Woven articles from synthetic yarns

Abstract

A woven panel is formed from a plurality of elongated yarns, with and without a center core. The core yarns provide mechanical strength for the woven material in supporting the coreless yarns when used in load bearing articles such as the seat or back portions of an article of furniture.

1 . A method of making a coated woven panel comprising forming a woven panel by weaving together a plurality of first polymer yarns with a plurality of polymer second yarns, said first and second yarns having an exposed outer surface and interstices therebetween with said woven panel, and coating at least a portion of said exposed outer surface of said first and second yarns and within said interstices with a colored coating composition.  
   
   
       2 . The method of  claim 1 , bonding said first and second yarns together within said interstices by said composition.  
   
   
       3 . The method of  claim 1 , further including applying a solvent for said polymer or thinner for said composition to said exposed outer surface of said first and second yarns and within said interstices.  
   
   
       4 . The method of  claim 3 , further including removing a portion of said composition from the exposed outer surface of said first and second yarns.  
   
   
       5 . The method of  claim 3 , wherein said polymer of said first and second yarns comprises PVC material and said colored coating composition comprises a film forming component, a color component, and at least one component selected from the group consisting of a solvent and a thinner.  
   
   
       6 . The method of  claim 3 , wherein said colored coating composition has adhesion properties for PVC material.  
   
   
       7 . The method of  claim 6 , wherein said colored coating composition includes a film forming component comprising PVC material.  
   
   
       8 . The method of  claim 1 , wherein said polymer of said first and second yarns comprises PVC material and said colored coating composition includes a film forming component of other than PVC material, and further including applying a solvent for said polymer to said exposed outer surface of said first and second yarns and within said interstices.  
   
   
       9 . The method of  claim 1 , wherein said colored coating composition non-uniformly covers the exposed outer surface of said first and second yarns.  
   
   
       10 . The method of  claim 1 , wherein said first and second yarns within said woven portion are adhered to each other along contiguous portions thereof.  
   
   
       11 . A method of making an article of furniture comprising providing a frame having the shape of an article of furniture and attaching a woven panel to said frame, said woven panel formed by weaving together a plurality of first polymer yarns with a plurality of polymer second yarns, said first and second yarns having an exposed outer surface and interstices therebetween within said woven panel, and coating at least a portion of said exposed outer surface of said first and second yarns and within said interstices with a colored coating composition.  
   
   
       12 . The method of  claim 11 , bonding said first and second yarns together within said interstices by said composition.  
   
   
       13 . The method of  claim 12 , further including applying a solvent for said polymer or thinner for said composition to said exposed outer surface of said first and second yarns and within said interstices.  
   
   
       14 . The method of  claim 13 , further including removing a portion of said composition from the exposed outer surface of said first and second yarns.  
   
   
       15 . The method of  claim 13 , wherein said polymer of said first and second yarns comprises PVC material and said colored coating composition comprises a film forming component, a color component, and at least one component selected from the group consisting of a solvent and a thinner.  
   
   
       16 . The method of  claim 15 , wherein said colored coating composition has adhesion properties for PVC material.  
   
   
       17 . The method of  claim 16 , wherein said colored coating composition includes a film forming component comprising PVC material.  
   
   
       18 . The method of  claim 11 , wherein said polymer of said first and second yarns comprises PVC material and said colored coating composition includes a film forming component of other than PVC material, and further including applying a solvent for said polymer to said exposed outer surface of said first and second yarns and within said interstices.  
   
   
       19 . The method of  claim 11 , wherein said colored coating composition non-uniformly covers the exposed outer surface of said first and second yarns.  
   
   
       20 . The method of  claim 11 , wherein said first and second yarns within said woven portion are adhered to each other along contiguous portions thereof.  
   
   
       21 . A method of bonding together a plurality of polymer yarns, said method comprising weaving a plurality of polymer yarns into a weave having interstices; at least partially filling said interstices with a coating composition; and applying a solvent for said polymer yarns or thinner for said composition within said interstices.  
   
   
       22 . The method of  claim 21 , wherein said solvent or thinner is selected from the group consisting of toluene, tetrahydroforan, cyclohexanone, ketones and mixtures thereof.  
   
   
       23 . The method of  claim 21 , wherein said composition comprises a film forming component, a color component, and at least one component selected from the group consisting of a solvent and a thinner.  
   
   
       24 . The method of  claim 21 , wherein said coating composition comprise PVC paint compositions and non PVC paint compositions.  
   
   
       25 . The method of  claim 21 , further including heating said weave after applying said solvent or thinner to a temperature sufficient to evaporate residual solvent or thinner within said interstices.  
   
   
       26 . The method of  claim 21 , wherein at least a first plurality of said polymer yarns comprises a single twisted yarn.  
   
   
       27 . The method of  claim 21 , wherein at least a first plurality of said polymer yarns comprise a composite twisted yarn compromising a plurality of polymer yarns twisted together.  
   
   
       28 . The method of  claim 21 , wherein said applying said solvent or thinner comprises forcing said solvent or thinner fluid into said interstices.  
   
   
       29 . The method of  claim 28 , wherein said forcing comprises applying said solvent or thinner to a cloth and wiping said cloth over the exposed outer surfaces of said plurality of polymer yarns thereby forcing said solvent or thinner into said interstices.  
   
   
       30 . A method of bonding together a plurality of twisted polymer yarns, said method comprising providing a weave of a plurality of twisted polymer yarns having interstices within said weave; at least partially filling said interstices with a coating composition; and applying a fluid at least within said interstices.  
   
   
       31 . The method of  claim 30 , wherein said fluid comprises a solvent for said polymer yarns or a thinner for said composition and wherein said composition comprises a film forming component, a color component, and at least one component selected from the group consisting of a solvent and a thinner.  
   
   
       32 . The method of  claim 31 , further including heating said weave after applying said solvent or thinner to a temperature sufficient to evaporate residual solvent or thinner within said interstices.  
   
   
       33 . The method of  claim 30 , wherein said applying said solvent or thinner comprises forcing said solvent or thinner fluid into said interstices.  
   
   
       34 . The method of  claim 33 , wherein said forcing comprises applying said solvent or thinner to a cloth and wiping said cloth over the exposed outer surfaces of said plurality of polymer yarns thereby forcing said solvent or thinner into said interstices.  
   
   
       35 . A method of making a weave having a washed out appearance, said method comprising weaving a plurality of polymer yarns into a weave; applying a colored composition to said plurality of polymer yarns within said weave; and removing at least a portion of said colored composition from said plurality of polymer yarns.  
   
   
       36 . The method of  claim 35 , wherein said colored composition comprises a film forming component, a color component, and at least one component selected from the group consisting of a solvent and a thinner.  
   
   
       37 . The method of  claim 35 , wherein said colored composition comprise PVC paint.  
   
   
       38 . The method of  claim 35 , wherein at least a first plurality of said polymer yarns comprises a single twisted yarn.  
   
   
       39 . The method of  claim 35 , wherein at least a first plurality of said polymer yarns comprise a composite twisted yarn compromising a plurality of polymer yarns twisted together.  
   
   
       40 . The method of  claim 35 , wherein said removing comprises wiping a cloth over the exposed outer surfaces of said plurality of polymer yarns thereby removing a portion of said colored composition.  
   
   
       41 . The method of  claim 40 , further including applying a solvent for said polymer yarns or a thinner for said colored composition to said cloth.  
   
   
       42 . The method of  claim 41 , wherein said solvent or thinner is selected from the group consisting of toluene, tetrahydroforan, cyclohexanone, ketones and mixtures thereof.