Patent Description:
In particular, ceiling panels formed from metals such as aluminium are known in the art. Such panels may be, for example, square or rectangular in shape when installed and viewed from below, or may instead be of a linear form. Linear panels have a length which is substantially greater than their width, the length generally being at least three times and more usually at least five times the width of the panel.

<CIT> describes a suspended ceiling arrangement including linear panels made from sheet metal such as aluminium. The panels have flanges which are slid into recesses in rails for holding the panels.

<CIT> describes linear panels made from sheet metal such as aluminium. The panels have flanges which are slid into recesses in rails for holding the panels.

<CIT> describes a method of constructing a multi-storey building from modular panel components. Each panel component comprises a framework of cold-formed C profile structural steel members including vertical members, horizontal members and optional diagonal cross-brace members. The vertical members include some load-bearing structural uprights of the finished building, each of which is provided with an end cap on each of its top and bottom ends, connected to the corresponding load-bearing structural upright by welding or by brazing. Each end cap comprises a back plate portion secured across the open side of the C profile of the associated structural upright, to side plate portions secured to opposite sides of the associated structural upright and an end plate portion which lies across the otherwise open end of the associated structural upright. The end plate portion is in continuous metal-to-metal contact with the associated load-bearing structural upright, so that in the finished building the end caps at the top ends of the load-bearing structural uprights of one storey are in contact, either directly or via one or more metal shim plates, with the interior faces of a C profile horizontal structural member spanning two or more structural uprights or with the end caps at the bottom ends of the load-bearing structural uprights to the next higher storey. This construction, relying as it does on continuous metal-to-metal contact, enables the building of higher structures than would otherwise be possible using cold formed C profile structural steel members.

Aluminium linear panels have the advantages of being relatively light and flame retardant, however, they do not generally exhibit favorable acoustic characteristics. It will be appreciated that in many circumstances it might be desirable to provide a ceiling and/or a wall having good sound absorbing properties. The present invention addresses this need.

According to the present invention there is provided a linear ceiling or wall panel comprising and formed from a woven or non-woven fibrous material, the panel being shaped to provide means for mounting the panel to a carrier and wherein the means for mounting the linear panel form an integral part of the panel, both the panel and the means for mounting the panel being formed from the fibrous material. Preferably the linear panel comprises and is formed from a thermoformable fibrous material. The entire linear panel may be formed from the fibrous material. Preferably the linear panel consists of the fibrous material and is free from other materials such as metal. The material may be a thermoformable woven fibrous material or may alternatively be a thermoformable non-woven fibrous material, such as felt, for example. Advantageously,
the linear panel is shaped to provide means for mounting the linear panel to a carrier which is attached to or suspended from a structural wall or ceiling. Preferably the means for mounting the linear panel form an integral part of the panel, both the panel and the means for mounting the panel being formed from the fibrous material.

By providing linear panels made from a fibrous material, the sound absorbing properties of a room can be greatly improved with respect to the prior art aluminium ceiling panels.

The means for mounting the panel may be, for example, a flange which extends along the whole or part of the length of the panel.

The panel may comprise a flange which extends along the whole length of the panel, or one or more flanges which extend along a part of the length of the panel and which permit the panel to be mounted along one side of the panel, such that the panel may extend from the ceiling in the form of a baffle.

Alternatively, the panel may comprise a flange which extends along the whole length of the panel, or one or more flanges which extend along a part of the length of the panel, one or more flanges being provided on both sides of the panel to permit the panel to be mounted along both sides of the panel.

The flange(s) are advantageously configured to engage with a corresponding recess in the carrier, to thereby permit panels to be mounted.

The length of the panel is at least three times the width of the panel. Preferably the length of the panel is at least five times the width of the panel.

The fibrous material may comprise synthetic fibers or may comprise a mixture of synthetic and non-synthetic fibers such as wool, cotton, etc. The fibrous material may comprise polyester fibers (PES) and/or may comprise polyethylene terephthalate (PET) fibers. The material may be a felt-type material. The material may comprise one or more types of polyester fibers. The material may comprise bi-core polyester fibers. The material may comprise a mixture of polyester fibers and other fibers such as carbon or aramid fibers. Alternatively the material may consist of polyester fibres. The material may consist of one or more types of bi-core polyester fibres, or may consist of a mixture of one or more types of bi-core fibres and one or more types of non-bi-core polyester fibres.

Advantageously the material comprises a mixture of bi-core polyester fibers and non-bi-core (i.e. single core/monocore) polyester fibers. The bi-core polyester fibers may comprise <NUM>-<NUM>% and more preferably <NUM>-<NUM>% of the total mass and/or volume and/or number of polyester fibers, and the non-bi-core polyester fibers may comprise <NUM>-<NUM>% and more preferably <NUM>-<NUM>% of the total mass and/or volume and/or number of polyester fibers. A ratio of approximately <NUM>%:<NUM>% of bi-core polyester fibers to non-bi-core polyester fibers may be used. Advantageously, a ratio of approximately <NUM>%:<NUM>% or approximately <NUM>%:<NUM>% of bi-core polyester fibers to non-bi-core polyester fibers may be used.

The bi-core polyester fibers may comprise an inner core formed from a first polyester material having a melting point of approximately <NUM> and an outer sheath formed from a second polyester material having a melting and/or softening temperature in the range of approximately <NUM> - <NUM> and more preferably in the range of approximately <NUM> - <NUM>.

The non-bi-core polyester fibers may be "normal" single core/monocore polyester fibers having a melting point of approximately <NUM>.

Alternatively the material may comprise only bi-core polyester fibers and no non-bi-core polyester fibers. In this case the bi-core polyester fibers may be of the same type or may be of different types having different properties including melting point, softening temperature, colour or fire resistant properties for example. The material may additionally comprise other fibers such as carbon or aramid fibers, for example.

Alternatively the material may comprise non-bi-core polyester fibers, with no bi-core polyester fibers present. In this case the non-bi-core polyester fibers may be of the same type or may be of different types having different properties including melting point, softening temperature, colour or fire resistant properties, for example. The material may additionally comprise other fibers such as carbon or aramid fibers, for example.

Preferably the polyester fibers have flame-retardant properties.

The fibrous material may have a weight in the range of <NUM>-<NUM>/m<NUM>. Advantageously the weight of the fibrous material is in the range of <NUM>-<NUM>/m<NUM>. The thickness of the fibrous material is preferably in the range of <NUM>-<NUM>, and more preferably in the range of <NUM>-<NUM>. The density of the fibrous material may be approximately <NUM>-<NUM>/cm<NUM>, preferably approximately <NUM>-<NUM>/cm<NUM> and more preferably approximately <NUM> - <NUM>/cm<NUM>.

The fibrous material is preferably able to be permanently formed into a desired shape at temperatures of approximately <NUM> to <NUM> and more preferably <NUM> to <NUM>. Advantageously the temperature range required to thermoform the material is <NUM> to <NUM>, more preferably <NUM> to <NUM> and even more preferably <NUM> to <NUM>.

The linear panel may comprise an elongate portion extending in a longitudinal direction of the linear panel and including two side walls and a central portion located between the side walls, and the linear panel may further comprise an end portion extending between the side walls and central portion at a longitudinal end of the linear panel. The elongate portion and the end portion of the linear panel may both comprise and be formed from a fibrous material. Preferably the material is thermoformable. The material may be a woven material or alternatively may be a non-woven material, such as felt, for example. Advantageously, the elongate portion and the end portion of the linear panel are formed from the same type of fibrous material. The elongate portion and the end portion of the linear panel may be formed from a single piece of the same fibrous material. Alternatively, the elongate portion and the end portion of the linear panel may be formed from two different pieces of the same or different fibrous material. Preferably, the fibrous material comprises at least one of the group consisting of: bi-core polyester fibres; two different types of polyester fibres having different melting points; a mixture of bi-core polyester fibres and single core polyester fibres.

The side walls of the linear panel may comprise flanges which extend inwardly. The flanges may extend inwardly and toward the central portion of the linear panel.

The end portion of the linear panel may include slots which are configured to receive the flanges of the side walls of the linear panel.

The side walls of the linear panel may each have a longitudinal end and a cut-out portion may be formed in the longitudinal end of each of the side walls. Preferably, corresponding tabs are provided on the end portion, each tab being configured to be received by a cut-out portion formed in the longitudinal end of a side wall.

If the elongate portion and the end portion of the linear panel are formed from two separate pieces of the same or different non-woven fibrous material, the end portion of the linear panel may comprise three regions, namely a first region which extends between the side walls and the central portion at a longitudinal end of the linear panel, and second and third regions which extend from opposite ends of the first region and which extend along part of the interior-facing surface of each side wall respectively. The side wall flanges may extend over at least part of the second and third regions of the end portion in order to retain the end portion in position. An adhesive may be provided between the interior-facing surface of a side wall and the second or third region of the end portion in order to assist in retaining the end portion in position.

If the elongate portion and the end portion of the linear panel are formed from a single piece of a fibrous material, the end portion may be substantially formed from an extension of the central portion and/or an extension of one or both of the side walls. An extension of the central portion is that part of the central portion which extends beyond the longitudinal end of the side walls of the linear panel. An extension of the side wall is that part of the side wall which extends beyond the longitudinal end of the central portion of the linear panel. By forming the elongate portion and the end portion of the linear panel from the same single piece of a fibrous material, the end portion may be folded through approximately <NUM>° or less to form an end portion which exhibits no discontinuities when viewed from below.

The extension of the central portion or side wall may be configured to be folded through approximately <NUM>° to thereby cover the open longitudinal end of the linear panel. This has the advantage that the open end of the linear panel is not visible from below, thereby enhancing the aesthetic quality of the panels. Furthermore, the end portion helps to prevent excessive dust and other undesirable elements from accumulating in the panel.

Alternatively, the extension of the central portion or side wall may be configured to be folded through an angle of less than <NUM>° so that the open longitudinal end of the linear panel is partly obscured by the end portion of the linear panel.

The central portion of the linear panel may extend in a plane substantially perpendicular to the plane in which the side walls extend, such that the side walls extend from the central portion and are substantially parallel to each other. Alternatively, the side walls may extend from the central portion at the same angle or at a different angle from each other, said angle or angles being greater than <NUM>° but less than <NUM>° such that the side walls extend away from each other.

The present invention will now be described by way of example only and with reference to the following drawings of which:.

<FIG> show three linear panels <NUM> formed from a thermoformable non-woven fibrous material. The panels of <FIG> are depicted in end view, or alternatively may be considered as a cross-sectional view through the panel. <FIG> shows an isometric view of the panel of <FIG>. The length <NUM> of the panels <NUM> of <FIG> is substantially greater than the width and the depth dimensions of the panel <NUM>, and is preferably at least five times the width and the depth of the panel <NUM>.

The panels <NUM> of <FIG> each have an engaging portion <NUM> comprising a flange <NUM>. The flange <NUM> is preferably formed integrally with a main portion <NUM> of the panel <NUM>, and the flange <NUM> is formed along the whole or part of the length <NUM> of the panel. The angle α between the flange <NUM> and main portion <NUM> of the panel is, in this example, an acute angle of approximately <NUM>°. The flange <NUM> is formed by applying heat to one or more of the sides of the panel material and applying pressure to deform part of the panel material along its length to form the flange <NUM>. In this example, the material comprises a mixture of bi-core polyester fibers and non-bi-core polyester fibers (i.e. "normal" monocore polyester fibers) in the ratio of approximately <NUM>:<NUM> or alternatively approximately <NUM>:<NUM>. The inner core of the bi-core polyester fibers and the fibers of the non-bi-core polyester fibers each have a melting point of approximately <NUM>. The outer sheath of the bi-core polyester fibers has a softening temperature of approximately <NUM>. When heat is applied at a temperature greater than the softening temperature of the outer sheath of the bi-core fibers but lower than the melting point of both the non-bi-core fibers and the inner core of the bi-core fibers, the outer sheath of the bi-core fibers will soften, start to melt and thereby bond the non-bi-core fibers and the inner core of the bi-core fibers to each other. By applying pressure during the heating process, part of the panel may be deformed along the whole or part of its length to provide a flange <NUM> at a desired angle with respect to the main portion <NUM> of the panel <NUM>. Once the panel has cooled, the flange will remain in the desired position, due to the thermoformable properties of the panel material.

The panel <NUM> may be provided with one flange extending along its length, as shown in <FIG>. Alternatively, depending upon the manufacturing methods used to produce the panel and aesthetic requirements of the panel, the side of the panel opposite to the flange <NUM> may be provided with a further flange <NUM> extending along part or whole of the length of the panel <NUM>. The further flange <NUM> may have an angle β with respect to the main portion <NUM> of the panel which is substantially the same as the angle α between the flange <NUM> and the main portion <NUM> of the panel, as shown in <FIG>. Alternatively, the further flange <NUM> may have a different angle β as desired. <FIG> shows a panel <NUM> having a further flange <NUM> having an angle β of approximately <NUM>°.

The panels of <FIG> may be assembled onto a carrier <NUM> as shown in <FIG>. The carrier is designed to be fixed to or adjacent to the structural ceiling and the engaging portion <NUM> of the panels of <FIG> is configured to slot into a complementary-shaped recess <NUM> in the carrier <NUM>. The linear panel <NUM>, once engaged with the carrier <NUM>, may then hang below the carrier (when the carrier is fixed to or adjacent to a structural ceiling) in the manner of a baffle as shown in <FIG>.

The linear panel may alternatively be of the form shown in <FIG>. <FIG> and <FIG> show an end or alternatively a cross-sectional view of a linear panel <NUM> comprising a main portion <NUM> having a U-shaped cross-section, the panel <NUM> further comprising engaging portions <NUM>. The engaging portions <NUM> each include a flange <NUM>. As can be seen more clearly in the isometric view depicted in <FIG>, the linear panel has a length <NUM>, the length <NUM> being substantially greater than the width w or depth d of the panel. In this example, flanges <NUM> are provided at both sides of the panel <NUM> and each extend along the whole or part of the length of the panel. <FIG> shows an end or alternatively a cross-sectional view of a linear panel 11a similar to that depicted in <FIG>, except that the panel 11a comprises a main portion <NUM> having a more rounded U-shaped cross-section than that of the panel <NUM> of <FIG>.

The panel may be made from the polyester fiber mix described above with respect to <FIG>. Again, the panel is formed by heating the thermoformable fibrous material to a temperature greater than the softening temperature of the outer sheath of the bi-core fibers, but lower than the melting point of both the non-bi-core fibers and the inner core of the bi-core fibers, where a mixture of non-bi-core and bi-core fibers are used. During heating, pressure is applied to the material to form the side walls <NUM> and the flanges <NUM>. To aid bending of the material, additional pressure can be applied to the portions of the material which are intended to be bent prior to carrying out bending of the material. This increases the density of the material whilst reducing its thickness, permitting the material to be more easily bent whilst providing greater strength to the bent portions <NUM> following cooling. This can be seen in the panel depicted in <FIG>.

Once the linear panel <NUM> has been formed and cooled, it may be assembled onto a carrier <NUM> as shown in <FIG>. The engaging portions <NUM> of each panel <NUM> are configured to slot into complementary-shaped recesses <NUM> in the carrier <NUM>, in a manner similar to that described with respect to <FIG>. Once the linear panels <NUM> are engaged with the carrier <NUM>, they may then hang below the carrier as shown in <FIG>. The spacing of the linear panels with respect to each other will be determined by the extent of coverage required, including aesthetic, acoustic and thermal considerations.

<FIG> depict views similar to <FIG>, respectively, of a linear panel <NUM>. The panel <NUM> has a U-shaped cross-section similar to that of the panel <NUM> of <FIG> (but might alternatively have a more rounded U-shaped cross-section as shown in <FIG>), however the flanges <NUM> of panel <NUM> extend in the opposite direction to those of panel <NUM>, i.e. outwardly rather than inwardly. The angle γ between the side walls <NUM> of the panel <NUM> and the flanges <NUM> may be substantially the same as the angle α of <FIG>, or may be a different angle. Again, the materials and temperatures employed in forming the linear panel may be similar to those described with respect to the earlier figures.

<FIG> shows the formed and cooled linear panel <NUM> assembled onto a carrier <NUM>. Again, the engaging portions <NUM> of each panel <NUM> are configured to slot into complementary-shaped recesses in the carrier <NUM>.

<FIG> depict two further examples of linear panels in accordance with the present invention. These Figs. show an end face or alternatively a cross-section through linear panels <NUM>, <NUM>, the linear panels <NUM>, <NUM> being formed from similar material and at a similar temperature to the previously described linear panels. However, panel <NUM> has outwardly extending flanges <NUM> which are substantially perpendicular to side walls <NUM> of the panel <NUM> and panel <NUM> has inwardly extending flanges <NUM> which are substantially perpendicular to side walls <NUM> of the panel <NUM>. As for the earlier examples, the engaging portions <NUM> of each of the panels <NUM>, <NUM> are configured to slot into complementary-shaped recesses in the carrier.

The linear panels may have, as can be seen from the examples, inwardly or outwardly extending flanges, and may have flanges which extend substantially parallel to the central portion <NUM> of the panel, and/or substantially parallel to the ceiling or wall and/or the carrier. Alternatively, the flanges <NUM> may extend at an acute angle with respect to the side walls <NUM> of the panel. Where the side walls <NUM> are not substantially perpendicular to the central portion <NUM>, the angle between the side walls <NUM> and the flanges <NUM> may be obtuse. In any case, the recesses in the carrier should be configured to receive and retain the engaging portions of the linear panel including the flanges. The stiffness of the thermoformed, non-woven fibrous material permits the panel to retain its thermoformed shape once mounted, and enables the flanges to remain substantially at the angles formed during the thermoforming process. This permits the panels to be installed on a carrier without losing their shape and prevents the engaging portions from deforming and thereby becoming free of the carrier.

In some embodiments of the invention, an end portion (e.g. an end cap) may be provided for the linear panel.

<FIG> shows an isometric view of a linear panel similar to that shown in <FIG>, the panel this time including an end portion <NUM>. The linear panel comprises an elongate portion <NUM> extending in a longitudinal direction of the linear panel and including two side walls <NUM> and a central portion <NUM> located between the side walls, as can be seen more clearly in <FIG>. The end portion of <FIG> is preferably formed from the same material as that of the panel. The end portion may be formed from a separate piece of material from the panel, or may be formed from the same single piece of material as the panel. These alternatives are described later. The end portion <NUM> is substantially shaped to slot into and thereby cover an open end of the linear panel. In this example, the linear panel is of a substantially rectangular cross-sectional shape, and the end portion is correspondingly of a substantially rectangular cross-sectional shape. The end portion <NUM> includes slots <NUM> for receiving the flanges <NUM> of the panel. Preferably, the slots tightly hold the flanges in position, thereby preventing the end portion <NUM> from moving.

Adhesive may be used to hold the end portion in position. Alternatively or additionally, a friction fit between the slots <NUM> and the flanges <NUM> and/or the longitudinal end <NUM> of the panel and the end portion <NUM> may utilized to prevent movement of the end portion.

In order to more securely hold the end portion in position, the side walls <NUM> at the longitudinal end of the panel may be provided with cut-out portions <NUM> for receiving a correspondingly shaped and sized tab <NUM> of the end portion <NUM>. <FIG> shows such an example where the tabs <NUM> and cut-out portions <NUM> have a square or rectangular shape, and <FIG> shows such an example where the tabs <NUM> and cut-out portions <NUM> have a dovetail shape. These examples show two tabs, one on each side of the end portion <NUM>. However, several tabs may instead be provided on each side of the end portion <NUM>, and a plurality of corresponding cut-out portions may be provided in the side walls at the longitudinal end of the panel. Alternatively, there may be one or more tabs provided on one side only of the end portion <NUM>.

<FIG> shows a plurality of linear panels <NUM> mounted to a carrier <NUM>. The linear panels each have an end portion <NUM>. End portions may be provided at one end or at both open ends of the linear panel.

<FIG> shows an end view of the linear panel of <FIG> this time including an end portion <NUM>. In this example, the end portion <NUM> includes two dovetail-shaped tabs <NUM>, one tab being located at each side of the end portion <NUM>, and being fitted into corresponding cut-out portions <NUM> in the side walls <NUM> at the longitudinal end of the linear panel. The end portion <NUM> also includes two slots <NUM> for receiving flanges <NUM>. In this example, the end portion <NUM> is formed from the same single piece of material as the panel. The end portion <NUM> is formed from an extension <NUM> of the central portion <NUM> of the panel, as shown in <FIG>, which shows a plan view of the panel. During manufacture, the desired shape and size of the extension <NUM> may be cut or stamped into the material, and then the extension <NUM> is folded (rotated by <NUM>°) about the fold line <NUM> so that the extension <NUM> covers the open end of the longitudinal panel as shown in <FIG>. The dovetail-shaped tabs <NUM> slot into the corresponding cut-out portions <NUM> in the side walls <NUM> of the panel, and the flanges <NUM> are received by the slots <NUM> of the end portion <NUM>. The end portion <NUM> may then be held in position by a friction fit between the longitudinal end <NUM> of the panel and the end portion <NUM>. If desired, adhesive may additionally be used.

<FIG> shows an end view of the linear panel of <FIG> this time including an end portion <NUM>. In this example, the end portion does not include tabs <NUM>, but tabs of any suitable shape could be provided if desired. In this example, the end portion <NUM> is formed from the same single piece of material as the panel. The end portion <NUM> is formed from an extension <NUM> of the central portion <NUM> of the panel, as shown in <FIG>, which shows a plan view of the panel. During manufacture, the desired shape and size of the extension <NUM> may be cut or stamped into the material, and then the extension <NUM> is folded (rotated by <NUM>°) about the fold line <NUM> so that the extension covers the open end of the longitudinal panel as shown in <FIG>. The end portion <NUM> is configured to fit immediately below the flanges <NUM>, which extend at substantially right angles to the side walls <NUM>, and so no slots need to be provided in the end portion <NUM>. The end portion <NUM> is maintained in position by a friction fit between the side walls <NUM>, the central portion <NUM> and the flanges <NUM> at the longitudinal end <NUM> of the panel and the end portion <NUM>. If desired, adhesive may additionally be used.

<FIG> shows an end view of the linear panel of <FIG> with a different end portion <NUM>. In this example, the end portion <NUM> does not include tabs <NUM>, but tabs of any suitable shape could be provided if desired. In this example, the end portion <NUM> is formed from the same single piece of material as the panel. The end portion <NUM> is formed from an extension <NUM> of the central portion <NUM> of the panel, as shown in <FIG>, which shows a plan view of the panel. During manufacture, the desired shape and size of the extension <NUM> may be cut or stamped into the material, and then the extension <NUM> is folded (rotated by <NUM>°) about the fold line <NUM> so that the extension covers the open end of the longitudinal panel as shown in <FIG>. This end portion <NUM> is configured to fit to be flush with the outside surface <NUM> of flanges <NUM>, but is otherwise identical to the end portion <NUM> described with respect to <FIG>. If desired, adhesive may additionally be used.

<FIG> shows an isometric view of the linear panel of <FIG> and <FIG> with the extension <NUM> which forms the end portion <NUM> extending from the central portion <NUM> of the linear panel in an unfolded state.

<FIG> shows an isometric view of the linear panel of <FIG> with an extension <NUM> which forms the end portion <NUM> extending from the central portion <NUM> of the linear panel in an unfolded state. However, in this embodiment, the extension <NUM> includes a tongue portion <NUM> which extends from the main extension body 37a in a direction away from the central portion <NUM> of the linear panel when in an unfolded state. The tongue portion <NUM> includes tabs <NUM> which extend from the tongue portion in a direction roughly perpendicular to the central portion <NUM> of the linear panel. The extension <NUM> may be folded about the fold line <NUM> so as to cover the longitudinal end of the linear panel as previously described with respect to <FIG>. A further fold line <NUM> is provided between the tongue portion <NUM> and the main extension body 37a to enable the tongue portion <NUM> to be folded with respect to the main extension body 37a. This permits the tabs <NUM> of the tongue portion <NUM> to hook underneath and thereby engage the flanges <NUM> of the linear panel.

In a different embodiment, the end portion <NUM> may be formed from a separate piece of material to the panel. The end portion may be formed, for example, by cutting out or by stamping out a blank from the material. The end portion <NUM> and the panel may be formed from the same type of material, or may be formed from different materials. <FIG> shows an end portion <NUM> having three regions, namely a first region <NUM>, a second region <NUM> and a third region <NUM>. The first region <NUM> is configured to cover the open end of a linear panel as shown in <FIG>, and is sized and shaped accordingly. In this example, the first region <NUM> is of a rectangular shape, and the second and third regions <NUM>, <NUM> extend from opposite ends of the first region in a direction substantially parallel to each other. This is because the linear panel into which the end portion <NUM> is to be inserted has a rectangular cross-sectional shape and the side walls <NUM> of the linear panel are substantially parallel to each other as shown in <FIG>. In other examples, the side walls <NUM> of the linear panel may extend towards or away from each other instead, and in such cases the second and third regions of the material <NUM> are configured to extend at a corresponding angle away from the first region such that, when the end portion <NUM> is inserted into the longitudinal end of the panel, the outer-facing surfaces <NUM> of the second and third regions <NUM>, <NUM> extend along part of the interior-facing surfaces of each side wall respectively. The flanges <NUM> may extend over part of the second and third regions to keep the end portion in position. Additionally, if desired, an adhesive may be provided between the interior-facing surface of the side walls <NUM> and the outer-facing surfaces <NUM> of the second and third regions.

Where no adhesive is provided, the end portion may easily be installed and removed as desired.

In these examples, the linear panel has a square or rectangular cross section, however, other panels such as those having a "U" or "V" shaped cross section are also contemplated.

The panel may be produced by roll forming, hot pressing, drawing the material through a heated mold, or by any other suitable means. Roll forming or drawing the material through a heated mold are the preferred methods of manufacture of the panel as these are a continuous process, thereby allowing the rapid production of panels of a desired length. Furthermore, these methods may also permit heating on one (the inner) surface of the panel only so that the other (the outer) surface of the panel retains a felt-like appearance due to minimal melting of the fibers on the outer surface. In the case of roll-forming, it is easy to alter the position of the rollers in order to produce panels having different widths, cross-sections, etc. Drawing the material through a heated mold has the advantage that the temperature of the mold may be more accurately controlled.

The above examples refer to a panel material comprising a mixture of bi-core polyester fibers and of non-bi-core (i.e. "normal" monocore) polyester fibers in the ratio of approximately <NUM>:<NUM> or alternatively approximately <NUM>:<NUM>. However, the ratio of bi-core polyester fibers to non-bi-core polyester fibers may be in the range of <NUM>:<NUM> to <NUM>:<NUM>. Additionally, non-synthetic fibers may be mixed with the polyester fibers. It is desirable to have at least <NUM>% synthetic fibers as it is easier to control the parameters of synthetic fibers, whereas non-synthetic fibers may exhibit significantly different properties with each batch. Where recycling is of importance, it is advantageous to limit the number of different types of fibers.

It is desirable, whatever the mix of fibers used, to form the panel at low temperatures as this reduces the amount of energy required to form the panel.

Additionally, panels formed in accordance with the present invention will retain a soft, felt-like appearance because the majority of the fibers will not have melted. Melted fibers become more densely packed together and fuse to form a smooth outer surface. Although this increases the strength of the material, it reduces its ability to absorb sound.

Therefore, for both aesthetic and acoustic considerations, it is desirable to provide fibers having different softening and/or melting points and form the panel at a low temperature such that only a minority of the fibers melt, leaving the panel with a soft, felt-like surface and lower density.

The material may be pre-treated by low temperature heating prior to use in forming a panel. This may help to stabilize the material and make it less prone to shrinkage or stretching during the manufacture of the panel.

Any desired additives such as flame-retardant chemicals or pigments may be introduced to the fibers and/or to the fibrous material prior to forming of the panel.

Claim 1:
A linear wall or ceiling panel (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) the panel being shaped to provide means (<NUM>) for mounting the panel to a carrier (<NUM>) and wherein the means (<NUM>) for mounting the linear panel form an integral part of the panel, characterized in that both the panel and the means for mounting the panel comprising and being formed from a woven or non-woven fibrous material.