Flexible veneer panel with metal mesh layer

A veneer panel is provided. The panel may comprise a face veneer, a metal mesh proximate the veneer, a backing layer proximate the metal mesh, and a thermoset adhesive bonding the wood veneer to the metal mesh and the backing layer. A method of making a veneer panel is also provided. The method may comprise the steps of forming a veneer assembly by stacking a face veneer, a metal mesh, and a backing layer, applying an adhesive material between a back surface of the face veneer and the metal mesh, and pressing the veneer assembly.

FIELD OF INVENTION

The present disclosure relates to decorative and structural panels, and, more specifically, to a flexible veneer panel with a metal mesh layer.

BACKGROUND

Current veneer panels may include paper-backed veneer panels, fleece-backed veneer panels, and two-ply veneer panels. In some instances, paper-backed veneer panels and fleece-backed veneer panels may tear or wrinkle. Each of the existing panels may also experience delamination in some applications. In other instances, these flexible panels may not be useable in vehicular applications due to limitations such as flammability of the panels. The two-ply veneer panel may provide flexibility but is also susceptible to being cracked and/or broken.

SUMMARY

A panel may comprise a wood veneer, a metal mesh proximate the veneer, a backing layer proximate the metal mesh, and a thermoset adhesive bonding the wood veneer to the metal mesh and the backing layer.

In various embodiments, the adhesive material may comprise at least one of a phenolic glue film or a phenolic surface film. The wood veneer may comprise a thickness from 0.015 inches to 0.030 inches. The thermoset adhesive may have penetrated into the wood veneer and the metal mesh. The metal mesh may comprise at least one of stainless steel or aluminum. The metal mesh may metal wires with a diameter from 0.0009 inches to 0.0019 inches. The metal mesh may comprise a 400 wire-per-inch wire mesh. The backing layer may comprise a second wood veneer.

A method of making a veneer panel may comprise the steps of forming a veneer assembly by stacking a face veneer, a metal mesh, and a backing layer, applying an adhesive material between a back surface of the face veneer and the metal mesh, and pressing the veneer assembly.

In various embodiments, the adhesive material may comprise at least one of a phenolic glue film or a phenolic surface film. The pressing the veneer assembly may further comprise heating the veneer assembly. The veneer panel may be flexed using a flex machine. The metal mesh may comprise at least one of stainless steel or aluminum. The metal mesh may also comprise metal wires with a diameter from 0.0009 inches to 0.0019 inches. The metal mesh may further comprise a 400 wire-per-inch mesh.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the exemplary embodiments of the disclosure, it should be understood that other embodiments may be realized and that logical changes and adaptations in design and construction may be made in accordance with this disclosure and the teachings herein. Thus, the detailed description herein is presented for purposes of illustration only and not limitation. The steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented.

Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact. Surface shading lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

A 3-ply wood veneer panel may comprise a metal mesh and/or metal fabric layer disposed between two wooden layers. Adhesive material may bond the three layers together with each layer having a thickness substantially less than the thickness of the other 2 dimensions. The resulting 3-ply panel may display flexibility relative to the plane formed by the two larger dimensions.

With reference toFIG. 1, a veneer panel100is shown, in accordance with various embodiments. Veneer panel100may be a veneer assembly with three or more layers stacked in the y-direction relative to the axes provided for reference. Veneer panel100may have a face veneer102that may comprise a thin layer of walnut, cherry, birch, rosewood, oak, maple, mahogany, hemlock, teak, walnut, or any other wood species. Face veneer102of veneer panel100may have a thickness T1ranging from 0.015 inches to 0.030 inches (0.38 mm to 0.76 mm) For example, face veneer102may comprise a thickness T1of 0.02 inches (0.508 mm) Face veneer102may further be sanded to provide a smooth, decorative surface for finishing. Veneer panel may be a flexible veneer panel. Veneer panel100may be formed in any dimensions, and readily be made into rectangular 4 foot by 8 foot (1.2 m to 2.4 m) panels. Veneer panels may also be cut into smaller sizes or varied shapes.

In various embodiments, an adhesive material104may be applied to a back surface of face veneer102. The adhesive material may be in the form of a thermoset adhesive, such as a phenolic glue film or a phenolic surface film, or any other suitable adhesive. Adhesive material104may have a thickness T2of 0.005 inches (0.13 mm), for example. A phenolic glue film may allow the glue to be cut in a sheet form and disposed between a back surface face veneer102and metal mesh106during the layup process.

In various embodiments, a metal mesh106may act as a core material for veneer panel100. Metal mesh106may be a woven metal material similar to a fabric. Metal mesh106may be woven on high-speed looms in various weaves (e.g., twill weave or square weave). The diameter of the wire in a metal mesh contributes more to the strength of a veneer panel than the type of weave of the mesh being. The metal mesh may range from 325 wire-per-inch mesh to 500 wire-per-inch (325 wire-per-2.54-cm to 500 wire-per-2.54-cm) mesh. For example, the metal mesh may be a 400 wire-per-inch (400 wire-per-2.54-cm) mesh or other fabric-like metal woven mesh.

In various embodiments, metal mesh106may be woven from metal wires, the metal wires having a diameter from 0.0009 inches (0.023 mm) to 0.0019 inches (0.048 mm) For example, a veneer panel may be made from a metal weave of wires with 0.0012 inch (0.0305 mm) diameter. Higher diameter wires may show through thin cuts of face veneer102or otherwise telegraph the presence of the woven wires behind face veneer102. Metal mesh106may thus have a thickness T3less than 0.05 inches (1.27 mm).

In various embodiments, metal mesh106may be made from any metallic material (e.g., aluminum, steel, or any other suitable metal). A corrosion resistant stainless steel such as T-316 stainless steel (16-18% chromium, 10-14% nickel, 0.8% max carbon, 2% max magnesium, 0.75% max silicon, 2-3% molybdenum) or T-304 stainless steel (18-20% chromium, 8-10.5% nickel, 0.8% max carbon, 2% max magnesium, 0.75% max silicon) may be suitable for its corrosion resistance. In that regard, the material for metal mesh106may be selected to resist reacting chemicals such as tannins in the wood and/or fire retardant surface treatments, depending on the desired application. Aluminum mesh may also be used and is of relatively light weight with generally low melting point. Thus, aluminum may be less fire resistant than steel but provides weight savings compared to steel. In that regard, various metals may be compared and selected for metal mesh106based on suitability to the final application of veneer panel100.

In various embodiments, an adhesive material108may be applied to a surface of metal mesh106on the opposite side of metal mesh106from adhesive material104. Thus, metal mesh106may be sandwiched between adhesive material104and adhesive material108. Adhesive material108may be in the form of a thermoset adhesive (e.g., a phenolic glue film or a phenolic surface film). Adhesive material108may have a thickness T4of 0.005 inches (0.13 mm), for example. A phenolic glue film may allow the glue to be cut in a sheet form and located between backing layer110and metal mesh106during the layup process.

In various embodiments, backing layer110may form the back surface of veneer panel100. Backing layer110may thus be hidden from sight in applications where only one side of veneer panel100is visible. Thus, backing layer110may be made from a less visually appealing and or mismatched material. Backing layer110may be a thin layer of walnut, cherry, birch, rosewood, oak, maple, mahogany, hemlock, teak, walnut, poplar, or any other wood species. Using a wood material for backing layer110, and particularly the same wood species as face veneer102, may result a more balanced coefficient of thermal expansion than other backing materials. Backing layer110may be a wooden layer with a thickness T5ranging from 0.015 inches to 0.030 inches (0.38 mm to 0.76 mm) For example, backing layer110may comprise a poplar layer with thickness T5of 0.02 inches (0.508 mm).

In various embodiments, the grain of the wood on backing layer110may be aligned with the grain of face veneer102for flexibility, or the grain of the wood on backing layer110may be disposed roughly orthogonal to the grain of face veneer102for increased stiffness. Backing layer110may further be sanded to provide a smooth surface with a consistent thickness. In various embodiments, backing layer110may be made from non-wood materials such as fiber-reinforced composite, paper, felt, or another suitable material.

With reference toFIG. 2, veneer panel100is shown in a 3-ply configuration with each layer fanned out for visibility. The layup for veneer panel100comprises face veneer102on a top surface. Adhesive material104may be a continuous sheet cut into a shape to mirror the shape of face veneer102and the other layers of veneer panel100. Metal mesh106may be disposed between adhesive material104and adhesive material108. A backing layer110may be disposed adjacent adhesive material108to form the bottom surface of veneer panel100. In that regard, backing layer110may provide support for veneer panel100. Face veneer102, adhesive material104, metal mesh106, adhesive material108, and backing layer110may each be a separate layer cut into the same shape and be aligned prior to a heat pressing treatment to form the veneer panel100.

With reference toFIG. 3, a veneer panel100is shown with a heat and/or pressure treatment (e.g., by pressing veneer panel100inside a press machine), in accordance with various embodiments. Pressure P may be a compressive force applied uniformly and/or substantially uniformly across the outer surfaces of veneer panel100through face veneer102and backing layer110. Veneer panel100may also be heated to reach the thermal threshold to set thermosetting adhesive materials.

In various embodiments, and in response to the increased temperature and pressure, adhesive material104may penetrate (in the y-direction) into fibers of the wood used for face veneer102as well as into metal mesh106. Metal mesh106and face veneer102may press together and contact one another or have a thin layer of adhesive remaining between one another. Similarly, in response to the increased temperature and pressure, adhesive material108may penetrate into the material (e.g., wood) used for backing layer110as well as into metal mesh106. Metal mesh106and backing layer110may press together and contact one another or have a thin layer of adhesive remaining between one another. Adhesive material104and adhesive material108may then thermoset and initiate cross-linking bonds. Adhesive material that has invaded into face veneer102, metal mesh106, and backing layer110may provide a strong adhesion and resist delamination.

In various embodiments, veneer panel100may be sanded after going through the press process to create more uniform surfaces. Veneer panel100may then be run through a flex machine to introduce small micro cracks into the panel by flexing the panel. The micro-cracks may not be visible to the naked eye but nonetheless may improve flexibility of the panel. The 3-ply sandwich construction of veneer panel100may resist breaking in the flex machine.