Patent Publication Number: US-2021180321-A1

Title: System and method of manufacturing a panel

Description:
CROSS-REFERENCES TO RELATED APPLICTIONS 
     This application claims priority to U.S. Provisional Application No. 62/947,241, filed on Dec. 12, 2019, the entire contents of which are incorporated by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present disclosure relates to systems and methods of manufacturing a panel, and more particularly manufacturing a panel including polyester scrap material. 
     BACKGROUND 
     Textile fabrics are used for numerous products across several different industries. Many textiles used to make products are made with or include polyester materials, which have a variety of different benefits. However, polyester can take a long time to decompose. Additionally, the process of making many of these products may result in scrap material that is often thrown away. 
     SUMMARY 
     In one embodiment, the disclosure provides a method of manufacturing a panel. The method includes obtaining a textile scrap, the textile scrap consisting essentially of polyester, mechanically separating the textile scrap into a plurality of textile yarns, where each of the plurality of textile yarns has a first melting point that is greater than a first temperature, and obtaining a plurality of staple fibers, where the plurality of staple fibers includes bicomponent fibers each having a melting point that is less than the first temperature. The method further includes blending the plurality of textile yarns with the plurality of staple fibers to form a mixed blend of textile yarns and staple fibers, and heating and compressing the mixed blend to form the panel. 
     In other embodiments, the disclosure provides a screen including a panel consisting essentially of a plurality of polyester textile yarns from a textile scrap, where the plurality of polyester textile yarns being non-homogeneous and having a first melting point that is greater than a first temperature, and a plurality of staple fibers, the plurality of staple fibers being homogeneous and having a melting point that is less than the first temperature, wherein the plurality of polyester textile yarns and the plurality of staple fibers are blended and bonded together. 
     In yet other embodiments, the disclosure provides a screen assembly including a first panel including a first side, a second side, and an edge extending around a perimeter of the first and second sides, and a second panel coupled to the first panel, where the second panel includes a first side, a second side, and an edge extending around a perimeter of the first and second sides, and wherein the first side of the second panel faces the first side of the first panel. A first fabric layer extends around the second side of the first panel, and a second fabric layer extends around the second side of the second panel. A first mount is coupled to the first side of the first panel, where the first mount includes a recess for receiving excess fabric from the first fabric layer. A second mount is coupled to the first side of the second panel, where the second mount includes a recess for receiving excess fabric from the second fabric layer, and wherein the second mount engages with the first mount. 
     Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is flow chart of a method of manufacturing a panel according to one embodiment. 
         FIG. 2  illustrates a cross-section of a monocomponent textile yarn according to one embodiment. 
         FIG. 3  illustrates a cross-section of a bicomponent staple fiber according to one embodiment. 
         FIG. 4A  is a perspective view of a panel according to one embodiment. 
         FIG. 4B  is a side view of the panel of  FIG. 4A . 
         FIG. 5  is a flow chart of a method of manufacturing a panel according to another embodiment. 
         FIG. 6A  is a first perspective view of panel with a layer of fabric wrapped around an outside side of the panel. 
         FIG. 6A  is a second perspective view of the panel of  6 A with a layer of fabric wrapped around an outside side of the panel. 
         FIG. 7A  is a schematic cross-sectional view of a panel including a facing, where the cross-section is taken along a plane generally parallel to the side of the panel. 
         FIG. 7B  is a schematic cross-sectional view of the panel of  FIG. 7A  including a facing, where the cross-section is taken along a plane generally perpendicular to the side of the panel. 
         FIG. 8A  is a schematic cross-sectional view of a screen according to one embodiment. 
         FIG. 8B  is a schematic cross-sectional view of a screen according to another embodiment. 
         FIG. 8C  is a schematic cross-sectional view of a screen according to another embodiment. 
         FIG. 8D  is a schematic cross-sectional view of a screen according to another embodiment. 
         FIG. 9  is a perspective view of a screen constructed according to one embodiment. 
         FIG. 10  is a plan view of a naked screen included in the screen construction of  FIG. 9 . 
         FIG. 11  is a perspective view of a portion of the naked screen of  FIG. 10  including cutouts according to one embodiment. 
         FIG. 12  is a plan view of the screen of  FIG. 9  including hardware and corner mounts. 
         FIG. 13  is a detailed view of the hardware and corner mounts of  FIG. 12 . 
         FIG. 14A  is a first perspective view of a corner mount according to one embodiment. 
         FIG. 14B  is a second perspective view of the corner mount of  FIG. 14A . 
         FIG. 15  is a plan view of the screen of  FIG. 10 . 
         FIG. 16  is a detailed view of a portion of the screen shown in  FIG. 15 . 
         FIG. 17  is a detailed view of a screen construction including hanging hardware. 
         FIG. 18  is a cross-sectional view taken along the line  18 - 18  of  FIG. 17 . 
     
    
    
     DETAILED DESCRIPTION 
     Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 
       FIG. 1  illustrates a method of manufacturing a panel. Although the method includes specific steps, all of the steps need not be performed or performed in the order presented. In some embodiments, the method may include other steps or may not include all of the steps depicted. Additionally or alternatively, the steps may be performed in different orders. The panel may be used as a naked panel or in a screen, as described herein. 
     The method  100  includes the step of obtaining a textile scrap (step  105 ). The textile scrap may consist essentially of polyester. That is, the textile scrap may be mainly composed of polyester, but may include some impurities or stray fibers from other materials. In other embodiments, the textile scrap may consist essentially of other polymers or a combination of polymers. For example, the textile scrap may include polypropylene. The method  100  also includes the step of mechanically separating the textile scrap into a plurality of textile yarns (step  110 ), where each of the textile yarns has a first melting point that is greater than a first temperature. In some embodiment, the plurality of textile yarns are non-homogeneous. In other words, the textile yarns are not necessarily the same shape, size, color, texture, etc. In some embodiments, the textile yarns may be considered unprocessed textile yarns, in that the textile yarns are not re-melted, re-polymerized, rewoven, and the like. Rather, the textile yarns are only mechanically processed by cutting and opening (e.g., combing) the yarns. The method  100  further includes the step of obtaining a plurality of polymer staple fibers (step  115 ). The staple fibers may be bicomponent fibers each having a melting point that is less than the first temperature. The method  100  then includes the step of blending the textile yarns with the staple fibers to form a mixed blend of textile yarns and staple fibers (step  120 ). In some embodiments, the mixed blend may be formed (e.g., stacked) into a mat or sheet. Finally, the method includes the step of heating and compressing the mixed blend to form the panel (step  125 ). 
     In step  105  of the method  100 , the textile scrap may be obtained from scrap materials that are left over from manufacturing processes that utilize textiles. In some embodiments, the textile scrap may be obtained from excess materials used during the manufacture of furniture. For example, excess upholstery fabric from chairs, couches, carpets, room separators, privacy panels, or other furniture may be used. In other embodiments, the textile scrape may be obtained from other industries, such as apparel, footwear, carpeting, curtains, and the like. The textile scrap may be obtained as either scrap material that is excess during the manufacturing process, or alternatively, may be obtained from preexisting products made with textiles. For example, when a product, such as a piece of furniture, becomes old or is no longer needed, the textile from the product may be removed and used in the method disclosed in  FIG. 1 . The textile scrap may be obtained from multiple different sources, resulting in multiple textiles of different types, colors, and textures. 
     The textile scrap may be a woven textile, a knit textile, or a non-woven textile. The textile scrap may include yarns of varying denier and/or varying lengths. The yarns of the textile scrap may be textured yarns, such as twisted, yarns, crimped yarns, air textured yarns, or other textures. Additionally, the yarns of the textile scrap may be non-homogenous, having a combination of denier, length, texture and colors. 
     The textile scrap obtained for use in the method  100  is composed of polyester yarns. Alternatively, the yarns may be other types of polymer yarns, such as polypropylene yarns. However, as noted above, the textile scrap may include imperfections or contaminants that are incidental to the (mostly) polyester textile. As used herein, the term yarns may refer to one or both warp yarns and weft yarns. The yarns of the textile scrap have a melting point that is above the first temperature. For example in some embodiments, the melting point of the textile yarns may be above 250° C. The melting point of yarns in the textile scrap may not be the same for each yarn. For example, some of the yarns in the textile scrap may have greater or lower melting point temperature than other yarns in the textile scrap. The first temperature is representative of a temperature that is lower than the melting point of the textile yarns with the lowest melting point. 
     After the textile scrap is obtained (step  105 ), the method  100  includes the step of mechanically separating the textile scrap (step  510 ). The separating process includes any known method of deconstructing the textile into separate pieces. For example, mechanically separating may include chopping or cutting the textile scrap into pieces. In some embodiments, the textile scrap is chopped into pieces of the same size, while in other embodiments, the textile scrap is chopped into pieces of varying sizes. The chopped pieces may have different lengths or widths. In some embodiments, the textile scrap is chopped into pieces having a length less than or greater than a predetermined length or width. For example, the textile scrap may be chopped into pieces having a length less than 90 mm. Similarly, in some embodiments, the textile scrap is chopped into piece having the same shape as one another, while in other embodiments, the textile scrap is chopped into pieces having varying shapes. The pieces may be cut into geometric shapes, such as rectangles, triangles, or circles. Alternatively, the pieces may be cut into random or irregular shapes. 
     In other embodiments, mechanically separating may also or alternatively include pulling apart the textile scrap. Pulling apart, or combing, helps separate individual yarns of the textile scrap from each other. Pulling apart the textile scraps may also open each yarn. The separated yarns may remain loosely connected together as chunks of yarns. In further embodiments, mechanically separating may include other known processes. 
     The separated textile yarns remain unprocessed. In other words, the separated textile yarns are not treated or further manipulated beyond being mechanically deconstructed. For example, in some embodiments, the unprocessed textile yarns are not manipulated beyond being chopped and combed. For example, the unprocessed textile yarns do not receive any chemical or heat treatment for the purpose of altering the structure of the textile yarns. However, in some embodiments, a chemical flame retardant may be added to the unprocessed textile yarns for the purpose of making the panel flame resistant or reduce smoke. In this embodiment, the chemical flame retardant is not intended to alter the textile yarns, but is merely an additive to the overall composition of the panel. The unprocessed textile yarns may be non-homogenous such that they have different properties, such as different lengths, denier, texture, and melting point temperatures. 
     Additionally, in some embodiments, the textile yarns may include monocomponent fibers. In other embodiments, the textile yarns may be exclusively monocomponent fibers. Each monocomponent fiber is composed of a single strand of material. The monocomponent fibers are each composed of a uniform material (e.g., polyester).  FIG. 2  illustrates one example of a monocomponent fiber  20 . 
     Referring back to  FIG. 1 , the method  100  further includes the step of obtaining a plurality of polymer staple fibers (step  115 ). Suitable polymer bi-component fibers are commercially available under the trade designation “PET bi-component fiber.” Similar to the textile yarns, the polymer staple fibers may include imperfections or contaminants that are incidental to the (mostly) polymer staple fiber. In the illustrated embodiment, the staple fibers are bicomponent or multicomponent fibers having two or more fibers with different melting points.  FIG. 3  illustrate one embodiment of a biocomponent staple fiber  30 . In the embodiment shown in  FIG. 3 , the staple fiber  30  is a bicomponent fiber having an inner strand or core  35  on an inner diameter portion of the staple fiber  30  and an outer sheath  40  on an outer diameter portion of the staple fiber. The outer sheath  40  surrounds the inner core  35 . In some embodiments, the staple fiber  30  may have an outer diameter of 40 denier or smaller. In other embodiments, the staple fiber  30  may have an outer diameter between 1.5 denier and 40 denier. The inner core  35  has a first melting point, and the outer sheath  40  has a second melting point that may be different than (e.g., lower than) the first melting point. In some embodiments, the first melting point is at least 5° C. higher than the second melting point. In other embodiments, the first melting point is at least 25° C. higher than the second melting point. Accordingly, the outer sheath  40  of the staple fiber  30  will begin to melt at a lower temperature than the inner core  35  of the staple fiber  30 . 
     As will be described in greater detail below, in the illustrated embodiment, the outer sheath  40  of the staple fiber  30  has a lower melting point than the textile yarns that were separated from the textile scrap. In other words, the outer sheaths  40  of the staple fibers  30  have melting points that are lower than the first temperature. In some embodiments, the inner core  35  of the staple fiber  30  may have a similar melting point temperature as the textile yarns. In other embodiments, the inner core  35  of the staple fibers  30  may have a higher or lower melting point temperature than the melting point temperature of the textile yarns. 
     Referring back to  FIG. 1 , the method  100  further includes the step of blending the textile yarns with the staple fibers to form a mixed blend of unprocessed textile yarns and staple fibers (step  120 ). For example, the textile yarns and the staple fibers may be deposited on a forming surface with a conventional carding process. The textile yarns and the staple fibers may be wet-laid or air-laid. As the components are deposited, the textile yarns and the staple fibers are mixed or otherwise dispersed with each other. The deposited textile yarns and the staple fibers may be directed through a cross lapper to help integrate the textile yarns and the staple fibers. In some embodiments, the textile yarns and the staple fibers may be mixed prior to being deposited. 
     In some embodiments, the mixed blend may include a greater percentage of textile yarns than staple fibers. In other embodiments, the mixed blend may include a greater percentage of staple fibers than textile yarns. In further embodiments, the mixed blend may include equal percentages of textile yarns and staple fibers. The mixed blend may have various ratios of unprocessed textile yarns to staple fibers depending on the desired properties of the panel. For example, when the mixed blend has a higher ratio of staple fibers to unprocessed textiles yarns, the resultant panel may be relatively stiffer. In other words, increasing the amount of staple fibers increases the stiffness of the panel. In some embodiments, the ratio of staple fibers to unprocessed textile yarns is 1:1. In other embodiments, a panel may include at least 50% staple fibers by weight. In further embodiments, the panel may include at least 40% staple fibers by weight. In other embodiments, the panel may include at least 60% staple fibers by weight. 
     After blending the unprocessed textile yarns with the staple fibers (step  120 ), the method  500  includes the step of heating and compressing the mixed blend to form a panel (step  125 ). In the illustrated embodiment, the mixed blend is heated and compressed simultaneously by heated rollers. However, in other embodiment, the mixed blend may be compressed and heated separately or at least by using separate tools that provide the compression and the heat. In some embodiments, the mixed blend may be bonded by through-air bonding, hot-oven bonding, infrared-heater bonding, or RF bonding. The duration and temperature of the bonding process is sufficiently long and high to melt the outer sheaths of the staple fibers, but not the textile yarns or the inner cores of the staple fibers. 
     In the illustrated embodiment, the panel is compressed into a flat panel (e.g., a wall-like structure). For example, the flat panel may be used as a privacy panel, a room separator, a backboard for posting notes, etc. In other embodiments, the panel may be compressed into a formed panel that has a non-flat shape. For example, a formed panel may be used to make portions of furniture, such as the body of a chair or the arm of a chair. Formed panels can be created by heating and compressing the mixed blend into a particular shape or form. 
     The mixed blend is heated at a temperature that is great enough to cause the outer sheaths of the staple fibers to melt, but low enough not to melt the textile yarns. More specifically, the mixed blend is heated at a temperature that is greater than the melting point temperature of the outer sheath of the staple fiber, but lower than the melting point temperature of the textile yarns. Heating the mixed blend at the temperature will result in the outer fiber of the staple fibers melting and binding together the other staple fibers and textile yarns of the mixed blend together to form a panel. In some embodiments, the mixed blend is heated at a temperature between 100° C. and 250° C. 
     After heating, the panel may be subject to one or more cooling processes and/or one or more subsequent heating processes. For example, relatively low temperature air may be passed over and/or through the panel to reduce the temperature of the panel. The panel may then be reheated (and re-cooled) as needed. In addition, the panel may be passed through one or more calendars to adjust the thickness of the panel to a desired thickness. Finally, in some embodiments, the panel may be cut to a desired size and shape. For example, the panel may be cut with an abrasive wire to achieve a clean edge. In other embodiments, the panel may be cut using other suitable cutting techniques, such as water jet, laser, oscillating knife, and the like. In addition to cutting the panel into a desired shape, the panel may have cut out portions, which may be adapted for different purposes. For example, a cut-out may be created to receive hardware designed to support a panel in an upright position, to increase stiffness, or to couple multiple panels together. The panel may also include recesses formed or cut into the panel to receive excess fabric material (i.e., layer of fabric). The panel may also be bent into a desired curvature rather than remaining a flat panel. 
       FIGS. 4A &amp; 4B  illustrate a panel  45  manufactured using the method  100 .  FIG. 4A  illustrates the panel  45  from a perspective view, while  FIG. 4B  illustrates the panel  45  from a side plan view. The illustrated panel  45  is generally rectangular. In particular, the illustrated panel  45  includes first and second opposed sides (or faces)  60   a,    60   b  and an edge  65  extending around the perimeter of the sides  60 . Additionally, the panel  45  includes a plurality of corners  70 . The corners  70  may be square corners (i.e., roughly  90  degree corners) or radius corners (i.e., rounded corners). However, in other embodiments, the panel  45  may have other shapes. 
     The panel  45  consists essentially of a plurality of textile yarns  405  from textile scraps and a plurality of staples fibers  55 . The textile yarns  405  and the staple fibers  55  are blended and bonded together to form the panel  45  as a monolithic structure. The panel  45  may be generally self-supporting, in that the panel  45  can stand on one of its edges without bending over. In some embodiments, the panel  45  may have a length or height of up to, for example, 72 inches. In some embodiments, the length or height may be between about 6 inches and about 72 inches. The panel  45  may also have a thickness between 0.05 inches and 1.5 inches. In some embodiments, the thickness may be less than 1.5 inches. In other embodiments, the thickness may be greater than 1.5 inches. In addition, the panel  45  may have a density between 500 grams per square meter (gsm) and 2500 gsm. In some embodiments, the panel  45  may be bent or curved into a desired shape to fit on furniture or other items. As such, the panel  45  may have a bend radius between 1.5 mm and 300 mm, depending on the thickness of the panel  45 . 
     In some embodiments, the panel  45  has a variety of different colors and textures. For example, in situations where multiple textiles are used having different colors and textures, the chunks of textile yarns will mesh together to form a panel with different colors and textures. For example, the panel  45  may have a spotted or a marbled look from the various textile yarns and staple fibers. 
     Since the panel  45  is composed (mostly) of polymer (e.g., polymer from textile scrap and polymer from staple fibers), the panel  45  itself may be recycled. For example, in some embodiments, the panel  45  may be mechanically separated and used as the textile scrap in the method  100  ( FIG. 1 ). In embodiments where two panels  45  are coupled together, the two panels  45  may be glued together with a polymer-based adhesive such that the combined panels  45  are still composed mostly of polymer. 
       FIG. 5  illustrates another method  500  of manufacturing a panel (identified generally as  150 ), or a screen. As used herein, the term “a naked panel” refers to a panel alone (i.e., without addition elements). The term “screen” may refer to a panel including additional elements, such as facings, fabric coverings, hardware, and the like, which may be used to finish the panel so that it may be used as a screen. The term “a panel” may refer to a naked panel or a panel including additional elements, such as facings, fabric coverings, hardware, etc. The method  500  is similar to the method  100  described above, and like steps may be performed in the same way. Reference is made to the description of the steps of method  100  for details of the steps of method  500  not included below. The method  500  does not need to include all of the illustrated steps or need to perform the steps in the order listed. 
     The illustrated method  500  includes steps of obtaining a textile scrap (step  505 ), chopping the textile scrap into pieces (step  510 ), and opening the pieces to separate the textile fabric into a plurality of textile yarns (step  515 ). The opening step  515  may be performed by pulling apart or combing the pieces of textile scrap. The method  500  also includes the steps of blending the plurality of textile yarns with a plurality of polymer staple fibers to form a mixed blend of textile yarns and staple fibers (step  520 ), stacking the mixed blend into a mat (step  525 ), heating the mat (step  530 ), compressing the mat (step  535 ), and cutting the mat into a panel  150  of a desired size and shape (step  540 ). For example, the panel  150  may be cut with an abrasive wire to achieve a clean edge. In other embodiments, the panel  150  may be cut using other suitable cutting techniques, such as water jet, laser, oscillating knife, and the like. In addition to cutting the panel  150  into a desired shape, the panel  150  may have cut out portions, which may be adapted for different purposes. For example, a cut-out may be created to receive hardware designed to support a panel  150  in an upright position, to increase stiffness, or to couple multiple panels  150  together. In some embodiments, the cut-outs may be formed by compressing sections of the panel  150 , rather than removing material from the panel  150 . The panel  150  may also be bent into a desired curvature rather than remaining a flat panel  150 . 
     As will be described in further detail below, after the panel  150  is cut to the desired size (step  540 ), the naked panel  150  may be finished (steps  545 ,  550 ,  555 ) in a variety of ways to form a screen  245 . The term “naked panel” refers to a panel  150  formed of textile yarns and polymer staple fibers, which is formed into a panel  150  or cut to a desired shape, as described in methods  100  or  500 . The naked panel  150  may then be finalized during the finishing process (steps  545 ,  550 ,  555 ) to ultimately form a screen  245 . The finishing process may include coupling the panel  150  to a second panel  150  (step  545 ), coupling one or more facings (identified generally as  155 ) to the panel  150  (step  550 ), and/or coupling the panel  150  to hardware or an attachment (e.g., a frame, a hanging member, a stand, etc.) (step  555 ). As will be understood, the method  500  may include one or more of the finishing steps (steps  545 ,  550 ,  555 ), which may be completed in any order. Alternatively, the method  500  may not include any finishing steps (steps  545 ,  550 ,  555 ), but rather may leave the panel  150  naked. It should be understood that the finishing steps (steps  545 ,  550 ,  555 ) may be applicable to either method  100  or method  500 . 
     Furthermore, the finishing steps (steps  545 ,  550 ,  555 ) described herein may be done prior to completing the naked panel  150 , or during the process of manufacturing the naked panel  150 . For example, in some embodiments, two or more panels  150  may be coupled together (step  545 ) during or before any of the other steps described in the method  500  (e.g., steps  530 - 540 ). Likewise, one or more facing  155  may be coupled to the panel  150  (step  550 ) during or before any of the other steps described in the method (e.g., steps  530 - 540 ). For example, a polyester-based adhesive may be used to couple a facing  155  to the panel  150  during steps  530  or  535 , while the mat (i.e., the panel  150 ) is being heated and compressed. Additionally, one or more hardware or attachments may be coupled to the panel  155  during or before any of the other steps described in the method (e.g., steps  530 - 540 ). 
     In one finishing step (step  545 ), two panels  150  may be coupled together. Coupling the two panels  150  together may increase the overall stiffness of the panels  150 . In addition, coupling the two panels  150  together allows other elements to be positioned or tucked between the panels  150 . For example, if either or both of the panels  150  are wrapped in fabric, edges of the fabric may be tucked between the two panels  150 . Likewise, support structures (e.g., rods, etc.) may be positioned between the panels  150  to increase the strength and stiffness of the panels  150 . Additionally, other hardware may be supported and/or partially hidden between two panels  150 . Hanging hardware or a support stand may be coupled between two panels  150  to help hold the panel(s) in an upright position or a hanging position. 
     The panels  150  may be coupled together using a variety of different processes. For example, the panels  150  may be bonded together through RF bonding, ultrasonic bonding, or IR bonding. Furthermore, the panels  150  may be coupled together using a mechanical coupling. Such a mechanical coupling may itself be hidden between the two panels  150  once the panels  150  are coupled together. 
     In some embodiments, the panel  150  may be covered by one or more facings  155  (i.e., a layer, a covering, or a partial covering) to create a desired visual appearance or to achieve a desired structural characteristic (step  550 ). In other words, a facing  155  made of a different material may be coupled to or wrapped around at least a portion of the panel  150  to improve the appearance of the panel  150  or provide a functional enhancement to the panel  150 . 
     A facing  155  may be arranged on the panel  150  in a variety of different manners. A facing  155  may cover the entire panel  150  or may wrap around only a portion of the panel  150 . For example, in some embodiments, a facing  155  may be wrapped around the sides of the panel  150  as well as around the edge. In other embodiments, a facing  155  may only extend across a side of the panel, but may not be wrapped around the edge of the panel  150 . Contrarily, in other embodiments, facing  155  may only be wrapped around the edge of the panel, but may not extend across a side of the panel  150 . In yet another embodiment, a facing  155  may be wrapped around the edge of the panel  150  and only a single side. 
     Furthermore, a single facing  155  may be used or multiple separate facings  155  may be used. In some embodiments, multiple facings  155  may be used on different portions of the panel  150 . For example, a first facing  155  may be wrapped around the edge of the panel  150  while a second facing  155  may be coupled to a side of the panel  150 . Similarly, in some embodiments, there may be more than one layer of facings  155  covering a portion of the panel  150 . For example, a first facing  155  may be coupled to the panel  150 , and a second facing  155  may overlay the first facing  155  to create a two layers of facings  155 . Additionally, when multiple facings  155  are used on a single panel  150 , each facing  155  may be composed of a different material or have different characteristics, such as texture, stiffness, strength, or visual appearance. In some embodiments, a first facing  155  may be used to enhance the structure of the panel  150  and a second facing  155  may be wrapped around the first facing  155  to enhance the visual appearance of the panel  150 . For example, the first facing  155  may increase rigidity of the panel  150  and provide sharp edges around the perimeter of the panel  150 . The second facing  155 , such as a fabric layer, may be wrapped around the first facing  155  to achieve a desired look. 
     As mentioned, the facing  155  may be used to improve the structural integrity of the panel  150  by, for example, adding rigidity or strength to the panel  150 . In some embodiments, the facing  155  may be composed of a material having greater rigidity or strength than the naked panel  150  in order to increase the overall rigidity and strength of the panel  150 . In other embodiments, the facing  155  may not have greater rigidity and strength than the naked panel, however, the facing  155  may increase rigidity and strength simply by adding additional layers to the panel  150 . Furthermore, in some embodiments, a facing  155  may be coupled to the panel  150  around the edges in order to increase the strength of the panel  150  along the edges. 
     In some embodiments, the facing  155  may be used to improve the smoothness of any side or edge of the panel  150 . For example, because the naked panel  150  is formed by mixing scraps of material together that are melted and/or pressed together, the panel  150  may have some uneven or bumpy texture. The facing  155  may have a smoother texture than the naked panel  150  and may be coupled to the side and/or edge of the panel  150  to increase the smoothness of the panel  150 . Similarly, the facing  155  may be used to inhibit warping or unintended curvature of the panel  150 . 
     Furthermore, in some embodiments, the facing  155  helps to create sharp edges and/or corners by reducing the rounding of corners and edges. More specifically, as shown schematically in  FIGS. 7A and 7B , the naked panel  150  may not have extremely straight, or sharp edges  180  and corners  185  (i.e., squared or  90  degree edges and corners). Rather, during the manufacturing process of the panel  150 , the edges  180  or corners  185  may unintentionally become rounded or warped. Accordingly, a facing  155  may be used to create sharper edges  180  and corners  185 . In some embodiments, a facing  155  may be coupled to the sides  190  of the panel  150  in order to create the sharp edges  180  and sharp corners  185 . Alternatively, the facing  155  may be coupled to the edge  180  of the panel  150  in order to create a sharp edge  180  or a sharp corner  185 . Further, in other embodiments, the facing  155  may be coupled to both the edge  180  and the side  190  of the panel  150 . In this embodiment, the facing  155  may include a single facing  155  that is wrapped around the edge  180  and the sides  190  of the panel  150 , or may include multiple separate facings  155 . For example, one facing  155  may be positioned around the edge  180  of the panel  150  and separate facings  155  may be positioned on each side  190  of the panel  150 . 
     The facings  155  may include a variety of different types of materials. In some embodiments, the facing  155  may include a paper-like material. In other embodiments, the facing  155  may include a non-woven scrim. For example, a facing  155  may be composed of a paper-like material, such as craft paper, resin impregnated paper, multi-layer resin-impregnated paper, or polyethylene lined paper. The facing  155  may be composed of a type of polymer based material such as, polyester, polypropylene, spunbond polyester or point bond polyester. The facing  155  may be composed of other materials such as aluminum foil, fiberglass, veneer, or a PET film. The facings  155  may also include a variety of different fabrics or decorative features to achieve a desired visual appearance. In some embodiments, the facings  155  may be composed essentially of polymer such that the entire panel  150  (including the facings  155 ) may be recycled. For example, the panel  150  and facings  155  may be recycled and used to create additional panels  150  as described herein in methods  100  and  500 . 
     In some embodiments, the panel  150  includes the same facings  155  on each side or side of the panel  150 , while in other embodiments, each side or side of the panel  150  may have a different facing  155  or series of facings  155 . In some embodiments, only one side of the panel  150  may include one or more facing  155 , while the other side of the panel  150  remains naked. Furthermore, the facings  155  may be double sided or single sided. Also, as previously mentioned, the facings  155  may be layered together to achieve a desired structure and/or visual appearance. In some embodiments, the panel  150  may include an additive to give the panel  150  fire resistant or fire-retardant properties. The additive may include, for example, other staple fibers, a spray, a powder, and the like. 
     Additionally, the facings  155  may be coupled to the panel  150  by a variety of different adhesives and/or mechanical coupling members. Likewise, two or more panels  150  may be coupled together by a variety of adhesives and or mechanical coupling members. For example, the following adhesives may be used to adhere a facing  155  to a panel  150  or two panels  150  together: web adhesive, liquid glue such as Seal Bond, caulk gun/pneumatic, hot melt (e.g., polyurethane), tape, pressure sensitive tape (PSA), or powder adhesives. Alternatively or additionally, a mechanical fastener may be used to coupled the facings  155  to the panel  150  or two panels  150  together. Mechanical facings  155  may include staples, nails, thread, pins, or other mechanical fasteners. 
     In addition to or alternatively to coupling a facing  155  to the panel  150 , a fabric layer  225  may be coupled to the panel  150 . In some embodiments, a layer of fabric  160  may be wrapped around the facings  155  to provide a desired aesthetic look. In other embodiments, the layer of fabric  160  may be coupled directly to the panel  150  without a facing  155  in between. The layer of fabric  160  may be wrapped around the entire panel  150  or may be wrapped around only a portion of the panel  150 . In some embodiments, a layer of fabric  160  may be wrapped around a first side of the panel  150  while leaving a second side of the panel  150  naked or covered with a facing  155 . This arrangement may be particularly useful in situations where two panels  150  are coupled together. For example, referring to  FIGS. 6A and 6B , the layer of fabric  160  covers a front side  165  of the panel  150  (i.e., an outwardly facing side or the panel) and the edges  170  of the panel  150 . In the illustrated embodiment, the layer of fabric  160  only covers a small portion of the rear side  175  of the panel  150  (i.e., an inwardly facing side of the panel) such that the majority of the rear side  175  the panel  150  remains naked. This arrangement of the layer of fabric  160  enables the edges of the layer of fabric  160  to be concealed between the two panels  150  once they are coupled together. Specifically, a second panel  150  may be prepared in a similar manner. The panels  150  may then be arranged with the naked (or primarily naked) rear sides  175  positioned inwardly and being coupled together. 
       FIGS. 8A-8D  schematically illustrate some exemplary embodiments of a screen  245 . These examples are for illustrative purposes and are not intended to be limiting. The screen  245  illustrated in  FIG. 8A  includes a naked panel  150  including a facing  155  composed of layer of paper  200 , such as resin-impregnated paper, on each side  190  of the panel  155 . The paper  200  is adhered to the panel  150  by a polymer, such as a polyester web adhesive  205 . The panel  150  further includes a layer of fabric  225  on one side. 
     The panel  150  illustrated in  FIG. 8B  includes a naked panel  150  including a facing  155  composed of a non-woven scrim  203  on one side  190  of the panel  150 . Additionally, the panel  150  includes a layer of fabric  225  covering the non-woven scrim  203 . In this embodiment, the opposite side of the panel  150  remains naked. 
       FIG. 8C  illustrates a panel  150  composed of a naked panel  150  surrounded by a first facing  155  composed of a layer of polyamide film  210  on each side  190 , followed by a second facing  155  composed of a layer of spunbond scrim  215  on each side  190 . 
       FIG. 8D  illustrates a panel  150  including a naked panel  150  including a facing  155  composed of a layer of polyamide film  210  on each side  190 , followed by a second facing composed of a pointbond scrim  220  on each side  190 . As previously mentioned, the panels  150  may not include the same facings  155  on each side of the panel  150 . For example, in some embodiments, a panel  150  may have additional or different facings  155  on one side of the panel  150  than the opposed side of the panel  150 . Additionally, any of the panels  150  shown in  FIGS. 8A-8D  may further include a layer of fabric surrounding the facings  155  shown. 
     Finally, the panel  150  may be coupled to one or more piece of hardware or attachments (step  555 ). For example, the panel  150  may be coupled to (e.g., positioned within) a frame that partially or fully surrounds an outer edge of the panel  150 . Alternatively, the panel  150  may be coupled to a hanging member (e.g., hook, clip, etc.) to hang the panel  150  from an overhead structure, such as a ceiling or beam. Alternatively, the panel  150  may be coupled to a stand to support the panel  150 . The stand may include wheels to move the panel  150  within a room or may be stationary within the room. In some embodiments, the panel  150  may be coupled to multiple attachments (e.g., a frame and a hanging member). Additionally, the panel  150  may include hardware to help secure a facing  155  to the panel  150  or to help couple two panels  150  together. For example, as described in further detail herein, a piece of hardware may be used to receive and conceal excess fabric from a layer of fabric  155 . 
       FIGS. 9-18  illustrate an exemplary screen  245  finished according to some of the finishing steps (steps  545 ,  550 ,  555 ) described herein. The illustrated screen  245  is formed from two individual panels  250   a,    250   b  that are coupled together. When multiple panels  250   a,    250   b  are coupled together, the screen  245  may also be referred to as a screen assembly. As previously mentioned, this may be done to increase stiffness and stability, or to make it easier to wrap the panels  250   a,    250   b  in a layer of fabric  255  and hide the ends or folds of the layer of fabric  255  between the two panels  250   a,    250   b.  Each panel  250   a,    250   b  is formed of textile scraps and staple fibers, as described with respect to methods  100  and  500 . The panels  250   a,    250   b  each have a first side  280   a,    280   b  and a second side  282   a,    282   b  opposite the first sides  280   a,    280   b,  respectively. When the panels  250   a,    250   b  are coupled together the first sides  280   a,    280   b  will be inwardly facing and will be coupled together. The second sides  282   a,    282   b  will be outwardly facing. 
     Before coupling the panels  250   a,    250   b  together, each panel  250   a,    250   b  is prepped as follows. The below description is described with respect to the first panel  250   a,  however, it should be understood that the second panel  250   b  may be prepared in a similar fashion. The first and second panels  250   a,    250   b  may then be coupled to together to complete the assembly of the screen  245 . 
     Referring to  FIGS. 10-11 , the panel  250   a  is cut to the desired size and shape. The illustrated panel  250   a  is a generally rectangular panel  250   a  with rounded corners  263 , or radius corners  263 . However, in other embodiments, the panel  250   a  may be cut into other shapes. Additionally, a plurality of cutouts or recesses  265  are formed (e.g., cut, compressed, etc.) in the panel  250   a  to accommodate various hardware  270 . In the illustrated embodiment, the cutouts  265  are formed into the first side  280   a  of the panel  250   a.  As previously mentioned, when the overall screen  245  construction is complete, the first side  280   a  of the first panel  250   a  will be inwardly facing and will be coupled to the first side  280   b  of the second panel  250   b.    
     One or more facing  155 , such as the facings illustrated in  FIGS. 8A-8D , may be coupled to the panel  250   a.  Specifically, one or more facings  155  may be coupled to one or both sides  280   a,    282   a  of the panel  250   a.  The one or more facings  155  may be coupled to the panel  250   a  at different stages in the process. For example, a facing  155  may be coupled to the panel  250   a  after the panel  250   a  is cut to the desired size and shape. Alternatively, the facing  155  may be coupled to the panel  250   a  prior to cutting the panel  250   a  to size and shape so that the facing  155  is cut together with the panel  250   a.    
     Furthermore, in some embodiments, multiple facings  155  may be coupled the panel  250   a  at different times during the process of finishing the overall panel  250   a  construction. For example, in one embodiment, a first facing  155  is coupled to the panel  250   a  prior to the panel  250   a  being cut to size and shape or prior to the cutouts  265  being formed. The first facing  155  may be a facing  155  adapted to improve a structural characteristic of the panel  250   a,  such as increasing the stiffness of the panel  250   a.  In this embodiment, a second facing  155  may be coupled to the panel  250   a  at a later stage in the process. For example, a second facing  155 or a layer of fabric  255  may be coupled to the panel  250   a  after the cutouts  265  are formed and after hardware  270  is installed on the panel  250   a.    
     Additionally, a layer of fabric  255  may be wrapped at least partially around the panel  250   a.  Specifically, one or more layer of fabric  255  may be coupled to one or both sides  280   a,    282   a  of the panel  250   a.  The one or more layer of fabric  255  may be coupled to the panel  250   a  at different stages in the process. For example, a layer of fabric  255  may be coupled to the panel  250   a  after the panel  250   a  is cut to the desired size and shape. Alternatively, the layer of fabric  255  may be coupled to the panel  250   a  prior to cutting the panel  250   a  to size and shape so that the layer of fabric  255  is cut together with the panel  250   a.  Furthermore, in some embodiments, multiple layer of fabric  255  may be coupled the panel  250   a  at different times during the process of finishing the overall panel  250   a  construction. 
     In the illustrated embodiment, the cutouts  265  include elongated channels  275 , which are formed in a first side  280   a  of the panel  250   a.  The channels  275  are sized and shaped to receive brackets  295 . In the illustrated embodiment, the panel  250   a  includes three channels  275 , however, in other embodiments, a greater or fewer number of channels  275  may be formed in the naked panel  250   a.  Additionally, corner cutouts or recesses  285  are formed in the naked panel  250   a.  The corner cutouts  285  are sized and shaped to receive additional hardware  270 , such as corner mounts  290 , which may be used to secure a layer of fabric  255  to the panel  250   a.  The corner mounts  290  may also be used to align and/or coupled the panel  250   a  to a second panel  250   b.  In the illustrated embodiment, the corner cutouts  285  create recessed corners  263 . 
     Referring to  FIGS. 12-13 , the hardware  270  is placed within the cutouts  265  of the panel  250   a.  In the illustrated embodiment, U-shaped brackets  295  are placed within the channels  275 . However, other types of brackets  295  may be used. The brackets  295  are adapted to be coupled to hanging hardware  335  or a stand to support the panel  250  in an upright position. Referring to  FIGS. 9 and 18 , the brackets  295  will eventually be coupled to hanging hardware  335 , which may be used to support the panel  250 . To that end, the brackets  295  include holes  310  ( FIGS. 13 and 16 ) for receiving fasteners, and the like. 
     In addition, corner mounts  290  are placed within the recessed corners (i.e., the corner cutouts  285 ) of the panel  250   a.    FIGS. 14A-14B  illustrate one embodiment of a corner mount  290 . The corner mounts  290  may be made of plastic, metal, or other rigid material. The illustrated corner mounts  290  are generally triangular shaped with a radius corner  305  that aligns with the radius corner  263  of the panel  250   a.  In other embodiments, the corner mount  290  may have a right angle or other shape based on the shape of the panel  250   a.  The illustrated corner mounts  290  include a plurality of cleats  300  to help position and maintain the corner mounts  290  within the corner cutouts  285 . In particular, the creates create grip/friction between the corner mount  290  and the corner cutout  285  to inhibit movement and slippage of the corner mounts  290 . 
     The corner mounts  290  may be added to the panel  250   a  to help maintain and reinforce the shape of the corner  263 . The corner mounts  290  may also help create a sharp corner  263  and/or edge  267  and inhibit warping. Furthermore, the corner mounts  290  may assist with wrapping the panel  250   a  in a layer of fabric  255 . For example, in the illustrated embodiment, the corner mounts  290  may receive the excess fabric from the layer of fabric  255  that occurs around the corners  263  of the panel  250   a.  To this end, corner mounts  290  include recesses  315  for receiving the excess fabric from the layer of fabric  255 . 
     Referring to  FIGS. 15-16 , the panel  250   a  is partially wrapped in a layer of fabric  255  to cover the second side  282   a  of the panel  250   a.  Specifically, a layer of fabric  255  is wrapped around the side  282   a  of the panel  250   a  which will ultimately be outwardly facing after the overall panel  250  construction is complete. To assist in wrapping of the layer of fabric  255 , the fabric may be cut into a pattern that reduces the overall amount of fabric to be tucked into the corner mounts  290 . As shown in the illustrated embodiment, the triangular portions of the fabric corners  263  are cut out to reduce the overall amount of fabric that is gathered around the corners  263 . Regardless, the excess fabric that from the layer of fabric  255  is received within a recess  315  of the corner mount  305 . 
     Furthermore, the corner mounts  290  may also be used to help align the two panels  250   a,    250   b  (i.e., the two panels halves) when the panels  250   a,    250   b  are coupled together. For example, as shown in  FIGS. 14A and 14B , the corner mounts  290  include circular alignment members  320 , which mate with or at least align with alignment members  320  on a corresponding corner mount  290  on the second panel  250   b.  In some embodiments, the corner mounts  290  may snap together in order to couple the two panels  250   a,    250   b  together. While in other embodiments, the corner mounts  290  only align the panels  250   a,    250   b,  but do not snap together. In either case, the panels  250   a,    250   b  may be secured together by either a bonding adhesive, heat treatment, pressing process, etc., as described herein. 
       FIGS. 9, 17, and 18  illustrate the panels  250   a,    250   b  after being coupled together (step  545 ) to form a completed panel  250  construction. As discussed above, each panel  250   a,    250   b  is coupled to one or more facings  155  or layer of fabrics  255  (step  550 ), and each panel  250   a,    250   b  is finished with cutouts  265  and hardware  270  (step  555 ). The two panels  250   a,    250   b  are then coupled together (step  545 ) to form a completed panel construction (also referred to as a screen assembly). In the illustrated embodiment, the panels  250   a,    250   b  are arranged with the cutouts  265  and hardware  270  positioned on an inwardly facing sides  280   a,    280   b  in order to at least partially conceal the cutouts  265  and hardware  270 . The layer of fabric  255  is wrapped around the sides  282   a,    282   b  of the panels  250   a,    250   b,  which will be arranged on the outside of the completed panel  250  construction. Notably, the edges  325  of the layer of fabric  255  are positioned on the inwardly facing sides  280   a,    280   b  of the panels  250   a,    250   b  to hide the edges  325  of the layer of fabric  255  and create a clean, finished look. Referring to  FIGS. 9 and 17 , one or more hanging hardware  270  is coupled to the panel  250  to support the panel  250  in an upright configuration. Specifically, the hanging hardware  335  is coupled to the concealed bracket  295 , as shown in  FIG. 18 . 
     The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present disclosure. As such, it will be appreciated that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present disclosure. Various features and advantages of the disclosure are set forth in the following claims.