Fire-resistant ultra-lightweight panel with three-dimensional surface design

Abstract

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 method 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® from DuPont) or any 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 thermoplastic, thermoset, thermobond or other fire resistant adhesive. The thickness of the finished composite may be around 1/16˜¼ 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.

Dependencies are inferred from the claim text.