Method and apparatus for an artificial twisted wicker strand

Abstract

A system and method for providing an artificial wicker strand and article of manufacture made therefrom is provided, wherein a plurality of strands of core yarn may be coated with, for example, a thermoplastic polymer. The yarn is extruded to apply the thermoplastic coating, twisted at least in pairs, heat-set, and permitted to cool. The strands are twisted to reflect light in similar manner as natural wicker. The twisted strands may then be used to form articles of manufacture. The twisted strands may be wrapped around an article of manufacture frame such that the frame is substantially covered by the twisted artificial wicker.

What is claimed is:  
     
         1 . An artificial wicker strand comprising: 
 a. a first elongated core yarn material of indeterminate length;    b. an first outer coating substantially surrounding said first elongated core yarn material providing a first coated core yarn material;    c. a second elongated core yarn material of indeterminate length;    d. a second outer coating substantially surrounding said second core yarn material providing a second coated core yarn material; and    e. wherein said first coated core yarn material and said second coated core yarn material are twisted with the first coated yarn material spiraling around said second coated core material.    
     
     
         2 . An artificial wicker strand according to  claim 1  wherein at least one of said first elongated core yarn and second elongated core yarn is comprised of a thermoplastic polymer with a fluid melting point greater than that of at least one of the first and second outer coating.  
     
     
         3 . An artificial wicker strand according to  claim 2 , wherein at least one of said first and second elongated core yarn is comprised of at least one of a thermoplastic polymer, a thermo set polymer, fiberglass, and a metallic wire.  
     
     
         4 . An artificial wicker strand according to  claim 3  wherein at least one of said first elongated core yarn and said second elongated core yarn is one of monofilament and stranded.  
     
     
         5 . An artificial wicker strand according to  claim 4  wherein at least one of said first and second outer coating comprises at least one of a thermoplastic polymer with a fluid melting point less than 350° F.  
     
     
         6 . An artificial wicker strand according to  claim 5  wherein at least of said first and second outer coating comprises at least one of a thermoplastic polymer, a polyvinyl chloride (PVC), a polyamide, a polyester, a polyolefin and a polyurethane.  
     
     
         7 . An artificial wicker strand comprising: 
 a. a first elongated core yarn material of indeterminate length;    b. a second elongated core yarn material of indeterminate length in proximity to said first elongated core yarn material;    c. an outer coating, said outer coating substantially surrounding said first elongated core yarn material and said second elongated core yarn material providing a coated core strand including a FIG. 8 cross-section; and    d. said coated core strand being twisted in a spiral-like shape.    
     
     
         8 . A artificial wicker strand according to  claim 7  wherein at least one of said first elongated core yarn and second elongated core yarn is comprised of one of a thermoplastic polymer with a fluid melting point greater than that of said outer coating.  
     
     
         9 . An artificial wicker strand according to  claim 8  wherein at least one of said first and second elongated core yarn comprises at least one of a thermoset polymer, fiberglass, and a metallic wire.  
     
     
         10 . An artificial wicker strand according to the  claim 7  wherein at least one of said first elongated core yarn and said second elongated core yarn is one of monofilament and stranded.  
     
     
         11 . An artificial wicker strand according to  claim 7 , wherein said outer coating comprises at least one of a thermoplastic polymer with a fluid melting point less than 350° F.  
     
     
         12 . An artificial wicker strand according to  claim 11 , wherein said outer coating comprises at least one of a thermoplastic polymer, a polyvinyl chloride (PVC), a polyamide, and a polyester, a polyolefin and a polyurethane.  
     
     
         13 . An article of manufacture having a wicker appearance comprising: 
 a. a frame having a shape of an article of manufacture, said frame including a structural member; and    b. an artificial wicker strand including at least a first and second elongated core yarn material of indeterminate length, said first core yarn material including a first outer coating substantially surrounding said first core yarn material and said second core yarn material including a second outer coating substantially surrounding said second core yarn materials, wherein at least a portion of said first outer coating of said first coated core yarn material is common to a portion of said second outer coating of said second coated core yarn material, said first and second coated core yarn materials being twisted into a spiral-like shape, wherein said twisted coated core yarn material is in substantial communication with at least said frame.    
     
     
         14 . An article of manufacture having a wicker appearance according to  claim 13 , wherein at least one of said first elongated core yarn and second elongated core yarn is comprised of one of a thermoplastic polymer with a fluid melting point greater than that of the coating material.  
     
     
         15 . An article of manufacture having a wicker appearance according to  claim 13 , wherein at least one of said first and second elongated core yarn is comprised of at least one of a thermoset polymer, fiberglass, or a metallic wire.  
     
     
         16 . A article of manufacture having a wicker appearance according to  claim 13 , wherein at least one of said first elongated core yarn material and said second elongated core yarn material is one of monofilament and stranded.  
     
     
         17 . A artificial of manufacture having a wicker appearance according to  claim 13 , wherein said outer coating comprises at least one of a thermoplastic polymer with a fluid melting point less than 350° F.  
     
     
         18 . An article of manufacture having a wicker appearance according to  claim 13  wherein said outer coating polyvinyl chloride (PVC), a polyamide, and a polyester, a polyolefin or a polyurethane.  
     
     
         19 . An article of manufacture having a wicker appearance according to  claim 13 , wherein said twisted coated core yarn material is wrapped around said structural member.  
     
     
         20 . An article of manufacture having a wicker appearance according to  claim 13  including a woven material including a warp strand and a weft strand, wherein at least one of said warp strand and said weft strand is comprised of said first and second coated elongated core yarn materials.  
     
     
         21 . A method of manufacturing an artificial wicker, comprising: 
 a. coating a first core yarn material of indeterminate length with an outer coating comprised of a thermoplastic polymer with a fluid meting point of less than 350° F., to produce a first coated core yarn material, wherein the coating is performed during extrusion of the core yarn material;    b. coating a second core yarn material of indeterminate length with an outer coating comprised of a thermoplastic polymer with a fluid meting point of less than 350° F., to produce a first coated core yarn material, wherein the coating is performed during extrusion of the core yarn material;    c. twisting the first coated core yarn material in spiral around the second core yarn material producing a first twisted coated core yarn material including reflections of light substantially similar to natural wicker;    d. heatsetting the first twisted coated core yarn material; and    e. permitting the first twisted coated core yarn material to cool.    
     
     
         22 . A method of manufacturing an artificial wicker according to  claim 21  further including coating a third core yarn material of indeterminate length with an outer coating comprised of a thermoplastic polymer with a fluid meting point of less than 350° F., to produce a third coated core yarn material, wherein the coating is performed during extrusion of the core yarn material: 
 a. coating a fourth core yarn material of indeterminate length with an outer coating comprised of a thermoplastic polymer with a fluid meting point of less than 350° F., to produce a fourth coated core yarn material, wherein the coating is performed during extrusion of the core yarn material;  
 b. twisting the third coated core yarn material in spiral around the fourth core yarn material producing a second twisted coated core yarn material including reflections of light substantially similar to natural wicker;  
 c. heatsetting the second twisted coated core yarn material;  
 d. permitting the second twisted coated core yarn material to cool; and  
 e. weaving a artificial woven material including a warp strand and a weft strand, wherein at least one of the warp strand is comprised of the first twisted coated core yarn material and the weft strand is comprised of the second twisted coated core yarn material.  
 
     
     
         23 . A method of manufacturing article of artificial wicker, comprising: 
 a. coating a first core yarn material of indeterminate length with an outer coating comprised of a thermoplastic polymer with a fluid meting point of less than 350° F., to produce a first coated core yarn material, wherein the coating is performed during extrusion of the core yarn material;    b. coating a second core yarn material of indeterminate length with an outer coating comprised of a thermoplastic polymer with a fluid meting point of less than 350° F., to produce a first coated core yarn material, wherein the coating is performed during extrusion of the core yarn material;    c. twisting the first coated core yarn material in spiral around the second core yarn material producing a twisted coated core yarn material including reflections of light substantially similar to natural wicker;    d. heatsetting the twisted coated core yarn material; and    e. permitting the twisted coated core yarn material to cool; and    f. wrapping the twisted coated core yarn material substantially covering a frame having a shape of an article of manufacture.