Fire resistant veneer assembly for aircraft interiors

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.

1 - 4 . (canceled) 
     
     
         5 . A method for making a fire resistant wood veneer assembly, comprising the following steps;
 a) laying up a decorative wood veneer, an aluminum foil layer and a non-decorative wood veneer with a thin film of phenolic adhesive resin applied directly between the decorative wood veneer and the aluminum foil and a thin film of phenolic adhesive resin applied directly between the aluminum foil and the non-decorative wood veneer to make a lay up having no intervening layers of paper or fabric,   b) pressing the lay up of step (a) 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,   c) pressing the decorative wood veneer layer against a platen and belt sanding the non-decorative wood veneer layer disposed on the side of the aluminum immediately opposite the decorative veneer layer so that the resulting sanded lay up has a generally uniform thickness.   
     
     
         6 . The method of  claim 5  further comprising the step(s) of:
 adding a thin film of adhesive to the exposed surface of the non-decorative wood veneer layer, placing a second layer aluminum foil backing on the thin film of adhesive and pressing the resulting lay up according to the process set forth in step (b) of  claim 5 . 
 
     
     
         7 . The method of  claim 5  further comprising the step(s) of:
 adding a thin film of adhesive to the exposed surface of the non-decorative wood veneer layer, placing a second layer aluminum foil backing on the thin film of adhesive, pressing the resulting lay up according to the process set forth in step (b) of  claim 5 , and covering the second layer of aluminum foil with a layer of pressure sensitive adhesive. 
 
     
     
         8 . The method of  claim 5 , wherein;
 the layer of aluminum foil is fashioned from aluminum that has been heat treated to increase its yield strength.   
     
     
         9 . The method of  claim 5 , wherein;
 the layer of aluminum foil has a thickness between 0.002 inches and 0.006 inches.   
     
     
         10 . The method of  claim 5 , wherein;
 the exposed surface of the non-decorative veneer is covered with a layer of pressure sensitive adhesive.   
     
     
         11 - 16 . (canceled)