Abstract:
Window treatment structures formed from a felted fibrous material such as needle punched felt as the material of construction. The felted fibrous material is adapted to accept grooved score lines to define living hinges for bending of the material to form top and/or side portions of the finished structure using a singe panel of such material.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application claims the benefit of and priority from my U.S. Provisional Application 60/472,331 filed May 21, 2003, the contents of which are incorporated herein in their entirety. 

   TECHNICAL FIELD 
   The present invention relates generally to window treatment structures such as cornices, lambrequins and the like. More particularly, the present invention relates to such structures of single or multi-piece construction formed from felted fibrous materials having a controlled degree of flexibility while maintaining substantial stability and strength. Such structures may be used in residential, commercial or hotel environments. 
   BACKGROUND OF THE INVENTION 
   Window treatment structures such as cornices and lambrequins are well known. Typically in the past such structures have been formed from board stock materials such as wood or the like with segments of such material being cut to predefined shapes and thereafter being nailed, stapled or glued together to yield a desired construction. While such materials have been useful, they have faced limitations due to their relatively high weight as well as their inability to be easily bent to different geometries. 
   SUMMARY OF THE INVENTION 
   This invention provides advantages and alternatives over the prior art by providing window treatment structures formed from a felted fibrous material such as needle punched felt as the material of construction in replacement for wood. The felted fibrous material is adapted to provide adequate strength to permit construction of three dimensional structures by use of standard joining techniques such as screws, nails, glue and the like if desired. The felted fibrous material is also adapted to accept grooved score lines to define living hinges for bending of the material to form top and/or side portions of the finished structure. Thus, the felted fibrous material affords the opportunity to bend and shape the material thereby allowing additional freedom in construction and use. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will now be described by way of example only, with reference to the accompanying drawings which constitute a portion of the specification herein and in which: 
       FIG. 1  is a view of the face of an exemplary box-like window cornice structure; 
       FIG. 2  is a view taken along line  2 — 2  in  FIG. 1 ; 
       FIG. 3  illustrates the components of a kit of flat stock material components for formation of a window cornice structure; 
       FIG. 4  illustrates a single piece of flat stock material for formation of a window cornice structure including an arrangement of score lines disposed across portions defining edges of the cornice structure and a scored hinge line between portions forming the face board and dust board segments of the final cornice; 
       FIG. 5  is a view similar to  FIG. 3 , wherein the piece of stock material defining the face board of the cornice includes a multiplicity of pre-marked patterns for patterned cutting by a user; 
       FIG. 6  is a view similar to  FIG. 4 , wherein the piece of stock material defining the face board of the cornice includes a multiplicity of pre-marked patterns for patterned cutting by a user; 
       FIGS. 7 and 8  illustrate an exemplary practice for formation of felted construction material adapted for use in the interior design articles of the present invention; 
       FIG. 9  is a schematic illustration of the felted construction material formed by the practice illustrated in  FIGS. 10 and 11 ; 
       FIG. 10  is a schematic illustration of the multi-layer felted construction material formed by the exemplary practice illustrated in  FIG. 11 ; 
       FIG. 11  illustrates an exemplary practice for formation of a multi-layer felted construction material adapted for use in the interior design articles of the present invention; and 
       FIG. 12  illustrates schematically the heat fusion of felted construction material. 
   

   While the present invention has been illustrated and generally described above and will hereinafter be described in conjunction with certain potentially preferred embodiments, procedures, and practices, it is to be understood that in no case is the invention to be limited to such illustrated and described embodiments, procedures, and practices. On the contrary, it is intended that the present invention shall extend to all alternatives, modifications, and equivalents as may embrace the principles of the present invention within the true scope and spirit thereof. 
   DESCRIPTION 
   Reference will now be made to the drawings, wherein, to the extent possible, like reference numerals are utilized to designate like components throughout the various views. In  FIGS. 1 and 2  there is illustrated an exemplary window cornice  10  for disposition in overhanging relation to a window designated generally as  9 . As illustrated, the cornice is of a substantially open bottom box-like construction so as to hang below a ceiling  11  and away from a wall  12 . As will be appreciated, while the upper surface of the cornice  10  is illustrated as being in abutting relation to the ceiling  11 , it may likewise be disposed at positions substantially below the ceiling  111  if desired. 
   In the exemplary construction illustrated in  FIGS. 1 and 2 , the cornice  10  includes a face board or face panel  13  of felted material as will be described further hereinafter affixed to the front edge of a dust board or top board  14  of felted material by fastening elements  15  such as screws, nails or the like. As will be described further hereinafter, the face panel  13  and the dust board  14  may also be formed as one piece with a score line defining a living hinge at the intersection. If desired, lateral side boards or returns  16  of felted material extend away from the face panel towards the wall  12 . The side boards  16  may be affixed to the sides of the top board  14  by fastening elements  15 . The side boards may also be formed as bendable wings extending away from the lateral sides of the face panel in the finished construction. In such a configuration bending takes place along one or more vertical score lines. The side boards may extend partially or completely along the length of the face panel. Upon construction, the cornice thus defines a box-like structure. In the event that no sideboards are utilized, a so called “valence” construction is obtained. A decorative fabric cover may be affixed across the surface of the cornice or valence by gluing, stapling or the like. 
   In  FIG. 3 , a first kit of stock material components for formation of a window cornice structure is illustrated wherein elements corresponding to those previously described are designated by like reference numerals in a  100  series. As shown, in this arrangement the face panel  113 , the dust board  114  and the returns or side boards  116  are each formed as a separate panels of desired geometry from felted construction material. The individual panels can then be fastened together with nails, screws, glue or the like to form a desired cornice or valence construction. 
   In  FIG. 4 , another assembly is illustrated for formation of a window cornice wherein elements corresponding to those previously described are designated by like reference numerals in a  200  series. As shown, in this assembly a single piece foldable material blank  209  of felted construction material is utilized. An arrangement of vertical score lines  231  is located along the lateral edges of the material blank  209  so as to permit formation of the side boards  216  and to define the face panel  213 . A hinge-forming substantially horizontal score line  233  is disposed at the intersection between the segment of the material blank defining the face panel  213  and the segment of the material blank defining the dust board  214 . According to one potentially preferred practice, the portions of the vertical score lines disposed along the edges of the dust board  214  define a pattern for cutting away the appropriate amount of excess material in the upper corner portions to permit the side boards  216  to be folded inwardly along the lower portions of the appropriate vertical score lines when the dust board is folded down. Thus, a user will typically cut along the portion of the appropriate vertical score line at the upper corners to permit removal of excess outboard material above the horizontal score line  233  while using the portion below the horizontal score line to form the side boards. 
   As will be appreciated, in the assemblies illustrated in  FIGS. 3 and 4 , the segments of material forming the face panels  113 ,  213  are pre-cut along the lower edge so as to provide a desired shape. While the exemplary constructions are illustrated as having a substantially straight lower edge, it is also contemplated that virtually any other geometry may be precut into the lower edge. By way of example only, and not limitation, such geometries may include scallops, (as in  FIG. 1 ), steps and the like. It is also contemplated that a user may shape the lower edge of the face panel to a desired geometry. 
     FIGS. 5 and 6  illustrate assemblies adapted to be shaped by a user. In  FIG. 5  there is shown an arrangement of separate panels substantially identical to those of  FIG. 3 , wherein elements corresponding to those previously described are designated by like reference numerals in a  300  series. In  FIG. 6  there is shown single piece foldable material blank  409  substantially identical to that of  FIG. 4 , wherein elements corresponding to those previously described are designated by like reference numerals in a  400  series. In the assemblies of  FIGS. 5 and 6 , the face panel portion  313 ,  413  includes a number of premarked pattern lines  315 ,  317 ,  415 ,  417  for a user to cut along to form a desired lower edge geometry. That is, a user may select a desired geometry corresponding to one of the pattern lines and then cut along that pattern line to achieve such geometry. According to one contemplated practice, the pattern lines may be different colors to aid in following a continuous pattern. While only two pattern lines are illustrated, it is contemplated that any number of pattern lines may be provided. Of course, a user may opt not to contour along any of the pattern lines in which case a straight lower edge is achieved. The incorporation of such patterns thus permits a substantial reduction in manufacturing and marketing complexity since a single style may be adapted to provide a number of different constructions. 
   As will be appreciated, the felted material forming the structures as previously described must have sufficient dimensional stability to permit the various components to be joined to one another and thereafter used in a structural capacity. Surprisingly, it has been found that fibrous felted materials such as needlepunched felts may be constructed to provide these requisite strength characteristics. In addition, these felted materials may be constructed to retain a controlled degree of flexibility which is useful in the bending of components along score lines without fracture. 
   One exemplary practice for the production of a fibrous felted material suitable for formation into dimensionally stable decorative interior design components as previously described is illustrated schematically in  FIGS. 7 and 8 . According to the illustrated practice, a blend of discrete length staple fibers  40  is passed through a carding unit  42  to yield a carded web material  48  which is taken up on an “A” frame  50  or other collection device. The carded web material  48  is preferably a relatively light weight material having sufficient internal coherency to undergo further processing. 
   The blend of fibers  40  preferably includes some percentage of a relatively low melting point constituent so as to permit the heat activated point bonding of fibers to one another at later processing stages. According to one contemplated practice, the blend of fibers  40  is made up of substantially entirely of polyester with about 30 percent to about 90 percent (preferably about 70 percent) of the fibers  40  being a standard PET polyester staple fiber. By way of example only, one standard PET polyester staple fiber which is believed to be suitable is characterized by an average length of about 3 inches and a denier per filament rating of about 6 dpf. However, other staple fibers may likewise be utilized if desired. According to this practice about 10 percent to about 70 percent (preferably about 30 percent) of the fibers  40  are bi-component polyester fibers incorporating a sheath of low melting point CO-PET polyester around a standard PET polyester core. The core/sheath bicomponent polyester fiber preferably has a denier per filament rating of about 2.5 to about 5.5 dpf. One such core/sheath fiber construction is believed to be available from Hoechst Celanese Corporation having a place of business in Salisbury, N.C., USA. As will be appreciated, upon the application of heat, the sheath material undergoes preferential flow and bonding to surrounding fiber constituents. Of course, other forms of low melting point material such as discrete fibers of low melting point material may also be utilized. Likewise, at least some percentage of the fibers  40  may be materials other than polyester. By way of example, it is contemplated that such materials may include nylon, polypropylene and the like. 
   As illustrated in  FIG. 8 , following formation of the rolls of carded web material  48 , according to a potentially preferred practice of the invention a plurality of such rolls of carded web material  48  may thereafter be conveyed through a combining and densification station  60 . At the combining and densification station  60 , the carded web material  48  is conveyed in layered orientation through a series of needle looms  62 ,  63 ,  64  to combine the layers of carded web material into a cohesive structure. According to one practice, the first needle loom  62  utilizes about fifty-two needles per inch in the machine direction in a thirty-two gauge regular barb spacing arrangement. The second needle loom  63  preferably has a greater needle density than the first needle loom  62 . By way of example only, in one contemplated practice the second needle loom  62  utilizes one hundred twenty five needles per inch in the machine direction in a thirty-six gauge regular barb spacing arrangement. The third needle loom  64  preferably utilizes about fifty-two needles per inch in the machine direction in a thirty-six gauge regular barb spacing arrangement. 
   In one contemplated practice, needles in each of the needle looms  62 ,  63 ,  64  are generally triangular in shape with nine barbs per needle although other needle arrangements and designs may likewise be utilized if desired. The resultant product leaving the combining and densification station  60  is an enhanced density batting material  66 . According to one potentially preferred practice, the enhanced density batting has a thickness in the range of about 0.45 to about 0.5 inches with a mass per unit area in the range of about 48.3 to about 51.2 ounces per square yard. Of course, it is to be understood that this enhanced density batting material  66  is exemplary only and that greater or lower thicknesses and/or different densities may likewise be utilized. In one contemplated practice, this enhanced density batting material is conveyed as a single layer to a heating press for compression and heat activation of the low melting point fiber constituents in a manner as will be described further hereinafter. 
   In the event that substantial thickness is desired in the article to be formed, it is contemplated that following formation of the enhanced density batting material  66 , a plurality of rolls of such enhanced density batting material  66  may be conveyed to a laminate formation station  70  as illustrated schematically in  FIG. 11 . At the laminate formation station, the enhanced density batting material  66  is preferably conveyed in overlying and underlying relation to an intermediate layer of adhesive material  72  thereby forming a multi-layer sandwich structure  76  in which the adhesive material  72  is disposed between layers of enhanced density batting material  66 . As will be appreciated, while the schematic processing line illustrated in  FIG. 11  incorporates only two layers of enhanced density batting material  66 , a larger number of layers of enhanced batting material  66  may likewise be used to form a sandwich structure with three or more layers as illustrated in  FIG. 10 . 
   According to the practice illustrated in  FIG. 11 , the juxtaposed layers of adhesive material  72  and enhanced batting material  66  are conveyed through an entangling needle loom  74  which serves to mechanically intermingle a portion of the fibers  40  from one or more layers of enhanced density batting material  66  with the adhesive material  72  and with the adjacent layer of batting or other material as may be incorporated within the sandwich structure  76  thereby mechanically binding fibers from the adjacent layers of the sandwich structure  76  together and increasing overall strength. Such a mechanical joining operation preferably results in a portion of the fibers  40  extending substantially across the boundary between two or more layers of the layered sandwich structure  76 . 
   While the adhesive material  72  may be any wet or dry adhesive as may be suitable to bind the adjacent layers of felted material together, it is contemplated that the adhesive material  72  will preferably be a dry adhesive in web form so as to promote ease of use of the adhesive in roll form and to further permit the relatively easy mechanical entangling to be carried out across the adhesive by the needle loom  74 . The adhesive material is preferably of a nature such that it can be activated upon demand through application of a predetermined driving force such as heat, hot gas, chemical interaction, ultrasonic energy, radio frequency radiation waves and the like. Further, it is contemplated that the adhesive should provide necessary resistance to heat, humidity and chemical interaction so as to avoid any premature delamination. One such heat activated adhesive fabric is believed to be available under the trade designation SPUNFAB® adhesive fabric from Dry Adhesive Technologies Inc. having a place of business at Cuyahoga Falls, Ohio, USA. According to a potentially preferred embodiment, the adhesive is SPUNFAB® type PA 1001 polyamide spunbonded adhesive fabric. However, other such adhesive fabrics of polyester, polyolefin, and ternary systems are also contemplated. 
   Regardless of whether a single layer structure or multi-layer structure is desired, it is contemplated that either a single layer of the enhanced density batting material  66  or the multi-layer sandwich structure  76  as previously described will preferably be conveyed through a hot press  80  ( FIG. 12 ) to activate the low melting point fiber constituent as well as any heat activated adhesive layers. According to one contemplated practice, the enhanced density batting material  66  or the multi-layer sandwich structure  76  is heated to a temperature of approximately 340 degrees Fahrenheit for a period sufficient to activate the low melting point fiber constituent. By way of example only, for a single layer structure having a starting thickness of about 0.5 inches, the period of heating will normally be about 6 minutes. The application of heat and pressure causes the low melting point material forming the sheath of the bicomponent fiber constituent to flow and form fusion bonding points with adjacent fibers once cooling takes place. The resultant heat fused felted fiber material  82  in either single layer or multi-layer form is preferably characterized by a thickness in the range of about 0.04 inches to about 2 inches with a mass per unit area in the range of about 6 ounces per square yard to about 400 ounces per square yard and a density of about 0.065 ounces per cubic inch to about 0.210 ounces per cubic inch. By way of example only, one heat fused compressed construction which is believed to be particularly versatile is a single layer construction having a thickness in the range of about 0.394 inches to about 0.480 inches (most preferably about 0.437 inches) with a mass per unit area of about 90 ounces per square yard to about 110 ounces per square yard (most preferably about 100 ounces per square yard). Multiple layer constructions may have similar densities although the mass per unit area may be greater. Of course, other density levels may likewise be utilized if desired. 
   The felted fiber material  82  is sufficiently stiff to be cut into board stock for subsequent formation into various interior decorative articles and furniture as previously described. However, due to the felted nature of the material and the fact that stiffness is imparted by a distribution of fusion bonding points between fibers, the material nonetheless retains a degree of flexibility permitting relatively easy bending manipulation. In this regard it is contemplated that stiffness may be adjusted as desired by adjusting the percentage of low melting point material in the fiber blend. In particular, it is contemplated that increasing the percentage of bicomponent fiber will result in increased stiffness due to the occurrence of a greater concentration of fusion bonding points. Likewise, reducing the percentage of bicomponent fiber will result in reduced stiffness due to the lower concentration of fusion bonding points. As previously indicated, the fiber blend preferably contains in the range of about 10 percent to about 70 percent bicomponent fibers. Importantly, it has also been found that localized bending may be enhanced by the incorporation of score lines extending partially but not completely through the material at locations where bending is desired. Preferably such score lines are generally “V” shaped with the apex projecting into the felted material. However, other cross-sectional geometries may likewise be utilized if desired. 
   As indicated, it is contemplated that the felted fiber material  82  used in forming the decorative articles and furniture according to the present invention may be useful over a wide range of thicknesses ranging from about 0.04 inches to about 2 inches. In this regard it is to be noted that if the panel is to have a thickness substantially greater than about ½ inch, the use of a multi-layer construction with an intermediate adhesive layer may be desirable. 
   It is to be understood that while the present invention has been illustrated and described in relation to potentially preferred embodiments, constructions, and procedures, such embodiments, constructions, and procedures are illustrative only and that the present invention is in no event to be limited thereto. Rather, it is contemplated that modifications and variations embodying the principles of the present invention will no doubt occur to those of ordinary skill in the art. It is therefore contemplated and intended that the present invention shall extend to all such modifications and variations as may incorporate the broad aspects of the present invention within the true scope and spirit thereof.