhered
to each other at least intermittently along a portion of their
outer surfaces.
42. The floor covering of claim 41, wherein said first and second
strands are adhered to each other at least intermittently along a
portion of their outer surfaces.
43. The floor covering of claim 41, wherein at least one of said
first and second strands differ from the other of said strands in
at least one of size, shape, surface configuration, coloration and
surface appearance.
44. The floor covering of claim 41, wherein each of said yarns have
a deformed outer surface and a non-uniform cross-section over their
length.
45. The floor covering of claim 41, wherein said weave has a
plurality of openings of sufficient size to allow the passage of
water therethrough.
46. The floor covering of claim 41, wherein said weave is devoid of
a backing member, whereby said weave is reversible.
47. A method of making a woven floor covering, said method
comprising weaving a plurality of yarns of polymer material each
having an outer surface to form a weave, at least one of said yarns
comprising first and second strands of polymer material twisted
together, and heating said weave to a sufficient temperature
wherein said plurality of yarns are adhered to each other along a
portion of their outer surfaces.
48. The method of claim 47, further including adhering said first
and second strands to each other over their length
contemporaneously during said heating.
49. The method of claim 47, wherein said temperature is below the
melting temperature of said polymer material.
50. The method of claim 47, wherein said weave is heated in an
environment having a temperature of 200-375.degree. F.
51. The method of claim 47, wherein at least one of said yarns
differ from another said yarns in at least of size, shape, surface
configuration, coloration and appearance.
52. The method of claim 47, wherein each of said yarns have a
deformed outer surface.
53. The method of claim 47, wherein each of said yarns have a
non-uniform cross-section over their length.
54. The method of claim 47, further including forming a plurality
of openings between said plurality of yarns within said weave, said
openings being of sufficient size to allow the passage of water
therethrough.
55. The method of claim 47, wherein said first and second strands
are adhered together by heating said strands prior to said
weaving.
56. The method of claim 47, wherein at least one of said first and
second strands differ from the other of said strands in at least
size, shape, surface, configuration, coloration and surface
appearance.
57. The method of claim 47, wherein said first and second strands
have a deformed outer surface.
58. The method of claim 47, further including attaching a binder
about the perimeter of said weave.
59. The method of claim 47, wherein said yarns are adhered to each
other intermittently over their outer surfaces.
60. A floor covering made in accordance with the method of claim
47.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of
co-pending U.S. patent application Ser. No. 10/290,638, filed Nov.
8, 2002, which is a continuation-in-part of co-pending U.S. patent
application Ser. No. 10/123,943, filed Apr. 17, 2002, which is a
continuation-in-part of co-pending U.S. patent application Ser. No.
10/073,634, filed Feb. 11, 2002, which is a continuation-in-part of
co-pending U.S. patent application Ser. No. 10/062,905, filed Jan.
31, 2002, entitled "Method of Making Furniture With Synthetic Woven
Material" which claims the benefit of U.S. Provisional Application
No. 60/336,819, filed Dec. 5, 2001; and a continuation-in-part of
co-pending U.S. Pat. No. 10/158,629 filed May 30, 2002, entitled
"Combination Weave Using Twisted And Non-Twisted Yarn," all of the
disclosures of which are hereby incorporated by reference
herein.
BACKGROUND OF THE INVENTION
[0002] The present invention relates in general to the field of
synthetic yarns and synthetic woven materials manufactured
therefrom for use in the construction of various articles, and more
particularly, to such articles and methods of stabilizing synthetic
yarn of multiple filaments, such as twisted yarns, and of
stabilizing woven synthetic yarn material using heat treatment
during the manufacturing process.
[0003] Natural wicker has been used in the manufacture of
furniture, baskets and other articles for many centuries. Natural
wicker articles are manufactured from the twigs or branches of
various plants that are first soaked in water in order to make them
pliable, then woven to form into the article and finally allowed to
dry. Furniture manufactured from wicker offers greater comfort than
furniture manufactured from some other materials because of
wicker's inherent compliancy. Further, wicker is light weight and
reasonably strong, making it an important material in the
manufacture of furniture.
[0004] The popularity of wicker articles has increased
significantly. The casual, informal appearance of wicker has made
it especially popular for use in furniture for enclosed porches and
other informal settings in homes, hotels and other establishments.
Natural wicker, however, has had limited use in the outdoor
furniture market, including patio furniture, pool furniture and the
like. This is because natural wicker softens and weakens when wet,
and is more susceptible to rotting and mildew than many other
natural and man-made furniture materials.
[0005] Woven wicker typically comprises a warp yarn, i.e., a yarn
running straight through the woven material and providing support,
and a weft yarn, i.e., a yarn used as filler that is woven around
the warp yarn. Numerous styles of weave are used in the manufacture
of wicker products. The various styles of weave result in a
different look, feel, strength and weight of the finished woven
product. In a simple weave pattern, the warp yarns are spaced apart
and arranged parallel to each other. The weft yarns are woven over
and under alternating warp yarns. Adjacent weft yarns pass on
opposite sides of a given warp yarn. Variations of this pattern,
such as passing the weft yarn over two adjacent warp yarns, are
known in the art.
[0006] Polymer yarns have also been used to manufacture wicker-like
products such as furniture. By way of example, a polymer yarn is
known which is constructed as an elongated body, such as of
indeterminate length, having a core surrounded by a
polyvinylchloride (PVC) outer coating, for example, foamed PVC
material which gives greater volume with less material. The outer
coating may be formed of other synthetic materials such as
polyamides, polyesters and the like. The yarn is typically made in
a single step using a coextrusion process, as is known in the art.
The inner core may include a single filament of polyester, or may
include a plurality of polyester filaments bundled to form a single
core. In addition, the core may be formed of other materials than
polyester, monofilament or stranded, such as polyamides and the
like. The core is designed to give the yarn greater mechanical
strength over yarns formed only of polymer material.
[0007] The polymer yarn being constructed from foamed PVC material
results in a lack of uniformity in the foaming of the PVC material
during the extrusion process. This produces a yarn which lacks a
uniform cylindrical appearance. Specifically, the outer surface of
the yarn is deformed, such as by having undulations, mounds and/or
depressed areas along the length of the yarn. The deformed shape of
the outer surface of the yarn results in the yarn having a more
natural look to that of real wicker. It is also known to provide
the exterior surface of the polymer yarn with one or more random
stripes of a contrasting color and/or one or more random grooves.
The stripes and grooves can be continuous and/or intermittent along
the exterior surface of the yarn. The yarn, however, can also have
a more uniform cylindrical shape, as well as other shapes such as
square, oval, triangular and the like. Polymer yarns as thus far
described are known from U.S. Pat. Nos. 5,704,690; 5,845,970; and
6,179,382, as well as U.S. Design Pat. Nos. 395,171; and 409,001,
the disclosures of which are incorporated herein by reference.
[0008] As in the case of natural wicker, polymer yarns have been
woven into a woven material which has been used in the manufacture
of casual furniture suitable for the outdoor furniture market,
including patio furniture, as well as for indoor use. Due to the
nature of polymer yarns, it has been known to subject the woven
material to a heat setting process prior to attaching the woven
material to the frame forming the finished product. In this regard,
a section of the woven material would be placed in an oven at an
elevated temperature to cause the polymer material to soften
whereby contiguous portions of the yarn would bond together
stabilizing the shape of the woven material. The heat set woven
material would be subsequently attached to the skeletal frame of a
product to form, for example, a seat portion or a back rest portion
of a furniture article.
[0009] Further, synthetic polymer yarns by virtue of their
suitability for use in an outdoor environment have enjoyed success
for various products. For example, synthetic yarns have been woven
into rugs and floor mats typically intended for indoor use. These
rugs generally include a binder along the rugs' edge, as well as a
backing material. The combination of the binder and backing
material provide dimensional stability to the rug. However, the
backing material frequently renders the rug unsuitable for outdoor
use. In this regard, in the case of rain, water will collect on top
of the rug forming puddles. In addition, water will collect between
the floor and the rugs' backing. This can create rotting and mildew
of the underlying floor.
[0010] This problem has been partially solved by a floor mat formed
by weaving twisted polymer yarn without the use of a backing
material or binder. However, the individual strands forming the
twisted yarn, as well as the woven rug itself, are not cohesively
formed. As a result, the floor mat lacks dimensional stability, is
flimsy in construction, as well as poorly maintaining its woven
structure during use.
[0011] It is therefore desirable to provide improvements in
synthetic yarns, in synthetic woven materials, and in manufacturing
processes for various articles including the use of polymer yarns
and woven material therefrom, and more particularly, to synthetic
twisted yarns and woven material therefrom which are subject to
heat during processing, which overcomes the disadvantages noted
with respect to the aforementioned articles, and in particular,
floor coverings.
SUMMARY OF THE INVENTION
[0012] In one embodiment of the present invention there is
described a woven floor covering comprising a plurality of warp
yarns of polymer material each having an outer surface, a plurality
of weft yarns of polymer material each having an outer surface, at
least one of the warp yarns or at least one of the weft yarns
comprising first and second strands of polymer material twisted
together over their length, the plurality of warp yarns and the
plurality of weft yarns being woven together to form a weave
therefrom, wherein the plurality of weft yarns and the plurality of
warp yarns are at least partially adhered to each other along a
portion of their outer surfaces.
[0013] In another embodiment of the present invention there is
described a woven floor covering comprising a plurality of warp
yarns each including a first and second strand of polymer material
twisted together, the first and second strands each having a
deformed outer surface, and a plurality of weft yarns each
including a third and fourth strand of polymer material twisted
together, the third and fourth strands each having a deformed outer
surface, the plurality of warp yarns and the plurality of weft
yarns woven together to form a weave devoid of a backing member,
wherein the plurality of weft yarns and the plurality of warp yarns
are at least partially adhered to each other over their length
along a portion of their outer surfaces, the weave having a
plurality of openings formed between the plurality of weft yarns
and the plurality of warp yarns of sufficient size to allow the
passage of water therethrough.
[0014] In another embodiment of the present invention there is
described a method of making a woven floor covering, the method
comprising weaving a plurality of weft yarns of polymer material
and a plurality of warp yarns of polymer material to form a weave,
at least one of the weft yarns or at least one of the warp yarns
comprising first and second strands of polymer material twisted
together over their length, and heating the weave to a sufficient
temperature wherein the plurality of weft yarns and the plurality
of warp yarns are at least partially adhered to each other over
their length.
[0015] In another embodiment of the present invention there is
described a method of making a woven floor covering, the method
comprising forming a plurality of weft yarns by twisting together
first and second strands of polymer material each having a deformed
outer surface and a non-uniform cross-section over their entire
length, forming a plurality of warp yarns by twisting together
third and fourth strands of polymer material each having a deformed
outer surface and a non-uniform cross-section over their length,
weaving the plurality of weft and the plurality of warp yarns to
form a weave therefrom, and heating the weave to a sufficient
temperature wherein the plurality of weft yarns and the plurality
of warp yarns are at least partially adhered to each other over
their length.
[0016] In another embodiment of the present invention there is
described a a woven floor covering comprising a plurality of yarns
of polymer material each having an outer surface, at least one of
the yarns comprising first and second strands of polymer material
twisted together, the plurality of yarns being woven together to
form a weave therefrom, wherein the plurality of yarns are adhered
to each other at least intermittently along a portion of their
outer surfaces.
[0017] In another embodiment of the present invention there is
described a method of making a woven floor covering, the method
comprising weaving a plurality of yarns of polymer material each
having an outer surface to form a weave, at least one of the yarns
comprising first and second strands of polymer material twisted
together, and heating the weave to a sufficient temperature wherein
the plurality of yarns are adhered to each other along a portion of
their outer surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above description, as well as further objects, features
and advantages of the present invention will be more fully
understood with reference to the following detailed description of
a method of making furniture with synthetic woven material, when
taken in conjunction with the accompanying drawings, wherein:
[0019] FIG. 1 is top plan view of a portion of a heat set twisted
polymer yarn constructed in accordance with one embodiment of the
present invention;
[0020] FIG. 2 is a diagrammatic illustration showing the
fabrication process of heat setting the twisted polymer yarn as
shown in FIG. 1;
[0021] FIG. 3 is a perspective view of a skeletal frame of an
article of furniture;
[0022] FIG. 4 is a top plan view of woven material constructed by
weaving the polymer yarn as shown in FIG. 1 in accordance with one
embodiment of the present invention;
[0023] FIG. 5 is a perspective view of an article of furniture in
the nature of a chair to which there is attached the woven material
as shown in FIG. 4 and components wrapped with the twisted polymer
yarn as shown in FIG. 1;
[0024] FIG. 6 depicts a process of twisting polymer yarn and heat
setting the twisted polymer yarn;
[0025] FIG. 7 is a perspective view of a polymer yarn constructed
in accordance with one embodiment;
[0026] FIG. 8 is a perspective view of woven material constructed
by weaving a combination of twisted and non-twisted polymer yarns
in accordance with one embodiment of the present invention;
[0027] FIG. 9 is a perspective view of woven material constructed
by weaving a combination of twisted and non-twisted polymer yarns
in accordance with one embodiment of the present invention; and
[0028] FIG. 10 is a top plan view of woven material constructed by
weaving polymer material forming a rug or mat therefrom.
DETAILED DESCRIPTION
[0029] In describing the various embodiments and preferred
embodiments of the subject matter illustrated and to be described
with respect to the drawings, specific terminology will be resorted
to for the sake of clarity. However, the invention is not intended
to be limited to the specific terms so selected, and is to be
understood that each specific term includes all technical
equivalence which operate in a similar manner to accomplish a
similar purpose.
[0030] Referring to the drawings, wherein like reference numerals
represent like elements, there is shown in FIG. 1 in accordance
with one embodiment of the present invention a twisted yarn of
indeterminate length designated generally by reference numeral 100.
The twisted yarn 100 is made of two strands or filaments 102, 104
of polymer material and maybe of the type and construction as
described in the aforementioned patents which have been
incorporated herein by reference, e.g., yarns having a deformed
outer surface and a non-uniform cross-section over their entire
length.
[0031] More specifically, as shown in FIG. 7, the strands or
filaments 102, 104 are constructed as an elongated body, such as of
indeterminate length having an elongated core 30 surrounded by a
polymer layer such as a PVC outer layer 50, for example, foamed PVC
material which gives greater volume with less material. However, it
is to be understood that the outer layer 50 may be formed of other
synthetic materials if desired such as polyamides, polyesters and
the like. The strands or filaments 102, 104 may be made in a single
step using a coextrusion process as is known in the art. The inner
core 30 may include a single filament of polyester, or may include
a plurality of polyester filaments bundled to form a single core.
In addition, the inner core 30 may be formed of other materials
than polyester, monofilament or stranded, such as polyamides and
the like. It is also contemplated that the inner core 30 can be
formed as a metal core such as an aluminum wire coated by the outer
polymer layer 50. The core 30 is designated to give the strands or
filaments 102, 104 greater mechanical strength. However, it is to
be understood that the core forms no part of the present invention
and may be eliminated if desired.
[0032] It is to be understood that other strands or filaments 102,
104 of polymer material of a different construction or polymer
material are also contemplated for use in producing a twisted yarn
100 or a weave of woven material therefrom in accordance with the
present invention. Further, although the twisted yarn 100 has been
illustrated as comprising two strands 102, 104, it is to be
understood that the twisted yarn can be constructed from greater
than two strands if so desired. In addition, it is not required
that the strands 102, 104 be identical in size, shape, surface
appearance, coloration, and/or surface configuration. For example,
a twisted elongated yarn can be constructed from an elongated first
yarn of polymer material twisted together with an elongated second
yarn forming a composite yarn having a twisted shape. One of the
first and second yarns may be different from the other one of the
first and second yarns in at least one or more of size, shape,
surface configuration, coloration and/or surface appearance. The
second elongated yarn may also be polymer material.
[0033] The twisted yarn may include an elongated third yarn twisted
together with the first and second yarns, or any other number of
additional yarns. The third yarn may be polymer material. The third
yarn may be substantially similar to one of the first and second
yarns in at least one of size, shape, surface configuration,
coloration and surface appearance. The third yarn may also be
different from the first and second yarns in at least one of size,
shape, surface configuration, coloration and surface appearance.
Further, one of the first and second yarns may be different from
the other one of the first and second yarns in all of size, shape,
surface configuration, coloration and surface appearance.
[0034] By way of further example, the twisted elongated yarn can be
constructed from an elongated first yarn, an elongated second yarn
and an elongated third yarn. The first, second and third yarns are
twisted together to form a composite twisted yarn, wherein at least
one of the yarns is polymer material. One of the first, second and
third yarns is preferably different from at least one of the other
two yarns in at least one of size, shape, surface configuration,
coloration and surface appearance. The first, second and third
yarns may all be polymer material. Each of the first, second and
third yarns may be different from each other in at least one of
size, shape, surface configuration, coloration and surface
appearance. Each of the first, second and third yarns may also be
different from each other in all of size, shape, surface
configuration, coloration and surface appearance. One of the first,
second and third yarns may be a natural material, e.g., cotton. By
use of various combinations of yarns of different sizes, twisted
yarns and weaves using twisted yarns and non-twisted yarns can
provide different textures, bulk and feel with less material.
[0035] Referring now to FIG. 2, there will be described a process
of manufacturing a twisted yarn 100 in accordance with one
embodiment of the present invention. As shown, there is provided a
source 106 of a continuous length of a strand 102 of polymer
material. A similar source 108 is provided for a continuous length
of another strand 104 of polymer material. Generally, the sources
106, 108 will be in the nature of a spool of an indeterminate
length of the strands 102, 104 of the polymer material.
[0036] In accordance with one embodiment, the individual strands
102, 104 are fed concurrently from the spools into an oven 110 for
heating at least the outer surface of the strands to a
predetermined temperature. In the case of PVC material, an oven
temperature of up to about 270.degree. F. has been found suitable
for use in accordance with the present invention. The temperature
of the oven 110 will take into consideration the type of the
polymer material forming the strands 102, 104, as well as the
linear rate in which the strands pass through the oven, for
example, the residence time in the oven. Based upon the oven
temperature and residence time of the strands 102, 104 within the
oven 110, at least the outer surface of the strands will heat up
to, but generally below, about their softening temperature. In the
case of PVC material, a temperature of the outer surface of the
strands 102, 104 in the range of 80.degree.-250.degree. F. is
contemplated. Lower oven temperatures with longer residence times
and higher oven temperatures with shorter residence times are
contemplated. It is preferable that the temperature of the strands
102, 104 do not reach their melting temperature where they would
lose their general shape. However, a slight melting of the outer
surface region of the strands 102, 104 is contemplated within the
scope of the present invention. Although the invention has been
described as heating both of the strands 102, 104, it is
contemplated to heat only one of the strands. The other strand may
be at room temperature or heated to a different temperature in a
separate oven.
[0037] It can be appreciated that the temperature of the oven will
vary according to the particular polymer material forming the
strands 102, 104, as well as the residence time for the strands
within the oven. For polymer material most suitable for use in
accordance with the present invention, a temperature range of 200
to 375.degree. F., and more preferably about 250 to 300.degree. F.
is contemplated. However, as the basis for determining the oven
temperature and residence time have been described herein, it is to
be understood that other temperatures can be selected for suitable
use with any polymer material in which to form a twisted yarn from
strands 102, 104.
[0038] As the heated strands 102, 104 exit the oven 110, they pass
through a conventional filament twisting apparatus 112. The
twisting apparatus 112 is operative for twisting the two strands
102, 104 together to form the twisted yarn 100 as best shown in
FIG. 1. The twisting apparatus 112 may be of any suitable
construction such as known in the rope art where continuous lengths
of filaments are twisted together. During the twisting process,
there is a degree of compression between the strands 102, 104
which, due to their heated temperature, results in the strands
bonding together to generally form a single integral strand having
a twisted configuration as shown in FIG. 1. The twisted strands are
accordingly heat set to prevent or resist their unwinding during
subsequent handling.
[0039] It is to be understood that it is not a requirement that the
strands 102, 104 be bonded integral over their entire length, but
rather, may have contiguous intermittent portions over their length
which are joined together whereby the twisted yarn 100 is prevented
from unraveling during the subsequent weaving process or handling.
As to be described hereinafter, the heat setting of the twisted
yarn may be delayed until further processing of a weave of woven
material made therefrom.
[0040] The twisted yarn 100 may be subject to air cooling, or
optionally, passed through a cooling device 114. The cooling device
114 may include a source of blowing ambient air, or air chilled to
aid in bringing the twisted yarn 100 to room or ambient
temperature. The resulting twisted yarn 100 is subsequently wound
upon a spool 116. It is also contemplated that the twisting
apparatus 112 may be positioned before the oven 110, as well as
providing separate ovens 110 for each strand 102, 104 operating at
the same or different temperature. Different process conditions are
contemplated where the strands 102, 104 are of a different
construction, composition or size.
[0041] The individual strands 102, 104 may be formed by hot
extrusion of polymer material through a die. It is therefore
contemplated that the strands 102, 104, while in a heated state
after extrusion, may be twisted in the twisting apparatus 112,
thereby eliminating the need for a separate oven 110. Depending
upon the exit temperature of the strands 102, 104 from the
extruder, the strands may be allowed to air cool or provided with a
separate cooling device 114 for either or both of the strands prior
to twisting.
[0042] In another embodiment as shown in FIG. 6, there is provided
a filament twisting apparatus 112 and an oven 110 for heat setting
the twisted yarn. As shown, polymer strands 102 and 104 are twisted
at room temperature by the filament twisting apparatus 112 and the
twisted composite yarn is then wound to a spool 115. The twisted
composite yarn is then unwound from the spool 115 into the oven 110
for heat setting, preferably below the melting temperature of the
yarn, more preferably at a yarn surface temperature of lower than
about 260.degree. F., and the most preferably lower than about
250.degree. F., e.g., 80.degree.-250.degree. F. The heat set
twisted composite yarn is subject to air-cooling, or optionally,
passed through a cooling device 114, and rewound to spool 116.
[0043] As thus far described, sufficiently heating one of the
elongated strands 102, 104 of polymer material causes the strands
upon twisting to at least partially adhere to one another to
prevent their unraveling. The twisting process may occur either
before or after the heating process. The heating may take place
either in an oven 110 or as a result of the strands 102, 104 being
formed by hot extrusion of the polymer material through a die. In
either case, at least one of the strands 102, 104 has been heated
to a predetermined temperature for at least partially adhering to
the other strand upon cooling.
[0044] It is however generally known that polymer materials can
possess shape memory characteristics. This shape retention
characteristic is dependent upon the nature and temperature of the
polymer material. It is contemplated that this property can be
utilized to form a twisted polymer yarn without the need of heating
at least one strand to an elevated temperature whereby the strands
will adhere to each other. By way of example, by heating at least
one, and preferably both of the strands 102, 104, to a temperature
of between 100.degree.-200.degree. F. prior to twisting, the heated
strands upon cooling will essentially maintain their twisted
configuration.
[0045] It is also contemplated that the slight heating of at least
one strand will allow the strand to relax so as to twist with an
additional strand, and retain its twisted shape upon cooling. The
heating will provide the strand with a sufficient heat set to
retain its shape. In accordance with this embodiment, it is not a
requirement of the present invention that the strands 102, 104 be
adhered to each other along a portion of their length such as by
heating at least one of the strands to higher temperatures such as
their softening temperature or above where the two strands are
integrally bonded or joined together. The heat setting of the
twisted yarn in accordance with this embodiment will be sufficient
to prevent the strands 102, 104 from unraveling during the weaving
process. However, the two strands 102, 104 can be stripped from
each other by opening the twist and separating the two strands if
desired. This is generally considered not possible when the strands
are adhered to each other in accordance with the prior
embodiment.
[0046] The strands 102, 104 may be heated prior to or after the
twisting operation. In addition, the strands 102, 104 may be heated
in one or more ovens to the same or different temperatures. In
addition, the strands 102, 104 may be heated as a result of their
hot extrusion from an extrusion die during their formation thereby
eliminating the need for an oven.
[0047] It is also contemplated that spools 106, 108 of the source
yarn may be placed in an oven to preheat the strands 102, 104 to
the desired temperature prior to twisting. It is also contemplated
that heating may be provided by placing the twisting apparatus 112
in an oven or arrange suitable heaters around the twisting
apparatus.
[0048] In accordance with a further aspect of the present
invention, it is not a requirement that the twisted yarn be heat
set, as previously described, prior to being woven into a desired
weave. As previously described, the twisted yarn 100 generally
includes at least two strands 102, 104 of polymer material which
are twisted together. However, it is also contemplated that a
single strand of polymer material may be twisted about its
longitudinal axis, for example, to form a spiral shaped strand
simulating a twisted yarn.
[0049] The twisted yarn 100 or single strands of twisted yarn can
be woven into various weaves to form woven material such as shown
in FIGS. 4, 8 and 9. The woven material and the individual strands
102, 104 which form the twisted yarn 100 can be simultaneously heat
set using the heat setting conditions and procedures as previously
described. Thus, the individual strands 102, 104 may be twisted
together to form a twisted yarn 100 without heating, subsequently
woven into a woven material, and then, heat set simultaneously with
heat setting of the woven material. This results in heat setting of
the individual strands 102, 104, as well as heat setting of the
twisted yarn 100 within the weave.
[0050] The woven material can be used in various applications such
as the making of wicker style furniture as previously described. In
addition, it is contemplated that the woven material can be used
for other purposes, for example, forming rugs, fabric for drapes,
cushions, lampshades, umbrellas, blinds, floor mats and the like.
By virtue of the woven material being formed from polymer material,
it is particularly suitable for use in outdoor applications or in
areas of high humidity.
[0051] In accordance with one embodiment of the present invention,
a product such as an article of furniture can be constructed from a
frame having the product's shape and at least one panel attached
thereto formed as a weave from a plurality of elongated members.
The article may include, for example, chairs, tables, couches,
stools, benches, rockers, lamps, trunks, umbrellas, etc. At least
one of the members includes an elongated first yarn of polymer
material twisted together with an elongated second yarn forming a
composite yarn having a twisted shape. One of the first and second
yarns may be different from the other one of the first and second
yarns in at least one of size, shape, surface configuration,
coloration and surface appearance. The first and second yarns may
be constructed as described in accordance with this application and
the aforementioned patents.
[0052] In accordance with another embodiment, at least one panel is
formed as a weave from a plurality of elongated members, at least
one of the members includes an elongated first yarn, an elongated
second yarn and an elongated third yarn. The first, second and
third yarns are twisted together to form a composite twisted yarn,
wherein at least one of the yarns is polymer material. One of the
first, second and third yarns is different from at least one of the
other two yarns in at least one of size, shape, surface
configuration, coloration and surface appearance. The first, second
and third yarns may be constructed as described in accordance with
this application and the aforementioned patents.
[0053] There will now be described one embodiment of using the
twisted yarn 100 in constructing an article of furniture such as a
chair, by way of one example. As shown in FIGS. 3 and 5, a chair
120 can be produced from a rigid skeletal frame 118 which will be
covered with a weave of woven material produced from the twisted
yarn 100. The frame 118, by way of illustration only, provides an
arm chair with a seat, a back rest, a pair of front legs, a pair of
back legs and a pair of side arms. The seat 124 (see FIG. 5) is
delineated by a connecting front member 126, a parallel spaced
apart back member 128 and a pair of parallel spaced apart side
members 130, 132. The front legs 134, 136 are constructed as
parallel spaced apart vertical members joined to the free ends of
the front member 126 and have outwardly turned extensions 137
providing the front legs with an L-shape. The front legs 134, 136
are arranged generally vertical to the floor as viewed from the
front and side of the chair 120.
[0054] The back legs 138, 140 are constructed from an angular
member attached to the free ends of the back member 128. The back
legs 138, 140 have generally parallel spaced apart upper members
142 extending vertically from the back member 128 as viewed from
the front and side and generally parallel spaced apart lower
members 144. The lower members 144 are arranged at a rearwardly
extending angle as viewed from the side and extend generally
vertical from the back member 128 as viewed from the rear of the
chair 120.
[0055] A generally U-shaped member 146 includes a center section
148 connected across the free ends of the upper members 142 of the
back legs 138, 140 and a pair of curved spaced apart side arm
members 150, 152 forming the side arms 154, 156 of the arm chair.
The free ends of the side arm members 150, 152 are attached to the
free ends of the extensions 137 of the respective front legs 134,
136. The side arm members 150, 152 are spaced apart wider at their
mouth where they connect to the extensions 137 then where they form
the center section 148. This arranges the side arms 154, 156
outwardly of the side members 130, 132. The upper members 142 of
the back legs 138, 140, the back member 128 and center section 148
delineate the back 178 of the chair 120.
[0056] A secondary frame can be used to provide attachment support
for the woven material utilized in covering the frame 118.
Specifically, a generally U-shaped elongated rod 158 having a shape
conforming substantially to the shape of the U-shaped member 146 is
connected thereto in underlying relationship by means of a
plurality of spaced apart ribs 160. Another secondary support frame
is positioned between the front and back legs 134, 136, 138, 140
underlying the seat 124. This secondary frame is constructed from a
front rod 162 connected between the front legs 134, 136, a back rod
164 connected between the back legs 138,140 and a pair of side rods
166, 168 arranged in parallel spaced apart relationship connected
between the front rod 162 and back rod 164 inwardly of their
terminal ends. An additional front rod 170 may be positioned
between the front legs 134, 136 underlying front rod 162.
[0057] Referring now to FIGS. 4 and 5, the frame 118 is covered by
weaving the twisted yarn 100 into a woven material to form panels
of woven material directly on the frame. A plurality of individual
strands of the twisted yarn 100 are attached to various portions of
the frame 118, for example, to the secondary frame as previously
described. The individual strands of the twisted yarn 100,as they
are attached to the frame 118,are directly woven into a
predetermined weave pattern, for example, see FIG. 4. As shown in
FIG. 4, the weave pattern is a 4.times.4 pattern of weft and warp
strands. However, the pattern may include any number of weft and
warp strands of twisted yarn 100, for example, a 2.times.2,
5.times.5, 6.times.6, 10.times.10, etc. In addition, it is not
required that the woven material be symmetrical. In this regard, it
is contemplated that the weave may comprise a 2.times.3, 3.times.5,
4.times.7, 2.times.5, 2.times.6, etc. weft and warp woven pattern.
In addition, the twisted yarn 100 may be woven into integral
designs. As such, the resulting panels of woven material, as shown
in FIG. 4, are woven in situ directly on the frame 118.
[0058] It is also contemplated that the panels of woven material
can be pre-weaved separately from the chair frame 118. In this
regard, any weave pattern can be woven from the twisted yarn 100,
and the woven panels subsequently attached to the frame 118. There
are two heat setting processes contemplated pursuant to the present
invention. One heat setting process concerns the heat setting of
the twisted yarn 100 vis--vis the individual strands 102, 104
before, during or after the twisting process. The other heat
setting process concerns heat setting a weave of woven polymer
material, whereby the woven weft and warped yarns, either twisted
or non-twisted yarns, are heat set to promote, for example, at
least partial adhesion to each other thereby stabilizing the weave
as a whole.
[0059] A weave of woven material such as, for example, as shown in
FIG. 4 may be heat set prior to attaching the weave to the frame
118 of an article of furniture. The conditions of heat setting the
woven material are contemplated to be similar to those employed for
heat setting the twisted yarn 100. In this regard, the woven
material can be placed in a continuous or batch over and heated to
a sufficient temperature whereby the weft and warped yarns, as well
as individual strands 102, 104 if a twisted yarn 100 is employed,
are at least partially adhered to each other over at least
intermittent portions thereof along their entire length. This heat
setting process will simultaneously stabilize both the twisted yarn
100 when employed, as well as the entire woven material with
respect to the weft and warped yarns. It is preferred that only a
single heat setting process be performed on the woven material. In
this regard, it is contemplated that multiple heat setting
processes may result in the individual strands 102, 104 having a
glazed over or shiny look which could distract from their
wicker-style look.
[0060] Referring to FIG. 5, there is illustrated a chair 120 which
has been fabricated by the in situ or separate weaving of the
twisted yarn 100 into woven material which is attached to the frame
118. As shown, the chair 120 includes a seat portion 124, a front
skirt portion 176, a back rest portion 178 and side portions 180.
The front and back legs 134, 136, 138, 140 are wrapped with a
continuous length of heat set twisted yarn 100. In this regard, the
twisted yarn 100 is wrapped in a compact spiral around the length
of each leg without weaving.
[0061] The twisted yarns have been described as being used as both
the weft yarns and the warp yarns to form the woven portion, which
is adhered to a frame 118 of a furniture article. As the twisted
yarns generally have a non-smooth exterior surface by virtue of
their twisted nature, their direct contact with a person's skin may
be considered by some to be uncomfortable. It has therefore been
found desirable in accordance with another embodiment to provide an
improvement in the manufacture of woven portions from synthetic
twisted yarns, which provide improved comfort to the user of the
furniture article.
[0062] Referring to FIG. 8, the frame 118 in accordance with the
disclosed embodiment is covered by weaving the twisted yarn 100 in
combination with strands of non-twisted yarn into a woven material
to form panels of woven material directly or indirectly on the
frame as previously described. The non-twisted yarn can have any
desired construction such as disclosed in the aforesaid patents, or
as disclosed by strands 102, 104, or as may be known generally. A
plurality of individual strands of twisted yarn 100, i.e., weft
yarn, are attached to various portions of the frame 118, for
example, to the secondary frame as previously described. The
individual strands of the non-twisted yarn 101, i.e., warp yarn are
woven with the twisted yarn 100, as they are attached to the frame
118 into a predetermined weave pattern. As shown in FIG. 8, the
weave pattern is a 4.times.4 pattern of weft and warp strands.
However, the pattern may include any number of weft and warp
strands of twisted and non-twisted yarn 100, 101, for example, a
2.times.2, 5.times.5, 6.times.6, 10.times.10, etc. In addition, it
is not required that the woven material be symmetrical. In this
regard, it is contemplated that the weave may comprise a 2.times.3,
3.times.5, 4.times.7, 2.times.5, 2.times.6, etc. weft and warp
woven pattern. In addition, the twisted and non-twisted yarn 100,
101, may be woven into integral designs. As such, the resulting
panels of woven material, as shown in FIG. 8, are woven in situ
directly on the frame 118.
[0063] As the twisted yarn 100 is formed from at least two strands
102, 104 of polymer material, it is preferred that the diameter of
the strands be smaller than the diameter of the non-twisted yarn
101. In the preferred embodiment, the overall diameter of the
twisted yarn 100 will have a similar overall diameter to a single
strand of the non-twisted yarn 101. This will result in a more
uniform appearance to the woven portion. However, it is not a
requirement that the diameter or shape of the twisted yarn 100 and
non-twisted yarn 101 be the same. By providing variations in the
size, shape, coloration and/or configuration of the twisted yarn
100 and non-twisted yarn 101, various aesthetic appearances can be
achieved.
[0064] During the weaving process, the twisted yarn 100 constitutes
the weft yarn, while the non-twisted yarn 101 constitutes the warp
yarn. As shown in FIG. 8, the non-twisted yarn 101 is woven about
the twisted yarn 100 as is known in the weaving art. This results
in the exposed surface of the non-twisted yarn 101 being generally
raised above the exposed surface of the twisted yarn 100. This
provides a more comfortable surface portion for the woven material
as the surface of the non-twisted yarn 101 is predominantly exposed
for contact with the skin of an individual occupying the article of
furniture.
[0065] Although in accordance with the thus far described
embodiment, the woven material is formed in situ on the frame, it
is contemplated that panels of pre-woven material may be adhered to
the frame. It is therefore contemplated that portions of the
article of furniture may be formed with woven material in situ,
other portions by attaching panels of pre-woven material thereto,
as well as variations thereof.
[0066] Referring to FIG. 9, there is disclosed another embodiment
of a weave incorporating a twisted yarn 100 in accordance with one
embodiment of the present invention. The weave as shown in FIG. 9
is a reverse combination weave from the weave as previously
described with respect to FIG. 8. In this regard, the twisted yarn
100 forms the warped yarns, while the non-twisted yarn 101 forms
the weft yarns. This reversal of the weft and warped yarns has been
found to provide a number of benefits to the finished woven
material. For example, during a machine weaving process, it has
been found easier to insert weft yarns 101 which have a smoother
outer surface than the twisted yarns 100. It has also been
determined that using the twisted yarn 100 as the warped yarn
minimizes or eliminated sagging of the woven material when
suspended or stretched across a frame such as when heat setting in
the case of making an article of furniture, in particular, a chair
and the like. Not withstanding the foregoing, the present invention
specifically encompasses the combination of twisted and non-twisted
yarns as either weft or warped yarns.
[0067] In accordance with another embodiment of the present
invention, the entire chair 120 is placed into an oven similar to
oven 110 in order to heat set the attached woven material similar
to that used in the production of the heat set twisted yarn. In the
case of the chair 120, it is contemplated that the oven will be a
batch oven, as opposed to a continuous oven 110 as described with
respect to the manufacture of the twisted yarn 100. In this regard,
the oven will typically be of sufficient size to hold a plurality
of chairs 120. The chairs will remain in the oven at a
predetermined temperature for a predetermined residence time to
cause the twisted yarns or non-twisted yarns to reach a temperature
up to but generally below about its softening temperature, whereby
contiguous portions of the twisted yarn 100 may at least partially
bond or fuse together within the weave, depending upon temperature,
when the chair is removed from the oven and allowed to cool. The
cooling process may take place either within the oven or outside
the oven by being subjected to ambient air. In addition, it is also
contemplated that a source of chilled air may be blown over the
heated chairs 120 either in a confined housing or in an open
area.
[0068] The temperature and residence time for the oven for heat
setting the woven polymer material are similar to those as thus far
described with respect to the twisted yarn. In addition, it is
contemplated that the woven material can be formed from other than
twisted yarn 100 as described. For example, individual filaments,
as well as plural filaments which are untwisted can also be used in
forming the woven material for adhering to the frame of the article
of furniture which is to be ultimately heat set. It is further
contemplated that strands of the twisted yarn 100 can also be woven
with non-twisted strands to form woven material for forming
portions of the article. Thus, it is to be understood, that various
constructions of polymer filaments may be woven to form the woven
material having various aesthetic appearances.
[0069] As previously described, it is contemplated that panels of
pre-woven material may be adhered to the frame and subsequently
heat set by placing the article of furniture in an oven as thus far
described. It is therefore contemplated that portions of the
article of furniture may be formed with woven material in situ,
other portions by attaching panels of pre-woven material thereto,
as well as variations thereof. In any event, the article of
furniture will be placed in an oven to heat set the woven material
including the polymer strands of twisted or non-twisted
strands.
[0070] Referring now to FIG. 10, we will be describing the
construction of a floor covering in the nature of a rug or mat, and
generally designated by reference numeral 200. The floor covering
200 is formed as a weave from twisted yarn 100 as thus far
described. For example, the twisted yarn 100 can be formed from any
number of strands 102, 104, which strands may be the same or
different as to size, shape, surface configuration, coloration and
surface appearance. Accordingly, any of the variations as
heretofore described with respect to the strands 102, 104 and/or
twisted yarn 100 may be incorporated into the floor covering 200.
It is also contemplated that portions of the floor covering 200 may
include non-twisted yarns in combination with twisted yarns 100,
such as forming the wet yarns and warped yarns. It is further
contemplated that the warped yarns may be twisted yarns and the wet
yarns be non-twisted yarns, or the wet yarns being twisted yarns
and the warped yarns being non-twisted yarns, as disclosed and
described with respect to FIGS. 8 and 9.
[0071] A floor covering 200 such as a rug or mat can be woven into
any desired pattern incorporating any number of twisted yarns 100
or non-twisted strands 102, 104, all of various size, shape,
surface configuration, coloration and surface appearance as
desirable to provide an aesthetically pleasing floor covering. By
forming a portion of the floor covering 200 from twisted yarn 100,
the twisted yarn provides a non-slip surface when being walked upon
to enhance traction. The floor covering 200, by virtue of being
constructed from synthetic material, is particularly suitable for
outdoor use in wet environments. The floor covering 200 is
constructed without a backing material. By eliminating the backing
material, water and air can penetrate through the openings formed
within the weave. This will allow for drainage and eliminate
pooling of water on or under the floor covering 200 where the floor
covering is used in an outdoor environment which is subject to
rain. In addition, the construction facilitates washing of the
floor covering using a hose and the like, whereby the water will
penetrate through the weave and drain therefrom. The openings in
the weave will also facilitate air drying. This construction of the
floor covering 200 will prevent rotting or mildew from forming
under the supporting floor. By way of example only, openings in the
order of 0.1 to 1.5 mm is considered sufficient to allow for water
passage and air circulation, although other sized openings smaller
and larger than the foregoing range are contemplated. Generally,
any opening or combination of openings sized to permit water
drainage will be useful in forming floor coverings 200 pursuant to
the present invention. The floor covering 200, by not being
provided with a backing, is also reversible during use.
[0072] The floor covering 200 may be heat set during its
manufacturing process as thus far described with respect to the
twisted yarn 100 or woven material formed therefrom, such as in
making an article of furniture as previously described. In this
regard, the twisted yarn 100 may be heat set during the twisting
process. The heat set twisted yarn 100 may then be woven to form
the floor covering 200. Subsequently, the floor covering 200 can be
heat set to stabilize the weft and warp yarns in the weave.
[0073] In the preferred embodiment, the twisted yarn 100 is not
heat set during the twisting operation. Subsequent to forming the
woven floor covering 200, the floor covering is subject to a single
heat setting process. As previously described, in this regard, the
weft and warp yarns will be at least partially, or fully, adhered
to each other, as well as the individual strands forming the
twisted yarn 100. The heat set floor covering 200 will maintain its
shape during use without the need of secondary assistance. For
example, it is not required that a frame be provided for the floor
covering 200 as in the case of an article of furniture as
previously described. However, if desired, a suitable frame may be
used about which a panel of woven material can be affixed in
forming the floor covering 200. In addition, it is not required
that a binding as is conventional on rugs be provided around the
edge of the floor covering 200. However, a binding 202 of synthetic
or natural materials may be adhered, such as by stitching, gluing,
thermal bonding and the like, around the perimeter of the floor
covering 200 if so desired.
[0074] Although the invention herein has been described with
reference to particular embodiments, it is to be understood that
these embodiments are merely illustrative of the principles and
application of the present invention. It is therefore to be
understood that numerous modifications may be made to the
illustrative embodiments and that other arrangements may be devised
without departing from the spirit and scope of the present
invention as defined by the appended claims.
* * * * *