FIELD

The present subject matter relates generally to the manufacture of linear panels, and, in particular, to methods for manufacturing linear panels formed from multi-layer panel material assemblies having differing inner and outer material layers.

BACKGROUND

Linear panels formed from metals, such as aluminum, are known in the art. Linear panels have a length which is substantially greater than their width, the length generally being at least twice the width of the panel and typically five or more times the width of the panel.

Linear panels formed from a metal have the advantage of being relatively light and flame-retardant. However, such panels do not generally exhibit favorable acoustic characteristics. It will be appreciated that, in many circumstances, it might be desirable to provide a ceiling or wall having good sound-absorbing properties. Such a need might be addressed by the provision of non-metallic or only partially metallic panels. However, improved techniques are needed for manufacturing such panels.

Accordingly, improved methods for manufacturing non-metallic or only partially metallic panels, such as panels formed at least partially from fibrous materials, that provide one or more enhanced or desired properties as compared to conventional metallic panels would be welcomed in the technology.

BRIEF DESCRIPTION

Aspects and advantages of the present subject matter will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the present subject matter.

In general, the present subject matter is directed to methods of manufacturing linear panels via an in-line process in which each panel is formed, at least in part, by an assembly of material layers. Specifically, in several embodiments, each panel is formed from a multi-layer panel material assembly including an inner material layer and an outer material layer, with the inner material layer differing from the outer material layer. In one embodiment, both the inner and outer material layers are formed from non-metallic materials (e.g., fibrous materials).

In one embodiment, the method includes drawing a multi-layer panel material assembly including differing inner and outer material layers along a processing path. In one embodiment, the method also includes heating the panel material assembly. Additionally, in one embodiment, the method includes forming the heated panel material assembly into a desired shape as the assembly is drawn along the processing path.

Moreover, in one embodiment, the present subject matter is directed to a linear panel formed from a multi-layer panel material assembly including differing inner and outer material layers. For example, in one embodiment, the inner material layer is formed from a material having a forming temperature that is less than a forming temperature of a material used to form the outer material layer.

These and other features, aspects and advantages of the present subject matter will become better understood with reference to the following Detailed Description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present subject matter and, together with the description, serve to explain the principles of the present subject matter.

This Brief Description is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Brief Description is not intended to identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.

