Synthetic yarn

Abstract

A synthetic wicker yarn with irregularities sufficient to simulate natural wickers, in which the irregularities are durable even during weaving. The yarn is formed from an elongated body with a generally round cross section. The body is of two layers of coextruded polymer an outer layer integrated around the inner layer. An irregular node having a protuberance formed of the polymer outer layer extends radially from the outer layer, with a clearance exposing the polymer inner layer, in a manner like decorticated wicker. The outer layer may be have a greater density and rigidity for durability of the irregularity. Also included is a method of manufacturing this yarn and furniture having the yarn.

Description

FIELD OF THE INVENTION

The invention relates to the field of furniture constructed with synthetic woven material. More particularly, the invention relates to synthetic wicker yarns, woven panels made from such yarns, and furniture constructed from such panels. The invention also relates to methods for forming the yarns, panels, and furniture.

BACKGROUND OF THE INVENTION

Natural wicker has been used for many years for the manufacture of furniture, baskets, and other household goods. Natural wicker comes from pliant plant fibers; less pliant plants may be steamed or soaked in water to enhance pliability. Some plants, such as willow switches, may be used in the form of the entire stalk. Fibers such as cane or rattan are often used after peeling the outer skin to reveal the core or inner cane. There are various types of cane or rattan, such as Manau, Kooboo, Batang, etc. Other plants traditionally used are bamboo, water hyacinth, banana leaf, and reeds. Fibers may be drawn both from the stems and from leaves, depending on the plant. Wicker may then be woven into furniture, baskets, or other products. Wicker is generally lightweight and strong and is comfortable to sit or recline on.

Wicker is available in numerous styles and designs and may be woven in numerous different patterns and arrangements. For example, wicker may be twisted or untwisted, flat or round, and may include natural surface features, such as stripes and grooves. Of course, these styles may be mixed and matched in a particular weave pattern as designed based on the purpose and aesthetic requirements of the product being manufactured.

Natural wicker does have several drawbacks. After harvesting, natural wicker materials dry out, and may easily be damaged by precipitation, sun, and wind. Exposure to weather will deteriorate natural fibers over time. Attempts to waterproof natural wicker add an additional fabrication step, and are rarely successful. Natural wicker will soften when it absorbs moisture, accelerating wear. Excessive moisture could make the wicker susceptible to rot and mildew. In addition, some canes or other natural fibers have become scarce due to deforestation.

In recent years, synthetic wicker has been developed from various polymers and similar materials that has some of the look and feel of plant materials, but is not susceptible to the drawbacks of natural wicker. The appearance of conventional synthetic wickers has generally been somewhat abstract, and dissimilar to the appearance of natural materials. Synthetic wicker yarns have generally been prepared by an extrusion process of a polymer through an extrusion die, which produces a consistent appearance for the yarn. Manufacturers have attempted to adopt consistent patterns that appear more organic when woven or twisted in a wicker panel or article of furniture.

An aspect of natural products is that there are variations in surface appearance, texture, splits, or coloration of the starting wicker yarn. For example, in some cases, the shape or thickness of the natural leaf could affect the characteristics of the wicker yarn. Such natural characteristics enhance the appearance and texture of the finished wicker panel or article of furniture.

Some approaches have undertaken the development of synthetic wicker yarns. Many of these yarns incorporate abstract features, such as grooves or stripes, which do not appear in nature. Although abstract features may have some effect when seen at a distance, they can appear artificial when seen closer up. When touched, these abstract features may not simulate the organic structure of natural fibers. These abstract features are less effective particularly for wicker furniture fabricated from larger yarns.

Additionally, the polymers used in conventional yarns have typically produced surfaces that can be slippery or otherwise unsuitable for retaining paint. Some manufacturers adopt an additional step of applying a primer and/or paint adapted to polymer surfaces. Other manufactures have attempted to address this issue by use of polymer washes having solvents that are active on both the polymer of the yarn and the polymer of the paint. However, such primers and solvents generally require additional processing, and can pose environmental and health hazards during use. It would be desirable to gain a two toned or contrasting appearance without these additional complications.

A synthetic wicker yarn simulating the features of organic yarn material would enhance the appearance of finished wicker items.

SUMMARY OF THE INVENTION

This application relates to a synthetic wicker yarn, a method for its manufacture, and furniture having the wicker yarn.

An aspect of the yarn is an elongated body having a generally round cross section. The body involves a first polymer forming an inner layer and a second polymer forming an outer layer. The second polymer may be co-extruded with or around the first polymer, so that the outer layer is integrated around the inner layer. In such extrusion, at least one node comprising at least one protuberance formed of the second polymer that extends radially outwardly from the outer layer. In addition, the second polymer may be extruded in such a manner as to define at least one clearance of the second polymer located adjacent to or near the protuberance. This clearance exposes a portion of the first polymer, and its border defines the surface separation of the first polymer and the second polymer at the node. This irregular node produces the effect of a decorticated wicker.

In one embodiment, the synthetic wicker yarn may have a clearance that is substantially oblong, with and the protuberance is located within the border of the node. Such an embodiment may optionally have an irregular border. An aspect of another embodiment is that the second polymer may have a greater rigidity than the first polymer. In some cases, the first polymer may have a first color and the second polymer may have a second color, with the first color being different from the second color.

The two polymers may be the same polymer materials, or different polymer materials. In one example, the first polymer and the second polymer are the same material and are selected from the group consisting of polyvinyl chloride, polyethylene, polypropylene and mixtures thereof. In another embodiment, the first polymer is LDPE and the second polymer is HDPE. Optionally, the first and second polymers are PE, and the first polymer has a density that is less than the second polymer. In some cases, the first and second polymers are PE and the first polymer has a density less than about 0.94 g/cc and the second polymer has a density greater than about 0.94 g/cc.

The foregoing wickers may have an outer layer of the yarn includes one or more features selected from the group comprising grooves, stripes, and raised lobes. In addition, the present invention extends to include article of furniture made with any of the foregoing wickers.

The present invention extends also to a method for producing a wicker yarn. This method involves the steps of providing a first polymer, providing a second polymer, heating the first polymer at a first temperature to form a first molten material, heating the second polymer at a second temperature to form a second molten material, feeding the first molten material into a first extruder at a desired rate to form an inner layer of a yarn having a desired cross section, conveying said first molten material through an open port of the second extruder, feeding the second molten material into a second extruder at a rate relative to the rate of extruding the first molten material so as to form an outer layer integrated around the inner layer with the outer layer having at least one node comprising at least one protuberance formed of the second polymer and extending radially from the outer layer, the second polymer being extruded in such a manner as to define at least one clearance adjacent to the protuberance by which a portion of the first polymer is exposed, the clearance having a border defining the separation of the first polymer and the second polymer at the node, and cooling the yarn.

This method optionally may have a first temperature that is greater than the second temperature. In another embodiment, this method may involve adding a first color concentrate in the first step and adding a second color concentrate in the second step. An alternate embodiment may involve the at least one clearance when it is substantially oblong and the protuberance is located within the border of the node. Another alternate embodiment may involve the at least one clearance when it is substantially oblong, the border is irregular, and the protuberance is located within the border of the node.

This method may optionally involve a second polymer that has a greater rigidity than the first polymer. This method may also involve a first polymer that has a first color and a second polymer that has a second color, with the first color is different from the second color. In some embodiments, the first polymer and the second polymer may be the same material, while in other embodiments the first and second polymers are polymer materials. In another embodiment, the first polymer and the second polymer are the same material and are selected from the group of polyvinyl chloride, polyethylene, and polypropylene. In some embodiments, the first polymer is LDPE and the second polymer is HDPE. In some embodiments, the first and second polymers are PE, and the first polymer has a density that is less than the second polymer. In an alternate embodiment, the first and second polymers are PE and the first polymer has a density less than about 0.94 g/cc and the second polymer has a density greater than about 0.94 g/cc. An optional aspect of the method is that the second die may be configured to produce an outer layer of the yarn having one or more features selected from the group comprising grooves, stripes, and raised lobes.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood in relation to the attached drawings illustrating preferred embodiments, wherein:

FIG. 1 is a perspective view of a natural rattan;

FIG. 2 is a perspective view of an embodiment of the present invention;

FIG. 3 is a longitudinal cross-section view of an embodiment of the present invention; and

FIG. 4 is a flow chart of an aspect of the method of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The invention relates to a synthetic yarn having certain advantageous features that enable the ability to simulate irregular, organic materials.

Natural wickers come in a wide variety of forms, each with its own appeal. Some natural wickers are used with the bark on, such as rattan cane. These “bark on” rattans are often taken from rarer stock that lacks knots, is consistent in diameter, and is consistent in color. These forms of rattan are valuable because they do not require substantial processing due to their lack of prominent irregularities. The more uniform a wicker, the more amenable it is to depiction using conventional polymer materials and methods for producing synthetic polymer yarns.

However, many types of rattan are not so uniform so as to permit use without treatment. Because of this, a more common natural product used in furniture is decorticated, or “bark off,” rattan cane. This type of product includes partially de-barking or decorticating the wicker. In practice, these natural materials may be hand or machine abraded in order to remove a desired level of the bark or outer skin of the natural material. Natural products processed this way may still have considerable variance in their appearance and diameter. The greater the processing and expense, the greater the level of uniformity for the product. However, some variance in appearance due to natural irregularities of rattan has become desirable for the decorative effect. Unlike bark on rattan, the irregularity or lack of uniformity in bark off rattan has been difficult to replicate using conventional polymer wicker and methods.

An aspect of irregularity in rattans is the natural variation caused by leaf sheaths, stem knees, or ocrea (also referred to as ochreae) of natural rattans. This aspect is not limited simply to rattan; other canes, grasses, and palms also have these irregularities. Ocrea, for example, is an extension of the leaf sheath beyond the point of petiole insertion. The petiole generally refers to a point of attachment of a leaf stalk to a stem. The ocrea may be in the form of the fusion of two stipules or layers of plant fiber forming a stipular sheath over the stem, as may be seen in FIG. 1. The fusion of two stipules is commonly seen in the form of a V or U along the length of the stem, defining an almost elliptical shape. In some cases, the stipular sheath separates from the stem, changing color. In FIG. 1, a natural rattan 1 is depicted, with natural stipular sheath 2 shown in contrast to leaves 4. Such complicated irregularities have been difficult to depict with conventional polymer methods.

Referring to the drawings, FIG. 2 shows an embodiment of the present invention. The yarn 10 comprises a combination of a first polymer 21 and a second polymer 11, together forming a multilayered elongated body having a desired cross section. Examples of suitable cross sectional shapes are round or substantially round for some embodiments. First polymer 21 forms an inner layer 29 of yarn 10 while second polymer 11 forms an outer layer 19 of yarn 10. The cross section is variable within the limits of representing real wicker yarn, as may be desired. In general, the effective diameter of the cross section of the outer layer 19 is less than that of the effective diameter of the cross section of the inner layer 29.

Yarn 10 includes at least one node 20 having a clearance 26 in outer layer 19 that exposes inner layer 29 (i.e., of second polymer 21), which when viewed gives an appearance like that of decortication and the residual irregularity of a stipular sheath of a natural wicker yarn. The node 20 includes a protuberance 24 from the surface of yarn 10 formed of first polymer 21. Protuberance 24 may optionally further include an expansion of the cross section of yarn 10, such as a knuckle in the material. First polymer 21 further defines a surface clearance 26 in outer layer 19 juxtaposed to protuberance 24, which exposes a portion of the second polymer 21 in inner layer 29. Clearance 26 has at least one border 22 defining the separation of the first polymer 21 and the second polymer 11.

Preferably, but not necessarily, clearance 26 may be of a somewhat irregular, or oblong shape. “Oblong” means that clearance 26 has a border 22 with at least one transverse segment or portion, optionally curved, but with an overall shape defined by border 22 as having dimensions that are longer along the length of yarn 10 than they are transverse to the length of yarn 10. Thus, the meaning of oblong may include, but is expressly not limited to, symmetrical shapes, such as an ellipse. “Irregular” generally means that borders 22 of clearance 26 may be, but are not required to be, inconsistent, fading, tapered, or broken—unlike the continuous, symmetric outline, for example, of a conventional oval or ellipse. For example, as shown in FIG. 2, clearance 26 may form an oblong U shape with a transverse segment at protuberance 24 (i.e., the bottom of the U), and the arms of the U (i.e., the vertical lines) running along the length of yarn 10, fading into outer layer 19. In other examples, clearance 26 may be shaped as a lozenge, an oblong fleck, an oblong streak, etc. The term “somewhat” is intended to include both regular and irregular shapes (i.e., having irregular borders 22).

The somewhat irregular border 22 and oblong shape is intended to simulate the separation between two stipules, which may vary widely among examples in nature. Preferably, but not necessarily, first polymer 21 and second polymer 11 are differing colors, shades, or tints, such that the clearance 26 contrasts with surrounding portions of yarn 10.

By way of guidance, the below table provides some examples of ranges of diameters that are typical for natural wicker yarns, and potential embodiments of the present invention.

TABLE 1
Sample Dimensions of Natural Wicker Yarns
Type of Wicker Yarn	Small Diameter (mm)	Large Diameter (mm)
Batang	20	36
Flat (1 mm thick)	5	16
Koobo	5	14
Manau	20	34
Poeleot	2	6
Traditional Weaving	1.5	20
Rattan
Rush	.2	6
Seagrass	3	6
Tohiti	12	28
Weaving Cane	2	15

For example, in one embodiment yarn 10 may simulate a natural Manau rattan and may have a generally round cross section with a diameter of about 20-40 mm. Protuberance 24 projects radially from outer layer 19 and, along with border 22, produce a roughness that breaks up the unnatural and undesirable smooth surface. In a simulated Manau embodiment having an average diameter of about 35 mm, for example, protuberance 24 may project or extend about 5 mm from outer layer 19, for an effective diameter of about 40 mm for the yarn at protuberance 24. Clearance 26 may have, but it is not required to have, a slight narrowing to give an effective diameter of about 30 mm. Protuberance 24 may have an irregular diameter or width on the order of the height of its projection, such as 5 mm. Clearance 26 is generally under 180-degrees and can vary greatly in length, as may be desired for the application. In some embodiments, it may be desirable for a first clearance 26 to taper off and merge with a second clearance 26. As discussed below in the method of manufacture, preferably protuberance 24 is proximate to border 22 and irregular so as to simulate naturally occurring wickers. In one embodiment, border 22 of clearance 26 may be smooth with the exception of the roughness provided by protuberance 24. In another embodiment, border 22 may also be a noticeable slope or transition from outer layer 19 to clearance 26.

Yarn 10 as shown in FIG. 2 may optionally include a separate reinforcing filament 17. Such a core filament 17 may be used to add strength to yarn 10, depending on the desired application. These filaments may be formed of any of a variety of suitable materials, so long as it is compatible with first polymer 21.

A longitudinal cross section view of an embodiment of yarn 10 is shown in FIG. 3, with the first polymer 21 and the second polymer 11 shown. Inner layer 29 is exposed at clearance 26. A portion of border 22 and protuberance 24 show the cessation of outer layer 19 at clearance 26.

Yarn 10 may be formed of a thermoplastic material capable of extrusion and suitable for the purpose described herein, such as thermoplastic polymers. Examples of suitable materials include, but are not limited to, polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), or various combinations thereof. In one embodiment, the yarn may be a blend of PP and PE.

One of the historic difficulties faced with synthetic wickers has been conflicting design considerations. For example, portions of polymer wickers projecting radially or otherwise elevated from a general surface may be susceptible to shearing off during weaving. However, if a synthetic wicker is sufficiently rigid to resist such shearing, it may be difficult to weave. It has been discovered that a two layer approach to material choice is preferable for embodiments used in weaving. An outer layer having higher rigidity provides effective simulation with improved resistance to de-lamination or shearing away of a protuberance from the rest of the wicker yarn during weaving and use. As noted above, yarns fabricated solely of higher rigidity materials may resist such shearing, but can be difficult to handle during weaving. Hence, the layered aspect combines the benefits of a rigid outer layer with a less rigid inner layer. The lower rigidity inner layer facilitates weaving and handling of the wicker yarn. Various combinations of polymers may be used generally with a lower rigidity polymer comprising an inner layer and a higher rigidity polymer comprising the outer layer. The thickness of the individual layers will depend on the type of wicker being simulated, the degree of flexibility required by the nature of the intended weave, the required strength for the application, and the actual polymer selected. Preferably, the two layers may be selected from chemically compatible polymers. Of course, embodiments directed to uses other than weaving, such as framing, may be suitable in a single material.

The modulus of rigidity may be calculated as:

$G=\frac{F/A}{\Delta x/h}=\frac{\mathrm{Fh}}{\Delta \mathrm{xA}}$

where the numerator is shear stress (force over area) and the denominator is the change in transverse displacement over the initial length. Alternate terms for this are the modulus of elasticity in torsion or modulus of elasticity in shear. The modulus of rigidity is equivalent to the torsional modulus, and is proportional to the Young's Modulus which, for elastomers, may be approximated by calculation of a secant modulus, given the nonlinear relationship between stress and strain for elastomers. The mechanical properties of polymers depend significantly on variables such as the extent and type of molecular branching, crystal structure, temperature, and the molecular weight. The density of a polymer is directly linked to the crystallinity or molecular bonding within the polymer, which affects its rigidity, stiffness, impact strength, etc. A higher density indicates a higher rigidity. Thus, selection of a polymer material for each of the layers of the yarn may be based on density with, for example, a lower density less rigid polymer selected for the inner layer.

Lower rigidity polymers are suitable for weaving, bending, torsion, and stretching. PE is one example of a lower rigidity polymer suitable for the present invention. PE is a thermoplastic which is characterized by its low cost, toughness, chemical resistance, low moisture absorption, high impact and tensile strength and ease of processing. One embodiment of yarn 10 may be fabricated from two types of PE. PE is often classified by density and thus, by the extent of branching of its molecules. Two commonly produced types of polyethylene are High Density Polyethylene (HDPE) and Low Density Polyethylene (LDPE). As a general rule, HDPE is stronger, impact resistant, and more rigid than LDPE, which tends to be more flexible.

HDPE is made up of substantially linear monomer chains, which permits the chains to bond closely to each other, enabling the higher density. HDPE thus has relatively greater tensile strength and rigidity associated with that higher density. LDPE is made up of substantially branched or non-linear monomer chains, which can inhibit the close bonding seen in HPDE. LDPE thus has a relatively lower tensile strength and rigidity, with weaker bonds to be formed between the monomers within the polymer. Importantly, the density and rigidity may vary within the categories of HPDE and LPDE, depending on the overall composition and treatment. For example, common extrusion grade LDPE can have a density of 0.91-0.94 g/cc and a secant modulus of 0.0830-0.245 GPa. Common extrusion grade HDPE can have a density of 0.94-0.96 g/cc and a secant modulus of 0.689-1.10 GPa.

Therefore, as discussed above, second polymer 11 may have a greater rigidity than first polymer 26. For example, second polymer 11 may be selected from a HDPE, and first polymer 26 may be selected from a LDPE. An additional benefit in this embodiment is that HDPE shrinks during cooling to an extent that is greater than the shrinkage of LDPE, forming a secure bonding between the layers. Alternatively, both second polymer 11 and first polymer 26 may be selected from different types of LPDE, wherein second polymer 11 rigidity is greater than that of first polymer 26.

An aspect of a method of fabrication is shown in FIG. 4. Yarn 10 may be fabricated by providing first and second polymers 21, 11 as discussed above, typically in granulated or pelletized forms of resin or polymer feed. The first and second polymers 21, 11 or resins are heated to form first and second molten materials. The temperature of the heat required to heat the first and second molten materials will vary depending on which materials were selected to comprise the first and second polymers. Optionally, the first molten material is heated to a temperature that is higher than that of the second molten material. For example, in an embodiment comprising PE as the first and second polymers, the first molten material formed therefrom may be heated to a temperature of about 160-185° C. and the second material may be heated to a temperature of 140-150° C. Without being bound to any particular theory, it is believed that the relation of the different temperatures of the first and second molten materials aid in the positive adhesion of outer layer 19 to inner layer 29.

Yarn 10 may be formed by co-extrusion. The first molten material is fed into a first extruder and through a die at a stable rate to form inner layer 29 of yarn 10 having a desired cross section defined by an orifice within the die. This inner layer 29 material is then conveyed through an open port or transfer tube to the output die of a second extruder. The rate of conveyance of the inner layer 29 and the rate of extrusion from the second extruder are configured so that the second molten material forms outer layer 19 over the inner layer 29. Preferably the first material is extruded at a stable rate, such as 15 kg/hr, to form inner layer 29. The transfer tube may relate to the second extruder die in either an in-line or cross head arrangement.

The second material may be extruded at a consistent or a variable rate. In order to provide the simulated features of a stipular sheath, there preferably is at least one relative variation in processing, such as a relative change in the rate of extrusion of the second molten material with respect to the conveyance of the inner layer 29. If for example, the baseline relationship is that the second molten material is extruded at a rate so as to uniformly cover inner layer 29 with an outer layer 19, then a relative slowing of the second extruder may produce a node 20 with a clearance 26. Thus, “relative” variation may be implemented by changing the rate of extrusion of the second molten material. Alternatively, “relative” variation may be implemented by changing the rate of conveyance of the inner layer 29.

The second molten material is thus fed into a second extruder through a die at a rate to form an outer layer 19 integrated around or covering inner layer 29. The outer layer 19 may include at least one node 20, the node 20 comprising at least one protuberance 24 formed of the second polymer 11 and extending radially from the outer layer 19, and defining an at least one clearance 26 adjacent to the protuberance 24 by which a portion of the first polymer 21 inner layer 29 is exposed. Such a clearance 26 has a border 22 defining the separation of the first polymer 21 and the second polymer 11 at the node 20. The shape of the clearance 26 and the protuberance 24 may be altered or controlled by the relative variations in processing discussed above. A more prolonged period of relative slowing in the extrusion of molten material for outer layer 19 may, for example, produce a larger clearance 26.

If desired, color concentrate may be added to the first and second polymers prior to heating in order to produce a relatively contrasting color between the layers at the clearance 26 of the node 20. In one embodiment, the first polymer comprises a first color and the second polymer comprises a second color, wherein the first color is different than the second color. The colors may be chosen based on the desired appearance of the finished yarn product, including colors which would simulate the appearance of natural wicker.

Following extrusion, the integrated inner 29 and outer layers 19 forming the synthetic yarn 10 may be cooled by conveying the synthetic wicker through a water bath. Faster cooling results in less crystallization and an overall less dense material. In one embodiment, cooling may be performed through a water bath at about 25-30° C. with replenishment of water at about 1 litre/second. The temperature and size of the water bath will vary depending on the total volume of the cooling tank, the length of the yarn in the tank, and the desired temperature of the yarn upon the exiting the tank.

In one embodiment, the at least one clearance 26 is substantially oblong, border 22 is somewhat irregular, and the protuberance 24 is located within the border 22 of the node 20. As described above, it has been discovered that the simulated wicker 10 performs well in terms of durability and weave-ability when the second polymer 11 has a greater rigidity than the first polymer 21. This may be achieved by use of the same polymer material selected with different densities, such as the LDPE and HDPE embodiment described above. However, a variety of polymers may be used, including polymers selected without limitation from the group of polyvinyl chloride, polyethylene, and polypropylene.

Optionally, the effective overall rigidity of the synthetic yarn 10 may be selected so that it may be twisted about its axis. Additional optional features may also be provided, such as raised lobes, depressions, color variation, longitudinal grooves depressed in the outer surface, stripes, or raised points. As used herein, reference to a “yarn” refers to the complete yarn used for creating woven panels of indeterminate length and the like. The present invention generally refers to yarns formed of a single strand, but a yarn could also include multiple such strands twisted together to form a composite yarn.

The yarn 10 of the present invention may be woven into various materials, including articles of furniture such as chairs, couches, ottomans, tables, benches, stools and the like. An article of furniture may be produced by providing a frame into which the yarn of the present invention is interwoven. The resulting article made with the yarn of the present invention has the look and feel of natural wicker, but with the benefits of the synthetic wicker yarn.

It is to be understood that the invention is not to be limited to the exact configuration as illustrated and described herein. Accordingly, all expedient modifications readily attainable by one of ordinary skill in the art from the disclosure set forth herein, or by routine experimentation therefrom, are deemed to be within the spirit and scope of the invention as defined by the appended claims.

Claims

1. A synthetic wicker yarn, comprising:

an elongated body having a generally round cross section, the body comprising a first polymer forming an inner layer, a second polymer forming an outer layer, the second polymer co-extruded with the first polymer such that the outer layer is integrated around the inner layer; and

at least one node comprising at least one protuberance formed of the second polymer and extending radially from the outer layer, the second polymer being extruded in such a manner as to define at least one clearance adjacent to the protuberance by which a portion of the first polymer is exposed, the clearance having a border defining the separation of the first polymer and the second polymer at the node.

2. The synthetic wicker yarn of claim 1, wherein the at least one clearance is substantially oblong and the protuberance is located within the border of the node.

3. The synthetic wicker yarn of claim 1, wherein the at least one clearance is substantially oblong, the border is irregular, and the protuberance is located within the border of the node.

4. The synthetic wicker yarn of claim 1, wherein the second polymer has a greater rigidity than the first polymer.

5. The yarn of claim 1, wherein the first polymer has a first color and the second polymer has a second color, wherein the first color is different from the second color.

6. The synthetic wicker yarn of claim 1, wherein the first polymer and the second polymer are the same material.

7. The synthetic wicker yarn of claim 1, wherein the first polymer and the second polymer are the same material and are selected from the group consisting of polyvinyl chloride, polyethylene, polypropylene and mixtures thereof.

8. The synthetic wicker yarn of claim 1, wherein the first polymer is LDPE and the second polymer is HDPE.

9. The synthetic wicker yarn of claim 1, wherein the first and second polymers are PE, and the first polymer has a density that is less than the second polymer.

10. The synthetic wicker yarn of claim 1, wherein the first and second polymers are PE and the first polymer has a density less than about 0.94 g/cc and the second polymer has a density greater than about 0.94 g/cc.

11. The synthetic wicker yarn of claim 1, wherein the first polymer is a different polymer material from the second polymer.

12. An article of furniture made with the synthetic wicker yarn according to claim 1.

13. The synthetic wicker yarn of claim 1, wherein the outer layer of the yarn includes one or more features selected from the group comprising grooves, stripes, and raised lobes.

14. A method for producing a wicker yarn, comprising the steps of:

(a) providing a first polymer;

(b) providing a second polymer;

(c) heating the first polymer at a first temperature to form a first molten material;

(d) heating the second polymer at a second temperature to form a second molten material;

(e) conveying said first molten material through an open port of the second extruder;

(f) feeding the second molten material into a second extruder at a rate relative to the rate of extruding the first molten material so as to form an outer layer integrated around the inner layer with the outer layer having at least one node comprising at least one protuberance formed of the second polymer and extending radially from the outer layer, the second polymer being extruded in such a manner as to define at least one clearance adjacent to the protuberance by which a portion of the first polymer is exposed, the clearance having a border defining the separation of the first polymer and the second polymer at the node; and

(g) cooling the yarn.

15. The method of claim 14, wherein the first temperature is greater than the second temperature.

16. The method of claim 14 wherein step (a) further includes the step of adding a first color concentrate and step (b) further includes the step of adding a second color concentrate.

17. The method of claim 14, wherein the at least one clearance is substantially oblong and the protuberance is located within the border of the node.

18. The method of claim 14, wherein the at least one clearance is substantially oblong, the border is irregular, and the protuberance is located within the border of the node.

19. The method of claim 14, wherein the second polymer has a greater rigidity than the first polymer.

20. The method of claim 14, wherein the first polymer has a first color and the second polymer has a second color, wherein the first color is different from the second color.

21. The method of claim 14, wherein the first polymer and the second polymer are the same material.

22. The method of claim 14, wherein the first polymer and the second polymer are the same material and are selected from the group of polyvinyl chloride, polyethylene, and polypropylene.

23. The method of claim 14, wherein the first polymer is LDPE and the second polymer is HDPE.

24. The method of claim 14, wherein the first and second polymers are PE, and the first polymer has a density that is less than the second polymer.

25. The method of claim 14, wherein the first and second polymers are PE and the first polymer has a density less than about 0.94 g/cc and the second polymer has a density greater than about 0.94 g/cc.

26. The method of claim 14, wherein the first polymer is a different polymer material from the second polymer.

27. The method of claim 14, wherein the second die is configured to produce an outer layer of the yarn having one or more features selected from the group comprising grooves, stripes, and raised lobes.