Synthetic yarn

Abstract

A synthetic wicker yarn with irregularities sufficient to simulate natural wickers, in which the irregularities are durable even during weaving. The yarn is formed from an elongated body with a generally round cross section. The body is of two layers of coextruded polymer an outer layer integrated around the inner layer. An irregular node having a protuberance formed of the polymer outer layer extends radially from the outer layer, with a clearance exposing the polymer inner layer, in a manner like decorticated wicker. The outer layer may be have a greater density and rigidity for durability of the irregularity. Also included is a method of manufacturing this yarn and furniture having the yarn.

1 . A synthetic wicker yarn, comprising:
 an elongated body having a generally round cross section, the body comprising a first polymer forming an inner layer, a second polymer forming an outer layer, the second polymer co-extruded with the first polymer such that the outer layer is integrated around the inner layer; and   at least one node comprising at least one protuberance formed of the second polymer and extending radially from the outer layer, the second polymer being extruded in such a manner as to define at least one clearance adjacent to the protuberance by which a portion of the first polymer is exposed, the clearance having a border defining the separation of the first polymer and the second polymer at the node.   
     
     
         2 . The synthetic wicker yarn of  claim 1 , wherein the at least one clearance is substantially oblong and the protuberance is located within the border of the node. 
     
     
         3 . The synthetic wicker yarn of  claim 1 , wherein the at least one clearance is substantially oblong, the border is irregular, and the protuberance is located within the border of the node. 
     
     
         4 . The synthetic wicker yarn of  claim 1 , wherein the second polymer has a greater rigidity than the first polymer. 
     
     
         5 . The yarn of  claim 1 , wherein the first polymer has a first color and the second polymer has a second color, wherein the first color is different from the second color. 
     
     
         6 . The synthetic wicker yarn of  claim 1 , wherein the first polymer and the second polymer are the same material. 
     
     
         7 . The synthetic wicker yarn of  claim 1 , wherein the first polymer and the second polymer are the same material and are selected from the group consisting of polyvinyl chloride, polyethylene, polypropylene and mixtures thereof. 
     
     
         8 . The synthetic wicker yarn of  claim 1 , wherein the first polymer is LDPE and the second polymer is HDPE. 
     
     
         9 . The synthetic wicker yarn of  claim 1 , wherein the first and second polymers are PE, and the first polymer has a density that is less than the second polymer. 
     
     
         10 . The synthetic wicker yarn of  claim 1 , wherein the first and second polymers are PE and the first polymer has a density less than about 0.94 g/cc and the second polymer has a density greater than about 0.94 g/cc. 
     
     
         11 . The synthetic wicker yarn of  claim 1 , wherein the first polymer is a different polymer material from the second polymer. 
     
     
         12 . An article of furniture made with the synthetic wicker yarn according to  claim 1 . 
     
     
         13 . The synthetic wicker yarn of  claim 1 , wherein the outer layer of the yarn includes one or more features selected from the group comprising grooves, stripes, and raised lobes. 
     
     
         14 . A method for producing a wicker yarn, comprising the steps of:
 (a) providing a first polymer;   (b) providing a second polymer;   (c) heating the first polymer at a first temperature to form a first molten material;   (d) heating the second polymer at a second temperature to form a second molten material;   (e) conveying said first molten material through an open port of the second extruder;   (f) feeding the second molten material into a second extruder at a rate relative to the rate of extruding the first molten material so as to form an outer layer integrated around the inner layer with the outer layer having at least one node comprising at least one protuberance formed of the second polymer and extending radially from the outer layer, the second polymer being extruded in such a manner as to define at least one clearance adjacent to the protuberance by which a portion of the first polymer is exposed, the clearance having a border defining the separation of the first polymer and the second polymer at the node; and   (g) cooling the yarn.   
     
     
         15 . The method of  claim 14 , wherein the first temperature is greater than the second temperature. 
     
     
         16 . The method of  claim 14  wherein step (a) further includes the step of adding a first color concentrate and step (b) further includes the step of adding a second color concentrate. 
     
     
         17 . The method of  claim 14 , wherein the at least one clearance is substantially oblong and the protuberance is located within the border of the node. 
     
     
         18 . The method of  claim 14 , wherein the at least one clearance is substantially oblong, the border is irregular, and the protuberance is located within the border of the node. 
     
     
         19 . The method of  claim 14 , wherein the second polymer has a greater rigidity than the first polymer. 
     
     
         20 . The method of  claim 14 , wherein the first polymer has a first color and the second polymer has a second color, wherein the first color is different from the second color. 
     
     
         21 . The method of  claim 14 , wherein the first polymer and the second polymer are the same material. 
     
     
         22 . The method of  claim 14 , wherein the first polymer and the second polymer are the same material and are selected from the group of polyvinyl chloride, polyethylene, and polypropylene. 
     
     
         23 . The method of  claim 14 , wherein the first polymer is LDPE and the second polymer is HDPE. 
     
     
         24 . The method of  claim 14 , wherein the first and second polymers are PE, and the first polymer has a density that is less than the second polymer. 
     
     
         25 . The method of  claim 14 , wherein the first and second polymers are PE and the first polymer has a density less than about 0.94 g/cc and the second polymer has a density greater than about 0.94 g/cc. 
     
     
         26 . The method of  claim 14 , wherein the first polymer is a different polymer material from the second polymer. 
     
     
         27 . The method of  claim 14 , wherein the second die is configured to produce an outer layer of the yarn having one or more features selected from the group comprising grooves, stripes, and raised lobes.