Patent Abstract:
A system to form smooth synthetic wicker yarn. The smooth synthetic wicker yarn is then reprocessed to form a naturally looking and feeling wicker yarn. In one aspect, a pair of top and bottom brushes with bristles score simultaneously a plurality of irregular 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.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    I. Field 
         [0002]    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. 
         [0003]    II. Background 
         [0004]    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. 
         [0005]    Wicker furniture has always been very popular and has been used as children&#39;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. 
         [0006]    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. 
         [0007]    Therefore there is a need for techniques to create textured wicker yarn that has a natural wicker look and feel. 
       SUMMARY 
       [0008]    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. 
         [0009]    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. 
         [0010]    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. 
         [0011]    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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  illustrates a high level block diagram of a system for making textured synthetic wicker yarn in accordance with one embodiment of the present invention. 
           [0013]      FIG. 2  illustrates a flowchart of a process for making textured synthetic wicker yarn in accordance with one embodiment of the present invention. 
           [0014]      FIG. 3  illustrates a smooth synthetic wicker yarn in accordance with one embodiment of the present invention. 
           [0015]      FIG. 4  illustrates brushes texturizing the synthetic wicker yarn in accordance with one embodiment of the present invention. 
           [0016]      FIG. 5  illustrates a weave pattern using the textured synthetic wicker yarn in accordance with one embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    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. 
         [0018]      FIG. 1  illustrates a high level block diagram of a system  100  for making textured synthetic wicker yarn in accordance with one embodiment of the present invention. The system  100  includes a mixer  102  for mixing raw material (e.g. polyvinyl chloride (PVC) or polyethylene (PE)) and a coloring agent to provide pigment to the textured synthetic wicker yarn  510  or  520  of  FIG. 5 . The mixer  102  is followed by an extruder  104  for extruding the mixture to create a smooth synthetic wicker yarn  300  ( FIG. 3 ). As best seen in  FIG. 3 , the smooth synthetic wicker yarn  300  is a relatively smooth yarn with little to no grooves, pocks, hair line crevices, etc. in or along a section of the outer surface of the synthetic wicker yarn. The extruder  104  is followed by a dryer  106  for drying the synthetic wicker yarn  300  so that it is generally set in shape and has a smooth surface texture. The term “set” refers to a yarn that will not become distorted under normal handling procedure. In one configuration, the synthetic wicker yarn  300  is flexible to permit weaving. 
         [0019]    The dryer  106  is followed brushes  108  rotated via motor  112 . In one configuration, there is at least one top brush  110 A and at least one bottom brush  110 B. The brushes  110 A and  110 B include bristles  420  wherein as the brushes  110 A and  110 B or  410 A and  410 B 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. 
         [0020]      FIG. 2  illustrates a flowchart of a process  200  for making textured synthetic wicker yarn in accordance with one embodiment of the present invention. The process  200  will be described in combination with  FIGS. 3 and 4 . The process  200  begins with block  202  where the raw material is prepared. Preparation of raw materials is made according to standards and desired rigidity of wicker yarn. According to current color trends, a coloring agent or paint is prepared. At block  204 , pre-production preparation of the extruder  104  to extrude a predetermined size and shape of the synthetic wicker yarn  300  takes place. During pre-production preparation of the extruder  104 , the raw materials are placed into relevant moulds. Meanwhile, the temperature of extruder  104  is raised to the process temperature between 150° C.-200° C. At block  206 , the raw material and the coloring agent are mixed. After the raw materials and coloring agents are mixed, the mixture is put into a funnel of the extruder  104 . 
         [0021]    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  ( FIG. 3 ) is created after molding, while the standard and size are control by the speed of extruder  104 . At block  210 , the extruded wicker yarn is cooled and dried. The smooth wicker yarn  300  is finalized and set after cooling. 
         [0022]    Referring now to  FIG. 4 , at block,  212 , the synthetic wicker yarn  300  is brushed 360° (360 degrees) in a single pass of the synthetic wicker yarn  300  between top and bottom brushes  410 A and  410 B. In order to make the smooth wicker yarn  300  look similar to natural wicker, the smooth wicker yarn  300  is reprocessed in order to change the texture the outer circumferential surface  302 . In one configuration, the texture is created by two or more of rounded steel brushes, driven by frequency conversion electromotor groups (motor  112 ). The smooth wicker yarn  300  passes through high speed running steel brushes  410 A and  410 B, and at the same time towing it by a traction engine in reverse direction so as to score, engrave or inscribe irregular hair lines, grooves or crevices in the outer circumferential surface  302  with the steel brushes  410 A and  410 B. Therefore, the irregular hairs and/or other irregular formations such as grooves, pocks, crevices, etc. will appear on the outer circumferential surface denoted at  402  of partially textured synthetic wicker yarn  400 . 
         [0023]      FIG. 5  illustrates a weave pattern  500  using the textured synthetic wicker yarn in accordance with one embodiment of the present invention. The weave pattern  500  includes a plurality of horizontal textured wicker yarn  510  and a plurality of vertical textured wicker yarn  520 . As can be readily seen in  FIG. 5 , as the brushes score, engrave or inscribe irregular hair lines, grooves or crevices in the outer circumferential surface  302 , the shavings of the scoring and engraving may remain affixed to the textured outer circumferential surface  402  and form hairs  540 . 
         [0024]    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. 
         [0025]    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.

Technology Classification (CPC): 3