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  Yarn having lateral projectionsUSPTO Application #: 20060116041Title: Yarn having lateral projections Abstract: An elongated polymer yarn includes a central body from which there extends a pair of spaced apart lateral projections. In one embodiment, the body is in the nature of a cylindrical member, while the projections are in the nature of flat planar members. The projections are arranged opposing one another about the body in co-planar arrangement, although angular arrangements are contemplated. (end of abstract) Agent: Lerner, David, Littenberg, Krumholz & Mentlik - Westfield, NJ, US Inventor: Chuan Kuei Hou USPTO Applicaton #: 20060116041 - Class: 442195000 (USPTO) Related Patent Categories: Fabric (woven, Knitted, Or Nonwoven Textile Or Cloth, Etc.), Woven Fabric (i.e., Woven Strand Or Strip Material), Including Strand Which Is Of Specific Structural Definition, Cross-sectional Configuration Of Strand Material Is Specified, Cross-sectional Configuration Of The Strand Material Is Other Than Circular The Patent Description & Claims data below is from USPTO Patent Application 20060116041. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS REFERENCES TO RELATED APPLICATIONS [0001] This application is a continuation-in-part of Application No. 29/218,209, filed on Nov. 30, 2004, entitled Yarn, the disclosure of which is incorporated herein by reference. BACKGROUND OF THE INVENTION [0002] Natural wicker has been used in the manufacture of furniture, baskets and other articles for many centuries. The casual, informal appearance of wicker has made it especially popular for use in enclosed porches and other informal settings in homes, hotels and other establishments. Natural wicker, however, has had limited use in the outdoor furniture market, including patio furniture, pool furniture and the like. This is because natural wicker softens and weakens when wet, and is more susceptible to rotting and mildew than many other natural and man-made furniture materials. [0003] Woven wicker typically comprises a weft yarn, i.e., a yarn running straight through the woven material, and a warp yarn, i.e., a yarn that is woven around the weft yarn. 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 a simple weave pattern, the weft yarns are spaced apart and arranged parallel to each other. The warp yarns are woven over and under alternating weft yarns. Adjacent warp yarns pass on opposite sides of a given weft yarn. [0004] Polymer yarns have also been used to manufacture wicker-like furniture. By way of example, a polymer yarn is known which is constructed as an elongated body, such as of indeterminate length, having a core surrounded by a sheath of polyvinylchloride (PVC) outer coating, for example, foamed and non foamed PVC material. Foamed PVC material gives greater volume with less material. The outer coating may be formed of other synthetic materials such as polyamides, polyesters and the like. The yarn is typically made in a single step using a coextrusion process, as is known in the art. The inner core may include a single filament of polyester, or may include a plurality of polyester filaments bundled to form a single core. In addition, the core may be formed of other materials than polyester such as metal, monofilament or stranded, such as polyamides and the like. The core is designed to give the yarn greater mechanical strength over yarns formed only of polymer material. This is considered more important when the outer layer is constructed from foamed polymer material. [0005] The polymer yarn being constructed from foamed PVC material results in a lack of uniformity in the foaming of the PVC material during the extrusion process. This produces a yarn which lacks a uniform cylindrical appearance. Specifically, the outer surface of the yarn is deformed, such as by having undulations, mounds and/or depressed areas along the length of the yarn. The deformed shape of the outer surface of the yarn results in the yarn having a more natural look to that of real wicker. It is also known to provide the exterior surface of the polymer yarn with one or more random stripes of a contrasting color and/or one or more random grooves. The stripes and grooves can be continuous and/or intermittent along the exterior surface of the yarn. The yarn, however, can also have a more uniform cylindrical shape, as well as other shapes such as square, oval, flat, triangular and the like. Polymer yarns as thus far described are known from U.S. Pat. Nos. 5,704,690, 5,845,970 and 6,179,382; as well as U.S. Design Pat. Nos. 395,171, 474,614 and 409,001; the disclosures of which are incorporated herein by reference. As in the case of natural wicker, polymer yarns have been woven into a woven material, which has been used in the manufacture of casual furniture suitable for the outdoor furniture market, including patio furniture, as well as for indoor use. [0006] There is known twisted composite yarns for use in manufacturing synthetic woven material for furniture articles in Applicant's U.S. Pat. Nos. 6,625,970, 6,705,020 and 6,725,640, the disclosures of which are incorporated herein by reference. These patents disclose various methods of heat setting multiple strand twisted yarns and forming same into a woven material for use in forming, for example, seat and back portions of a furniture article. The twisted yarns are used as both the weft yarns and the warp yarns to form the woven portion, which is adhered to a frame of a furniture article. There is also disclosed the application of multiple strands twisted and single strand non-twisted synthetic yarns for use in manufacturing synthetic woven material for furniture articles in Applicant's co-pending application Ser. No. 10/158,629, entitled "Combination Weave Using Twisted and Non-Twisted Yarn" which was filed on May 30, 2002, the disclosure of which is also incorporated herein by reference. [0007] It is therefore desirable to provide improvements in polymer yarns and polymer woven material made therefrom for use in furniture articles and accessories therefore including, for example, the use of strands of polymer yarns of various shapes and woven material therefrom. SUMMARY OF THE INVENTION [0008] In accordance with one embodiment of the present invention there is described a woven panel comprising a plurality of polymer first yarns woven together with a plurality of polymer second yarns forming a woven panel therefrom, at least one of the first and second yarns including an elongated body and first and second projections extending outwardly from the body at spaced apart locations. [0009] In accordance with a further embodiment of the present invention there is described an article of furniture comprising a frame having the shape of an article of furniture, and a woven panel attached to the frame, the woven panel comprising a plurality of polymer first yarns woven together with a plurality of polymer second yarns forming a woven panel therefrom, at least one of the first and second yarns including an elongated body and first and second projections extending outwardly from the body at spaced apart locations. [0010] In accordance with a further embodiment of the present invention there is described a polymer yarn comprising an elongated body having first and second projections extending outwardly from the body at spaced apart locations. [0011] In accordance with a further embodiment of the present invention there is described a polymer yarn comprising a cylindrical elongated body having first and second flat projections extending outwardly from the body opposing one another in a substantially common plane. [0012] In accordance with a further embodiment of the present invention there is described a polymer yarn comprising an elongated flat member having first and second opposing surfaces, a first shaped elongated member extending from the first surface midway therealong, and a second shaped elongated member extending from the second surface midway therealong, the first and second shaped elongated members opposing one another. BRIEF DESCRIPTION OF THE DRAWINGS [0013] The above description, as well as further objects, features and advantages of the present invention will be more fully understood with reference to the following detailed description of Woven Articles from Synthetic Yarns, when taken in conjunction with the accompanying drawings, wherein: [0014] FIG. 1 is a top plan view of a portion of a single strand of a polymer yarn in accordance with one embodiment; [0015] FIG. 2 is a top plan view of a self-twisted polymer yarn in accordance with another embodiment; [0016] FIG. 3 is a cross-sectional view of a polymer yarn having nodes in accordance with another embodiment; [0017] FIG. 4 is a diagrammatic illustration showing one fabrication process for a self-twisted polymer yarn; [0018] FIG. 5 is a top plan view of a composite yarn formed form twisting multiple strands together in accordance with another embodiment; [0019] FIG. 6 is a diagrammatic illustration showing one fabrication process for a composite twisted yarn; [0020] FIG. 7 is a top plan view of a portion of a single strand of polymer yarn in accordance with one embodiment; Continue reading... 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