Method of making furniture with synthetic woven material

• US 20030115849A1
• Filed: 11/08/2002
• Published: 06/26/2003
• Est. Priority Date: 12/05/2001
• Status: Active Grant

• Current Assignee: Casual Living Worldwide Incorporated (Brown Jordan, Inc.)
• Original Assignee: Sun Isle Casual Furniture, LLC
• Inventors: Schwartz, Larry
• Granted Patent: US 7,076,939 B2
• Time in Patent Office: Days
• US Class Current: 57/238
• CPC Class Codes: A47C 5/02 of woven material, e.g. basket chairs
• CPC Class Codes: A47C 7/02 Seat parts adaptation of seats to mounting in tubular chairs A47C5/06; such parts not restricted to chairs A47C23/00; removable upholstered units or cushions A47C27/00
• CPC Class Codes: D02G 3/24 Bulked yarns or threads, e.g. formed from staple fibre components with different relaxation characteristics
• CPC Class Codes: D02G 3/28 Doubled, plied, or cabled threads D02G3/32, D02G3/36 take precedence; effect yarns D02G3/34; details of spindles, e.g. bearings D01H7/86
• CPC Class Codes: D03D 1/00 Woven fabrics designed to make specified articles
• CPC Class Codes: D03D 1/0029 Doormats
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/587 adhesive; fusible
• CPC Class Codes: D03D 29/00 Hand looms
• CPC Class Codes: D10B 2321/041 polyvinyl chloride or polyvinylidene chloride
• CPC Class Codes: D10B 2331/02 polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/04 polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2401/041 thermoplastic; thermosetting
• CPC Class Codes: D10B 2503/00 Domestic or personal
• CPC Class Codes: D10B 2503/04 Floor or wall coverings; Carpets
• CPC Class Codes: D10B 2505/08 Upholstery, mattresses

Abstract

An article of furniture is made from elongated polymer filaments. The polymer filaments may be monofilaments or plural filaments which are twisted together and heat set to prevent their untwisting during the subsequent weaving process. The heat setting of the polymer filaments is achieved by heating the polymer material either before or after the twisting process.

Claims

1. A twisted elongated yam comprising an elongated first yarn of polymer material twisted together with an elongated second yam forming a composite yarn having a twisted shape, wherein one of said first and second yams is different from the other one of said first and second yams in at least one of size, shape, surface configuration and surface appearance.

2. The yarn of claim 1, wherein said second elongated yarn comprises polymer material.

3. The yarn of claim 1, further including an elongated third yarn twisted together with said first and second yarns.

4. The yarn of claim 3, wherein said third yarn comprises polymer material.

5. The yarn of claim 3, wherein said third yarn is substantially similar to one of said first and second yams in at least one of size, shape, surface configuration and surface appearance.

6. The yarn of claim 3, wherein said third yarn is different from said first and second yams in at least one of size, shape, surface configuration and surface appearance.

7. The yarn of claim 3, wherein said third yarn is similar to one of said first and second yarns in size, shape, surface configuration and surface appearance.

8. The yam of claim 3, wherein said third yarn is different from said first and second yams in size, shape, surface configuration and surface appearance.

9. The yarn of claim 4, wherein said second yam comprises polymer material.

10. The yarn of claim 1, wherein said one of said first and second yams is different from the other one of said first and second yarns in size, shape, surface configuration and surface appearance.

11. The yam of claim 1, wherein said surface appearance comprise coloration.

12. A twisted elongated yam comprising an elongated first yam, an elongated second yarn and an elongated third yam, said first, second and third yams twisted together to form a composite twisted yarn, wherein at least one of said yams comprises polymer material, and wherein one of said first, second and third yams is different from at least one of the other two yarns in at least one of size, shape, surface configuration and surface appearance.

13. The yam of claim 12, wherein said first, second and third yams comprise polymer material.

14. The yam of claim 12, wherein said surface appearance comprises coloration.

15. The yam of claim 12, wherein each of said first, second and third yams are different from each other in at least one of size, shape, surface configuration and surface appearance.

16. The yarn of claim 12, wherein each of said first, second and third yams are different from each other in size, shape, surface configuration and surface appearance.

17. The yam of claim 12, wherein one of said first, second and third yams comprise natural material.

18. An article of furniture comprising a frame having a shape of an article of furniture and at least one panel attached thereto formed as a weave from a plurality of elongated members, at least one of said members comprising an elongated first yarn of polymer material twisted together with an elongated second yam forming a composite yam having a twisted shape, wherein one of said first and second yams is different from the other one of said first and second yarns in at least one of size, shape, surface configuration and surface appearance.

19. The article of claim 18, wherein said second elongated yarn comprises polymer material.

20. The article of claim 18, further including an elongated third yarn twisted together with said first and second yarns.

21. The article of claim 20, wherein said third yam comprises polymer material.

22. The article of claim 20, wherein said third yam is substantially similar to one of said first and second yams in at least one of size, shape, surface, configuration and surface appearance.

23. The article of claim 20, wherein said third yam is different from said first and second yams in at least one of size, shape, surface configuration and surface appearance.

24. The article of claim 20, wherein said third yam is similar to one of said first and second yarns in size, shape, surface configuration and surface appearance.

25. The article of claim 20, wherein said third yam is different from said first and second yarns in size, shape, surface configuration and surface appearance.

26. The article of claim 21, wherein said second yam comprises polymer material.

27. The article of claim 18, wherein said one of said first and second yarns is different from the other one of said first and second yarns in size, shape, surface configuration and surface appearance.

28. The article of claim 18, wherein said surface appearance comprise coloration.

29. An article of furniture comprising a frame having a shape of an article of furniture and at least one panel attached thereto formed as a weave from a plurality of elongated members, at least one of said member comprising an elongated first yarn, an elongated second yam and an elongated third yam, said first, second and third yams twisted together to form a composite twisted yarn, wherein at least one of said yarns comprises polymer material, and wherein one of said first, second and third yarns is different from at least one of the other two yams in at least one of size, shape, surface configuration and surface appearance.

30. The article of claim 29, wherein said first, second and third yarns comprise polymer material.

31. The article of claim 29, wherein said surface appearance comprises coloration.

32. The article of claim 29, wherein each of said first, second and third yams are different from each other in at least one of size, shape, surface configuration and surface appearance.

33. The article of claim 29, wherein each of said first, second and third yams are different from each other in size, shape, surface configuration and surface appearance.

34. The article of claim 29, wherein one of said first, second and third yarns comprise natural material.