System and method of fastenerless construction of a decorative article

A system and method of constructing a substantially decorative article without the need for fasteners. In one exemplary embodiment of the invention, the decorative article is a woven basket. One or more retainers are provided to retain the material used to construct the outer surface of the decorative article. Each retainer is provided with a channel for receiving one end of the material used to construct the surface of the decorative article. The channels are able to retain the ends of the material used to construct the surface of the decorative article without the need for fasteners. If the material used to construct the surface of the decorative article is sufficiently rigid, the decorative article will be self-supporting. If the material used to construct the surface of the decorative article is not sufficiently self-supporting, supports may be located between the retainers. The channels may be oriented at an angle, or may be provided with a texture, to assist in retaining the material used to construct the surface of the decorative article.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to a system and method for constructing a decorative article without the need for fasteners. More particularly, the present invention is a system and method for securing a substantially decorative construction material, such as, for example, the weave of a basket or the fabric of a lampshade, without the need for a fastener or fasteners. The present invention employs at least one, and typically a pair of particularly shaped and sized retainers, each having a groove or channel therein for accepting a portion of the construction material.

When constructing decorative articles such as woven baskets, lampshades, or other similar and substantially hollow structures, it is generally required at some point in the construction process to employ fasteners, such as, for example, nails, staples, screws, bolts, or adhesives, in order to secure the material forming the shell (outer surface) of the article. Although such fasteners are adequate to secure the material, they are often unsightly and, therefore, undesirable. This may be especially true if the fasteners must be located on a highly visible portion of the finished article.

The system and method of the present invention allows such decorative articles to be constructed without the need for such fasteners. The system and method of the present invention allows for a finished decorative article that is generally more aesthetically pleasing than a similar article manufactured using the aforementioned fasteners. More particularly, the system and method of the present invention employs at least one and, more commonly, a pair of retainers, each having a groove or channel located around the periphery thereof. When constructing a substantially hollow basket, for example, a retainer pair may be used, consisting of a solid and hollow ring of some thickness sufficient to house the groove or channel. It should be realized, however, that the retainers may be of practically any shape, as necessary to provide the desired outer shape of the article being produced.

In use, the retainers will typically lie in substantially parallel planes that are spaced apart by some predetermined distance. Thus, there is generally a top and bottom, or left and right retainer. The retainer pair may be of the same size, or may be of different size, depending on the desired shape of the article being produced. If the item being produced is manufactured of a substantially rigid material, the material itself may maintain the retainer pair in a spatial relationship. Alternatively, if the item being produced is manufactured or covered by a substantially non-rigid material, supports may be used to maintain the retainer pair in a particular spatial relationship.

During the manufacturing process, a portion of each end of the material forming the outer surface of the article is inserted into and retained by the groove or channel in each of the retainers. For example, when manufacturing a typical woven basket, one end of each of a plurality of vertical weavings is placed into the channel around the periphery of a bottom retainer. Horizontal weaving weavings may then be interlaced with the vertical weavings to form a basket. Once the placement of the horizontal weavings is complete, or nearly complete, the other end of each vertical weaving may be inserted into the channel in the top retainer. The vertical weavings will be held in the channels and, thus, a basket may be constructed without the need for any fasteners. Other materials may be held by the retainers in a similar manner. For example, a lampshade could be assembled by employing thin support rods to maintain a spacing of the retainers. The fabric lampshade covering may thereafter be wrapped around the periphery of the shape created by the retainers, with each end thereof being tucked into the channel in the respective retainer.

The material forming the outer surface of the article being produced may be held in the channel by a number of actions. For example, in the case of basket material, the bending of the vertical weavings will cause the portion thereof inserted into the channel to exert a force against one surface of the channel. This force may be sufficient to retain the weaving ends in the channels. The channel may also be cut at some angle with respect to horizontal to exacerbate the amount of force exerted by the bent material residing therein. Alternatively, the channel may be formed at some particular width, which will retain by friction the material that will be inserted therein. By forming the channel to be only slightly wider than the thickness of the material to be inserted therein, and then forcing the material into the channel, frictional forces will act to resist removal of the material therefrom. It is also contemplated that the channel in each retainer may be provided with a rough texture, or otherwise be treated to enhance its ability to retain the material introduced thereto.

The system and method of the present invention allows for the fastenerless construction of a variety of decorative items, thereby enhancing the aesthetic appearance thereof. The system and method of the present invention can be better understood by reference to the detailed description of certain exemplary embodiments found below.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(S)

As can be appreciated by one skilled in the art upon reference to the written description and drawings, that the system and method of the present invention can be used to accomplish the fastenerless manufacture of a wide variety of decorative items. However, for purposes of clarity, the system and method of the present invention will be described in detail below only with respect to the manufacture of an exemplary woven basket and fabric lampshade. It is to be understood, however, that these exemplary embodiments are provided for illustration only, and are in no way intended to limit the scope of the present invention thereto.

FIGS. 1–3are directed to one embodiment of the system and method of the present invention, wherein a pair of channel containing retainers are employed to create a woven basket. In typical woven basket manufacture, the structure of the basket is begun at the base. In common basket designs, this typically involves providing a block of wood to which a plurality of vertical weavings may be affixed—although it may also be possible to simply fasten together the bottom ends of each vertical weaving. The vertical weavings are normally affixed to the base block (or to each other) by means of fasteners, such as nails, screws, staples, reeds, or twine. The base block is dimensioned, and the vertical weavings are provided at some predetermined length, to result in a basket of some particular height and circumference, or width (as determined by the horizontal weavings). Once the vertical weavings have been affixed to the base block, the horizontal weavings may be woven therethrough. After the last horizontal weaving has been installed at the top of the basket, a band of weaving material is typically wrapped around the top circumference, and each of the vertical weavings is then fastened thereto. Typically this fastening process also employs nails, screws, or staples, each of which is generally visible on the finished basket.

The system and method of the present invention allows such a basket to be constructed without the use of nails, screws, staples or adhesives. Referring toFIGS. 1–2A, one embodiment of a retainer pair10of the present invention that can be used to construct a similar basket may be observed. The retainer pair10is shown to consist of a bottom retainer15and a top retainer20. The top retainer20is in the form of a hollow ring to allow for access to the inside of the basket once the weaving process is complete. The bottom retainer15consists of a substantially solid disc, which will form the bottom portion of the basket upon completion of the weaving process. Each of the bottom and top retainers15,20can be seen to have its own retaining channel25,30for accepting and retaining a portion of the vertical weavings of the basket.

Referring specifically toFIG. 2A, each retaining channel25,30can be seen to extend some distance into its respective retainer15,20. The depth, and also the height (width) of the channel will depend on the particular construction material that will be inserted therein, as well as the particular item being constructed. Although the channels25,30are shown to be oriented substantially parallel to the top and bottom surface of each retainer15,20, it should be realized that the channels can also be placed therein at an angle. For example, as shown inFIG. 2B, the angle of the channel30bin the top retainer20bcan be oriented downward, toward the bottom surface thereof, thereby increasing the bend in the ends of the vertical weavings once they are inserted into the channel. By employing such a channel angle, additional holding power may be generated, as the greater bending of the material placed therein may cause a correspondingly greater upward force of the material against the channel's upper wall. A similar design may be employed for the channel25bof the bottom retainer15b.

As can also be observed inFIGS. 1–3, the retainer pair10is designed to have a separated spatial relationship. When used to form a basket, the top retainer20is designed to reside some distance D away from the bottom retainer15. The distance D will depend upon the desired dimensions of the finished basket. The retainer pair10is also shown to have a substantially planar spatial relationship in this particular embodiment of the present invention. Preferably, the retainer pair10is substantially parallel, so that the top and bottom surface of the finished basket will also be substantially parallel. To impart a uniform shape to the finished basket, the centerlines of each retainer15,20are also preferably aligned, as shown.

A basket35constructed using the system and method of the present invention is depicted inFIG. 3. The basket35is shown to be of woven construction, and to employ the top retainer20and bottom retainer15shown inFIGS. 1 and 2A. The basket35is constructed by initially inserting a first end40aof each of a plurality of vertical weaving members40into the channel25of the bottom retainer15. The vertical weaving members40are preferably substantially equidistantly disposed around the perimeter of the bottom retainer15. Once the first end40aof each of the vertical weaving members40has been inserted into the channel25in the bottom retainer15, the horizontal weaving members45may be installed to the basket35. Typically, the horizontal weaving members45are woven between the vertical weaving members40starting near the bottom of the basket35, and working upward. During the weaving process, the bottom retainer15acts to hold the vertical weaving members40in place.

Once all of the horizontal weaving members45, or a substantial portion thereof, have been woven into position, the second ends40bof the vertical weaving members40are inserted into the channel30in the top retainer20. Any uninstalled horizontal weaving members45may then be added or, if all the horizontal weaving members have already been installed, the weaving process and, thus, the basket35is complete. The shape and weaving of the basket35will be maintained due to retainment of the vertical weaving members40by the channels25,30in the top and bottom retainers15,20. Because the vertical weaving members40in this embodiment are semi-rigid, the desired spacing between the top retainer20and the bottom retainer15will be substantially maintained without additional support. Therefore, a woven basket35may be completely constructed without the use of any unsightly fasteners, such as nails, staples or screws.

FIGS. 4–6are directed to an alternate embodiment of the system and method of the present invention, wherein a pair of channel containing retainers are employed to create a lampshade. In typical lampshade manufacture, an upper and lower wire ring are connected by a number of substantially upright connecting wires. The wire rings and connecting wires may be of different sizes and lengths, depending on the desired shape of the finished lampshade. The wire material is typically sufficiently rigid so that a self-supporting wireframe is created by the connection of the wire rings and connecting wires. A covering material, such as a fabric, is then typically wrapped around the wire frame to form the outer surface of the lampshade. Generally, the covering material is affixed at each end to the corresponding upper and lower wire ring. Typically, affixation is accomplished by folding the covering material over the wire rings and then sewing or bonding the material to itself.

While the above described method is sufficient to construct a lampshade, it does not allow the covering material of the lampshade to be removed for cleaning, nor for the covering material to be easily replaced with new material, such as may be desired when redecorating. By employing the retainers of the present invention, an aesthetically pleasing lampshade may be created without the need for permanent fastening, or the use of fasteners. The retainers of the present invention also permit the covering material of the lampshade to be removed without damage thereto, whereafter the material may be reattached, or may be replaced with a different covering material.

A retainer pair50for use in constructing a lampshade is best observed by reference toFIGS. 4 and 5. As can be seen, the retainer pair consists of a top retainer55and a bottom retainer60. Both the top retainer55and bottom retainer60are in the form of a hollow ring to allow the lampshade to be placed onto the light fixture and to allow light therefrom to shine upward from the lampshade once installed. Each of the top and bottom retainers55,60can be seen to have its own retaining channel65,70for accepting and retaining a portion of the covering material of the lampshade.

Referring specifically toFIG. 5, each retaining channel65,70can be seen to extend some distance into its respective retainer55,60. The depth, and also the height (width) of the channel will depend on the particular covering material that will be inserted therein. Although the channels65,70are shown to be oriented substantially parallel to the top and bottom surface of each retainer55,60, it should be realized that, similar to the embodiment of the retainer of the present invention shown inFIG. 2B, the channels can also be placed therein at an angle. Preferably, when a material such as a typical lampshade covering material is to be held by the retainers55,60, the channels65,70are sized to result in a friction fit with the material inserted thereto. It may also be possible to impart a texture to, or otherwise treat the interior of the channels65,70to enhance their ability to retain the material inserted therein.

As can also be observed inFIGS. 4–6, the retainer pair50is designed to have the separated spatial relationship required to form a lampshade. The top retainer55is designed to reside some distance D′ away from the bottom retainer60. The distance D′ will depend upon the desired dimensions of the finished lampshade. Because the material typically used to cover a lampshade is not sufficiently rigid to maintain the spatial relationship of the retainer pair50, support rods75are inserted therebetween. In this particular embodiment, four support rods75are employed, however, the number of support rods may vary depending on the design of the lampshade. The support rods75may be located inward of the outside edge of the retainers55,60(as shown) or, may be located to be aligned with the outside edge of the retainers to provide additional support to the covering material to be applied. Alternatively, if a sufficiently rigid covering material is used, the support rods75may be rendered unnecessary. The retainer pair50is also shown to be substantially planar. In this particular embodiment, the retainer pair50is substantially parallel, so that the top and bottom surface of the finished lampshade will also be substantially parallel. However, the retainer pair50may have a different orientation, depending on the desired shape of the lampshade. To impart a uniform shape to the lampshade, the centerlines of each retainer55,60are also preferably aligned, as shown.

A lampshade80constructed using the system and method of the present invention is depicted inFIG. 6. The lampshade80is shown to consist of the top retainer55and bottom retainer60, connected by a number of the support rods75, as shown inFIGS. 4 and 5. The lampshade80is finished by wrapping an appropriately cut piece of covering material85around the circumference of the retainer pair50, and inserting the top edge and bottom edge thereof into the channels65,70in the top and bottom retainers55,60, respectively. The covering material85may be sized to provide an overlapping vertical seam (not shown) upon installation. In this embodiment, friction between the covering material85and the inside surface of each channel65,70acts to hold the covering material firmly in place after insertion. Consequently, a lampshade may be constructed that is aesthetically pleasing, that requires no permanent fasteners, and wherein the covering material85thereof may be removed or replaced without damage to either the covering material or to the retainers55,60.

Both the woven basket embodiment and the lampshade embodiment of the present invention described in detail above employ a retainer pair having a circular profile. However, it should be realized that the retainer pair may be of a multitude of other shapes, such as, for example, square, rectangular, triangular, or a plurality of other polygonal shapes. The shape of the retainer pair will depend on the desired shape of the article being constructed therewith. Additionally, the spatial relationship may be different than that illustrated in the above exemplary embodiments. For example, the spacing between the retainer pair may vary, and/or the retainer pair may be oriented in a non-parallel manner.

Other embodiments of the present invention are also contemplated to be within the scope of the present invention, although not specifically described herein. For example, more than two retainers may be used, wherein there is a top retainer and a bottom retainer, with an intermediate retainer disposed therebetween. In such an embodiment, the intermediate retainer may be provided with two channels, each to receive one end from one of two different groups or pieces of covering material. Alternatively, the intermediate retainer may employ a single groove, sized to receive one end from both groups or pieces of covering material. As discussed above, it is also contemplated that the interior of the channels located in the retainers of the present invention may be provided with a rough texture, or be otherwise treated to maximize their holding power on the material that will be introduced thereto.

As can be deduced from an examination of the above exemplary embodiments of the present invention, the channel containing retainers may be employed to provide for fastenerless construction of a variety of decorative articles. Thus, while the previous exemplary embodiments detail the construction of a woven basket and a lampshade, it is to be understood that the scope of the present invention is not limited thereto. As such, while certain embodiments of the present invention are described in detail above, the scope of the invention is not to be considered limited by such disclosure, and modifications are possible without departing from the spirit of the invention as evidenced by the following claims: