Three-dimensional panels and methods of manufacture

Abstract

Methods, devices, and systems are described for three-dimensional panels. Panels have a plurality of protruding strips formed integrally with the panel and projecting outward from a frontside of the panel. Each protruding strip has an arched cross-sectional profile along its length, providing a curved or raised surface relative to a plane of the panel. Methods of manufacturing the three-dimensional panel include forming two slits in a panel, the two slits passing from the backside of the panel to the frontside of the panel. The method further comprises forming at least two partial cuts between the two slits, the partial cuts being made at the backside of the panel, the partial cuts being perpendicular in direction to the two slits. The method further comprises inserting at least one of a block or a support at the backside of the panel to form a protruding strip.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to: U.S. Provisional Application No. 63 / 789,932 entitled “THREE-DIMENSIONAL PANELS AND METHODS OF MANUFACTURE” and filed on Apr. 16, 2025, the disclosures of which are incorporated herein by reference in their entirety.TECHNICAL FIELD

[0002] The disclosed technology relates generally to panels. More specifically, the present disclosed technology relates to three-dimensional panels and coverings capable of insulating sound and creating patterned art.BACKGROUND

[0003] Acoustical panels are used to form soundproofing interior surfaces. They typically come in the form of ceiling panels, wall panels, and partitions (e.g., partitions between office cubicles), and are used in commercial buildings, residential buildings, public buildings, auditoriums, etc. The panels include acoustical characteristics derived from the materials selected for their manufacture and from their ability to accept sound-absorbing perforation. The panels are generally planar.SUMMARY

[0004] The present disclosure provides methods, systems, and articles of manufacture for three-dimensional panels.

[0005] The present disclosure relates generally to panels having outwardly projecting features. In some aspects, a panel is provided including a plurality of protruding strips formed integrally with the panel and projecting outward from a frontside of the panel. Each protruding strip has an arched cross-sectional profile along its length, providing a curved or raised surface relative to a plane of the panel.

[0006] In one aspect, the panel includes a frontside and an opposing backside, with multiple protruding strips extending outward from the frontside. Each protruding strip may include an apex that extends away from the plane of the panel by a distance determined, at least in part, by a thickness of a block or support inserted at the backside of the panel. The protruding strips may transition gradually and smoothly from a flat surface of the panel to the apex to form a continuous arched profile. In some embodiments, the protruding strip has a thickness equal to a thickness of the panel, and a gap may be formed between a backside surface of the panel and a bottom portion of the protruding strip based on insertion of the block. A backside surface of the block may be flush with the backside of the panel, and a width of the block may correspond to a width of the protruding strip.

[0007] In another aspect, the plurality of protruding strips may be arranged in a staggered configuration across the frontside of the panel. Adjacent protruding strips may be offset horizontally relative to one another, while being vertically aligned with other protruding strips positioned above or below. Such arrangements allow repetitive, offset protruding features to be formed across the panel.

[0008] In another aspect, a method for forming a protruding strip in a panel is disclosed. The method may include forming two slits extending from the backside of the panel to the frontside, and forming one or more partial cuts between the slits on the backside of the panel, the partial cuts being oriented perpendicular to the slits. At least one block or support is inserted at the backside of the panel to cause material between the slits to project outward from the frontside, thereby forming a protruding strip having an arched profile. The protruding strip may include a central apex region and sloped portions on opposing sides, with the slits defining vertical edges of the sloped and central regions. The extent of projection of the apex may be determined by a thickness of the inserted block, and the block or support may be sized and positioned such that a surface thereof is flush with the backside of the panel.

[0009] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. While certain features of the currently disclosed subject matter are described for illustrative purposes, it should be readily understood that such features are not intended to be limiting. The claims that follow this disclosure are intended to define the scope of the protected subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The embodiments herein may be better understood by referring to the following description in conjunction with the accompanying drawings in which like reference numerals indicate identically or functionally similar elements, of which:

[0011] FIG. 1 depicts a top view of an example of protruding strips across an acoustic panel;

[0012] FIG. 2 depicts a back view of an example of an acoustic panel having protruding strips;

[0013] FIG. 3 depicts another back view of an example of an acoustic panel having protruding strips;

[0014] FIG. 4 depicts a perspective view of an example of an acoustic panel having protruding strips;

[0015] FIG. 5 depicts a perspective view of an example of multiple acoustic panels having protruding strips;

[0016] FIG. 6 depicts a side view of an example of protruding strips across an acoustic panel;

[0017] FIG. 7 depicts a bottom view of an example of protruding strips across an acoustic panel; and

[0018] FIG. 8 depicts another perspective view of an example of an acoustic panel having protruding strips.

[0019] Like reference numbers and designations in the various drawings indicate like elements.DETAILED DESCRIPTION

[0020] The methods, systems, and apparatuses described herein are for three-dimensional panels and methods of manufacture. In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols generally identify similar components, unless context dictates otherwise. The illustrative alternatives described in the detailed description, drawings, and claims are not meant to be limiting. Other alternatives may be used and other changes may be made without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and make part of this application.

[0021] The three-dimensional panels may include a geometric frame and a series of protrusions that form arched bridges across the frontside of the planar geometric frame. The three-dimensional panels may be attached to a wall, a surface, or be suspended from the ceiling. The three-dimensional panels may be patterned to form a tessellated work of art. In some embodiments, the three-dimensional panels are acoustic panels configured to reduce the transmission of sound from one side of the panel to the other and to absorb or diffuse sound waves incident on the frontside of the panel. The acoustic panels may be constructed from acoustically absorptive materials including, but not limited to, mineral fiber board, fiberglass board, cellulose fiber board, foam, wood fiber board, perforated metal, or any combination thereof. The protruding strips may enhance the acoustic performance of the panels by increasing the effective surface area of the panel that interacts with incident sound waves, by creating air pockets or cavities between the protruding strips and the base surface of the panel and by scattering and diffusing incident sound waves in multiple directions to reduce specular reflections and flutter echo within an enclosed space. The three-dimensional panels described herein may be particularly well suited for installation in recording studios, home theaters, offices, auditoriums, conference rooms, classrooms, and other spaces where acoustic performance and aesthetic appeal are both important considerations.

[0022] FIG. 1 depicts a top view of protruding strips 3520 across an acoustic panel 3510. The acoustic panel 3510 may reduce the noise transmitted from one side of the panel to the other side of the panel. The protruding strips 3520 may raise above a top surface of the acoustic panel 3510. The protruding strips 3520 may be longitudinal in a vertical direction. The protruding strips 3520 may be oriented in a vertical direction. The protruding strips 3520 may taper from a center portion to an edge portion. The protruding strips 3520 may have an apex in the center portion and two sloped portions that extend from either side of the center portion. The apex in the center portion may extend further away from the top surface of the acoustic panel 3510 than the sloped portions. The top surface of the acoustic panel 3510 may be flat in comparison to the protruding strips 3520.

[0023] The protruding strips 3520 may be raised strips of the acoustic panel 3510 having two straight vertical edges. The two straight vertical edges may be equal in length and may define the edges of the sloped portion and the center portion. The two straight vertical edges may be protrusions of the acoustic panel 3510 formed by cutting and raising from the acoustic panel 3510 itself. The two straight vertical edges may have top points and bottom points that correspond to and define the beginning of the sloped portions. The middle points of each of the two straight edges may correspond to and define the center portion having the apex of the protruding strips 3520.

[0024] The protruding strips 3520 may form arching bridges using the two vertical edges. The arching bridges may extend vertically across the substrate of the acoustic panel 3510. The top ends and the bottom ends of the two vertical edges may define the two opposing ends of an arching bridge that spans between the ends of the two vertical edges. The top end of the arching bridge may be defined by the top ends of the two vertical edges. The bottom end of the arching bridge may be defined by the bottom ends of the two vertical edges. The top surfaces of the top end and the bottom end of the arching bridge may be continuous with the top surface of the acoustic panel 3510. The arching bridge may have been formed from the acoustic panel 3510 itself. The arching bridge may extend away from the top surface of the acoustic panel 3510 to form the protruding strips 3520 in response to cutting the two straight vertical edges.

[0025] FIG. 2 depicts a back view of an acoustic panel 3510 having protruding strips 3520. The protruding strips 3520 may be formed by cutting slits on the long sides of the to-be formed arching bridge on the backside of the acoustic panel 3510. The slits cut on the long sides may extend all the way through the thickness or depth of the acoustic panel 3510. The protruding strips 3520 may also be formed by making scores or cuts at a partial depth of the acoustic panel 3510 at the short sides of the to-be formed arching bridge on the backside of the acoustic panel 3510. The cuts at a partial depth relieve tension on the backside to form the arching bridge.

[0026] In some embodiments, a support for the arching bridge may be inserted at the backside of the acoustic panel 3510. The support for the arching bridge may be a block 3610 having a width that matches the width of the arching bridge. The block 3610 may be aligned with the center portion of the arching bridge to support the apex of the arching bridge. The block 3610 may be glued to the backside of the arching bridge at the backside of the acoustic panel 3510. In some embodiments, an insert may be inserted between the two vertical lines to form protruding strips aligning with the contour of the top surface of the insert. In some embodiments, the blocks and / or the inserts enhance the performance of acoustic panel 3510 by dampening sound. In some embodiments, a hot meld adhesive may be used for securing the block 3610 to the backside of the acoustic panel 3510.

[0027] The thickness of the block 3610 may be approximately the same as the thickness of the acoustic panel 3510. The backside of the block 3610 may be flush with the backside of the acoustic panel 3510 when inserted. The thickness of the block 3610 may determine how far the apex of the center portion of the arching bridge extends away from the top surface of the acoustic panel 3510. In some embodiments, the thickness of the block 3610 may be less than the thickness of the acoustic panel 3510 to avoid exposing the block 3610 at the frontside of the acoustic panel 3510. In some embodiments, the block 3610 may be moved to a different position at the backside of the arching bridge for repositioning the apex of the arching bridge at the frontside of the acoustic panel 3510.

[0028] The advantages of this method of forming the protruding strips 3520 are that the method creates an air gap in the backside of the acoustic panel 3510 without the use of ex-pensive machines for tooling the gap. The air gap may further dampen sound passing through the acoustic panel 3510. Another advantage of this method of forming the protruding strips 3520 is the sound-dampening properties of inserted blocks 3610 to the backside of the acoustic panel 3510 that form the protruding strips 3520 without requiring heat treatments.

[0029] FIG. 3 depicts another back view of an acoustic panel 3510 having protruding strips 3520. FIG. 3 illustrates the acoustic panel 3510 prior to the insertion of blocks 3610 or supports, showing the panel 3510 in an intermediate stage of manufacture. In this intermediate stage, the two slits defining the long sides of each arching bridge are visible as through-cuts extending entirely through the thickness of the acoustic panel 3510 from the backside to the frontside. The partial cuts at the short ends of each to-be-formed arching bridge are also visible on the backside of the acoustic panel 3510, extending partially through the thickness of the acoustic panel 3510 in a direction perpendicular to the two slits. In some embodiments, the partial cuts relieve the internal tension of the material of the acoustic panel 3510 at the ends of the arching bridge, enabling the material between the two slits to bow or arch away from the plane of the acoustic panel 3510 when a block 3610 or support is inserted from the backside. In some embodiments, the partial cuts may be scored rather than fully cut through, so as to serve as a controlled fold line for the arching bridge. The acoustic panel 3510 shown in FIG. 3 may be fabricated from mineral fiber, fiberglass, cellulose, wood fiber, metal, polymer, or any other suitable acoustic substrate material. The material of the acoustic panel 3510 may have sufficient flexibility to permit the arching of the protruding strips 3520 without fracturing when the blocks 3610 or supports are inserted.

[0030] FIG. 4 depicts a perspective view of an acoustic panel 3510 having protruding strips 3520. The protruding strips 3520 may form a pattern in the frontside of the acoustic panel 3510. The pattern can be random, alternating, staggered, or rhythmic. Any number of protruding strips 3520 may be formed on the acoustic panel 3510. As shown in FIG. 4, the protruding strips 3520 project outward from the frontside of the acoustic panel 3510 where each strip 3520 forms an arched or bowed profile when viewed from the side. The arched profile of each protruding strip 3520 may result from the bowing of the panel material between the two slits when pushed outward by the block 3610 or support inserted from the backside. The protruding strips 3520 may be substantially parallel to one another, extending in a generally vertical direction along the face of the acoustic panel 3510. In some embodiments, adjacent protruding strips 3520 may be offset from one another in the vertical direction to create a staggered arrangement across the face of the acoustic panel 3510, as illustrated in FIG. 4. The staggered arrangement of the protruding strips 3520 may enhance the acoustic diffusion properties of the acoustic panel 3510 by scattering incident sound waves in multiple directions across the face of the panel. The acoustic panel 3510 may be configured for installation as a wall panel, ceiling panel, or partition. The protruding strips 3520 on the frontside of the acoustic panel 3510 may face the interior space to interact with sound waves in that space.

[0031] FIG. 5 depicts a perspective view of multiple acoustic panels having protruding strips. The acoustic panels may be aligned side-by-side against a wall to form an acoustic barrier at the wall. FIG. 5 depicts a perspective view of multiple acoustic panels 3510 having protruding strips 3520. The acoustic panels 3510 may be aligned side-by-side against a wall to form an acoustic barrier at the wall. As shown in FIG. 5, three acoustic panels 3510 are arranged in a side-by-side configuration, with adjacent panels 3510 sharing or abutting edges. The protruding strips 3520 of adjacent panels 3510 may be aligned or offset relative to one another to form a continuous pattern or tessellated design across the combined surface of the multiple panels 3510. In some embodiments, the protruding strips 3520 of adjacent panels 3510 may be arranged to create a seamless visual continuation of the pattern across the panel boundaries, such that the assembly of multiple panels 3510 appears as a unified decorative and acoustic surface. The arrangement of multiple acoustic panels 3510 may allow for the cover-age of large wall or ceiling areas with a modular system that can be configured and reconfigured as needed. The acoustic panels 3510 may be installed in rows, columns, or any combination thereof. The combined assembly of multiple acoustic panels 3510 may provide greater sound absorption, sound diffusion, and noise reduction than a single panel 3510, and may also form an architectural or decorative feature of an interior space. In some embodiments, the panels 3510 within the assembly may have protruding strips 3520 arranged in complementary patterns so that the strips 3520 of one panel 3510 interleave visually or physically with those of an adjacent panel 3510 to further enhance the acoustic and aesthetic properties of the combined installation.

[0032] FIG. 6 depicts a side view of an example of protruding strips across an acoustic panel. FIG. 6 depicts a side view of an example of protruding strips 3520 across an acoustic panel 3510. The side view of FIG. 6 reveals the edge profile of the acoustic panel 3510 and illustrates the extent to which the protruding strips 3520 project outward from the frontside of the acoustic panel 3510. As seen from the side, the protruding strips 3520 create a series of protrusions along the face of the acoustic panel 3510, each protruding strip 3520 having an arched cross-sectional profile in the direction perpendicular to the long axis of the strip 3520. The apex of each protruding strip 3520 extends away from the plane of the acoustic panel 3510 by a distance that may be determined by the thickness of the block 3610 or support inserted at the backside of the acoustic panel 3510. In some embodiments, the distance of the apex from the surface of the acoustic panel 3510 may be between approximately ⅛ inch and approximately 2 inches, depending on the thickness of the acoustic panel 3510 and the dimensions of the block 3610 or support. The side view of FIG. 6 also shows that the ends of each protruding strip 3520, where the slits terminate and the partial cuts are located, lie substantially in the same plane as the frontside surface of the acoustic panel 3510, so that the transition between the flat surface of the acoustic panel 3510 and each protruding strip 3520 is gradual and smooth. This smooth transition may avoid sharp edges or discontinuities on the frontside of the acoustic panel 3510 that could be hazardous or aesthetically undesirable. The overall thickness of the acoustic panel assembly at any given location, including the protruding strips 3520, is the sum of the panel thickness and the projection distance of the apex of the protruding strips 3520 from the panel surface.

[0033] FIG. 7 depicts a bottom view of an example of protruding strips across an acoustic panel. FIG. 7 depicts a bottom view of an example of protruding strips 3520 across an acoustic panel 3510. The bottom view of FIG. 7 shows the acoustic panel 3510 as seen from the end, revealing the footprint of the protruding strips 3520 as they extend along the length of the acoustic panel 3510. In this view, the protruding strips 3520 appear as a series of raised elements spaced across the face of the acoustic panel 3510. The spacing between adjacent protruding strips 3520 may be uniform or variable. In some embodiments, the spacing between adjacent protruding strips 3520 may be selected to optimize sound diffusion across a range of frequencies. The flat regions of the acoustic panel 3510 between adjacent protruding strips 3520 remain in the plane of the panel surface and provide structural support and continuity to the panel assembly. The bottom view also illustrates that each protruding strip 3520 has a finite length along the face of the acoustic panel 3510, with the ends of each strip 3520 transitioning back to the plane of the acoustic panel 3510 at the locations of the partial cuts. In some embodiments, the length of each protruding strip 3520 may be between approximately 1 inch and approximately 12 inches, and the width of each protruding strip 3520 may be between approximately ¼ inch and approximately 3 inches. In some embodiments, the protruding strips 3520 may all be of the same length and width, or may vary in length and / or width across the face of the acoustic panel 3510 to create a more complex and varied visual and acoustic pattern.

[0034] FIG. 8 depicts another perspective view of an example of an acoustic panel having protruding strips 3520. FIG. 8 depicts another perspective view of an example of an acoustic panel 3510 having protruding strips 3520. FIG. 8 illustrates the acoustic panel 3510 from a viewing angle that emphasizes the three-dimensional quality of the protruding strips 3520 and the depth created across the face of the acoustic panel 3510. As shown in FIG. 8, the protruding strips 3520 are distributed across substantially the entire face of the acoustic panel 3510 in a staggered arrangement, and the arched profile of each strip 3520 is visible from this perspective, demonstrating the graduated transition from the flat surface of the acoustic panel 3510 to the apex of each strip 3520 and back to the flat surface. The protruding strips 3520 of FIG. 8 may include curved sides, reflecting the natural curvature that results from bowing the panel material outward when the block 3610 or support is inserted at the backside. The three-dimensional surface created by the array of protruding strips 3520 on the frontside of the acoustic panel 3510 provides both an acoustically functional surface and an aesthetically distinctive visual texture that may be used as an architectural design element. A method of manufacturing the three-dimensional geometric panel may include forming two slits in an acoustic panel 3510, the acoustic panel 3510 having a frontside and a backside, the two slits passing from the backside of the acoustic panel 3510 to the frontside of the acoustic panel 3510. The method may include forming at least two partial cuts between the two slits, the partial cuts being made at the backside of the acoustic panel 3510, the partial cuts being perpendicular in direction to the two slits. The method may include inserting at least one of a block 3610 or a support at the backside of the acoustic panel 3510 to form a protruding strip 3520. In some embodiments, the method may further include repeating the forming and inserting steps to create a plurality of protruding strips 3520 distributed across the face of the acoustic panel 3510 in any desired pattern, including staggered, offset, random, alternating, or other arrangements as illustrated in the figures herein. The method may further include securing two or more acoustic panels 3510 side-by-side to form a larger acoustic surface assembly as described with reference to FIG. 5.

[0035] In some embodiments, the two slits may extend vertically across the frontside of the acoustic panel 3510 and the two partial cuts extend horizontally across the backside of the acoustic panel 3510. The protruding strip 3520 may have the same thickness as the acoustic panel 3510. The protruding strip 3520 may have an apex in a center portion, and the protruding strip 3520 has two sloped portions that extend from either side of the center portion. The protruding strip 3520 may include two slits defining vertical edges of the sloped portion and the center portion.

[0036] In some embodiments, a top surface of the acoustic panel 3510 may be flat in comparison to the protruding strip 3520. The two slits may be equal in length. The width of at least one of the block 3610 or the support may be equal to the width of the protruding strip 3520. In some embodiments, the inserting of the at least one of the block 3610 or the support may form an air gap between a surface at the backside of the acoustic panel 3510 and a bottom of the protruding strip 3520. A surface of the at least one of the block 3610 or the support may be flush with the backside of the acoustic panel 3510.

[0037] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0038] Unless specifically stated or obvious from context, as used herein, the term “about” is understood as within a range of normal tolerance in the art, for example within 2 standard deviations of the mean. “About” may be understood as within 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, 0.1%, 0.05%, or 0.01% of the stated value. Unless otherwise clear from the context, all numerical values provided herein are modified by the term “about.”

[0039] The many features and advantages of the disclosure are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the disclosure which fall within the true spirit and scope of the disclosure. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the disclosure.

[0040] In the descriptions above and in the claims, phrases such as “at least one of” or “one or more of” may occur followed by a conjunctive list of elements or features. The term “and / or” may also occur in a list of two or more elements or features. Unless otherwise implicitly or explicitly contradicted by the context in which it is used, such a phrase is intended to mean any of the listed elements or features individually or any of the recited elements or features in combination with any of the other recited elements or features. For example, the phrases “at least one of A and B;”“one or more of A and B;” and “A and / or B” are each intended to mean “A alone, B alone, or A and B together.” A similar interpretation is also intended for lists including three or more items. For example, the phrases “at least one of A, B, and C;”“one or more of A, B, and C;” and “A, B, and / or C” are each intended to mean “A alone, B alone, C alone, A and B together, A and C together, B and C together, or A and B and C together.” Use of the term “based on,” above and in the claims is intended to mean, “based at least in part on,” such that an unrecited feature or element is also permissible.

[0041] The implementations set forth in the foregoing description do not represent all implementations consistent with the subject matter described herein. Instead, they are merely some examples consistent with aspects related to the described subject matter. Although a few variations have been described in detail herein, other modifications or additions are possible. In particular, further features and / or variations can be provided in addition to those set forth herein. For example, the implementations described above can be directed to various combinations and sub-combinations of the disclosed features and / or combinations and sub-combinations of one or more features further to those disclosed herein. In addition, the logic flows depicted in the accompanying figures and / or described herein do not necessarily require the particular order shown, or sequential order, to achieve desirable results. The scope of the following claims may include other implementations or embodiments.

[0042] The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment.

Claims

1. A panel comprising:a plurality of protruding strips in the panel, each protruding strip of the plurality of protruding strips projecting outward from a frontside of the panel, the panel having a backside opposite the frontside,wherein each protruding strip of the plurality of protruding strips has an arched cross-sectional profile along a length of the protruding strip.

2. The panel of claim 1, wherein each protruding strip of the plurality of protruding strips has an apex, the apex of each protruding strip extending away from a plane of the panel by a distance determined by a thickness of a block inserted at the backside of the panel.

3. The panel of claim 2, wherein each protruding strip of the plurality of protruding strips has a gradual and smooth transition between a flat surface of the frontside of the panel and the apex.

4. The panel of claim 2, wherein a width the block is equal to the width of the protruding strip.

5. The panel of claim 2, wherein a gap is formed between a surface at the backside of the panel and a bottom of the protruding strip based on the inserted block.

6. The panel of claim 2, wherein a back surface of the block is flush with the backside of the panel.

7. The panel of claim 1, wherein a protruding strip of the plurality of protruding strips is offset from a right adjacent protruding strip and a left adjacent protruding strip in a horizontal direction.

8. The panel of claim 1, wherein a protruding strip of the plurality of protruding strips is aligned with a top adjacent protruding strip and a bottom adjacent protruding strip in a vertical direction.

9. The panel of claim 1, wherein a protruding strip of the plurality of protruding strips has the same thickness as the panel.

10. A panel comprising:a plurality of protruding strips in the panel across a frontside of the panel in a staggered arrangement, each protruding strip of the plurality of protruding strips projecting outward from the frontside of the panel, the panel having a backside opposite the frontside,wherein each protruding strip of the plurality of protruding strips has an arched cross-sectional profile along a length of the protruding strip.

11. A method comprising:forming two slits in a panel, the panel having a frontside and a backside, the two slits passing from the backside of the panel to the frontside of the panel;forming at least two partial cuts between the two slits, the partial cuts being made at the backside of the panel, the partial cuts being perpendicular in direction to the two slits; andinserting at least one of a block or a support at the backside of the panel to form a protruding strip.

12. The method of claim 11, wherein the two slits extend vertically across the frontside of the panel and the two partial cuts extend horizontally across the backside of the panel.

13. The method of claim 11, wherein the protruding strip has the same thickness as the panel.

14. The method of claim 11, wherein the protruding strip has an apex in a center portion, and the protruding strip has two sloped portions that extend from either side of the center portion.

15. The method of claim 14, wherein the two slits define vertical edges of the sloped portion and the center portion.

16. The method of claim 14, wherein the apex extends away from a plane of the panel by a distance determined by a thickness of the block inserted at the backside of the panel.

17. The method of claim 11, wherein the two slits are equal in length.

18. The method of claim 11, wherein a width of at least one of the block or the support is equal to a width of the protruding strip.

19. The method of claim 11, wherein the inserting of the at least one of the block or the support forms a gap between a surface at the backside of the panel and a bottom of the protruding strip.

20. The method of claim 11, wherein a surface of the at least one of the block or the support is flush with the backside of the panel.

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