Articles of stabilized fibrous construction material

Abstract

Felted fibrous construction materials and articles formed therefrom. The felted fibrous construction 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. Panels of the felted fibrous construction material also provide substantial impact resistance when used in storm shutter applications.

1 . A three dimensional cabinet structure comprising a plurality of panels adapted to be adjoined to one another such that said panels define a three dimensional structural body of said cabinet structure, wherein at least a portion of said panels comprise a fibrous felted material, wherein said fibrous felted material comprises a plurality of entangled polymeric fibers and wherein at least a portion of said entangled polymeric fibers are melt fused together such that a plurality of fiber to fiber fusion bonding points are distributed within said fibrous felted material.  
   
   
       2 . The invention as recited in  claim 1 , wherein said fibrous felted material consists essentially of a blend of entangled polyester fibers.  
   
   
       3 . The invention as recited in  claim 2 , wherein the blend of entangled polyester fibers includes a first portion of polyester fibers characterized by a first melting point and at least a second portion of polyester fibers comprising a low melting point polyester constituent characterized by a second melting point which is lower than the first melting point.  
   
   
       4 . The invention as recited in  claim 3 , wherein at least a percentage of said second portion of polyester fibers comprise a sheath of said low melting point polyester constituent disposed in surrounding relation to a core of polyester having a melting point greater than the low melting point polyester constituent.  
   
   
       5 . The invention as recited in  claim 3 , wherein the low melting point polyester constituent is characterized by a melting point of less than about 340 degrees Fahrenheit.  
   
   
       6 . The invention as recited in  claim 1 , wherein the cabinet structure comprises at least one panel comprising of said fibrous felted material forming a top surface of the cabinet structure and a plurality of panels of said fibrous felted material forming sides of the cabinet.  
   
   
       7 . The invention as recited in  claim 6 , wherein the cabinet structure includes at least one door comprising at least one panel comprising said fibrous felted material.  
   
   
       8 . The invention as recited in  claim 6 , wherein the cabinet structure includes at least one drawer comprising at least one panel comprising said fibrous felted material.  
   
   
       9 . The invention as recited in  claim 1 , wherein at least a portion of the panels comprising said fibrous felted material further comprise a non-fiber outer surface layer of cured resin.  
   
   
       10 . The invention as recited in  claim 1 , wherein at least a portion of the panels comprising said fibrous felted material further comprise at least one layer of stabilizing material.  
   
   
       11 . The invention as recited in  claim 10 , wherein at least a portion of said fibrous felted material is disposed between a pair of opposing layers of stabilizing material at least partially covered with a cured resin.  
   
   
       12 . An exterior storm shutter for a dwelling comprising at least one panel comprising fibrous felted material wherein said fibrous felted material comprises a plurality of entangled polymeric fibers and wherein at least a portion of said entangled polymeric fibers are melt fused together such that a plurality of fiber to fiber fusion bonding points are distributed within said fibrous felted material.  
   
   
       13 . The invention as recited in  claim 12 , wherein said fibrous felted material consists essentially of a blend of entangled polyester fibers.  
   
   
       14 . The invention as recited in  claim 13 , wherein the blend of entangled polyester fibers includes a first portion of polyester fibers characterized by a first melting point and at least a second portion of polyester fibers comprising a low melting point polyester constituent characterized by a second melting point which is lower than the first melting point.  
   
   
       15 . The invention as recited in  claim 14 , wherein at least a percentage of said second portion of polyester fibers comprise a sheath of said low melting point polyester constituent disposed in surrounding relation to a core of polyester having a melting point greater than the low melting point polyester constituent.  
   
   
       16 . The invention as recited in  claim 15 , wherein the low melting point polyester constituent is characterized by a melting point of less than about 340 degrees Fahrenheit.  
   
   
       17 . The invention as recited in  claim 12  wherein at least a portion of the panels comprising said fibrous felted material further comprise a non-fiber outer surface layer of cured resin.  
   
   
       18 . The invention as recited in  claim 12  wherein at least a portion of the panels comprising said fibrous felted material further comprise at least one layer of stabilizing material.  
   
   
       19 . The invention as recited in  claim 18 , wherein at least a portion of said fibrous felted material is disposed between a pair of opposing layers of stabilizing material at least partially covered with cured resin.