Method of forming a linear panel from multi-layer panel material assemblies

Patent metadata

Field	Value
Publication number	US-11433592-B2
Application number	US-201916564151-A
Country	US
Kind code	B2
Filing date	Sep 9, 2019
Priority date	Sep 12, 2018
Publication date	Sep 6, 2022
Grant date	Sep 6, 2022

Abstract

In one aspect of the present subject matter, a method of forming a linear panel includes drawing a multi-layer panel material assembly having differing inner and outer material layers along a processing path. The method also includes heating the panel material assembly. In addition, the method includes forming the heated panel material assembly into a desired shape as the assembly is drawn along the processing path. Additionally, in another aspect of the present subject matter, a linear panel includes a body formed from a multi-layer panel material assembly having differing inner and outer material layers.

First claim

The invention claimed is:

1. A method of forming a linear panel, the method comprising:
drawing a multi-layer panel material assembly along a processing path, the panel material assembly comprising an inner material layer and an outer material layer, the inner material layer differing from the outer material layer;
heating the panel material assembly to a processing temperature as the panel material assembly is drawn along the processing path, the processing temperature being greater than a forming temperature of the inner material layer and less than a forming temperature of the outer material layer;
forming the heated panel material assembly into a panel body having a desired panel shape, the panel body including a panel wall and first and second sidewalls extending outwardly from the panel wall, first sides of each of the panel wall, first sidewall, and second sidewall defining an inner surface of the panel body and opposed second sides of each of the panel wall, first sidewall and second sidewall defining an outer surface of the panel body; and
cooling the panel material assembly after it has been formed into the desired panel shape and as the panel material assembly is drawn along the processing path;
wherein:
the inner material layer extends along the first sides of each of the panel wall, first sidewall, and second sidewall and forms the inner surface of the panel body; and
the outer material layer extends along the opposed second sides of each of the panel wall, first sidewall, and second sidewall and forms the outer surface of the panel body.

2. The method of claim 1 , further comprising forming the panel material assembly as part of an in-line process while a downstream portion of the panel material assembly is being drawn along the processing path.

3. The method of claim 2 , wherein forming the panel material assembly comprises coupling an inner strip of material to an outer strip of material to form the inner and outer material layers, respectively, of the panel material assembly.

4. The method of claim 3 , further comprising heating the inner strip of material to facilitate adherence of the inner strip of material to the outer strip of material.

5. The method of claim 4 , wherein the inner strip of material is heated to a temperature that is equal to or greater than a melting temperature of a material forming the inner strip of material.

6. The method of claim 3 , wherein forming the panel material assembly further comprises pressing the inner and outer strips of material together to facilitate adherence of the inner strip of material to the outer strip of material.

7. The method of claim 3 , wherein:
the panel material assembly further comprises an intermediate layer disposed between the inner material layer and the outer material layer; and
forming the panel material assembly further comprises heating the intermediate layer to facilitate adherence of the inner strip of material to the outer strip of material.

8. The method of claim 1 , wherein the outer material layer is formed from a fibrous felt material.

9. The method of claim 1 , wherein the inner material layer is formed from a thermoformable fibrous material or a thermoformable film material.

10. The method of claim 1 , wherein a thickness ratio of a thickness of the inner material layer to a thickness of the outer material layer ranges from greater than 1:1 to less than 4:1.

11. A method of forming a linear panel, the method comprising:
coupling separate strips of material together to form a layered material assembly including an inner material layer and an outer material layer as a downstream portion of the layered material assembly is being drawn along a processing path, the inner material layer differing from the outer material layer;
heating the layered material assembly to a processing temperature as the layered material assembly is drawn along the processing path, the processing temperature being greater than a forming temperature of the inner material layer and less than a forming temperature of the outer material layer; and
forming the heated layered material assembly into a panel body having a desired panel shape, the panel body including a panel wall and first and second sidewalls extending outwardly from the panel wall, first sides of each of the panel wall, first sidewall, and second sidewall defining an inner surface of the panel body and opposed second sides of each of the panel wall, first sidewall and second sidewall defining an outer surface of the panel body;
wherein:
the inner material layer extends along the first sides of each of the panel wall, first sidewall, and second sidewall and forms the inner surface of the panel body; and
the outer material layer extends along the opposed second sides of each of the panel wall, first sidewall, and second sidewall and forms the outer surface of the panel body.

12. The method of claim 11 , wherein coupling separate strips of material together to form the layered material comprises coupling an inner strip of material to an outer strip of material to form the inner and outer material layers, respectively, of the panel material assembly.

13. The method of claim 12 , further comprising heating the inner strip of material to facilitate adherence of the inner strip of material to the outer strip of material.

14. The method of claim 13 , wherein the inner strip of material is heated to a temperature equal to or greater than a melting temperature of a material forming the inner strip of material.

15. The method of claim 12 , wherein forming the panel material assembly further comprises pressing the inner and outer strips of material together to facilitate adherence of the inner strip of material to the outer strip of material.

16. The method of claim 11 , wherein the outer material layer is formed from a fibrous felt material.

17. The method of claim 11 , wherein the inner material layer is formed from a thermoformable fibrous material or a thermoformable film material.

Assignees

• Hunter Douglas Ind Bv

Inventors

• Van Rees Pieter

Classifications

• B32B27/12

  next to a fibrous or filamentary layer · CPC title

• B32B5/265

  characterised by one fibrous or filamentary layer being a non-woven fabric layer · CPC title

• B32B5/262

  characterised by one fibrous or filamentary layer being a woven fabric layer · CPC title

• B32B3/16

  secured to a flexible backing · CPC title

• B32B3/02

  characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)} · CPC title