Patent Description:
Various veneer panels are used in aircraft. Certain veneer panels may be susceptible to tearing, wrinkling, and curling. Further, veneer panels may experience delamination in some applications. In other instances, the veneer panels may not be useable in vehicular applications due to other limitations such as conformance with flammability regulations. Veneer panels are disclosed in <CIT>, <CIT> and <CIT>.

A veneer panel is provided as defined by claim <NUM>.

In various embodiments, the thermally conductive backing layer comprises an annealed aluminum.

In various embodiments, a thickness of the first adhesive material is <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

In various embodiments, a thickness of the second adhesive material is between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

The veneer panel further comprises a third adhesive material disposed between the first inner layer and the second inner layer, wherein the third adhesive material bonds the first inner layer to the second inner layer.

In various embodiments, a thickness of the thermally conductive backing layer is between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

In various embodiments, a thickness of the face veneer is between <NUM> inches and <NUM> inches (i.e., from <NUM> to <NUM>).

In various embodiments, a thickness of the first inner layer is between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

In various embodiments, a thickness of the second inner layer is between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

In various embodiments, the thermally conductive backing layer comprises an aluminum.

In various embodiments, a thickness of the first adhesive material is <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>) and a thickness of the second adhesive material is between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

A method of manufacturing a veneer panel is provided as defined by claim <NUM>.

In various embodiments, the thermally conductive backing layer comprises an aluminum, a thickness of the thermally conductive backing layer is between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration.

Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Surface shading lines may be used throughout the figures to denote different parts but not necessarily to denote the same or different materials.

It should be appreciated that considerable benefits will be realized for the safety of passengers and crew in aircraft flying throughout the world to provide a flame resistant wood veneer panel for the construction of aviation interior structures which meets the stringent vertical flammability requirements of Federal Aviation Requirement (FAR) <NUM>, which is part of the Title <NUM> of the Code of Federal Regulations (CFR), issued by the Federal Aviation Administration (FAA), such as the present four-ply flame retardant veneer panel system discussed in greater detail hereinafter.

Four-ply wood veneer panels, according to the present disclosure, may be mounted to furniture (e.g., cabinetry, tables, chairs, etc.) or other elements within an aircraft interior. Four-ply wood veneer panels, according to the present disclosure, comprise two chemically treated wooden inner layers disposed between a thermally conductive backing layer and a face veneer layer. Adhesive material bond the four layers together. The resulting four-ply panel may provide increased heat and flame resistance.

Four-ply wood veneer panels, according to the present disclosure, may be configured to address fire retardancy on two fronts: first, by releasing noncombustible gasses from a fire retardant chemical impregnated in a two-ply inner panel that extinguishes the flames, and second, by drawing heat away from the flame, via a thermally conductive backing layer, to extinguish the flame.

Referring now to <FIG>, an aircraft interior <NUM> including various elements comprising aviation veneer panels <NUM> is shown, in accordance with various embodiments. Aviation veneer panels <NUM> include four-ply veneer panels, as described below, mounted or otherwise coupled to a substrate (e.g., cabinetry, tables, chairs, hand rails, etc.).

Referring now to <FIG>, formation of a four-ply flame retardant veneer panel system <NUM> comprising two fire-treated inner layers and a thermally conductive backing layer is illustrated, according to various embodiments. Four-ply flame retardant veneer panel system <NUM> may be formed by first forming a flame retardant two-ply panel <NUM> comprising a first fire-treated inner layer <NUM> (also referred to herein as a first inner layer) and a second fire-treated inner layer <NUM> (also referred to herein as a second inner layer). First inner layer <NUM> includes a first surface <NUM> and a second surface <NUM> opposite first surface <NUM>. First inner layer <NUM> may comprise a thin layer of poplar wood, or other wood species. In various embodiments, a thickness T2 of first inner layer <NUM> extending from first surface <NUM> to second surface <NUM> may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>). In various embodiments, T2 may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>). In various embodiments, T2 may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

Second inner layer <NUM> may be similar to first inner layer <NUM>. In this regard, second inner layer <NUM> includes a first surface <NUM> and a second surface <NUM> opposite first surface <NUM>. First inner layer <NUM> may comprise a thin layer of poplar wood, or other wood species. In various embodiments, a thickness T3 of second inner layer <NUM> extending from first surface <NUM> to second surface <NUM> may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>). In various embodiments, T3 may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>). In various embodiments, T3 may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

In various embodiments, a wood grain of first inner layer <NUM> is oriented in a first direction, such as the X-direction for example, and a wood grain of second inner layer <NUM> is oriented in a second direction, such as the Y direction for example. In this manner, the wood grains of first inner layer <NUM> and second inner layer <NUM> are oriented perpendicular to one another to create a tension-balanced two-ply panel <NUM> once the first inner layer <NUM> and second inner layer <NUM> are cured together via an adhesive material <NUM> (also referred to herein as a third adhesive).

In various embodiments, adhesive material <NUM> may be applied over second surface <NUM> of first inner layer <NUM>, i.e., between first inner layer <NUM> and second inner layer <NUM>. In various embodiments, adhesive material <NUM> may be applied over first surface <NUM> of second inner layer <NUM>, i.e., between first inner layer <NUM> and second inner layer <NUM>. In various embodiments, adhesive material <NUM> comprises a phenolic resin. In various embodiments, adhesive material <NUM> comprises a vinyl-phenolic resin. In various embodiments, adhesive material <NUM> may be in the form of a thermoset adhesive, such as a dry film phenolic adhesive. A dry film phenolic adhesive may allow adhesive material <NUM> to be cut in a sheet form and disposed between second surface <NUM> of first inner layer <NUM> and first surface <NUM> of second inner layer <NUM> during the layup process. In various embodiments, a thickness T4 of adhesive material <NUM> extending from a first surface <NUM> of adhesive material <NUM> to a second surface <NUM> of adhesive material <NUM> may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

With reference to <FIG>, a heat and/or pressure treatment of two-ply panel <NUM> (e.g., pressing two-ply panel <NUM> inside a press machine) is illustrated, in accordance with various embodiments. Pressure P may be a compressive force applied uniformly and/or substantially uniformly across the outer surfaces of two-ply panel <NUM> through first inner layer <NUM> and second inner layer <NUM>. Two-ply panel <NUM> may also be heated to reach a thermal threshold necessary to cure the adhesive material <NUM> to bond first inner layer <NUM> to second inner layer <NUM>. For example, the adhesive material <NUM> may wet second surface <NUM> of first inner layer <NUM> and first surface <NUM> of second inner layer <NUM>.

With reference to <FIG>, two-ply panel <NUM> is treated with a flame retardant <NUM> for fire protection. Flame retardant <NUM> may comprise a bromide solution. In this regard flame retardant <NUM> may be a brominated flame retardant. Other flame retardants contemplated herein include halogenic chemicals, phosphates, acids, chitosan, boric acid, ammonium borates, ammonium polyphosphate, melamine, borates, silicates, organic silicone, zinc borates, metal hydroxides, sulfonates, graphite or graphene, intumescence, sodium hex metaphosphate, polyethylenimine, among others.

In various embodiments, two-ply panel <NUM> is soaked with the flame retardant <NUM>. In various embodiments, the flame retardant <NUM> is brushed or rolled onto two-ply panel <NUM>. In various embodiments, two-ply panel <NUM> is placed into a bath of the flame retardant <NUM> for a pre-determined duration. The flame retardant <NUM> may be absorbed into the two-ply panel <NUM>. The flame retardant <NUM> is carried by the two-ply panel <NUM>. In response to being burned, for example during a fire, the flame retardant <NUM> - which is infused in two-ply panel <NUM> - emits a gas to suffocate the flames and extinguish the fire. In this regard, flame retardant <NUM> may act as a gas phase flame retardant by forming a blanket of noncombustible gasses around the flame front. In various embodiments, two-ply panel <NUM> is sanded down to a desired thickness after being treated with the flame retardant <NUM>.

With combined reference to <FIG>, four-ply flame retardant veneer panel system <NUM> is further formed by adding a face veneer layer <NUM> and a thermally conductive backing layer <NUM> to opposite faces of flame retardant two-ply panel <NUM>.

Face veneer layer <NUM> may comprise a thin layer of wood, such as walnut, cherry, birch, rosewood, oak, maple, mahogany, hemlock, teak, walnut, or other wood species. Face veneer layer <NUM> may be manufactured from most wood species, common and exotic alike. Face veneer layer <NUM> may also be a manufactured product comprising one or more natural wood(s) and/or synthetic materials, referred to herein as "composite wood. " Face veneer layer <NUM> may include a first surface <NUM> (also referred to as a face surface) and a second surface <NUM> (also referred to as a back surface) opposite first surface <NUM>. Back surface <NUM> of face veneer layer <NUM> may be oriented toward thermally conductive backing layer <NUM>. In various embodiments, first surface <NUM> of face veneer layer <NUM> may be sanded to provide a smooth, decorative surface for finishing. In various embodiments, a thickness T1 of face veneer layer <NUM> extending from first surface <NUM> to second surface <NUM> may be between <NUM> inches and <NUM> inches (i.e., from <NUM> to <NUM>). The face veneer layer <NUM> is not treated with a flame retardant.

In various embodiments, an adhesive material <NUM> (also referred to herein as a first adhesive material) may be applied over first surface <NUM> of two-ply panel <NUM>, i.e., between face veneer layer <NUM> and first inner layer <NUM>. In various embodiments, adhesive material <NUM> may be applied over second surface <NUM> of face veneer layer <NUM>, i.e., between face veneer layer <NUM> and first inner layer <NUM>. The adhesive material <NUM> comprises a phenolic resin. In various embodiments, adhesive material <NUM> comprises a vinyl-phenolic resin. In various embodiments, adhesive material <NUM> may be in the form of a thermoset adhesive, such as a dry film phenolic adhesive. A dry film phenolic adhesive may allow adhesive material <NUM> to be cut in a sheet form and disposed between second surface <NUM> of face veneer layer <NUM> and first surface <NUM> of first inner layer <NUM> during the layup process. In various embodiments, a thickness T6 of adhesive material <NUM> extending from a first surface <NUM> of adhesive material <NUM> to a second surface <NUM> of adhesive material <NUM> may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

Thermally conductive backing layer <NUM> may comprise a material having a thermally conductivity of <NUM> W/m·K or greater. In various embodiments, thermally conductive backing layer <NUM> comprises a metal. Thermally conductive backing layer <NUM> may comprise one or more layers of aluminum or an aluminum alloy. In various embodiments, thermally conductive backing layer <NUM> comprises a thin sheet of annealed aluminum. In various embodiments, thermally conductive backing layer <NUM> may comprise an aluminum foil layer. Thermally conductive backing layer <NUM> includes a first surface <NUM> and a second surface <NUM> opposite first surface <NUM>. In various embodiments, a thickness T5 of thermally conductive backing layer <NUM> extending from first surface <NUM> to second surface <NUM> may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>). In various embodiments, T5 may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

An adhesive material <NUM> (also referred to herein as a second adhesive) is applied over second surface <NUM> of two-ply panel <NUM>, i.e., between thermally conductive backing layer <NUM> and second inner layer <NUM>. In various embodiments, adhesive material <NUM> may be applied over first surface <NUM> of thermally conductive backing layer <NUM>, i.e., between thermally conductive backing layer <NUM> and second inner layer <NUM>. The adhesive material <NUM> comprises an acrylic adhesive. In various embodiments, adhesive material <NUM> comprises a flame-retardant acrylic adhesive. In various embodiments, adhesive material <NUM> may be in the form of a thermoset adhesive, such as a dry film acrylic adhesive. A dry film acrylic adhesive may allow adhesive material <NUM> to be cut in a sheet form and disposed between first surface <NUM> of thermally conductive backing layer <NUM> and second surface <NUM> of second inner layer <NUM> during the layup process. In various embodiments, a thickness T7 of adhesive material <NUM> extending from a first surface <NUM> of adhesive material <NUM> to a second surface <NUM> of adhesive material <NUM> may be between <NUM> inches and <NUM> inches (i.e., between <NUM> and <NUM>).

With momentary reference to <FIG>, a heat and/or pressure treatment of veneer panel system <NUM> (e.g., pressing veneer panel system <NUM> inside a press machine) is illustrated, in accordance with various embodiments. Pressure P may be a compressive force applied uniformly and/or substantially uniformly across the outer surfaces of veneer panel system <NUM> through face veneer layer <NUM>, first inner layer <NUM>, second inner layer <NUM>, and thermally conductive backing layer <NUM>. Veneer panel system <NUM> may also be heated to reach a thermal threshold necessary to cure the adhesive material <NUM> to bond first inner layer <NUM> of two-ply panel <NUM> to face veneer layer <NUM> and bond second inner layer <NUM> of two-ply panel <NUM> to thermally conductive backing layer <NUM>. For example, the adhesive material <NUM> may wet second surface <NUM> of face veneer layer <NUM> and first surface <NUM> of first inner layer <NUM>. Likewise, adhesive material <NUM> may wet first surface <NUM> of thermally conductive backing layer <NUM> and second surface <NUM> of second inner layer <NUM>. Second surface <NUM> of thermally conductive backing layer <NUM> may be exposed.

Veneer panel system <NUM> may be formed in any dimensions, and may readily be made into rectangular <NUM> foot by <NUM> foot (i.e., <NUM> by <NUM>) panels. Veneer panel system <NUM> may also be cut into smaller sizes or varied shapes, depending on the substrate (e.g., cabinet, table, rail, etc.) to which veneer panel system <NUM> may be mounted.

Veneer panel system <NUM> may be configured to address fire retardancy on two fronts: first, by releasing noncombustible gasses from the flame retardant solution (i.e., flame retardant <NUM>) of two-ply panel <NUM> that extinguishes the flames, and second, by drawing heat away from the flame, via thermally conductive backing layer <NUM>, to extinguish the flame. Veneer panel system <NUM> may comply with FAR <NUM>.

With reference to <FIG>, a method <NUM> of making a veneer panel comprises stacking a first inner layer and a second inner layer (step <NUM>). Method <NUM> comprises disposing a third adhesive material between the first inner layer and the second inner layer (step <NUM>). Method <NUM> comprises applying heat and pressure to the first inner layer, the third adhesive material, and the second inner layer to create a two-ply panel comprising the first inner layer, the third adhesive material, and the second inner layer (step <NUM>). Method <NUM> comprises treating the two-ply panel with a flame retardant (step <NUM>). Method <NUM> comprises stacking a face veneer, the two-ply panel, and a thermally conductive backing layer (step <NUM>). Method <NUM> comprises disposing a first adhesive material between the two-ply panel and the face veneer (step <NUM>). Method <NUM> comprises disposing a second adhesive material between the thermally conductive backing layer and the two-ply panel (step <NUM>). Method <NUM> comprises applying heat and pressure to at least the face veneer, the thermally conductive backing layer, the first adhesive material, and the second adhesive material (step <NUM>).

With combined reference to <FIG>, and with particular focus on <FIG>, step <NUM> comprises stacking first inner layer <NUM> and second inner layer <NUM>. Step <NUM> comprises disposing adhesive material <NUM> between first inner layer <NUM> and second inner layer <NUM>. With particular focus on <FIG>, step <NUM> comprises applying heat and pressure to first inner layer <NUM>, adhesive material <NUM>, and second inner layer <NUM> to create two-ply panel <NUM> comprising first inner layer <NUM>, adhesive material <NUM>, and second inner layer <NUM>. With particular focus on <FIG>, step <NUM> comprises treating two-ply panel <NUM> with flame retardant <NUM>. With particular focus on <FIG>, step <NUM> comprises stacking face veneer layer <NUM>, the two-ply panel <NUM>, and thermally conductive backing layer <NUM>. Step <NUM> comprises disposing adhesive material <NUM> between the two-ply panel <NUM> and the face veneer layer <NUM>. Step <NUM> comprises disposing adhesive material <NUM> between the thermally conductive backing layer <NUM> and the two-ply panel <NUM>. With particular focus on <FIG>, step <NUM> comprises applying heat and pressure to the stack comprising the face veneer layer <NUM>, the two-ply panel <NUM>, the thermally conductive backing layer <NUM>, the first adhesive material <NUM>, the second adhesive material <NUM>, and the third adhesive material <NUM>. In various embodiments, heat is applied by placing the stack into a hot platen press machine for a predetermined duration. In various embodiments, step <NUM> is performed subsequent to step <NUM>.

Claim 1:
A veneer panel (<NUM>), comprising:
a non-flame retardant-treated face veneer (<NUM>);
a two-ply panel (<NUM>) bonded to the face veneer, the two-ply panel comprising a first inner layer (<NUM>) bonded to the face veneer (<NUM>) and a second inner layer (<NUM>) bonded to the first inner layer (<NUM>), wherein the first inner layer and the second inner layer are treated with a flame retardant; a thermally conductive backing layer (<NUM>) bonded to the two-ply panel (<NUM>), the thermally conductive backing layer (<NUM>) disposed opposite the two-ply panel (<NUM>) from the face veneer (<NUM>); and
a first adhesive material (<NUM>) disposed between the face veneer and the two-ply panel, wherein the first adhesive material bonds the two-ply panel to a back surface of the face veneer;
a second adhesive material (<NUM>) disposed between the thermally conductive backing layer and the two-ply panel, wherein the second adhesive material bonds the two-ply panel to the thermally conductive backing layer; and a third adhesive material (<NUM>) between the first inner layer (<NUM>) and the second inner layer (<NUM>);
wherein the first adhesive material comprises a phenolic adhesive and the second adhesive material comprises an acrylic adhesive, and wherein the two-ply panel comprises wood.