WO2009148851A1

WO2009148851A1 - Office panel

Info

Publication number: WO2009148851A1
Application number: PCT/US2009/044927
Authority: WO
Inventors: Julie L. York; Kenneth Assink; Sherry L. Graham
Original assignee: Illinois Tool Works Inc
Current assignee: Illinois Tool Works Inc
Priority date: 2008-06-03
Filing date: 2009-05-22
Publication date: 2009-12-10
Anticipated expiration: 2010-12-03

Abstract

A panel, such as an office panel, includes an integral finished peripheral edge. In one embodiment, the panel includes a structural layer and a visible outer surface layer. The structural layer may be molded such that its upper surface has a three-dimensional surface contour pattern. The visible outer later is attached to the upper surface and is conformed to the surface contour pattern of the structural layer. The edge portions of both layers are drawn around the side edge of a tool during the molding process, such that the edge of the outer layer covers substantially all of the edge portion of said structural layer to form an integral finished edge on the panel.

Description

OFFICE PANEL

CROSS REFERENCE TO RELATED APPLICATION

[0001] This Non-Provisional Application claims benefit to United States Provisional Application Serial No. 61/058,345 filed June 3, 2008.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to office panels, and more particularly to an apparatus and method for producing office panels with a three dimensional surface pattern.

[0003] Office panels are well known, for instance, for use as privacy screens, cubicle dividers, and other organizational features for the office environment, and in some cases in home offices or other commercial or residential applications. These panels typically include a front, visible surface attached to a structural backer. The visible surface is commonly a decorative fabric, and the backer may be foam, fiberboard, fiberglass or another rigid or semi-rigid material attached to the visible surface with an adhesive. In some cases, office panels may have additional functional characteristics, such as for use as a tackboard.

[0004] As the push for more aesthetically pleasing office environments continues, office panels with three dimensional visible surfaces have been developed, providing surface patterns or shapes on the exterior surface of the office panel to reduce the repetition and monotony often created by the typical flat office panel. One type of three dimensional panel includes a visible outer layer, a heat activated adhesive scrim layer and a structural non-woven polyester fiber layer. The three layers are heated in an oven to activate the adhesive and heat the polyester fiber to a moldable temperature, and then moved to a mold assembly. The mold assembly, typically formed from aluminum, includes an upper mold and a lower mold that can be pressed together to mold the heated layer assembly. At least one of the molds has a surface shaped to the desired shape of the panel surface, and the molds are pressed together to form the layers assembly into the desired shape. The molded assembly is cut with a die to a desired size. Final edge preparations are often done by hand to wrap the edges of the visible layer around the sides of the structural layer and adhere them to the structural layer. SUMMARY OF THE INVENTION

[0005] The embodiments of the present invention provide a panel having a main portion with a three-dimensional surface contour and an integral, finished edge portion extending from the main portion.

[0006] In one embodiment, the panel includes a structural layer and a visible outer surface layer. The structural layer has a main portion including an upper surface and a lower surface, and a peripheral edge portion extending downwardly from the main portion. The structural layer is molded such that the upper surface of the main portion has a three-dimensional surface contour pattern. The visible outer later is attached to the upper surface of the main portion of the structural layer. A first portion of the outer layer extends over the upper surface of the structural layer and is conformed to the surface contour pattern of the structural layer. The outer layer has an edge portion that extends from the first portion. The edge portion covers substantially all of the edge portion of said structural layer to form an integral finished edge on the panel.

[0007] In one embodiment, the panel with finished edge is formed by the steps of (1) providing a first tool having an upper surface, a side edge, and a cutting surface, the upper surface spaced above the cutting surface; (2) providing a second tool having a perimeter die blade; (3) placing a heated panel blank between the first tool and the second tool, the panel blank having a structural layer, an outer surface layer, and an adhesive layer, the panel blank having a main portion, and an edge portion; and (4) moving at least one of the first tool and the second tool to compress the main portion of the panel blank between the first tool and the second tool, and to contact the outer surface layer with the perimeter die blade, the perimeter die blade drawing the edge portion of the panel blank over the side edge of the first tool, with the outer surface layer extending over substantially all of the structural layer within the edge portion.

[0008] In one embodiment, the method for forming the panel may include forming a three-dimensional surface contour on the main portion of the panel blank by compressing the panel blank between an mold surface on the first tool and a mold surface on the second tool. The method may further include selecting a particular perimeter die blade that is capable of drawing the edge portion of the panel blank around the edge of the first tool, and also cut the panel blank at the location where the panel blank engages the cutting surface of the first tool. [0009] The present invention provides a cost effective, aesthetically pleasing panel for use in office furniture or a variety of alternative applications. The visible outer layer may be an aesthetically pleasing material, while the structural layer provides the necessary structural characteristics. The panel may be formed in a single molding step that creates both a three-dimensional surface on the main portion of the panel, as well as a finished edge portion.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Fig. 1 is a perspective view of a three dimensional panel according to one embodiment of the present invention.

[0011] Fig. 2 is a front view of three layers of material according to one embodiment.

[0012] Fig. 3 is a top perspective view of a corner of the three dimensional panel.

[0013] Fig. 4 is a bottom perspective view of a corner of the three dimensional panel.

[0014] Fig. 5 is a front view of the upper and lower tools in a spaced apart position with a heated panel blank in between according to one embodiment of the present invention.

[0015] Fig. 6 is a cross sectional view of a three dimensional panel formed in a tool according to one embodiment.

[0016] Fig. 7 is perspective view of five layers of material according to a second embodiment of the present invention.

[0017] Fig. 8 is a front perspective view of a three dimensional panel according to another embodiment of the present invention.

[0018] Fig. 9 is a front perspective view of a three dimensional panel according to another embodiment of the present invention.

[0019] Fig. 10 is a perspective view of a three dimensional panel according to another embodiment of the present invention. [0020] Fig. 11 is a perspective view of a three dimensional panel according to another embodiment of the present invention.

[0021] Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of "including" and "comprising" and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

[0022] A three dimensional panel 10 and a system and method for making a three dimensional panel are shown in the Figures. The panel 10 generally includes an outer surface, an inner surface and a wrapped, finished outer edge. The apparatus for making the panel generally includes at least one mold having a surface that is shaped to form the panel to a desired three dimensional surface, and a die blade that is sized to cut the perimeter of the panel to a desired size. As the panel blank is pressed in the tool, the mold forms the desired surface in the panel 10 and the die blade pulls the edges of the blank downwardly to form the finished edge on the panel 10.

I. Panel Structure

[0023] In one embodiment, the panel 10 is formed from a plurality of layers. As illustrated in Figs. 1 and 2, in one embodiment, the panel 10 is formed from a first layer, known as the "A" layer, a second layer, known as the "B" layer and a third layer, known as the "C" layer. The first layer forms the visible outer surface of the panel, and may be formed from a variety of materials, such as polyester, polyethylene or another plastic fiber, or a paper based scrim that may be a mixture of wood pulp and polyester fiber, or another natural fiber. The first layer may have a variety textures that are desirable for the visible, finished outer surface, and it may be colored with a desired color. In one embodiment, the A layer is opaque, such that the other layers cannot be seen through the A layer in the finished product. [0024] The C layer is typically a structural layer that is capable of being molded into a desired shape. As shown, the C layer is a non-woven polyester mat. In one embodiment, it may be formed from a non-woven mat of 20 oz./yd² polyethylene terephthalate (PET) having a 25/75 blend (25% matrix fiber + 75% low melt bico/binder fiber). In one embodiment, the material used for the structural layer has a binder activation temperature that is greater than 200 degrees F. Alternatively, the structural layer may be formed from another non- woven polymeric mat, or a blend of polymeric and natural fibers, or from another moldable material. The B layer is an adhesive layer that binds the A layer and the C layer together. It may be a heat activated adhesive. The particular adhesive material used for the adhesive layer is dependent on the materials used for the A and C layers, as the adhesive must be capable of bonding the A layer to the C layer. Conventional adhesives that may be used include: 50 g/yd² Bostik PE75, 14 g/yd² Spunfab PA-1541-050, and Spunfab D0213S-060, although a wide variety of other known adhesive layers or webs may be used.

[0025] In another embodiment, the panel may include more than three layers. For instance, as shown in Fig. 7, the panel may include five layers. In the Fig. 7 embodiment, the panel includes the A, B and C layers as described above, and it additionally includes a D layer that is a second adhesive layer positioned next to the C layer on the opposite side as the B layer, and an E layer that forms a visible lower surface. The E layer may be formed from the same types of materials as the A layer, or it may be formed of a structural layer that adds a degree of stiffness to the panel. Additional layers of adhesives and additional structural layers may be added to adjust the thickness and structure of the panel as desired. In yet another alternative embodiment, the panel may be comprised of a single structural layer, for instance, a structural layer that has a desired color such that the outer layer of the structural layer will be the visible layer of the final panel.

[0026] Figs. 1, 3-4, and 8-11 show views of various molded three dimensional panels. More particularly, Fig. 1 shows a molded panel according to one embodiment, wherein the panel 10 includes a plurality of concave, circular indentations 20. Figs. 3 and 4 show close-up views of the finished edge 22, which can be included in any of the panel embodiments. Fig. 3 shows a top partial view, including the indentations 20 formed during the molding process. Fig. 4 shows a bottom partial view of the panel 10, including the convex protrusions 21 that form the rear surface of the indentations 20. [0027] As shown in Figs. 3-4, the panel 10 generally includes an upper surface 13 formed primarily of the A layer, a lower surface 15 opposite the upper surface 13 and formed primarily of the C layer, and an edge portion 22. The edge portion 22 of the panel extends downwardly from generally horizontal main portion 23 at the periphery of the panel 10. As shown, the edge portion 22 includes an interior surface 27 formed by the edge portion 28 of the C layer and an exterior surface 29 formed by the edge portion 26 of the A layer. The edge portion 22 of the panel 10 has a finished appearance due to the edge portion 26 of the A layer being wrapped around substantially the entire edge portion 28 of the C layer. This results from the edge portions 26, 28 of both the A and C layers being pulled downwardly during the die cut process described below, with the edge of the A layer being pulled over the edge of the C layer. In the embodiment illustrated in Figs. 3 and 4, the A layer extends over substantially all of the C layer, such that only a small portion of the terminal edge 24 of the C layer is visible from the side of the panel 10. The finished edge portion 22 may extend around the entire panel 10, including the corners 30, or, alternatively, the finished edge may extend around predetermined portions of the panel 10. In one embodiment, the edge of the A layer is pulled completely over the edge of the C layer, such that no portion of the C layer is visible from the side of the panel.

[0028] Figs. 8-11 show various alternative embodiments of the panel, which are substantially the same as the embodiment shown in Figs. 1-4, except that they are provided with alternative surface contour patterns by using molds with different mold surfaces. Fig. 8 shows a molded panel 12 according to one embodiment, wherein the panel 12 includes a plurality of convex, circular projections 14 extending outwardly from the generally planar front surface 13 of the panel 12. Of course, a wide variety of shapes could otherwise be formed into the panel, depending on the shape of the mold surface. Fig. 9 shows an embodiment of a panel 40 including a plurality of evenly spaced, generally square protrusions 42 in the front surface 44 of the panel 40. Fig. 10 shows an embodiment of a panel 50 including a plurality of serpentine-shaped protrusions 52 that are generally evenly spaced apart across the front surface 54 of the panel 50. Fig. 11 shows an embodiment of a panel 60 including a plurality of generally rectangular shaped indentations 62 that are generally evenly spaced apart across the front surface 64 of the panel 60.

II. Tooling [0029] Figs. 5-6 show one embodiment of the tooling that may be used to form the panels. Referring to Fig. 5, in one embodiment, the tooling includes an upper tool 90 and a lower tool 100 that can be pressed together about a pre-heated panel blank 11 of the layered materials, for instance, with hydraulic arms attached to one or both of the tools or another conventional method. As shown in Figs. 5 and 6, in one embodiment, the lower tool 100 includes a base 102 that may be mounted to a support structure (not shown). In one embodiment, the base 102 is formed from plywood or aluminum, but a variety of materials can be used. In one embodiment, the base 102 includes an upper surface 106, with an approximately 1" tall, 4 point blunt rule die 110 mounted thereto. Alternatively, the die 110 may be mounted to the support structure (not shown) and extend upwardly through an opening in the base 102. The die 110 generally extends upwardly from the base 102 to form a perimeter side edge for the lower mold 114. As illustrated, the die blade 110 forms a generally square perimeter, which is approximately the desired size of the perimeter of the finished three dimensional panel 10. The perimeter shape may be varied from application to application, depending on the desired shape of the panel 10.

[0030] The lower mold 114 is fitted within the perimeter formed by the lower die 110. The lower mold 114 made be formed form a variety of materials, such as aluminum, polycarbonate, REN or masonite. In the illustrated embodiment, the lower mold 114 is aluminum. The lower mold 114 generally includes an upper surface 118 and a bottom surface 120. The upper surface 118 may be provided with a predetermined contour for forming the panel blank into a desired shape. As shown, the upper surface 118 includes a plurality of circular, concave indentations, or dimples, 122 defined therein. In one embodiment, the dimples 122 are spaced slightly apart from each other and aligned in rows along the upper surface 118, with partial dimples 122 located near the perimeter of the lower mold 114. Alternatively, the upper surface 118 may be provided with a variety of other contours, in order to form panels with different surface patterns and shapes (such as the panels shown in Figs. 8-11). In the illustrated embodiment, the bottom surface 120 of the lower form 114 is mounted to a masonite filler 124 that is mounted to the base 102, for instance, by conventional fasteners or a conventional adhesive. In another embodiment, the bottom surface 120 may be mounted directly to the base 102. The bottom surface 120 may be generally flat, or, as illustrated in Fig. 6, it may be contoured to correspond to the contour of the upper surface 118, such that the lower form 114 has a uniform thickness. [0031] As shown in Figs. 5 and 6, a cutting plate 130 may be attached to the upper surface 106 of the base 102 around the outside of the perimeter die 110. The cutting plate 130 is designed to receive impact from a blade 36 on the upper tool (discussed below), and, in one embodiment, is removably attached to the base 102, for instance, with a plurality of fasteners (not shown), such that the cutting plate 130 can be replaced after it is worn out. In one embodiment, the cutting plate 130 is formed from nylon or aluminum, or from another material that is capable of outlasting high density polyethylene, and, preferably, a material that is capable of outlasting high density polyethylene 10:1.

[0032] Figs. 5 and 6 also show an embodiment of the upper tool 90, spaced above the lower tool 100 and directed downwardly so it is capable of forming the blank 11 between the upper 90 and lower 100 tools. In this embodiment, the upper tool 90 includes a top base 92 that is generally similar to the base 102 of the lower tool 100. As shown, the top base 92 is a generally flat support plate that includes an upper surface 142 and a lower surface 144. The top base may be formed from a variety of materials, such as aluminum or plywood. The upper surface 142 is mounted to a support structure (not shown), which may include a hydraulic arm (not shown) or other apparatus for raising and lowering the upper tool 90.

[0033] In one embodiment, the upper tool 90 includes an upper mold 146 and a perimeter die blade 36. The upper mold 146 includes an upper surface 148 and a lower surface 105. In the illustrated embodiment, the upper surface 146 is mounted to a filler 34, that is made from masonite, or another generally hard material, and mounted to the top base 92. The lower surface 105 may have a three-dimensional shaped contour pattern, and, in the embodiment shown in Figs. 5-6, it includes a plurality of dome-shaped protrusions 160 that align with the dimples 122 on the lower mold 114. As with the lower mold 114, the upper form may be made from a variety of materials, such as aluminum, polycarbonate, REN or masonite.

[0034] The perimeter blade 36 extends around the perimeter of the upper form 146, and is sized to cut the perimeter of the panel blank 11 to form a finished panel 10 with the desired exterior dimensions. In the illustrated embodiment, the blade 36 extends in a generally square shape that is slightly larger than the perimeter of the lower form 114 formed by the lower die 110. This forms a gap between the blade 38 and the die 110 when the tools are closed together that has approximately the desired thickness of the finished panel edge 22. As shown in Fig. 6, the blade 36 may be particularly selected to aid in forming the finished edge 22 on the panel 10. More particularly, the size, shape and sharpness of the blade 36 may be specifically selected in order to provide a blade 36 that is capable of pulling the edge portion 22 of the panel blank 11 over the edge of the lower die 110. In one embodiment, the tip 38 is a 4-point, steel ruled, center beveled die blade; however, some panel materials may be cut more easily than others, and may require a duller tipped blade, and some panel materials may be tougher to cut than others, and may require a sharper die blade. In the illustrated embodiment, the blade 36 includes a base 37 that extends through a notch in the top base 92 and is mounted to the support structure (not shown). Alternatively, the blade 36 may be mounted directly to the base 92 or other support structure. The tip 38 of the blade 36 extends beyond the lower surface 105 of the upper mold 146, in order to create the desired depth of the edge portion 22 of the panel 10. In the illustrated embodiment, the tip 38 of the blade 36 extends about 0.375" beyond the lower surface 105 of the upper form 146.

[0035] As shown in Figs. 5 and 6, the upper tool 90 may additionally include an exterior foam section 32, or sections 32. The exterior foam 32 provides pressure to the perimeter edge of the blank 11 as the edge is pulled by the tip 38 of the blade 36 over the edge of the lower tool 100 to prevent wrinkling and other blemishes on the edge of the panel 10. The outer foam 32 may be flush against the outer surface of the blade, and it may extend around the entire blade or portions thereof. The foam 32 may additionally protect the tooling operator from contacting the cutting edge 38. The foam 32 may be made of any type of compressible material, including foam, such as polyurethane.

III. Method of Manufacturing the Panel Using the Tooling

[0036] In general, manufacture of a panel 10 according to one embodiment of the present invention includes placing the blank 11 - including a desired number of layers arranged appropriately on top of each other - into a conventional oven and heating the oven to a temperature that is above the melting temperature of the structural layer, and above the temperature necessary to activate the adhesive, if any. The heated blank 11 is then placed on top of the lower tool 100, with the A layer facing the upper tool 90. The upper tool 90 is then lowered (or the lower tool raised) to compress the heated blank 11 between the upper 90 and lower 100 tools. [0037] As the tools 90 and 100 close together, the heated blank 11 is pressed between the upper form 146 and the lower form 114, and molded into the shape of the contoured surfaces of the upper 146 and lower 114 forms. In the illustrated embodiment, the protrusions 160 on the upper form 146 align with the dimples 122 on the lower form 114 to compress the blank 11, forming the spaced apart, concave, circular dimples 20 in the finished panel 10. In addition, due to the particular selection of the die blade 36, the edge portion of the blank 11 - which will form the edge portion 22 of the finished panel 10 - is pulled around the edge of the die 110 of the lower tool 100 by the tip 38 of the die blade 36, forming a downwardly extending edge portion 22 on the finished panel 10. In the illustrated embodiment, the edge of the A layer is pulled down over substantially all of the edge of the structural C layer to form an aesthetically pleasing finished edge 22. Alternatively, in a single layer embodiment, the edge of the structural layer is pulled downward to have a finished appearance.

[0038] The die blade 36 may extend downwardly until the tip 38 engages the surface of the cutting plate 130, cutting the terminal edge 24 of the panel 10 as the panel 10 is pinched between the blade tip 38 and the cutting plate 130. The tools 90, 100 may then be moved apart from each other, and the finished panel 10 removed and cooled, such that it hardens in its formed state. It should be understood that although both top 146 and bottom 114 molds are shown in the illustrated embodiment, other embodiments may include only a top or bottom form for shaping only one surface of the panel 10. Further, in one embodiment, the tool may not include a mold surface, and may simply be used to form flat panels with finished edges.

[0039] Variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.

[0040] Various features of the invention are set forth in the following claims.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A panel comprising: a structural layer having a main portion including an upper surface and a lower surface, and a peripheral edge portion extending downwardly from said main portion, said peripheral edge having an external surface and an internal surface, said structural layer being molded such that said upper surface of said main portion has a three- dimensional surface contour pattern; and a visible outer later attached to said upper surface of said main portion of said structural layer, said visible outer layer having an first portion extending over said upper surface of said structural layer and conformed to said surface contour pattern, said visible outer layer having an edge portion that extends from said first portion, wherein said edge covers substantially all of said exterior surface of said peripheral edge portion of said structural layer.

2. The panel of claim 1 wherein said peripheral edge portion of said structure layer extends around the entire periphery of said structural layer.

3. The panel of claim 2 wherein said first portion of said visible outer layer covers all of said upper surface of said main portion of said structural layer.

4. The panel of claim 3 including an adhesive layer between said structural layer and said visible outer layer.

5. The panel of claim 4 wherein said structural layer is a non- woven polyester mat.

6. The panel of claim 5 wherein said structural layer is a non- woven polyethylene terephthalate mat.

7. The panel of claim 6 wherein said adhesive layer is a heat activated adhesive.

8. The panel of claim 7 including a visible lower surface layer attached to said lower surface of said structural layer.

9. A method for forming a three dimensional structural panel, comprising: providing a moldable structural layer having an upper surface and a lower surface; providing an outer surface layer adjacent to the upper surface of the structural layer; providing a heat activated adhesive between the structural layer and the outer surface layer; heating the structural layer, the outer surface layer and the adhesive to a temperature that activates the adhesive and attaches the structural layer to the outer layer to form a heated panel blank; placing the heated panel blank between a first tool and a second tool, with the outer surface layer facing the first tool, at least one of the first and second tools including a form having a three-dimensional surface contour pattern, the first tool including a perimeter die blade; moving at least one of the first and second tools to compress the heated panel blank between the tools, the three-dimensional surface contour pattern on the one of the first and second tools forming a corresponding three-dimensional contour pattern on the outer surface layer and the upper surface of the structural layer, the perimeter die blade engaging the outer surface layer and drawing an edge portion of the outer surface layer and an edge portion of the structural layer around a side edge of the second tool, wherein the edge portion of the outer layer covers substantially all of the edge portion of the edge portion of the structural layer, forming a finished edge on the panel.

10. The method of claim 9 wherein the upper tool includes an upper form and the lower tool includes a lower form, the upper and lower forms including cooperating three-dimensional contour patterns.

11. The method of claim 10 wherein said upper form includes a plurality of spaced apart, convex protrusions and said lower formed includes a plurality of spaced apart, concave dimples, each of said dimples aligned with one of said protrusions.

12. The method of claim 9 wherein the second tool includes a cutting surface extending around the side edge of the second tool, the side edge of the second tool extending above the cutting surface, the perimeter die blade on the first tool drawing the edge portions of the structural layer and the outer layer around the side edge of the second tool, the perimeter die blade extending downwardly to the cutting surface, such that the perimeter die blade cuts the edge portions of the structural layer and the outer layer when the edge portions contact the cutting surface.

13. The method of claim 12 including the step of selecting the perimeter die blade such that the die blade a tip does not cut the edge portions of the structural layer and the outer layer until at least one of the layers contacts the cutting surface.

14. A panel having a finished peripheral edge produced by the steps of: providing a first tool having an upper surface, a side edge, and a cutting surface, the upper surface spaced above the cutting surface; providing a second tool having a perimeter die blade; placing a heated panel blank between the first tool and the second tool, the panel blank having a structural layer, an outer surface layer, and an adhesive layer, the panel blank having a main portion, and an edge portion; moving at least one of the first tool and the second tool to compress the main portion of the panel blank between the first tool and the second tool, and to contact the outer surface layer with the perimeter die blade, the perimeter die blade drawing the edge portion of the panel blank over the side edge of the first tool, the outer surface layer extending over substantially all of the structural layer within the edge portion.

15. The panel of claim 14 wherein the step of moving at least one of the first and second tools includes moving the perimeter die blade into contact with the cutting surface, the die blade cutting the panel blank at the location where the panel blank is forced into contact with the cutting surface by the perimeter die blade.

16. The panel of claim 15 wherein the main portion of the panel includes a three-dimensional surface contour that is formed by a similarly shaped mold surface on one of the first tool and the second tool when main portion is compressed between the first tool and the second tool.

17. The panel of claim 16 wherein the three-dimensional surface contour is formed by compressing the main portion of the panel blank between a mold surface on the first tool and a mold surface on the second tool.

18. The panel of claim 17 where the edge portion of the blank is drawn around the side edge of the first tool such that the edge portion extends approximately perpendicular to the main portion.

19. The panel of claim 18 wherein the perimeter die blade is a 4 point steel ruled die blade.

20. The panel of claim 19 wherein the structural layer is a non-woven polymeric mat.