FIRE-RESISTANT ULTRA-LIGHTWEIGHT PANEL WITH THREE-DIMENSIONAL SURFACE DESIGN

• Main Authors: DAVIS, GEORGE KALOGRIDIS, TSAI, LIING LIU
• Format: Patent
• Language: English; French
• Published: 18.08.2006
• Subjects: LAYERED PRODUCTS; LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT ORNON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM; PERFORMING OPERATIONS; TRANSPORTING

The invention relates to an ultra-lightweight heat and flame resistant (or retardant) composite panel having a three-dimensional artistic design on the surface, and a metho d for making the lightweight heat and flame resistant composite panel. One aspect of the invention is a system and method for creating a composite panel from high performance heat and flame resistant materials, such as aramid polyamide polymers (for example, NOMEX.RTM. from DuPont) or a ny other fire-retardant or fire-retardant treated material, which can be bonded to another layer of fire-retardant material such as paper, fabric, honeycomb or foam. The fire-retardant materials can be bonded by a welding machine such as an ultrasonic machine, or attached by a thermoplasti c, thermoset, thermobond or other fire resistant adhesive. The thickness of the finished composite may be around 1/16~1/4 inch. The composite can then be decorated, and carved (or embossed) with or without inserting a fire-retardant material between the layers prior to carving to give a three-dimensional decorative surface. The steps of decorating and carving may be performed in either sequence-coloring followed by carving, or carving followed by coloring. Alternatively, one or more layers may be printed prior to forming the composite. A clear finish with fire retardant agent is then placed on the surface of the composite.