Combination weave using twisted and nontwisted yarn

• US 6,935,383 B2
• Filed: 05/30/2002
• Issued: 08/30/2005
• Est. Priority Date: 12/05/2001
• Status: Expired due to Fees

• Current Assignee: Casual Living Worldwide Incorporated (Brown Jordan, Inc.)
• Original Assignee: Sun Isle Casual Furniture, LLC
• Inventors: Schwartz, Larry
• Primary Examiner(s): Calvert, John J.
• Assistant Examiner(s): Muromoto, Jr., Robert H.
• Application Number:
  US10/158,629
• Publication Number:
  US 20030221741A1
• Time in Patent Office: 1,188 Days
• Field of Search: 139/426.TW, 139/383.R, 139/420.A, 139/426.R
• US Class Current: 139/426.0TW
• 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 15/47 multicomponent, e.g. blended yarns or threads multicomponent fibres or filaments D03D15/292
• CPC Class Codes: D03D 29/00 Hand looms
• CPC Class Codes: D10B 2321/041 polyvinyl chloride or polyvinylidene chloride
• 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 woven with polymer strands of non-twisted yarn to form a woven portion of material. The woven portion can be used to form the seat or back rest of a seating article of furniture for indoor or outdoor use.

Claims

1. A weave forming a woven panel adapted for use in a user supporting article of furnitire for supporting a portion of the user'"'"'s body, said weave comprising a plurality of elongated non-twisted polymer strands, and a plurality of elongated twisted polymer strands, said non-twisted strands and said twisted strands woven together forming said woven panel wherein said twisted and said non-twisted strands each have exposed upper surfaces, said non-twisted strands having portions of said exposed upper surfaces above portions of said exposed upper surfaces of said twisted strands.

2. The weave of claim 1, wherein each of said twisted strands comprise at least a pair of polymer strands twisted together.

3. The weave of claim 2, wherein the twisted polymer strands are twisted together over their entire length.

4. The weave of claim 1, wherein the number of non-twisted strands is the same as the number of twisted strands.

5. The weave of claim 1, wherein the number of non-twisted strands is different from the number of twisted strands.

6. The weave of claim 1, wherein each of said non-twisted strands are woven about said twisted strands.

7. A woven panel adapted for use in a user supporting article of furniture for supporting a portion of the user'"'"'s body, said woven panel comprising a plurality of elongated non-twisted polymer warp strands, each of said warp strands comprising a single polymer strand, a plurality of elongated twisted polymer weft strands, each of said weft strands comprising at least two polymer strands twisted together over their entire length, said weft strands and said warp strands having an exposed upper surface, wherein said exposed upper surface of said warp strands is arranged above said exposed upper surface of said weft strands in said woven panel.

8. The woven pattern of claim 7, wherein the number of warp strands is the same as the number of weft strands.

9. The woven panel of claim 7, wherein the number of warp strands is different from the number of weft strands.

10. An article of furniture comprising a frame having the shape of an article of furniture, and a weave of polymer material attached to said frame, said weave comprising a plurality of elongated non-twisted polymer wrap strands and a plurality of elongated twisted polymer weft strands.

11. The article of claim 10, wherein each of said weft strands comprise at least a pair of polymer strands twisted together.

12. The article of claim 11, wherein the twisted polymer strands are twisted together over their entire length.

13. The article of claim 10, wherein the number of warp strands is the same as the number of weft strands.

14. The article of claim 10, wherein the number of warp strands is different from the number of weft strands.

15. The article of claim 10, wherein each of said warp strands are woven about said weft strands.

16. The article of claim 15, wherein said weft and warp strands have an exposed upper surface, said warp strands have said exposed upper surface above said exposed upper surface of said weft strands within said weave.

17. The article of claim 10, wherein said weave forms a back rest portion of said article of furniture.

18. The article of claim 10, wherein said weave forms a seat portion of said article of furniture.

19. An article of furniture comprising a frame having the shape of an article of furniture, and a woven portion of polymer material attached to said frame, said woven portion comprising a plurality of elongated non-twisted polymer warp strands, each of said warp strands comprising a single polymer strand, a plurality of elongated twisted polymer weft strands, each of said weft strands comprising at least two polymer strands twisted together over their entire length, said weft strands and said warp strands having an exposed upper surface, wherein said exposed upper surface of said warp strands are arranged above said exposed upper surface of said weft strands within said woven portion.

20. The article of claim 19, wherein the number of warp strands is the same as the number of weft strands.

21. The article of claim 19, wherein the number of warp strands is different from the number of weft strands.

22. The article of claim 19, wherein said weave forms a back rest portion of said article of furniture.

23. The article of claim 19, wherein said weave forms a seat portion of said article of furniture.

24. A method of making an article of furniture comprising providing a frame having the shape of an article of furniture, providing a plurality of weft yarns of twisted polymer strands, weaving a plurality of warp yarns of non twisted polymer strands with said plurality of weft yarns to form a woven material, adhering said plurality of weft yarns and warp yarns to said frame, wherein said plurality of weft yarns and said warp yarns have ah exposed upper surface, wherein the exposed upper surface of said warp yarns are arranged above the upper surface of adjacent weft yarns.

25. The method of claim 24, wherein said plurality of warp and weft yarns are attached to said frame prior to weaving said plurality of warp yarns.

26. The method of claim 24, wherein said woven material is formed prior to attaching said plurality of warp and weft yarns to said frame.