Abstract:
A flame resistant wood veneer assembly in the four embodiments, includes a decorative wood veneer layer, and a combination of aluminum foil layer(s)/backing(s) and a non-decorative wood veneer layer(s)/backing(s), the aluminum foil layer is bonded to the decorative wood veneer layer and between the non-decorative wood veneer layer(s)/backing(s) with phenolic adhesive at high pressure and high temperature wherein the high pressure is at least 150 pounds per square inch and the high temperature is at least 275 degrees Fahrenheit and where such high pressure and temperature is applied for at least four minutes. The resulting assembly is preferably wide belt sanded to produce a smooth, flat veneer product.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims benefit of and is a divisional of U.S. application Ser. No. 11/973,686, filed Oct. 10, 2007. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to fire resistant laminated natural wood veneer assemblies for aircraft assemblies and methods for making such veneer assemblies. 
       BACKGROUND OF THE INVENTION 
       [0003]    Part 25 of Title 14 of the Code of Federal Regulations sets forth a stringent Federal Aviation Administration (FAA) vertical flammability test for materials proposed for aircraft interiors. More particularly, the standards for flammability tests, heat release rate tests and smoke emission tests for proposed aircraft cabin materials are very stringent for aircraft capable of carrying 20 or more passengers. In the past, such test standards have impeded the use of natural wood veneers in aircraft for carrying fewer than 20 passengers and have generally precluded the use of such natural wood veneers in aircraft carrying more than 20 passengers. One solution, for aircraft carrying fewer than 20 passengers has been the application of fire retardant chemicals to wood veneers. But in many cases, fire needed is a veneer assembly which does not require the use of fire retardant chemicals and which is inherently flame resistant. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention provides an inherently flame resistant 2-ply veneer assembly. The present veneer assembly generally includes a decorative wood veneer and an aluminum foil backing bonded together in a laminated veneer assembly. The method for making the flame resistant veneer assembly includes laying up a decorative wood veneer and an aluminum foil backing with a thin film of phenolic adhesive between decorative wood veneers and the aluminum foil. The lay up is then pressed preferably at a pressure between 150 psi and 250 psi and at a temperature between 275 degrees F. and 325 degrees F. for four to six minutes. It is preferable that after the assembly is pressed under high pressure and temperature, the assembly is precision sanded using wide belt sanders. The decorative veneer surface may flattened by precision belt sanding. When sanding of the decorative veneer surface the object being to limit the amount of decorative veneer removed by sanding as much as possible. In some applications, a 2-ply embodiment having only an aluminum foil backing is advantageous where weight may be an issue and for easily forming the laminated veneer assembly for a preferred shape requirement. Also in some applications, having an aluminum foil backing is advantageous for bonding with specific adhesive(s) to various substrates such as honeycomb core. A pressure sensitive adhesive (PSA) may be added to the aluminum foil backing for bonding to various panels and other substrates. 
         [0005]    In a second three ply embodiment of the invention, a non-decorative layer may be bonded to the back of the aluminum foil layer by means of a second thin film of phenolic adhesive in a bonding process substantially like the high pressure, high temperature process described above. The bonding of the non-decorative layer is preferably conducted in the same bonding operation as the bonding the decorative wood veneer and the aluminum foil backing. It is preferable that after the three ply assembly is pressed under high pressure and temperature and that the assembly is precision sanded using wide belt sanders. The non-decorative veneer backing is initially precision sanded in order to flatten the veneer assembly. The decorative veneer surface may also be sanded with the object being to limit the amount of decorative veneer removed by sanding. In some applications having a non-decorative wood backing is advantageous for bonding with specific adhesive(s) to various substrates such as honeycomb core. A pressure sensitive adhesive (PSA) may be added to the non-decorative veneer for bonding to various panels and other substrates. 
         [0006]    In a third embodiment of the invention, a 4-ply, a second aluminum foil layer may be bonded to the back of the non-decorative wood veneer by a second phenolic bonding process substantially like the high pressure, high temperature process described above. The bonding of the second aluminum foil layer should preferably occur after the above-described wide belt sanding of the non-decorative layer operations and before sanding the decorative veneer surface. The decorative veneer surface may also be sanded after the second phenolic bonding process with the object being to limit the amount of decorative veneer removed by sanding as much as possible. In some applications, having an aluminum foil backing is advantageous for bonding with specific adhesive(s) to various substrates such as honeycomb core. A pressure sensitive adhesive (PSA) may be added to the second aluminum foil layer for bonding to various panels and other substrates. 
         [0007]    In a five ply fourth embodiment of the invention, a second aluminum foil layer and a second non-decorative wood veneer layer may be bonded to the back of the decorative wood veneer layer. It is preferable that after the assembly is pressed under high pressure and temperature, the assembly is precision sanded using wide belt sanders. The second non-decorative veneer backing is initially precision sanded in order to flatten the veneer assembly. The decorative veneer surface may also be sanded with the object being to limit the amount of decorative veneer removed by sanding as much as possible. This 5-ply embodiment provides a less flexible veneer assembly thereby providing additional strength when required. In some applications, having a non-decorative wood veneer backing may be advantageous for bonding with specific adhesive(s) to various substrates such as honeycomb core. A pressure sensitive adhesive (PSA) may be added to the second non-decorative veneer layer for bonding to various panels and 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective cross-section diagram illustrating a first veneer assembly embodiment. 
           [0009]      FIG. 1A  is a cross-section diagram illustrating the first veneer assembly embodiment before wide belt sanding. 
           [0010]      FIG. 1B  is a cross-section diagram illustrating the first veneer assembly embodiment after wide belt sanding. 
           [0011]      FIG. 1C  is a cross-section diagram illustrating the first veneer assembly embodiment with an added layer of pressure sensitive adhesive including a release paper. 
           [0012]      FIG. 2  is a perspective cross-section diagram illustrating a second veneer assembly embodiment. 
           [0013]      FIG. 2A  is a cross-section diagram illustrating the second veneer assembly embodiment before wide belt sanding. 
           [0014]      FIG. 2B  is a cross-section diagram illustrating the second veneer assembly embodiment after wide belt sanding. 
           [0015]      FIG. 2C  is a cross-section diagram illustrating the second veneer assembly embodiment with an added layer of pressure sensitive adhesive including a release paper. 
           [0016]      FIG. 3  is a perspective cross-section diagram illustrating a third veneer assembly embodiment. 
           [0017]      FIG. 3A  is a cross-section diagram illustrating the third veneer assembly embodiment before wide belt sanding. 
           [0018]      FIG. 3B  is a cross-section diagram illustrating the third veneer assembly embodiment after wide belt sanding. 
           [0019]      FIG. 3C  is a cross-section diagram illustrating the third veneer assembly embodiment with an added layer of pressure sensitive adhesive including a release paper. 
           [0020]      FIG. 4  is a perspective cross-section diagram illustrating a fourth veneer assembly embodiment. 
           [0021]      FIG. 4A  is a cross-section diagram illustrating the fourth veneer assembly embodiment before wide belt sanding. 
           [0022]      FIG. 4B  is a cross-section diagram illustrating the fourth veneer assembly embodiment after wide belt sanding. 
           [0023]      FIG. 4C  is a cross-section diagram illustrating the fourth veneer assembly embodiment with an added layer of pressure sensitive adhesive including a release paper. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    Referring to  FIG. 1 , an example, fire resistant 2-ply veneer assembly  10  for aircraft interiors is shown including a decorative wood veneer layer  20 , a layer of phenolic adhesive  22  and an aluminum foil backing  30 . The veneer structure  10  shown in  FIG. 1  may be considered as a lay up which is first arranged and then pressed at elevated temperature to produce a bonded laminated structure. In  FIG. 1 , the edges of each layer are shown recessed within the underlying layer for ease of illustration. As can be seen in  FIG. 1 , a thin film of phenolic adhesives  22  is interposed between decorative wood veneer layer  20  and aluminum foil layer  30 . Decorative wood veneer layer  20  may be fashioned from any one of a multitude of decorative woods. Phenolic adhesive is activated by high pressure and high temperature. Thus, the lay-up shown in  FIG. 1  is preferably pressed at a pressure between 150 psi and 250 psi and at a temperature between 275 degrees F. and 325 degrees F. for four to six minutes. This high pressure, high temperature pressing operation activates the phenolic adhesive and results in a permanently bonded veneer assembly. 
         [0025]      FIG. 1A  illustrates veneer assembly  9 , which indicates a veneer assembly, which is not completed. Veneer assembly  9  has not been processed through a wide belt sanding operation. As is shown in  FIG. 1A , decorative veneer layer  20  of unsanded veneer assembly  9  typically has residues from the manufacturing process and slight variations in thickness. Precision wide belt sanding is well known in the art. The object of the precision wide belt sanding operation is to remove any residues from the manufacturing process and flatten outer surface  20 A of decorative veneer layer  20  in order to produce a finished veneer assembly having a substantially uniform thickness. In the precision wide belt sanding operation, outer surface  30 A of aluminum foil layer  30  is pressed against a feed belt and platen while multi wide belt sanding heads remove material from outer surface  20 A of decorative veneer layer  20 . Thus any residues from the manufacturing process and the variations in thickness in veneer layer  20  are largely eliminated by removing material from decorative layer  20  as shown in  FIG. 1B . 
         [0026]      FIG. 1C  shows veneer laminate  10  with an additional layer of pressure sensitive adhesive (PSA)  30 B. Typically, PSA includes a release paper ( 30 C), which can be peeled away prior to placement on a substrate surface. 
         [0027]    Referring to  FIG. 2 , an example, fire resistant 3-ply veneer assembly  200  for aircraft interiors is shown including a decorative wood veneer layer  220 , an aluminum foil layer  230  and a non-decorative veneer backing  240 . The veneer structure  200  shown in  FIG. 2  may be considered as a lay up which is first arranged and then pressed at elevated temperature to produce a bonded laminated structure. In  FIG. 2 , the edges of each layer are shown recessed within the underlying layer for ease of illustration. As can be seen in  FIG. 2 , thin films of phenolic adhesives  222  and  232  are interposed between decorative wood veneer layer  20  and aluminum foil layer  230  and between aluminum foil layer  230  and non-decorative wood veneer layer  240 . Decorative wood veneer layer  220  may be fashioned from any one of a multitude of decorative woods. Non-decorative wood veneer layer  240  is preferably fashioned from poplar. As described above, a phenolic adhesive is activated by high pressure and high temperature. Thus, the lay-up shown in  FIG. 2  is preferably pressed at a pressure between 150 psi and 250 psi and at a temperature between 275 degrees F. and 325 degrees F. for four to six minutes. This high pressure, high temperature pressing operation activates the phenolic adhesive and results in a permanently bonded veneer assembly. 
         [0028]      FIG. 2A  illustrates veneer assembly  190 , which indicates a veneer assembly, which is not completed. Veneer assembly  190  has not been processed through a wide belt sanding operation. As is shown in  FIG. 2A , decorative veneer layer  220  of unsanded veneer assembly  190  typically has residues from the manufacturing process and slight variations in thickness. The same is the case for non-decorative veneer layer  240 . Precision wide belt sanding is well known in the art. The object of the precision wide belt sanding operation is flatten the outer surface  240 A of non-decorative veneer layer  240  in order to produce a finished veneer assembly having a substantially uniform thickness. In this precision wide belt sanding operation, outer surface  220 A of decorative veneer  220  is pressed against a feed belt and platen while multi wide belt sanding heads removes material from outer surface  240 A of non-decorative veneer layer  240 . Thus the variations in thickness in veneer layers  220  and  240  are largely eliminated by removing material from non-decorative veneer layer  240  as shown in  FIG. 2B . A completed, wide belt sanded veneer assembly  200  is shown in  FIG. 2B . In  FIG. 2B , decorative veneer surface  220 A may also be sanded to remove any residues from the manufacturing process and flatten the outer surface  220 A of decorative veneer layer  220  in a wide belt sanding operation—but only very slightly in order to preserve as much of the thickness of decorative veneer layer  220  as possible. In  FIG. 2B , the resulting sanded assembly may have internal variations but will present a substantially flat decorative veneer surface  220 A. Close inspection of  FIG. 2B  reveals that the outside surface of decorative veneer layer  220 , namely surface  220 A is generally flat. Further, in  FIG. 2B , aluminum foil layer  230  now undulates in a way that corresponds to the initial variation of decorative veneer layer  220  shown in  FIG. 2A . In  FIG. 2B , non-decorative veneer layer  240  varies in thickness and the outside surface  240 A of non-decorative veneer layer  240  is generally flat. In effect, material has been removed from non-decorative veneer layer  240  to compensate for the variations in thickness originally present in the veneers. Accordingly, if the wide belt sanded veneer assembly  200  shown in  FIG. 2B  is mounted to a flat substrate surface, outside surface  220 A of decorative veneer layer  220  will present a surface that is sufficiently flat and smooth for a high quality aircraft interior finish.  FIG. 2C  shows veneer laminate  200 . Non-decorative veneer layer  240  may include an optional layer of pressure sensitive adhesive (PSA)  240 B. Typically, PSA includes a release paper ( 40 C), which can be peeled away prior to placement on a substrate surface. 
         [0029]    Referring to  FIG. 3 , an example fire resistant 4-ply veneer assembly  300  for aircraft interiors is shown including a decorative wood veneer layer  20 , an aluminum foil layer  30 , a non-decorative veneer layer  40  and an aluminum foil backing  50 . The veneer structure  300  shown in  FIG. 3  may be manufactured using two different manufacturing options. 
         [0030]    The first option is as follows. The veneer structure  300  shown in  FIG. 3  may be considered as a lay-up, which is first, arranged and then pressed at elevated temperature to produce a bonded laminated structure. In  FIG. 3 , the edges of each layer are shown recessed within the underlying layer for ease of illustration. As can be seen in  FIG. 3 , thin films of phenolic adhesives  322 ,  332  and  342  are interposed between decorative wood veneer layer  320  and aluminum foil layer  330 , between aluminum foil layer  330  and non-decorative wood veneer layer  430  and between non-decorative wood veneer layer  240  and aluminum foil backing  250 . Decorative wood veneer layer  220  may be fashioned from any one of a multitude of decorative woods. Non-decorative wood veneer layer  340  is preferably fashioned from poplar. Phenolic adhesive is activated by high pressure and high temperature. Thus, the lay-up shown in  FIG. 3  is preferably pressed at a pressure between 150 psi and 250 psi and at a temperature between 275 degrees F. and 325 degrees F. for four to six minutes. This high pressure, high temperature pressing operation activates the phenolic adhesive and results in a permanently bonded veneer assembly. 
         [0031]      FIG. 3A  illustrates veneer assembly  290 , which indicates a veneer assembly, which is not completed. Veneer assembly  290  has not been processed through a wide belt sanding operation. As is shown in  FIG. 3A , decorative veneer layer  320  of unsanded veneer assembly  290  typically has residues from the manufacturing process and slight variations in thickness. The same is the case for non-decorative veneer layer  340 . As described above, the residues from manufacturing may be removed in a precision belt sanding operation. Thus with precision belt sanding variations presented by outer surface  320 A of decorative veneer layer  320  in order to produced a finished veneer assembly having a substantially uniform thickness. Outer surface  320 A is chosen because it is the only veneer surface that is exposed for sanding. In the precision wide belt sanding operation, outer surface  350 A, an aluminum foil surface, is pressed against a feed belt and platen while multi wide belt sanding heads remove material from outer surface  320 A of decorative veneer layer  320 . Thus the variations in thickness in veneer layers  20  and  40  are largely eliminated by removing material from non-decorative veneer layer  20  as shown in  FIG. 3B . A completed, wide belt sanded veneer assembly  300  is shown in  FIG. 3B . In  FIG. 3B , decorative veneer surface  320 A may also be sanded to remove any residues from the manufacturing process and flatten the outer surface  320 A of decorative veneer layer  320  in a wide belt sanding operation—but only very slightly in order to preserve as much of the thickness of decorative veneer layer  20  as possible. In  FIG. 3B , the resulting sanded assembly may have internal variations but will present a substantially flat decorative veneer surface  320 A. In effect, material has been removed from decorative veneer layer  320  to compensate for the variations in thickness originally present in the veneers. Accordingly, if the wide belt sanded veneer assembly  300  shown in  FIG. 3B  is mounted to a flat substrate surface, outside surface  20 A of decorative veneer layer  20  will present a surface that is sufficiently flat and smooth for a high quality aircraft interior finish.  FIG. 3C  shows veneer laminate  300 . Aluminum layer  350  may include an optional layer of pressure sensitive adhesive (PSA)  350 B. Typically, PSA includes a release paper ( 350 C), which can be peeled away prior to placement on a substrate. 
         [0032]    A second option for veneer structure  300  is made possible by dividing the lay up into two steps, a first step which produces a laminate which presents an exposed layer of non-decorative veneer and a second step which covers that non-decorative veneer with a second layer of aluminum foil. Thus, to make the veneer structure  300  shown in  FIG. 3  an additional pressing operation and a different sanding operation sequence are required. The veneer structure  300  shown in  FIG. 3  may be considered as a double lay up which is first arranged and then pressed in two separate operations at elevated temperature to produce a bonded laminated structure. In the first pressing operation decorative veneer  320 , phenolic adhesive  322 , aluminum foil  330 , phenolic adhesive  332  and non-decorative veneer  340  are bonded to make an assembly with non-decorative veneer  340  exposed. Thin film of adhesive  342  and the aluminum foil backing  330  will be added in a second pressing operation to the back of non-decorative veneer  340 . 
         [0033]    Thus the product of the first pressing operation described above is precision sanded by pressing outside surface  320 A of decorative veneer  320  against a platin and precision sanding non-decorative veneer  340  to take out variations in the veneer layers. Then, the lay-up shown in  FIG. 3  is preferably pressed a second time at the pressures, temperatures and durations described above. To complete a wide belt sanded veneer assembly  300  as shown in  FIG. 3B , outer surface  320 A may be sanded to remove any residues from the manufacturing process and flatten the outer surface  320 A of decorative veneer layer  320  in a wide belt sanding operation—but only very slightly in order to preserve as much of the thickness of decorative veneer layer  320  as possible. Thus the variations in thickness in veneer layers  320  and  340  are largely eliminated by removing material from decorative veneer layer  340  as shown in  FIG. 3B . A completed, wide belt sanded veneer assembly  300  is shown in  FIG. 3B . In  FIG. 3B , the resulting sanded assembly may have internal variations but will present a substantially flat decorative veneer surface  320 A. Close inspection of  FIG. 3B  reveals that the outside surface of decorative veneer layer  320 , namely surface  320 A is generally flat.  FIG. 3C  shows veneer laminate  300  with an extra layer of adhesive  350 B. Aluminum layer  50  may include an optional layer of pressure sensitive adhesive (PSA)  350 B. Typically, PSA includes a release paper  350 C, which can be peeled away prior to placement on a substrate. 
         [0034]    Referring to  FIG. 4 , an example fire resistant 5-ply veneer assembly  400  for aircraft interiors is shown including a decorative wood veneer layer  420 , an aluminum foil layer  430 , a non-decorative veneer backing  440 , an aluminum foil layer  450  and non-decorative veneer backing  460 . The veneer structure  400  shown in  FIG. 4  may be considered as a lay up which is first arranged and then pressed at elevated temperature to produce a bonded laminated structure. In  FIG. 4 , the edges of each layer are shown recessed within the underlying layer for ease of illustration. As can be seen in  FIG. 4 , thin films of phenolic adhesives  422 ,  432 ,  442  and  452  are interposed between decorative wood veneer layer  420  and aluminum foil layer  430 , between aluminum foil layer  430  and non-decorative wood veneer layer  440 , between non-decorative wood veneer layer  440  and aluminum foil layer  450  and between aluminum foil layer  450  and non-decorative wood veneer layer  460 . A noted above, phenolic adhesive is activated by high pressure and high temperature.  FIG. 4A  illustrates veneer assembly  390 , which indicates a veneer assembly, which is not completed. Veneer assembly  390  has not been processed through a wide belt sanding operation. As is shown in  FIG. 4A , decorative veneer layer  420  of unsanded veneer assembly  390  typically has residues from the manufacturing process and slight variations in thickness. The same is the case for non-decorative veneer layers  440  and  460 . In the precision wide belt sanding operation, outer surface  420 A is pressed against a feed belt and platen while multi wide belt sanding heads removes material from outer surface  460 A of non-decorative veneer layer  460 . Thus the variations in thickness in veneer layers  420 ,  440  and  460  are largely eliminated by removing material from non-decorative veneer layer  460  as shown in  FIG. 4B . A completed, wide belt sanded veneer assembly  400  is shown in  FIG. 4B . In  FIG. 4B , decorative veneer surface  420 A may also be sanded to remove any residues from the manufacturing process and flatten the outer surface  420 A of decorative veneer layer  420  in a wide belt sanding operation—but only very slightly in order to preserve as much of the thickness of decorative veneer layer  420  as possible. In  FIG. 4B , the resulting sanded assembly may have internal variations but will present a substantially flat decorative veneer surface  420 A. Close inspection of  FIG. 4B  reveals that the outside surface of decorative veneer layer  420  namely surface  420 A is generally flat. Further, in  FIG. 4B , aluminum foil layers  430  and  450  now undulates in a way that corresponds to the initial variation of decorative veneer layer  20  shown in  FIG. 4A . In  FIG. 4B , non-decorative veneer layer  440  and  460  varies in thickness and the outside surface  460 A of non-decorative veneer layer  460  is generally flat. In effect, material has been removed from non-decorative veneer layer  460  to compensate for the variations in thickness originally present in the veneers. Accordingly, if the wide belt sanded veneer assembly  400  shown in  FIG. 4B  is mounted to a flat substrate surface, outside surface  420 A of decorative veneer layer  420  will present a surface that is sufficiently flat and smooth for a high quality aircraft interior finish. Decorative veneer surface  420 A may also be sanded in a wide belt sanding operation—but only very slightly in order to preserve as much of the thickness of decorative veneer layer  420  as possible.  FIG. 4C  shows veneer laminate  400 . Non-decorative veneer layer  460  may include an optional layer of pressure sensitive adhesive (PSA)  60 B. Typically, PSA includes a release paper ( 60 C), which can be peeled away prior to placement on a substrate surface. 
         [0035]    Flame tests have shown that the resulting veneer assembly  100  (2-ply) is highly flame resistant. Tests have shown that the best results, in terms of flame resistance and minimum weight, are achieved if the thickness of the decorative veneer layer generally about 0.024 inches prior to sanding operations and if the thickness of the aluminum foil layer is between 0.002 inches and 0.006 inches with the most preferable thickness being about 0.003 to 0.005 inches. It should be noted that 0.024 or 1/42 inches is a standard thickness for wood veneers.  FIG. 1C  shows veneer laminate  100 . Aluminum foil backing may include an optional layer of pressure sensitive adhesive (PSA)  30 B. Typically, PSA includes a release paper  30 C, which can be peeled away prior to placement on a substrate surface. 
         [0036]    Flame tests have shown that the resulting veneer assembly  200  (3-ply) is highly flame resistant. Tests have shown that the best results, in terms of flame resistance and minimum weight, are achieved if the thickness of the decorative veneer layer generally about 0.024 inches prior to sanding operations and if the thickness of the aluminum foil layer is between 0.002 inches and 0.006 inches with the most preferable thickness being about 0.003 to 0.005 inches. It should be noted that 0.024 or 1/42 inches is a standard thickness for wood veneers.  FIG. 2C  shows veneer laminate  200 . Non-decorative wood veneer backing may include an optional layer of pressure sensitive adhesive (PSA)  230 B. Typically, PSA includes a release paper  230 C, which can be peeled away prior to placement on a substrate surface. 
         [0037]    Flame tests have shown that the resulting veneer assembly  300  (4-ply) is highly flame resistant. Tests have shown that the best results, in terms of flame resistance and minimum weight, are achieved if the thickness of the decorative veneer layer and non-decorative veneer layers generally about 0.024 inches prior to sanding operations and if the thickness of the aluminum foil layers are between 0.002 inches and 0.006 inches with the most preferable thickness being about 0.003 to 0.005 inches. It should be noted that 0.024 or 1/42 inches is a standard thickness for wood veneers.  FIG. 3C  shows veneer laminate  300 . Aluminum foil layer may include an optional layer of pressure sensitive adhesive (PSA)  50 B. Typically, PSA includes a release paper  350 C, which can be peeled away prior to placement on a substrate surface. 
         [0038]    Flame tests have shown that the resulting veneer assembly  400  is highly flame resistant. Tests have shown that the best results, in terms of flame resistance and minimum weight, are achieved if the thickness of the decorative veneer layer and non-decorative veneer layers are generally about 0.024 inches prior to sanding operations and if the thickness of the aluminum foil layer is between 0.002 inches and 0.006 inches with the most preferable thickness being about 0.003 to 0.005 inches. It should be noted that 0.024 or 1/42 inches is a standard thickness for wood veneers.  FIG. 4C  shows veneer laminate  400 . Non-decorative backing may include an optional layer of pressure sensitive adhesive (PSA)  460 B. Typically, PSA includes a release paper  460 C, which can be peeled away prior to placement on a substrate surface. 
         [0039]      FIGS. 1 and 3  shows fire resistant veneer assembly  100  and  300 . Veneer assembly  300  includes a completed veneer assembly  200  and an additional aluminum foil layer  50 . Some types of substrates for aircraft interior panels include nomex cores or other materials, which can be more easily bonded to aluminum. Accordingly, for some applications it is advantageous to have a veneer assembly, which further includes an aluminum foil backing. This additional layer of aluminum foil also further increases the flame resistance of the veneer assembly. Aluminum foil layer  50  may have a thickness ranging between 0.0005 inches and 0.006 inches. Preference will generally be given to the thinnest foil possible since each additional 0.001 inches in thickness of aluminum foil adds approximately 0.46 pounds to every standard 48 inch×96 inch sheet of finished veneer assembly. A weight of 0.46 pounds is deemed to be a significant amount of weight in the aircraft industry. If aluminum foil layer  50  is not added for additional flame resistance, then aluminum foil layer  50  need only be thick enough to provide a surface for bonding to some types of substrates. 
         [0040]    As can be seen from the above description, veneer assemblies  100 ,  200 ,  300  and  400  provide light, strong, fire resistant veneer assemblies. Applicant&#39;s test of all of the above veneer assemblies have shown that these veneer assemblies are capable of passing very stringent flame tests mandated by the FAA. 
         [0041]    It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except in so far as such limitations are included in the following claims and allowable equivalents thereof: