Composite panel usable for forming a surface

Abstract

Embodiments of the disclosure pertain to a panel usable for forming a surface, the panel having an at least one finish element; a backing material; and a polyurethane material cured between the at least one finish element and the backing material. Upon curing, the polyurethane material forms a structural substrate having a first side and a second side. Upon curing, the backing material is adhesively bonded to the first side. Also upon curing, the at least one finish element is adhesively bonded to the second side.

What is claimed is: 
     
         1 . A composite panel usable for forming a surface, the panel comprising:
 an at least one finish element;   a backing material, the backing material configured to provide the panel with a reduced thickness, a reduced weight, or combinations thereof; and   a polyurethane material cured between the at least one finish element and the backing material, wherein upon curing, the polyurethane material forms a structural substrate having a first side and a second side, wherein upon curing, the backing material is adhesively bonded to the first side, and wherein upon the curing, the at least one finish element is adhesively bonded to the second side.   
     
     
         2 . The composite panel of  claim 1 , the panel further comprising a particulate material disposed proximate to the first side of the structural substrate, and between a first finish element and a second element, wherein the structure substrate material bonds the particulate material to said at least one finish element and the backing material. 
     
     
         3 . The composite panel of  claim 2 , wherein the layer of substrate material at least partially occupies interstices between particles of the particulate material. 
     
     
         4 . The composite panel of  claim 3 , wherein the particulate material comprises a binder composition. 
     
     
         5 . The composite panel of  claim 1 , wherein the at least one finish element comprises magnesium oxide, and wherein the at least one finish element is configured to further provide the panel with a reduced thickness, a reduced weight, or combinations thereof. 
     
     
         6 . The composite panel of  claim 1 , wherein the at least one finish element comprises a body having an interior surface bonded to the structural substrate, and wherein the at least one finish element comprises and an exterior surface has a coating comprising cement, clay, and an aggregate, and wherein the coating provides said at least one finish element with an appearance of a natural clay brick. 
     
     
         7 . The composite panel of  claim 6 , wherein the clay comprises clay dust, and wherein the aggregate comprises sand. 
     
     
         8 . The composite panel of  claim 1 , wherein the panel is configured for installation on at least one of an exterior wall of a building, an interior wall of a building, a floor, a ceiling, a roof, a counter, a backsplash, and combinations thereof. 
     
     
         9 . A composite panel usable for forming a surface, the panel comprising:
 a first finish element and a second finish element;   a backing material;   a cured polyurethane material having a first side and a second side, the cured polyurethane material being cured between the first finish element and the backing material; and   a particulate material disposed proximate to the first side, and between the first finish element and the second finish element;   wherein the backing material is adhesively bonded to the first side, and wherein the first finish element is adhesively bonded to the second side.   
     
     
         10 . The composite panel of  claim 9 , wherein the cured polyurethane material bonds the particulate material to the first finish element. 
     
     
         11 . The composite panel of  claim 10 , wherein the cured polyurethane material at least partially occupies interstices between particles of the particulate material. 
     
     
         12 . The composite panel of  claim 11 , wherein the particulate material comprises a binder composition. 
     
     
         13 . The composite panel of  claim 12 , wherein at least one of the first finish element and the second finish element comprises magnesium oxide, and wherein at least one of the first finish element and the second finish element is configured to further provide the panel with a reduced thickness, a reduced weight, or combinations thereof. 
     
     
         14 . The composite panel of  claim 13 , wherein the first finish element comprises a body having an interior surface bonded to the structural substrate, and wherein the first finish element comprises and an exterior surface has a coating comprising cement, clay, and an aggregate, and wherein the coating provides said at least one finish element with an appearance of a natural clay brick. 
     
     
         15 . The composite panel of  claim 14 , wherein the clay comprises clay dust, and wherein the aggregate comprises sand. 
     
     
         16 . The composite panel of  claim 15 , wherein the composite panel is configured for installation on at least one of an exterior wall of a building, an interior wall of a building, a floor, a ceiling, a roof, a counter, a backsplash, and combinations thereof.