Patent Application
20090286081
I. Field
This invention relates generally to synthetic yarn and, more specifically, to system and method for manufacturing textured synthetic wicker yarn that has the look and feel of natural wicker.
II. Background
Currently, the polymer wicker yarn is extruded to different sixes and shapes according to its use in a particular article of manufacture such as chairs, sofas, etc. But the surface of the polymer wicker yarn is relatively smooth, carrying distinct character of plastic. It lacks of natural aesthetic feeling and look of the natural wicker.
Wicker furniture has always been very popular and has been used as children's furniture, as well as, patio furniture. However, natural wicker has a limited life cycle in the outdoors as the weather affects the strength and durability of the wicker. For example, the wicker is susceptible to rotting as the result of exposure to rain. Moreover, natural wicker is generally painted to provide consumers a variety of colors to match their home decor. However, the expansion and contraction properties of natural wicker such as based on varying temperatures or swelling from being soaked by rain, causes the painted coating on the wicker to crack and peel.
Because of the popularity of wicker furniture, many attempts have been made to create a synthetic wicker that is more durable when exposed to the weather and aesthetically pleasing for current outdoor living spaces. However, the synthetic wicker yarns are generally smooth and do not have a natural wicker feel and look.
Therefore there is a need for techniques to create textured wicker yarn that has a natural wicker look and feel.
The present invention provides a method and system for mixing raw material and a coloring agent; extruding the mixture into wicker yarn; and scoring with rotating brushes a circumferential outer surface of the extruded wicker yarn to texture the wicker yarn to have a natural wicker look and feel.
The present invention contemplates a system comprising a mixer operable to mix raw synthetic material and a coloring agent to form a mixture; an extruder operable to extrude the mixture into smooth synthetic wicker yarn; and a pair of top and bottom brushes with bristles being operable to score simultaneously a plurality of hair lines in the circumferential outer surface of the smooth synthetic wicker yarn to texture the smooth synthetic wicker yarn to have a natural wicker appearance.
A wicker yarn, in one configuration, is provided that comprises an elongated section of molded synthetic material having formed therein irregular lines, crevices and radiating therefrom hairs of the synthetic material, the hairs created by scoring of the irregular lines and crevices in the synthetic material.
In addition to the above objects and features, additional objects, features and advantages will become apparent in view of the specification, drawings and appended claims.
The present invention now will be described more fully hereinafter which reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments by which the invention may be practiced. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Among other things, the present invention may be embodied as methods or devices. Accordingly, the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment or an embodiment combining software and hardware pieces. The following description is, therefore, not to be taken in a limiting sense.
The dryer 106 is followed brushes 108 rotated via motor 112. In one configuration, there is at least one top brush 110A and at least one bottom brush 110B. The brushes 110A and 110B include bristles 420 wherein as the brushes 110A and 110B or 410A and 410B are rotated, as the synthetic wicker yarn 300 is traverses between the top and bottom brushes, the bristles 420 create, grooves, pocks, hair line crevices, etc. and texturizes simultaneously the outer surface of the synthetic wicker yarn 300. In one configuration, the bristles 420 of the brushes are capable of contacting 360 degrees of the outer surface 302 of wicker yarn 300. Hence, the entire circumferential outer surface 302 is texturized to have a look and feel of natural wicker.
At block 208, the mixture is extruded where the mixture of raw materials and coloring agent is smelt down to ropy liquids. The smooth wicker yarn 300 (
Referring now to
According to this invention, the weave pattern 500 or other weave patterns may be used to manufacture articles such as leisure furniture so that the furniture will look more natural look and feel. Numerous styles of weave are used in the manufacture of wicker furniture. The various styles of weave result in a different look, feel, strength and weight of the finished woven product. In the weave pattern 500, 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.
The previous description of the present invention is provided to enable a person skilled in the art to make or use the invention. Various modifications to these configurations will be readily apparent to those skilled in the art, and the principles defined herein may be applied to other configurations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the embodiments shown but is to be accorded the broadest scope consistent with the principles and features disclosed herein above.
