CN2804137Y - 织成的面板和包括一框架以及织成的面板的家具产品 - Google Patents

织成的面板和包括一框架以及织成的面板的家具产品 Download PDF

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Publication number
CN2804137Y
CN2804137Y CNU2004200740883U CN200420074088U CN2804137Y CN 2804137 Y CN2804137 Y CN 2804137Y CN U2004200740883 U CNU2004200740883 U CN U2004200740883U CN 200420074088 U CN200420074088 U CN 200420074088U CN 2804137 Y CN2804137 Y CN 2804137Y
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China
Prior art keywords
yarn
yarns
polymeric material
panel
fuse
Prior art date
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Expired - Lifetime
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CNU2004200740883U
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English (en)
Inventor
L·斯瓦茨
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sun-Island Relaxation Furniture Co., Ltd.
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Sun Isle USA LLC
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Publication date
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47C—CHAIRS; SOFAS; BEDS
    • A47C5/00—Chairs of special materials
    • A47C5/02—Chairs of special materials of woven material, e.g. basket chairs
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/26—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre with characteristics dependent on the amount or direction of twist
    • D02G3/28—Doubled, plied, or cabled threads
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/26—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre with characteristics dependent on the amount or direction of twist
    • D02G3/28—Doubled, plied, or cabled threads
    • D02G3/286—Doubled, plied, or cabled threads with alternatively "S" and "Z" direction of twist, e.g. Self-twist process
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/36—Cored or coated yarns or threads
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/20—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads
    • D03D15/283—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the material of the fibres or filaments constituting the yarns or threads synthetic polymer-based, e.g. polyamide or polyester fibres
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/30—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments
    • D03D15/37—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the fibres or filaments with specific cross-section or surface shape
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/44—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads with specific cross-section or surface shape
    • D03D15/46—Flat yarns, e.g. tapes or films
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D03D15/47—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads multicomponent, e.g. blended yarns or threads
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/54—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/06—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain multicolour or other optical effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/04—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of halogenated hydrocarbons
    • D10B2321/041—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polymers of halogenated hydrocarbons polyvinyl chloride or polyvinylidene chloride
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/08—Physical properties foamed
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/08—Upholstery, mattresses
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    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
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    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
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    • Y10T442/183—Synthetic polymeric fiber
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Abstract

本实用新型提供了一种织成的面板和包括一框架以及织成的面板的家具产品，该面板由多根带有和不带有一中央芯子的细长的纱形成。当用在承载产品，例如一家具制品的座位和靠背中时，有芯纱对织成的材料在支承无芯纱中提供了机械强度。

Description

织成的面板和包括一框架以及织成的面板的家具产品
技术领域
本实用新型总地涉及具有一支承芯子的一聚合物纱和设有一支承芯子的聚合物纱的使用，尤其涉及织成的面板和包括一框架以及织成的面板的家具产品。芯子纱的存在提供了在织造中所要求的机械强度，以使在没有一支承芯子的纱的使用中具有更大的灵活性。
背景技术
许多世纪以来，在家具、蓝子和其它物品的制造中已使用了天然的柳条。柳条的不规则的、随机的外表使它尤其普遍地用于家庭、宾馆和其它机构的关闭的门廓和其它普通的设置中。但是对于室外家具市场、包括庭院家具、游泳池家具等天然柳条的使用受到了限制。这是因为天然柳条在潮湿时变得柔软和脆弱，较许多天然和人造的家具材料更易于腐烂和发霉。
织造的柳条通常包括一纬纱，即笔直地通过织成的材料运行的一纱，和一径纱，即围绕纬纱织造的一纱。在柳条家具的制造中使用许多类型的织物组织。许多类型的织物组织产生了织成的产品的不同的外观、手感、强度和重量。在一简单的织造图形中，诸纬纱相互分开和平行排列。诸径纱交替地在纬纱上和下织造。相邻的径纱在某一根纬纱的诸相对侧上通过。
也使用聚合物纱制造像柳条的家具。举例来说，一聚合物纱是已知的，它被构造成一细长的本体，如具有不固定长度的，并具有被聚氯乙烯(PVC)外复层的一外壳所包围的一芯子，该聚氯乙烯外复层例如是发泡的和非发泡的PVC材料。发泡的PVC材料用较少材料有较大的体积。可以用例如聚酰胺、聚酯等其它合成材料形成外复层。通常在使用本领域是已知的共挤压加工的一单个步骤中制造该纱。内芯可以包括聚酯的一单根长丝，或可以包括成束为一单根芯子的多根聚酯长丝。此外，可以用聚酯以外的其它材料，例如金属、单丝或绞线的，例如聚酰胺等形成芯子。在这方面，认为内芯102是基本部分，以致给予该纱充分的强度，能使由其形成的织成面板用于承载场合，例如在家具应用中的座位座部和靠背。在由发泡的聚合材料构成外层时这被认为是更重要的。
由发泡的PVC材料构造聚合物纱造成在挤压加工期间、PVC材料的发泡中的不均匀性。这产生了缺乏一均匀圆柱形外表的一根纱。尤其，该纱的外表面变形，例如沿着纱的长度具有波纹、小团和/或凹入区域。纱的外表面的变形形状造成纱具有较真柳条的外观更自然的外观。还已知提供了带有一对比色的一个或多个随机的条纹和/或一个或多个随机的沟槽的聚合物纱的外表面。沿着该纱的外表面该诸条纹和沟槽可以是连续的和/或间断的。但是，该纱还能够具有一较均匀的圆柱形状，以及例如方形、椭圆形、扁平的、三角形的其它形状。从美国专利号5,704,690，5,845,970和6,179,382以及美国设计专利号395,171，474,614和409,001已知以上所述的聚合物纱，这些专利的揭示内容结合在这里供参考。如在天然柳条的情况中那样，将聚合物纱织造成用于制造适合包括庭院家具的室外家具市场以及室内使用的普通家具的一织成的材料。
发明内容
在本实用新型的一实施例提供了一织成的面板中，叙述了一织成的面板，它包括多根各具有一基本芯子的聚合物第一纱与多根各具有一表面芯子的聚合物第二纱织造在一起，形成由其产生的一织成面板。
在本实用新型的另一实施例中，叙述了一织成的面板，它包括各具有一基本芯子的多根第一纱与各具有一表面芯子的多根第二纱，诸第一纱和诸第二纱织造在一起以形成一织成的面板，诸第一纱包括包围一第二材料的基本芯子的第一聚合材料的外壳；以及，诸第二纱包括一个具有一不同于第三聚合物材料的第四材料的表面芯子的第三聚合物材料的本体。
在本实用新型的再一实施例中，叙述了一织成的面板，它包括多根各具有一基本芯子的聚合物第一纱与多根各具有一表面芯子的聚合物第二纱，诸聚合物第一纱和聚合物第二纱织造在一起以形成一织成的面板；诸第一纱包括一细长的第一单纱和一细长的第二单纱，该第一单纱具有一个包围第二聚合物材料的一基本芯子的第一聚合物材料的外壳，该第二单纱具有一个包围第四聚合物材料的一基本芯子的第三聚合物材料的外壳，第一和第二单纱在它们的长度内加捻在一起；以及，诸第二纱包括一个具有不同于第五聚合物材料的一第六聚合物材料的表面芯子的第五聚合物材料的本体。
在本实用新型的又一实施例中，叙述了一家具产品，它包括一框架和一织成的面板，该框架具有一家具产品的形状，该织成的面板连接于该框架，该织成的面板包括多根各具有一基本芯子的聚合物的第一纱与多根各具有一表面芯子的聚合物的第二纱，诸第一纱和第二纱织造在一起以形成一织成的面板。
在本实用新型的又一实施例中，叙述了一家具产品，它包括具有一家具产品的形状的一框架和连接于该框架的一织成的面板，该织成的面板包括多根第一纱和多根第二纱，诸第一纱包括一个包围一第二材料的基本芯子的第一聚合物材料的外壳，诸第二纱包括一个具有一不同于第三聚合物材料的第四材料的表面芯子的第三聚合物材料的本体。
在本实用新型的又一实施例中，叙述了一家具产品，它包括一个具有一家具产品的形状的框架和一个连接于该框架的织成的面板；该织成的面板包括多根第一纱和多根第二纱；诸第一纱包括一细长的第一单纱和一细长的第二单纱，该第一单纱具有一个包围一第二聚合物材料的基本芯子的第一聚合物材料的外壳，该第二单纱具有一个包围一第四聚合物材料的基本芯子的第三聚合物材料的外壳；该第二纱包括一个具有一不同于第五聚合物材料的第六材料的表面芯子的第五聚合物材料的本体。
附图说明
参阅以下结合附图的无芯合成纱和由其织造的产品的详细叙述将会更全面理解本实用新型的以上叙述以及进一步的目的、特征和优点，在附图中：
图1是按照一实施例的一有芯合成纱的一段单根纱的一俯视平面图；
图2是按照另一实施例的自加捻的有芯聚合物纱的一俯视平面图；
图3是示出关于自加捻的聚合物纱的一制造过程的一示意图；
图4是按照另一实施例的、将多根有芯纱加捻在一起形成一复合纱的一俯视平面图；
图5是示出关于复合的加捻纱线的一制造过程的一示意图；
图6是按照一实施例的一段单根无芯聚合物纱的一俯视平面图；
图7是按照另一实施例的一段单根无芯聚合物纱的一俯视平面图；
图8A和B是按照另一实施例的、一段单根无芯和无表面芯子的聚合物纱的立体图。
图9是一家具制品的一框架的一立体图；
图10是包括聚合物纱的一织成的部分的一家具产品的一立体图；以及
图11是按照本实用新型的一实施例的、通过织造多根聚合物纱构成织成的材料的一俯视平面图。
具体实施方式
在结合附图示出和将要叙述的主题的诸较佳实施例的叙述中，为清楚起见将使用特定的专门术语。但是，本实用新型不打算局限于如此选择的特定范围，应理解各特定范围包括以一类似方式完成一类似目的的所有技术等价物。
参阅附图，其中相同的标号代表相同的部分，在按照本实用新型的一实施例的图1中，用标号“100”总地表示不定长度的、较佳地由PVC材料制成的一单根纱。在该较佳实施例中，纱100具有由例如PVC材料的聚合物材料的一聚合物外套104包围的、如以上所述的聚酯材料或金属的一芯子102。该芯子102在外套104内可以处于中央或偏心位置。在这方面，要求该基本内芯子102能给于该纱充分的机械强度，以使由其形成的织成的面板能用于承载的场合，例如用于家具应用的座位底部和靠背。纱100可以被制成为如在上述诸专利中所述的类型和结构的聚合物材料的一单根纱。如此，纱100可以有一均匀的外表面和/或横剖面，或是沿着它的外表面变形的和具有在它的长度内的一不均匀横剖面的纱，以及是其外套104经发泡或未发泡的纱。但是，还考虑一不同结构或聚合物材料的聚合物材料的诸其它外套104或诸芯子102用于生产按照本实用新型的一纱100和织成的材料的一织造组织。
在按照本实用新型的另一实施例的图2中示出了以标号“106”总地表示的不定长度的较佳地由PVC材料制成的一单根纱。纱106也具有由一外套106包围的、如以上所述的聚酯芯子102。如此，纱106可以具有一均匀的外表面和/或横剖面，或是沿着它的外表面变形的和具有在它的长度内的一不均匀的横剖面的纱，以及是其外套108经发泡或未发泡的纱。但是，还考虑一不同结构或聚合物材料的复合物材料的诸其它外套108用于生产按照本实用新型的一自捻纱106和织成材料的一织物组织。自捻纱100还可以较佳地是一加捻纱106或一纱106。
纱100、106可以具有任何形状、尺寸、表面装饰和/或颜色。例如纱100、106可以是扁平的、椭圆形的、方形的、矩形的、多边形的等。还考虑在形成一织物组织部分中可以利用纱100、106的任何变化。举个例子，纱100、106可由不同颜色的聚合物材料共挤压而形成。在这方面，沿着它的长度纵向延伸的纱100、106的一部分可以是一种颜色，另一部分是由不同颜色或聚合物材料共挤压而形成。当对纱100加捻时，尽管仅使用了一单根纱，变化的颜色提供给自捻纱106带有加捻的多色的多根纱的一独特的装饰外观。从而，应理解可以织造如所述的诸聚合物纱100、106的不同结构，形成具有不同的美学外观的一织成材料。
现在参阅图3，将叙述由一未加捻纱100制造一自捻纱106的一工艺。如图所示，提供一连续段的聚合物材料的单根纱100的一供应源110。通常，该供应源100将具有一聚合物材料的、不定长度纱100的筒子的特性。但是，考虑到供应源110可以是适合于保持纱100和输送该纱以进行生产的任何设备。
首先可以从筒子将单根纱100供应到一炉子112内，在该炉内纱被加热到一预定温度。在PVC材料的情况下，在一例子中炉子温度为约270°F将是适当的。加热纱100的作用是降低它的记忆保持性能，以防止该纱在织造之前退捻。但是，加热不是本实用新型必需的或要求的，如果被使用了加热，可以在其它炉温下完成。选择炉子112的温度通常将考虑形成纱100的聚合物材料的类型以及纱线通过炉子112的线速度，例如在炉子112内的停留时间。在炉温和纱100在炉子112内的停留时间的基础上，能够将纱100加热至释放或降低它的记忆性能的一温度。
可以理解：炉温将按照形成单纱100的具体的聚合物材料以及单纱在炉内的停留时间以及所要求的单纱100的记忆释放程度(degree of memory relief)而变化。对于按照本实用新型的最适合使用的聚合材料，考虑200°F至450°F。但是，因为在此已叙述了关于决定炉温和停留时间的基础，所以可以理解的是为了适应于形成一自捻纱106的任何聚合物可以选择其它温度。
随着纱100离开炉子112，它通过了一传统的加捻设备114。该加捻设备114是用于加捻纱100，以形成如图2清楚地所示的自捻纱106。在本领域里众所周知：在加捻单纱以形成一S捻(s-twist)或一Z捻(Z-twist)时产生了一捻度(twist)。这两捻度对应于顺时针和逆时针加捻，一个是另一个的镜面对称图形。在一织物组织中一S捻的纱的外观与一Z捻的纱的外观不同。在一单根纱的情况下，纱将在自身上以一螺旋线加捻，从而根据加捻方向产生一S捻或一Z捻。加捻设备114可以是例如在本领域为已知的加捻连续长度的长丝用的任何合适的结构。
如果加热，自捻纱106可以受到空气冷却，或可选择地使之通过一冷却装置116。冷却装置116可以包括吹送环境空气或冷空气的一气源，以有助于将自捻纱100的温度降至室温或环境温度。随后将所得到的纱106卷绕在一筒子118上。还可考虑加捻设备114可以位于炉子112之前，在纱卷绕在筒子118上之后提供一炉子加热纱106。还可考虑可以直接将加捻设备114放在炉子112内。
将聚合物材料通过一模子的热挤压形成纱100。因此，考虑在挤压之后、在一有些被加热的状态下可以在加捻设备114内加捻纱100，从而不使用一单独的炉子112。根据纱100离开挤压机的出口温度，可以让纱受空气冷却，或设置用于在加捻之前的对纱的一单独的冷却装置116。
考虑到仅仅纱的稍许加热将使纱充分松驰，以致在加捻之后保持它的加捻形状，例如80-100°F。加热将充分的热量提供给纱，以基本保持它的加捻形状。可以在加捻加工之前或以后对纱106加热。此外，作为在纱的成形期间离开一挤压模的它的热挤压的结果，可以加热纱106，从而不需要如以上所述的任何随后的加热。虽然较佳的是加热纱106，以降低它的某些记忆保持性能，但是本实用新型并不要求在将纱织成用于一产品，例如一家具产品的一织成的材料之前加热纱100。在这方面，考虑将织成的材料在一炉子内热定型，如后面所述。
参阅图4，示出总地由标号“120”表示的不定长度的一复合的加捻纱线。复合纱线120由聚合物材料的两根纱制成，它可以是被加捻在一起的如这里所述的类型和结构。虽然复合纱线120被示为包括两根纱，但是可以理解：如果需要，纱线可以由两根以上的纱构成。不要求诸根纱100在尺寸、形状、表面、外观、颜色和/或表面结构方面相同。
现在参阅图5，将叙述按照本实用新型的一实施例的、制造一复合的加捻纱线120用的一加工工艺，该工艺类似于形成自捻线106的工艺。如图所示，提供聚合物材料的一连续段的纱100的供应源110。对于聚合物材料的一连续段的另一根纱100提供一类似供应源110。通常，诸供应源110将具有聚合物材料的纱100的不定长度的一筒子的特性。
按照一实施例，同时将诸根单纱100从筒子输送进入一炉子112，用于将诸根单纱加热至一预定温度，从而降低或基本消除纱的记忆特性。还考虑能够将诸根单纱100加热至一足够的温度，以使诸根单纱将被软化，从而一旦冷却在它们的外表面上至少局部地相互粘合。实现纱100之间粘合所需的温度将高于引起纱失去它们的记忆特性所要求的温度。选择炉子112的温度将考虑形成纱100的聚合物材料的类型以及例如线速度、在炉子内的停留时间。虽然将该工艺叙述为加热两根单纱100，但也考虑仅加热其中的一根单纱。另一根单纱100可以为室温，或在一单独的炉子内加热至一不同温度。
随着诸根纱100离开炉子112，它们通过了一传统的长丝加捻设备122。加捻设备122用于将两根单纱100加捻，以形成复合的加捻的纱线120。加捻设备122可以是如纱线领域已知的、将诸连续段的长丝加捻在一起用的任何合适的结构。充分地加热聚合物材料的诸细长纱100的一根纱，一旦加捻就引起诸纱至少部分相互粘合，以防止它们散开。加捻工艺可以发生在加热过程之前或之后。加热可以发生在炉子112内，或作为聚合物材料通过一模子的热挤压形成纱的结果。
也可考虑到可以将纱的供应源的诸筒子110放在一炉子内，以在加捻之前将纱100预热至所要求的温度。还可设想可以通过将加捻设备114放在一炉子内或在加捻设备周围放置适当的加热器提供加热，或加热复合的加捻纱100的诸筒子118。
还考虑到：至少一根纱100的稍许加热可使该纱松驰，以致用一附加的纱加捻，一旦冷却就保持它的加捻形状。但是，不要求在生产一复合的加捻纱120时加热纱100。复合的加捻纱120在如以下所述的、由其形成一织物组织之后能够对它进行热定形。因此不要求例如通过加热至少一根纱到达它的软化温度从而沿着多根纱100的长度的任何部分使它们相互粘附在一起。
在本申请人的美国专利6,625,970和7,705,020中揭示了加捻的复合纱用于制造用于家具产品的合成的织成材料，该专利的揭示内容结合在这里供参考。这些专利揭示了热定形多根加捻的纱线和将其形成一织成的材料，例如用于形成一家具产品的座位和靠背部分的许多方法。利用诸加捻纱作为径纱和纬纱，以形成粘附于一家具产品的一框架的织成部分。在本申请人于2002年5月30日提交、标题为“利用加捻的和未加捻的纱的组合的织物组织”、申请号为10/158,629的待批专利申请中还揭示了多根加捻的和单根未加捻合成纱在制造用于家具产品的合成的织成材料中的应用，该专利的揭示内容也被结合在本文中以供参考。
已叙述了如包括一芯子102和纱100、106。本实用新型专门考虑没有一芯子的纱与具有一支承芯子的纱100、106进行织造的应用。具有一芯子102的一纱的制造通常造成较低的加工速度和较高的制造成本。此外，具有一芯子的纱具有关于纱的形状方面的限制。例如，通常不可能生产出包含一芯子的一扁平的纱。通过去除芯子，在织成材料中能够实现纱的附加设计。但是，由于一无芯纱通常缺少机械强度，已经发现由无芯和有芯纱织成的面板将具有关于在如本文所揭示的多种家具产品等中使用的织成材料所必要的强度。显然，可以相信无芯纱将不可使用在承载的例如一物具产品的座位和靠背部分的某些应用场合的织成材料中。
如图6所示，一根无芯纱124除了设有芯子102之外在结构上可以类似于纱100，即具有相同纱材料的一实心的聚合物芯体。参阅图7，无芯纱126类似于纱124，但是包括一空心区域128或空腔。该空心区域128没有任何材料。通过具有一空心区域128，可以将无芯纱126叙述为设有由不同于形成该纱的材料的一材料的一芯子的一本体，这是因为不认为空心区域为一材料，而是不存在或没有任何材料。从而，考虑到在织造加工期间，纱126在某些部位会具有被弄平的趋势，对织造组织提供一不同的外观。空心区域128可以具有各种尺寸和通常将沿着纱126的整个长度延伸，以及可以位于纱126的中心或偏心处。
参阅图8A，它示出了一扁平的无芯纱。由于扁平，这意味着纱130具有大约1∶2的厚度对宽度的比值。但是，厚度对宽度的比值可以为所需要的值，例如1∶5，1∶10，1∶15等。这比值由通过使用无芯纱130和具有一芯子102的纱结合所产生的织物组织所希望有的美学效果确定。应理解纱124、126、130像纱100可以是均匀的或不均匀的，可以是任何颜色或多色的，以及可以有任何尺寸。无芯纱130还可以具有一个或多个空心区域128，该区域可以位于其中心或偏心处。还考虑可以由发泡的PVC材料形成纱124、126、130，以致该纱具有一变形的外表面和在它们的整个长度上的一不均匀的横剖面。还考虑可以使用其它聚合物形成纱124、126、130，例如聚酯等。
参阅图8B，它示出了包括一个或多个表面内芯子133的一平的纱131。在这方面，考虑如图8A所示的无芯纱130可以设置有一个或多个事实上是表面的内芯子133。如此，诸表面芯子133自身不对纱133提供用于一承载的织成的面板的充分的机械强度，例如用于在家具应用中的座位底部和靠背。由于平的纱131在横剖面中的尺寸较小，从而表面芯子133在横剖面方面通常小于基本芯子102。表面芯子133可以是与基本芯子102为相同的材料。但是，因为它的尺寸较小，也将没有与基本芯子相同的机械强度。
为此，要求具有一表面芯子133的纱133与前面所述的具有一基本内芯102的其它纱进行织造。也就是说，上述纱的基本内芯子102自身或与具有一表面芯子133的纱131组合将会提供所要求的机械强度，以使所形成的织成面板用于承载场合。因此，术语“表面的”芯子是意味着在一纱中的一芯子自身将不提供用在承载场合中的、在由其产生的织成的面板中的足够的机械强度。另一方面，具有一基本内芯的一纱是将对该纱提供足够的机械强度的纱，以用于承载场合。如此，在将具有一表面芯子133的纱用于承载的场合，要求它们与具有一基本内芯子的纱进行织造。
现在将叙述有芯纱100、106和无芯纱124、126、130或具有一表面芯子133的纱131在形成织成部分中的应用。按照一实施例，加捻的或不加埝的许多有芯纱与许多无芯纱织造，形成一织成材料，用于形成一产品的诸部分。将会理解能够按照本实用新型的揭示内容生产许多家具产品，例如床、椅子、遮篷材料、台子、长凳、小凳、衣箱、垫席等。应理解有芯纱100、106和无芯纱124、126、130或具有一表面芯子133的纱131的其它组合和结构可以用于形成关于这一产品的织造组织。还考虑了家具型式和纱材料的任何变化。
如图9和10所示，由一刚性框架214可以生产一椅子，该框架将被由本实用新型的纱的复合织造生产的一织成材料的一织物组织包复。仅仅为了用来说明，在此，框架214提供了具有一座位、一靠背、一对前腿部分、一对后腿部分和一对扶手的一有扶手的椅子。通过连接前构件220、一平行分开的后构件222和一对平行分开的侧向构件224、226构成座位218(见图10)的轮廓。诸前腿部228、230被构造成连接前构件220的诸自由端的平行分开的诸垂直件，并具有向外转的延伸部分232，使诸前腿部呈L形。当从椅子216的前方和侧向观察时，前腿部228、230被设置成大体垂直于地面。
由连接于后构件222的诸自由端的一倾斜构件构成后腿部分234、236。后腿部分234、236具有大致平行分开的、从后构件222垂直延伸的诸上部238(当从前方和侧向观察时)和大体平行分开的诸下部240。该后部240被设置成从侧向观察时处于一向后延伸角度的倾斜位置和从椅子216的后方观察时大体从后构件222垂直延伸。
一大体U形件242包括横越诸后腿部分234、236的诸上部238的诸自由端的、被连接的一中央段244和形成有扶手的椅子的侧向扶手250、252的一对弯曲的、分开的侧向扶手段246、248。诸侧向扶手段246、248的自由端连接于各前腿部228、230的延伸部分232的自由端。诸侧向扶手段246、248在它们连接于诸延伸部分232的它们的入口部位分开得比它们形成中央段244处更宽些。这结构将扶手部分250、252设置在诸侧向构件224、226的外部。诸后腿部分234、236的诸上部238、后构件222和中央段244构成椅子216的靠背254。
可以利用一辅助框架提供用于在复盖框架214时利用的织成材料的连接支承。具体说，一具有与U形件242的形状基本一致的形状的大体U形细长杆256藉助许多分开的凸条258连结于U形件242的下方。另一辅助框架位于座位218下方的前和后腿部228、230、234、236之间。由连接在诸前腿部分228、230之间的一前杆260，连接在诸后腿部分234、236之间的一后杆262和在前杆260与后杆262之间、在它们的诸终端的内部的、以相互平行分开关系设置的一对侧杆264、266构成了这个辅助框架。一附加的前杆268可以位于诸前腿部228、230之间而在前杆260之下。
现在参阅图10和11，通过例如将纱106、130或具有一表面芯子133的纱131织造成一织成材料，以形成直接在框架214上的织成材料的诸面板，以复盖该框架。通过织造将上述的为任何组合方式的任何纱织造成连接于框架214的织成材料来制造椅子216。如图所示，椅子216包括一座位部分218、一前裙边部分270、一靠背部分254和诸侧向部分272。可以用一段连续的纱裹绕前和后腿部228、230、234、236。许多单根纱106、130可以附连于框架214的许多部分，例如以上所述的辅助框架。
在一实施例中，多根自捻纱106和多根扁平纱130和131织造，当它们连接于框架214时成为一预定的织造图案。如以上所述，某些纱是纬纱，同时另外一些纱是径纱。还可考虑无捻纱100和其它类型的纱，例如加捻的复合纱线120和/或多股加捻纱线以及在上述申请和专利中所揭示的纱能够织造在一起，以形成带有无芯纱124、126、130的这些织成材料。
通过组合不同外观和特性的诸纱，能够获得多种美学和组织纹理效果。自捻线106可以形成为在织成材料中的径纱或纬纱。类似地，无芯纱124、126、130或具有一表面芯子133的纱131可以形成为在织成材料中的径纱或纬纱。如此，在有芯纱100、106中的芯子102将提供用于所生产的织成材料的必要的实际强度。
还考虑到：由于有芯纱100、106的芯子102将提供用于由它们形成的织成材料的充分强度，尽管在无芯纱122、124、130或具有一表面芯子133的纱131中没有芯子也是如此。通常，考虑有芯纱100、106将在织成材料中的径纱方向运动，同时无芯纱122、124、130或具有一表面芯子133的纱131将在纬纱方向运动，但是，这不是本实用新型的一要求。还考虑到能够将形成径和/或纬纱的混合的诸无芯或有芯纱织成一织成材料。
已了解到在椅子216的使用时期，各纱可能在织造组织中移动。对在椅子216上的织成材料的热定形有助于防止在椅子的不同部分中的纱的移动。为了类似于在复合的加捻纱120的生产中使用的对所附连的织成材料进行热定形，能将带有被附连的织成部分的整个椅子放在类似于炉子112的一炉子内。在椅子的情况中，与对于复合的加捻纱的制造所述的一连续炉子112相反，考虑炉子将是一批量炉子。在这方面，该炉子通常将有足够的尺寸以容纳多个椅子216。诸椅子216将保留在有一预定温度的炉子112内一预定的停留时间，以引起纱线热定形，在诸椅子从炉子取出和让其冷却时，纱的诸接触部分可以粘合在一起。
热定形过程稳定了径和纬纱，以防止它们在织物组织中移动，以及对可以用作为径纱和纬纱的各根纱进行热定形。已经发现：使用某些聚合物纱的织成材料的热定形引起织成材料下垂，从而有损于该产品的美观。已发现：通过使用自捻纱106作为径或纬纱、单独利用或与如本文所述的其它纱组合使用，在织成的聚合物材料的热定形过程中基本消除了下垂。
虽然是按照较佳实施例在框架上在现场形成织成的材料，但考虑可以将预先织成的材料的诸面板粘接于框架和随后通过将该家具产品放在上述的炉子内进行热定形。因此考虑在现场用织成的材料可以形成该家具产品的许多部分，其它许多部分通过对其附连预先织成的材料的诸面板及其变化形式形成。在任一情况中，能够将家具产品放在一炉子内，以热定形织成的材料。也考虑在预先织成的材料粘接到家具产品之前可以将预先织成的材料放在一炉子内，用于热定形，从而不需要热定形整个家具产品。
虽然本文已参照特定实施例叙述了本实用新型，应该理解这些实施例仅仅说明本实用新型的原理和应用。因此应该理解对所示的实施例可以做出许多修改和可以设计其它的方案而不脱离由所附权利要求书所规定本实用新型的原理和范围。

Claims (35)

1.一种织成的面板，其特征在于多根各具有一基本芯子的聚合物材料的第一纱，所述多根第一纱与多根各具有一表面芯子的聚合物材料的第二纱织造在一起以形成一织成的面板。
2.如权利要求1的织成的面板，其特征在于：诸所述第一纱包括一个第一聚合物材料的外壳，该外壳包围第二材料的基本芯子；以及，诸所述第二纱包括一第三聚合物材料的本体，该本体具有不同于第三聚合物材料的第四聚合物材料的表面芯子。
3.如权利要求1的织成的面板，其特征在于：诸所述第一纱包括一细长的第一单纱和一细长的第二单纱，该第一单纱具有第一聚合物材料的外壳，该外壳包围一第二聚合物材料的基本芯子，该第二单纱具有第三聚合物材料的外壳，该外壳包围一第四聚合物材料的基本芯子，所述第一和第二单纱在它们的长度内加捻在一起；以及，诸所述第二纱包括一第五聚合物材料的本体，该本体具有不同于第五聚合物材料的第六聚合物材料的表面芯子。
4.如权利要求1、2或3的织成的面板，其特征在于：所述表面芯子的横剖面小于所述基本芯子的横剖面。
5.如权利要求1、2或3的织成的面板，其特征在于：诸所述第一纱包括一加捻纱。
6.如权利要求1、2或3的织成的面板，其特征在于：诸所述第二纱具有一平的外形。
7.如权利要求1、2或3的织成的面板，其特征在于：诸所述第一纱具有一变形的外表面和在它们的整个长度上的一不均匀的横剖面。
8.如权利要求1或2的织成的面板，其特征在于：诸所述第一纱包括至少一对加捻在一起的聚合物单纱，以形成一复合的加捻纱。
9.如权利要求1、2或3的织成的面板，其特征在于：多根所述第一纱至少局部地粘接于多根所述第二纱。
10.如权利要求2的织成的面板，其特征在于：所述第一和第三聚合物材料是相同的聚合物材料。
11.如权利要求2的织成的面板，其特征在于：所述第二材料不同于所述第一和第三聚合物材料。
12.如权利要求1，2或3的织成的面板，其特征在于：多根所述第一纱在颜色、构形、表面外观、形状和尺寸中之至少一方面不同于多根所述第二纱。
13.如权利要求3的织成的面板，其特征在于：所述第一和第三聚合物材料是相同的聚合物材料。
14.如权利要求3的织成的面板，其特征在于：所述第一、第三和第五聚合物材料是相同的聚合物材料。
15.如权利要求3的织成的面板，其特征在于：所述第五聚合物材料不同于所述第一和第三聚合物材料的其中之一。
16.如权利要求3的织成的面板，其特征在于：所述第一和第二单纱各具有一变形的外表面和在它们的整个长度上的一不均匀的横剖面。
17.如权利要求3的织成的面板，其特征在于：多根所述第一单纱至少局部地粘接于多根所述第二单纱。
18.如权利要求1、2或3的织成的面板，其特征在于：多根所述第一纱在它们的整个接触的外表面上粘接于多根所述第二纱。
19.一种家具产品，它包括一框架和一织成的面板，该框架具有一家具产品的形状，该织成的面板连接于该框架，该织成的面板的特征在于多根各具有一基本芯子的聚合物材料的第一纱，所述多根第一纱与多根各具有一表面芯子的聚合物材料的第二纱织造在一起以形成一织成的面板。
20.如权利要求19的产品，其特征在于：诸所述第一纱包括一第一聚合物材料的外壳，该外壳包围一第二材料的基本芯子；以及，诸所述第二纱包括一第三聚合物材料的本体，该本体具有不同于所述第三聚合物材料的第四聚合物材料的表面芯子。
21.如权利要求19的产品，其特征在于：诸所述第一纱包括一细长的第一单纱和一细长的第二单纱，该第一单纱具有第一聚合物材料的外壳，该外壳包围一第二聚合物材料的基本芯子，该第二单纱具有第三聚合物材料的外壳，该外壳包围一第四聚合物材料的基本芯子，所述第一和第二单纱在它们的长度内加捻在一起；以及，诸所述第二纱包括一第五聚合物材料的本体，该本体具有不同于第五聚合物材料的第六聚合物材料的表面芯子。
22.如权利要求19、20或21的产品，其特征在于：所述表面芯子的横剖面小于所述基本芯子的横剖面。
23.如权利要求19、20或21的产品，其特征在于：诸所述第一纱包括一加捻纱。
24.如权利要求19、20或21的产品，其特征在于：诸所述第二纱具有一平的形状。
25.如权利要求19、20或21的产品，其特征在于：诸所述第二纱具有一变形的外表面和在它们的整个长度上的一不均匀的横剖面。
26.如权利要求19或20的产品，其特征在于：所述诸第一纱包括至少一对加捻在一起的聚合物单纱，以形成一复合的加捻纱。
27.如权利要求19、20或21的产品，其特征在于：多根所述第一纱至少局部地粘接于多根所述第二纱。
28.如权利要求20的产品，其特征在于：所述第一和第三聚合物材料是相同的聚合物材料。
29.如权利要求20的产品，其特征在于：所述第二材料是不同于所述第一和第三聚合物材料的材料。
30.如权利要求21的产品，其特征在于：所述第一和第三聚合物材料是相同的聚合物材料。
31.如权利要求21的产品，其特征在于：所述第一、第三和第五聚合物材料是相同的聚合物材料。
32.如权利要求21的产品，其特征在于：所述第五聚合物材料是不同于所述第一和第三聚合物材料的其中之一。
33.如权利要求21的产品，其特征在于：所述第一和第二单纱各具有一变形的外表面和在它们的整个长度上的一不均匀的横剖面。
34.如权利要求21的产品，其特征在于：多根所述第一单纱至少局部地粘接于多根所述第二单纱。
35.如权利要求19、20或21的产品，其特征在于：多根所述第一纱在它们的整个接触的外表面上粘接于多根所述第二纱。
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CNU2004200740883U Expired - Lifetime CN2804137Y (zh) 2003-11-18 2004-08-24 织成的面板和包括一框架以及织成的面板的家具产品
CNU2004201174426U Expired - Lifetime CN2823306Y (zh) 2003-11-18 2004-11-18 一种机织面板及由其构成的家具制品
CNU2005200024337U Expired - Lifetime CN2791078Y (zh) 2003-11-18 2004-11-18 由聚合物纱线制成的机织面板
CNU2005201290313U Expired - Lifetime CN2870614Y (zh) 2003-11-18 2004-11-18 家具制品、用于其的机织面板和聚合物纱线
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US8641944B2 (en) 2009-12-23 2014-02-04 Oliver Wang Synthetic yarn
US11202508B2 (en) 2017-08-28 2021-12-21 Agio International Co., Ltd Q-shaped wicker furniture

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US20060099867A1 (en) 2006-05-11
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US7892989B2 (en) 2011-02-22
US20060021668A1 (en) 2006-02-02
CN2791078Y (zh) 2006-06-28
US20050191923A1 (en) 2005-09-01
US7472535B2 (en) 2009-01-06
US20100242253A1 (en) 2010-09-30
CN2904808Y (zh) 2007-05-30
US7700022B2 (en) 2010-04-20
US20050106975A1 (en) 2005-05-19
US20050103396A1 (en) 2005-05-19
US7476630B2 (en) 2009-01-13
US8052907B2 (en) 2011-11-08
CN2870614Y (zh) 2007-02-21
CN2823285Y (zh) 2006-10-04

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