US20050142968A1 - Translucent, flame resistant composite materials - Google Patents
Translucent, flame resistant composite materials Download PDFInfo
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- US20050142968A1 US20050142968A1 US10/707,612 US70761203A US2005142968A1 US 20050142968 A1 US20050142968 A1 US 20050142968A1 US 70761203 A US70761203 A US 70761203A US 2005142968 A1 US2005142968 A1 US 2005142968A1
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- glass fibers
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- polyphenylsulfone
- composite material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
- C08J5/043—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/414—Translucent
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/18—Aircraft
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2381/00—Characterised by the use of macromolecular compounds obtained by reactions forming in the main chain of the macromolecule a linkage containing sulfur with or without nitrogen, oxygen, or carbon only; Polysulfones; Derivatives of such polymers
- C08J2381/06—Polysulfones; Polyethersulfones
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2631—Coating or impregnation provides heat or fire protection
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2926—Coated or impregnated inorganic fiber fabric
- Y10T442/2992—Coated or impregnated glass fiber fabric
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3472—Woven fabric including an additional woven fabric layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3976—Including strand which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous composition, water solubility, heat shrinkability, etc.]
Definitions
- the present invention generally relates to composite materials and more specifically to translucent, flame resistant composite materials that may be used in aircraft interiors and other aerospace applications.
- the interiors of commercial aircraft are typically formed with a large number of components in many shapes and forms that have both practical and aesthetic functions. It is also highly desirable that certain of these components be translucent, i.e. that these panels should allow light to pass through them for various purposes (i.e. be transmissive). Examples of translucent interior components may include but are not limited to partitions, windscreens, class dividers, privacy curtains, sidewalls, ceilings, doorway linings, lighting fixtures, backlit control panels, stow bin doors, tray tables, proximity lighting, and window bezels.
- FAR 25.853 and Appendix F flammability resistance properties
- Prior art plastic materials used in commercial aircraft could not typically achieve the combination of a desired transmissivity of light while meeting FAA requirements in terms of flammability resistance properties (FAR 25.853 and Appendix F), vertical burn, smoke emissions tests, and toxic fume emissions tests.
- interior components have typically been made of non-translucent (opaque), or marginally translucent plastic materials that meet these FAA requirements.
- the present invention discloses composite materials that meet or exceed the FAA requirements in terms of flammability resistance properties (FAR 25.853 and Appendix F), including heat release, vertical burn, smoke emissions tests, and toxic fume emissions tests.
- the composite materials are post-processed to form various translucent components used throughout the interior of a cabin on an aircraft that allow transmissivity of desirable amounts of light.
- the composite material consists of long glass fibers encapsulated within a polyphenylsulfone (PPSU) substrate material.
- the long glass fibers are preferably configured within a loose weave or may alternatively be unidirectional in nature so long as the fibers meet the requirements for light transmission and flammability.
- the composite material is formed as a two-layer or three-layer system.
- the glass fibers are laminated to one side of the PPSU substrate.
- the glass fibers are sandwiched between and laminated to two layers of the PPSU substrate.
- the preferred manufacturing processes identified for forming the two-layer or three-layer panels a thermal pressing process and a continuous fiber impregnation process.
- the composite material is cut and thermoformed or bended to the shape of the final part.
- FIGS. 1-14 illustrate various perspective views of a cabin region of a commercial aircraft having translucent components formed according to the present invention
- FIG. 15 is a side view a two-layer composite material having weaved fibrous material used to form the translucent components of FIGS. 1-14 ;
- FIG. 16 a side view a three-layer composite material used to form the translucent components of FIGS. 1-14 ;
- FIG. 17 a side view a two-layer composite material having unidirectional fibers used to form the translucent components of FIGS. 1-14 .
- the present invention describes the formation of composite materials that are ideally suited for use as translucent components for various devices contained within cabin areas of commercial aircraft due to their light transmissivity properties and flame retardancy.
- the composite materials may be used in other applications not directly related to commercial aircraft.
- the composite materials could find usage in other aerospace applications or even in non-aerospace applications such as automotive applications.
- FIGS. 1-14 illustrate various views of an interior, or cabin region 12 , of a commercial aircraft 10 .
- the aircraft 10 has a wide variety of translucent components 14 that are traditionally found within the cabin region 12 that are formed from a novel composite material 70 that is the subject of the present invention.
- the components 14 formed are light transmissive to allow for a pleasing glow or to allow for use as primary lighting within the cabin region 12 .
- the materials also meet flammability standards.
- the standard test method for heat release is the Ohio State University heat release test as found in FAR 25.853, Part IV, in which the maximum allowable average heat release for interior panels contained with the cabin area of commercial airlines does not exceed 65 kw/m 2 as measure at a two minute interval and for a peak rate at five minutes. This is also known in the industry as the 65/65 standard (peak heat release/total heat release).
- the translucent components 14 also meet Federal Aviation Association (FAA) certification requirements for materials used overhead in the passenger cabin area 12 . These certification requirements state that the composite material 70 must not drip or dislodge from their designated flight configuration such that they inhibit egress when exposed to a temperature of 500 degrees Fahrenheit (260 degrees Celsius) for five minutes.
- FAA Federal Aviation Association
- Non-limiting examples of translucent components 14 that are formed from the composite material 70 of the present invention include, countertops 16 , cabinet enclosures 18 such as wastebaskets, tray tables 20 , backlit lighted signs 22 such as emergency exit signs 24 , illuminating window panels 26 having light emitting diode displays 28 , window bezels 30 , class dividers 32 , privacy partitions 34 , backlit ceiling panels 36 , direct lighting ceiling panels 38 , lighted doors 40 , lighted door latches 42 , doorway linings 44 , proximity lights 46 , stow bin doors 48 , privacy curtains 50 , translucent door handles 52 (capable of changing from red to green, for example), translucent amenities cabinets 54 , translucent sink decks 56 for lavatories and kitchens (with or without an appropriate undersink enclosure 58 ), doorway liners 60 , stow bin latch handles 62 , lighted phones 64 , and backlit control panels 66 . While these components 14 are illustrated in one preferred arrangement, it is understood that the number, type, and
- FIGS. 15-17 illustrate three preferred composite materials 70 that can subsequently be post-processed to form the translucent components 14 of FIGS. 1-14 .
- FIG. 15 illustrates a two-layer composite material
- FIG. 16 illustrates a three-layer composite material
- FIG. 17 illustrates another preferred two-layer composite material utilizing a unidirectional fiberglass material. Each is described below.
- a two-layer composite material 70 is formed by laminating a layer of weaved fibrous material 72 to a substrate material 74 .
- a three-layer composite material 70 is formed by introducing second layer of substrate material 76 having the same composition as first layer 74 such that the fibrous material 72 is sandwiched and laminated between first and second layer 74 , 76 .
- a unidirectional, nonweaved fibrous material 72 is laminated to the substrate material to form another two-layer translucent composite material 70 .
- one three-layer composite material 70 consists of a weaved fibrous material 72 sandwiched between and laminated to the first layer 74 and second layer 76 as in FIG. 16 .
- two layers of fibrous material 72 could be introduced to a top and bottom surface of the substrate material 74 to form another composite material 70 .
- the substrate material 74 is chosen based on the application for which it is utilized. In the case of airplane interior components 14 , the substrate material 74 is chosen to allow adequate light transmissivity for the desired component.
- the substrate material 74 has the ability to soften to permit lamination of the fibrous material 72 as well as being able to be post processed to form a translucent component 14 having a desired shape and thickness. It is also desirable that the substrate material 74 is low cost, durable, and is available in varying thickness to provide design flexibility. Additionally, the substrate material 74 should be compatible with the fibrous material 72 and resist degradation due to light, heat, and stress.
- thermoplastic resin that meets these requirements is polyphenylsulfone, otherwise known as PPSU.
- PPSU is a translucent thermoplastic material typically that is relatively light transmissive and typically has a light brown tint.
- many grades of PPSU are commercially available, each having slightly varying transmissivity and flammability resistant properties.
- Radel PPSU available from Solvay Advanced Polymers, LLC.
- the fibrous material 72 is added to the PPSU substrate 74 , 76 material to provide retention of the composite panel 60 in the event of fire.
- the fibrous material 72 laminated within the substrate or substrates 74 , 76 allows compliance with the FAA certification requirement for flammability resistance properties, including heat release, vertical burn, smoke emissions tests, and toxic fume emissions tests.
- Long glass fibers 78 are preferred for use as the fibrous material 72 , 70 due to their ability to act as thermal insulators, their ability to allow the substrate 70 to pass flammability tests, their ability to not overly decrease light transmissivity, and their overall appearance within the PPSU substrate 74 , 76 .
- the long glass fibers 78 utilized should have a thread count that is coarse enough to allow sufficient light transmission between the fibers 78 and through the substrate 74 , 76 . Also, there should be sufficient volume of fibers 78 in the fibrous material 72 , 70 to produce a thermal insulation capacity necessary to achieve the minimum flammability properties. Further, visible fibers 78 in the composite material 70 should have a consistent appearance. Additionally, sufficient density of fibers 78 should be present to ensure article retention.
- the long glass fibers 78 have melting temperatures substantially above the melting temperature of the PPSU substrate 74 .
- the glass fibers are able to support the PPSU substrate 74 once the PPSU substrate 74 is softened at about 500 degrees Fahrenheit.
- Two types of glass fibers 78 that meet these criteria are e-glass and s-glass fibers.
- the fiber 78 density, thickness, and orientation are all properties that may be optimized for a particular application.
- a higher density of fibers 78 , or thicker fibers 78 , within the PPSU substrate 74 will provide additional strength and will act as a heat sink when exposed to fire while adversely affecting light transmissivity and overall weight.
- a particular fiber orientation, or fiber weave may also affect weight, flammability, overhead fire retention, material strength, and light transmission.
- the fiber density, thickness, and orientation will be set to allow maximum transmissivity while maintaining the 65/65 standard.
- the density of glass fiber for example, may be increased compared to backlit light signs 22 , as transmissivity of light is not necessary.
- the composite material 70 may be formed by many different and unique methods. Two preferred methods for forming the composite material 70 are the thermal pressing process and the continuous fiber impregnation process. Each is described below with respect to the two-layer composite material 70 of FIG. 15 . However, as one of ordinary skill recognizes, the same preferred processes may be manipulated slightly to form the three-layer composite material 70 of FIG. 16 or the two-layer composite material 70 having unidirectional fibers 78 as in FIG. 17 .
- the substrate material 74 and fibrous material 72 are first introduced within a mold.
- the mold is first heated under controlled pressure to soften the substrate material 74 . This is known as the preheating stage.
- higher heat and pressure are introduced to laminate the fibrous material 72 to the substrate material 74 .
- the higher heat and pressure allows the impregnation of the embedded glass fibers 78 and substantially encapsulates the fibers 78 with the PPSU substrate material 74 , therein forming the composite material 70 .
- the composite material is cooled under controlled heat and pressure conditions to control internal stresses and warpage.
- a composite sheet 60 of about 0.1 inches in thickness is formed by first introducing the PPSU substrate material 74 and fibrous material 72 to a mold. Next, in the preheating stage, the mold is heated to about 535 degrees Fahrenheit over about 15 minutes.
- the mold is then held at 535 degrees for about 55 minutes at during the impregnation stage. During this time, the pressure is ratcheted upward slowly to prevent outgassing of the PPSU substrate material, therein preventing bubbles formed within the composite sheet 70 .
- the pressure is maintained at about 15 pounds per square inch part pressure. Between 5 and 27 minutes, the pressure is maintained at about 50 pounds per square inch part pressure. Between 27 and 47 minutes, the pressure is maintained at about 100 pounds per square inch part pressure. Finally, between 47 and 55 minutes, the pressure is maintained at about 200 pounds per square inch part pressure.
- the composite part is allowed to slowly cool down to 235 degrees Fahrenheit under constant pressure of about 200 pounds per square inch part pressure.
- the cooling rate is maintained at about 5 degrees Fahrenheit per minute, thus this portion of the cooling stage lasts approximately one hour to control internal stresses and warpage of the forming composite part.
- the temperature within the mold is slowly decreased to about 150 degrees Fahrenheit and 100 pounds per square inch part pressure to further control internal stresses and warpage. Finally, the mold is opened and the composite sheet 70 is allowed to cool to room temperature.
- the thermal pressing technique has many benefits over other techniques used for forming composite materials.
- the fibers 78 are substantially encapsulated with the PPSU substrate material.
- thermal pressing at a temperature below the melting point of the PPSU substrate allows sufficient flex without yield.
- the thermal pressing technique also allows the incorporation of decorative features into the composite material. For example, a screen print may be added to the fibers 78 prior to adding the fibers 78 to the PPSU substrate material 74 .
- molten PPSU resin making up the substrate material 74 is introduced from an extruder having a die set between a pair of rollers contained within a calendar roll stack.
- a sheet layer of fibrous material 72 is unrolled from a roller onto the molten layer between the first set of rollers.
- the calendar roll stack preferably containing three or more stainless steel calendar rolls stacked vertically, presses the fibrous material sheet layer and molten layer to a desired thickness, therein impregnating the PPSU resin within the fibrous material 72 .
- the composite material 70 formed then is removed from the calendar rolls stack on a conveyor belt line and allowed to cool, therein forming a cooled, hardened composite sheet 70 .
- the continuous impregnation technique offers slightly different benefits to the thermal pressing technique.
- the composite sheet material 70 may be formed at a quicker rate than with the thermal pressing technique. This is also cost effective.
- the thickness of the material formed may be easily modified by adjusting the clearance gap between the respective rollers of the calendar stack. Additionally, the process also automates impregnation techniques that would otherwise have to be accomplished manually.
- the composite material 70 is then available to be post-processed for the desired application.
- the type of post processing depends upon the component 14 , and typically involves cutting, bending or thermoforming the part to a desired shape and size.
- a privacy curtain 50 must remain flexible, and is thus formed as a very thin composite material.
- a countertop 16 must be able to support items placed upon it, and thus is formed with a thickness much greater than the privacy curtain 50 .
- the amount of light transmissivity may vary based upon the ultimate use of the component.
- an emergency exit sign 24 may be formed of a thin composite material 70 and with a lower fiber thread per unit area, therein allowing maximum light transmissivity.
- a ceiling may be formed with minimal light transmissivity having higher fiber thread count per unit area, therein providing maximum flammability resistance.
- the component 14 is then available for use within the cabin area 12 .
- the composite material 70 having the desired light transmissivity and flame resistant characteristics as described above is bent, cut thermoformed or otherwise post-processed in methods well known in the art to shape and size the part to the desired configuration.
Abstract
A translucent composite material that can be used in various airplane interior applications that allows sufficient light transmissivity while preferably meeting Federal Aviation Administration (FAA) flammability requirements for overhead materials in the cabin of a commercial aircraft. The material also meets FAA standards regarding vertical burn, smoke emissions tests, and toxic fume emissions tests. The composite material is formed by laminating long glass fibers and (PPSU) into a composite sheet under controlled heat and pressure. The composite sheet is then cut, bent or thermoformed to form the desired part. The parts formed are available for a wide variety of uses within the passenger cabin of a commercial aircraft. The long glass fibers may be unidirectional or weaved into a glass cloth like material. While preferably formed for airplane interior applications, these components may also be used in other aerospace or non-aerospace applications.
Description
- The present invention generally relates to composite materials and more specifically to translucent, flame resistant composite materials that may be used in aircraft interiors and other aerospace applications.
- The interiors of commercial aircraft are typically formed with a large number of components in many shapes and forms that have both practical and aesthetic functions. It is also highly desirable that certain of these components be translucent, i.e. that these panels should allow light to pass through them for various purposes (i.e. be transmissive). Examples of translucent interior components may include but are not limited to partitions, windscreens, class dividers, privacy curtains, sidewalls, ceilings, doorway linings, lighting fixtures, backlit control panels, stow bin doors, tray tables, proximity lighting, and window bezels.
- Besides translucency, materials used in aircraft interior components must meet strict Federal Aviation Administration (FAA) requirements in terms of flammability resistance properties (FAR 25.853 and Appendix F), including heat release, vertical burn, smoke emissions tests, and toxic fume emissions tests. For example, the standard test method for heat release is the Ohio State University heat release test as found in FAR 25.853 Part IV.
- Prior art plastic materials used in commercial aircraft could not typically achieve the combination of a desired transmissivity of light while meeting FAA requirements in terms of flammability resistance properties (FAR 25.853 and Appendix F), vertical burn, smoke emissions tests, and toxic fume emissions tests. As such, interior components have typically been made of non-translucent (opaque), or marginally translucent plastic materials that meet these FAA requirements.
- It is highly desirable to form a composite material that can be post-processed to form substantially translucent interior components for use in commercial aircraft cabins that meets or exceeds FAA requirements as described above. It is also desirable that such a material be low cost in terms of manufacture and raw material costs. It is also highly desirable that such a composite material be low weight and easily conformable to form a potentially limitless variety of shapes and configurations for these components.
- The present invention discloses composite materials that meet or exceed the FAA requirements in terms of flammability resistance properties (FAR 25.853 and Appendix F), including heat release, vertical burn, smoke emissions tests, and toxic fume emissions tests. The composite materials are post-processed to form various translucent components used throughout the interior of a cabin on an aircraft that allow transmissivity of desirable amounts of light.
- The composite material consists of long glass fibers encapsulated within a polyphenylsulfone (PPSU) substrate material. The long glass fibers are preferably configured within a loose weave or may alternatively be unidirectional in nature so long as the fibers meet the requirements for light transmission and flammability.
- The composite material is formed as a two-layer or three-layer system. In the two-layer system, the glass fibers are laminated to one side of the PPSU substrate. In a three-layer system, the glass fibers are sandwiched between and laminated to two layers of the PPSU substrate. The preferred manufacturing processes identified for forming the two-layer or three-layer panels a thermal pressing process and a continuous fiber impregnation process. The composite material is cut and thermoformed or bended to the shape of the final part.
- Other objects and advantages of the present invention will become apparent upon considering the following detailed description and appended claims, and upon reference to the accompanying drawings.
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FIGS. 1-14 illustrate various perspective views of a cabin region of a commercial aircraft having translucent components formed according to the present invention; -
FIG. 15 is a side view a two-layer composite material having weaved fibrous material used to form the translucent components ofFIGS. 1-14 ; -
FIG. 16 a side view a three-layer composite material used to form the translucent components ofFIGS. 1-14 ; and -
FIG. 17 a side view a two-layer composite material having unidirectional fibers used to form the translucent components ofFIGS. 1-14 . - The present invention describes the formation of composite materials that are ideally suited for use as translucent components for various devices contained within cabin areas of commercial aircraft due to their light transmissivity properties and flame retardancy. As one of ordinary skill recognizes, however, the composite materials may be used in other applications not directly related to commercial aircraft. For example, the composite materials could find usage in other aerospace applications or even in non-aerospace applications such as automotive applications.
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FIGS. 1-14 illustrate various views of an interior, orcabin region 12, of acommercial aircraft 10. Theaircraft 10 has a wide variety of translucent components 14 that are traditionally found within thecabin region 12 that are formed from a novelcomposite material 70 that is the subject of the present invention. - The components 14 formed are light transmissive to allow for a pleasing glow or to allow for use as primary lighting within the
cabin region 12. - The materials also meet flammability standards. For example, the standard test method for heat release is the Ohio State University heat release test as found in FAR 25.853, Part IV, in which the maximum allowable average heat release for interior panels contained with the cabin area of commercial airlines does not exceed 65 kw/m2 as measure at a two minute interval and for a peak rate at five minutes. This is also known in the industry as the 65/65 standard (peak heat release/total heat release).
- The translucent components 14 also meet Federal Aviation Association (FAA) certification requirements for materials used overhead in the
passenger cabin area 12. These certification requirements state that thecomposite material 70 must not drip or dislodge from their designated flight configuration such that they inhibit egress when exposed to a temperature of 500 degrees Fahrenheit (260 degrees Celsius) for five minutes. - Non-limiting examples of translucent components 14 that are formed from the
composite material 70 of the present invention include,countertops 16,cabinet enclosures 18 such as wastebaskets, tray tables 20, backlit lightedsigns 22 such asemergency exit signs 24,illuminating window panels 26 having light emitting diode displays 28,window bezels 30,class dividers 32,privacy partitions 34, backlit ceiling panels 36, directlighting ceiling panels 38, lighteddoors 40, lighteddoor latches 42, doorway linings 44,proximity lights 46, stow bin doors 48,privacy curtains 50, translucent door handles 52 (capable of changing from red to green, for example),translucent amenities cabinets 54,translucent sink decks 56 for lavatories and kitchens (with or without an appropriate undersink enclosure 58),doorway liners 60, stowbin latch handles 62,lighted phones 64, and backlit control panels 66. While these components 14 are illustrated in one preferred arrangement, it is understood that the number, type, and location of these translucent components 14 may vary greatly among various types ofcommercial aircraft 10 are not meant to be limited to the illustrated arrangement. -
FIGS. 15-17 illustrate three preferredcomposite materials 70 that can subsequently be post-processed to form the translucent components 14 ofFIGS. 1-14 .FIG. 15 illustrates a two-layer composite material, whileFIG. 16 illustrates a three-layer composite material. In addition,FIG. 17 illustrates another preferred two-layer composite material utilizing a unidirectional fiberglass material. Each is described below. - Referring now to
FIG. 15 , a two-layercomposite material 70 is formed by laminating a layer of weavedfibrous material 72 to asubstrate material 74. InFIG. 16 , a three-layercomposite material 70 is formed by introducing second layer ofsubstrate material 76 having the same composition asfirst layer 74 such that thefibrous material 72 is sandwiched and laminated between first andsecond layer FIG. 17 , a unidirectional, nonweavedfibrous material 72 is laminated to the substrate material to form another two-layer translucentcomposite material 70. - Of course, while three preferred embodiments are illustrated in
FIGS. 15-17 , other preferred embodiments are specifically contemplated. For instance, one three-layercomposite material 70 consists of a weavedfibrous material 72 sandwiched between and laminated to thefirst layer 74 andsecond layer 76 as inFIG. 16 . Also, two layers of fibrous material 72 (weaved or unidirectional) could be introduced to a top and bottom surface of thesubstrate material 74 to form anothercomposite material 70. - The
substrate material 74 is chosen based on the application for which it is utilized. In the case of airplane interior components 14, thesubstrate material 74 is chosen to allow adequate light transmissivity for the desired component. Thesubstrate material 74 has the ability to soften to permit lamination of thefibrous material 72 as well as being able to be post processed to form a translucent component 14 having a desired shape and thickness. It is also desirable that thesubstrate material 74 is low cost, durable, and is available in varying thickness to provide design flexibility. Additionally, thesubstrate material 74 should be compatible with thefibrous material 72 and resist degradation due to light, heat, and stress. - One thermoplastic resin that meets these requirements is polyphenylsulfone, otherwise known as PPSU. PPSU is a translucent thermoplastic material typically that is relatively light transmissive and typically has a light brown tint. As one of ordinary skill appreciates, many grades of PPSU are commercially available, each having slightly varying transmissivity and flammability resistant properties. One preferred PPSU material is Radel PPSU, available from Solvay Advanced Polymers, LLC.
- The
fibrous material 72 is added to thePPSU substrate composite panel 60 in the event of fire. Thefibrous material 72 laminated within the substrate orsubstrates Long glass fibers 78 are preferred for use as thefibrous material substrate 70 to pass flammability tests, their ability to not overly decrease light transmissivity, and their overall appearance within thePPSU substrate - The
long glass fibers 78 utilized should have a thread count that is coarse enough to allow sufficient light transmission between thefibers 78 and through thesubstrate fibers 78 in thefibrous material visible fibers 78 in thecomposite material 70 should have a consistent appearance. Additionally, sufficient density offibers 78 should be present to ensure article retention. - Preferably, the
long glass fibers 78 have melting temperatures substantially above the melting temperature of thePPSU substrate 74. Preferably, the glass fibers are able to support thePPSU substrate 74 once thePPSU substrate 74 is softened at about 500 degrees Fahrenheit. Two types ofglass fibers 78 that meet these criteria are e-glass and s-glass fibers. - The
fiber 78 density, thickness, and orientation are all properties that may be optimized for a particular application. A higher density offibers 78, orthicker fibers 78, within thePPSU substrate 74 will provide additional strength and will act as a heat sink when exposed to fire while adversely affecting light transmissivity and overall weight. A particular fiber orientation, or fiber weave, may also affect weight, flammability, overhead fire retention, material strength, and light transmission. Thus, if more light transmission is desired, such as in an backlitlight sign 22 or emergency exit sign, the fiber density, thickness, and orientation will be set to allow maximum transmissivity while maintaining the 65/65 standard. With tray tables 20, the density of glass fiber, for example, may be increased compared to backlitlight signs 22, as transmissivity of light is not necessary. - The
composite material 70 may be formed by many different and unique methods. Two preferred methods for forming thecomposite material 70 are the thermal pressing process and the continuous fiber impregnation process. Each is described below with respect to the two-layer composite material 70 ofFIG. 15 . However, as one of ordinary skill recognizes, the same preferred processes may be manipulated slightly to form the three-layer composite material 70 ofFIG. 16 or the two-layer composite material 70 havingunidirectional fibers 78 as inFIG. 17 . - In the thermal pressing process, the
substrate material 74 andfibrous material 72 are first introduced within a mold. The mold is first heated under controlled pressure to soften thesubstrate material 74. This is known as the preheating stage. Next, in the impregnation stage, higher heat and pressure are introduced to laminate thefibrous material 72 to thesubstrate material 74. The higher heat and pressure allows the impregnation of the embeddedglass fibers 78 and substantially encapsulates thefibers 78 with thePPSU substrate material 74, therein forming thecomposite material 70. Finally, in the cooling stage, the composite material is cooled under controlled heat and pressure conditions to control internal stresses and warpage. - In one preferred example of this process, a
composite sheet 60 of about 0.1 inches in thickness is formed by first introducing thePPSU substrate material 74 andfibrous material 72 to a mold. Next, in the preheating stage, the mold is heated to about 535 degrees Fahrenheit over about 15 minutes. - The mold is then held at 535 degrees for about 55 minutes at during the impregnation stage. During this time, the pressure is ratcheted upward slowly to prevent outgassing of the PPSU substrate material, therein preventing bubbles formed within the
composite sheet 70. Thus, between 0 and 5 minutes, the pressure is maintained at about 15 pounds per square inch part pressure. Between 5 and 27 minutes, the pressure is maintained at about 50 pounds per square inch part pressure. Between 27 and 47 minutes, the pressure is maintained at about 100 pounds per square inch part pressure. Finally, between 47 and 55 minutes, the pressure is maintained at about 200 pounds per square inch part pressure. - Next, in the cooling stage, the composite part is allowed to slowly cool down to 235 degrees Fahrenheit under constant pressure of about 200 pounds per square inch part pressure. The cooling rate is maintained at about 5 degrees Fahrenheit per minute, thus this portion of the cooling stage lasts approximately one hour to control internal stresses and warpage of the forming composite part.
- Next, to further cool the composite part, the temperature within the mold is slowly decreased to about 150 degrees Fahrenheit and 100 pounds per square inch part pressure to further control internal stresses and warpage. Finally, the mold is opened and the
composite sheet 70 is allowed to cool to room temperature. - The thermal pressing technique has many benefits over other techniques used for forming composite materials. First, the
fibers 78 are substantially encapsulated with the PPSU substrate material. Also, thermal pressing at a temperature below the melting point of the PPSU substrate allows sufficient flex without yield. Finally, the thermal pressing technique also allows the incorporation of decorative features into the composite material. For example, a screen print may be added to thefibers 78 prior to adding thefibers 78 to thePPSU substrate material 74. - In the continuous impregnation technique, molten PPSU resin making up the
substrate material 74 is introduced from an extruder having a die set between a pair of rollers contained within a calendar roll stack. At the same time, a sheet layer offibrous material 72 is unrolled from a roller onto the molten layer between the first set of rollers. The calendar roll stack, preferably containing three or more stainless steel calendar rolls stacked vertically, presses the fibrous material sheet layer and molten layer to a desired thickness, therein impregnating the PPSU resin within thefibrous material 72. Thecomposite material 70 formed then is removed from the calendar rolls stack on a conveyor belt line and allowed to cool, therein forming a cooled, hardenedcomposite sheet 70. - The continuous impregnation technique offers slightly different benefits to the thermal pressing technique. For example, because the process is continuous, the
composite sheet material 70 may be formed at a quicker rate than with the thermal pressing technique. This is also cost effective. Also, the thickness of the material formed may be easily modified by adjusting the clearance gap between the respective rollers of the calendar stack. Additionally, the process also automates impregnation techniques that would otherwise have to be accomplished manually. - After the
composite material 70 is formed by either of the preferred techniques described above or by any other techniques known to those of skill in the art, thecomposite material 70 is then available to be post-processed for the desired application. The type of post processing depends upon the component 14, and typically involves cutting, bending or thermoforming the part to a desired shape and size. - For example, a
privacy curtain 50 must remain flexible, and is thus formed as a very thin composite material. Conversely, acountertop 16 must be able to support items placed upon it, and thus is formed with a thickness much greater than theprivacy curtain 50. - Also, for example, the amount of light transmissivity may vary based upon the ultimate use of the component. Thus, an
emergency exit sign 24 may be formed of a thincomposite material 70 and with a lower fiber thread per unit area, therein allowing maximum light transmissivity. Conversely, a ceiling may be formed with minimal light transmissivity having higher fiber thread count per unit area, therein providing maximum flammability resistance. - The component 14 is then available for use within the
cabin area 12. To form the component, thecomposite material 70 having the desired light transmissivity and flame resistant characteristics as described above is bent, cut thermoformed or otherwise post-processed in methods well known in the art to shape and size the part to the desired configuration. - While the invention has been described in terms of preferred embodiments, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings.
Claims (40)
1. A two-layer composite material for use in translucent, flame-resistant components, the composite material comprising:
a polyphenylsulfone substrate material; and
a plurality of long glass fibers substantially embedded within said polyphenylsulfone substrate material such that the composite material has an average allowable heat release not to exceed a 65/65 standard.
2. The two-layer composite material of claim 1 , wherein said plurality of long glass fibers comprises a plurality of unidirectional long glass fibers.
3. The two-layer composite material of claim 1 , wherein said plurality of long glass fibers is selected from the group consisting of a plurality of long s-type glass fibers and a plurality of long e-type glass fibers.
4. The two-layer composite material of claim 1 , wherein said translucent, flame-resistant components comprises an interior component contained within a commercial aircraft.
5. The two-layer composite material of claim 4 , wherein said interior component is selected from the group consisting of a countertop, a cabinet enclosure, a tray table, a backlit lighted sign, an illuminating window panel, a window bezel, a class divider, a privacy partition, a backlit ceiling panel, a direct lighting ceiling panel, a backlit control panel, a lighted door, a lighted door latch, a doorway lining, a proximity light, a stow bin door, a privacy curtain, a translucent door handle, a translucent amenities cabinet, a translucent sink deck a doorway liner, a stow bin latch handle, and a lighted phone.
6. The two-layer composite material of claim 1 , wherein said plurality of long glass fibers comprises a weaved glass cloth material having a plurality of long glass fibers.
7. The two-layer composite material of claim 6 , wherein said plurality of long glass fibers is selected from the group consisting of a plurality of long e-type glass fibers and a plurality of long s-type glass fibers.
8. A three-layer composite material for use in translucent, flame-resistant components, the composite material comprising:
a first layer of a polyphenylsulfone substrate material;
a second layer of said polyphenylsulfone substrate material; and
a plurality of long glass fibers sandwiched between and substantially embedded within said first layer and said second layer such that the composite material has an average allowable heat release not to exceed a 65/65 standard.
9. The three-layer composite material of claim 8 , wherein said plurality of long glass fibers comprises a plurality of unidirectional long glass fibers.
10. The three-layer composite material of claim 8 , wherein said plurality of long glass fibers comprises a plurality of long e-type glass fibers.
11. The three-layer composite material of claim 8 , wherein said plurality of long glass fibers comprises a plurality of long s-type glass fibers.
12. The three-layer composite material of claim 8 , wherein said translucent, flame-resistant components comprises an interior component contained within a commercial aircraft.
13. The three-layer composite material of claim 12 , wherein said interior component is selected from the group consisting of a countertop, a cabinet enclosure, a tray table, a backlit lighted sign, an illuminating window panel, a window bezel, a dass divider, a privacy partition, a backlit ceiling panel, a direct lighting ceiling panel, a backlit control panel, a lighted door, a lighted door latch, a doorway lining, a proximity light, a stow bin door, a privacy curtain, a translucent door handle, a translucent amenities cabinet, a translucent sink deck a doorway liner, a stow bin latch handle, and a lighted phone.
14. The three-layer composite material of claim 8 , wherein said plurality of long glass fibers comprises a weaved glass cloth material having a plurality of long glass fibers.
15. The three-layer composite material of claim 14 , wherein said plurality of long glass fibers is selected from the group consisting of a plurality of long e-type glass fibers and a plurality of long s-type glass fibers.
16. A three-layer composite material for use in translucent, flame-resistant components, the composite material comprising:
a first layer of a plurality of long glass fibers
a second layer of said plurality of long glass fibers; and
a layer of polyphenylsulfone substrate material sandwiched between and embedding said first layer and said second layer such that the composite material has an average allowable heat release not to exceed a 65/65 standard.
17. The three-layer composite material of claim 16 , wherein said plurality of long glass fibers is selected from the group consisting of a plurality of long s-type glass fibers and a plurality of long e-type glass fibers.
18. The three-layer composite material of claim 16 , wherein said plurality of long glass fibers comprises a weaved glass cloth material having a plurality of long glass fibers.
19. A method for forming a composite material for use in translucent, flame-resistant components, the method comprising:
introducing a layer of polyphenylsulfone substrate material to a mold;
introducing a fibrous material onto an entire top surface of said polyphenylsulfone substrate material within said mold, said fibrous material comprising a plurality of long glass fibers;
preheating said mold to a first temperature to soften said polyphenylsulfone substrate material;
laminating said fibrous material to said polyphenylsulfone substrate material such that said plurality of long glass fibers are substantially encapsulated within said polyphenylsulfone substrate material while substantially preventing said polyphenylsulfone substrate from outgassing;
cooling said mold under controlled heat and pressure to form the composite material; and
removing said composite material from said mold.
20. The method of claim 19 , wherein introducing a fibrous material comprises introducing a plurality of unidirectional long glass fibers onto an entire top surface of said polyphenylsulfone substrate material within said mold.
21. The method of claim 19 , wherein introducing a fibrous material comprises introducing a weaved glass fiber layer onto an entire top surface of said polyphenylsulfone substrate material within said mold, said weaved glass fiber layer comprising a plurality of long glass fibers.
22. The method of claim 19 , wherein preheating said mold comprises preheating said mold to about 535 degrees Fahrenheit over about 15 minutes to soften said polyphenylsulfone substrate material.
23. The method of claim 22 , wherein laminating said fibrous material to said polyphenylsulfone substrate material comprises:
holding said mold at about 535 degrees Fahrenheit for 0 minutes to about 55 minutes;
increasing said pressure of said mold at 0 minutes to about 15 pounds per square inch part pressure;
holding said mold at about 15 pounds per square inch part pressure between about 0 minutes and about 5 minutes;
increasing said pressure from about 15 pounds per square inch part pressure to about 50 pounds per square inch part pressure at 5 minutes;
holding said mold at about 50 pounds per square inch part pressure between about 5 minutes and about 27 minutes;
increasing said pressure from about 50 pounds per square inch part pressure to about 100 pounds per square inch part pressure at 27 minutes;
holding said mold at about 100 pounds per square inch part pressure between about 27 minutes and about 47 minutes;
increasing said pressure from about 100 pounds per square inch part pressure to about 200 pounds per square inch part pressure at 47 minutes; and
holding said mold at about 200 pounds per square inch part pressure between about 47 minutes and about 55 minutes.
24. The method of claim 23 , wherein cooling said mold comprises:
slowly cooling said mold from about 535 degrees Fahrenheit to about 235 degrees Fahrenheit at 200 pounds per square inch part pressure at a cooling rate of about 5 degrees Fahrenheit per minute; and
further cooling said mold to about 150 degrees Fahrenheit at about 100 pounds per square inch part pressure.
25. A method for forming a composite material for use in translucent, flame-resistant components, the method comprising; a polyphenylsulfone substrate material to an extruder;
melting said polyphenylsulfone substrate material within said extruder;
introducing said melted polyphenylsulfone substrate material to a calendar roll stack;
introducing a fibrous material layer onto a top surface of said first portion within said calendar roll stack, said fibrous substrate material layer comprising a plurality of long glass fibers;
pressing said fibrous substrate material layer within said melted polyphenylsulfone substrate material within said calendar roll stack to form the composite material such that said plurality of long glass fibers are substantially encapsulated within said melted polyphenylsulfone substrate material; and
removing the composite material from the calendar roll stack.
26. The method of claim 25 , wherein introducing a fibrous material layer comprises introducing a layer of unidirectional long glass fibers onto an entire top surface of said melted polyphenylsulfone substrate material within said calendar roll stack.
27. The method of claim 25 , wherein introducing a fibrous material layer comprises introducing a weaved glass fiber layer onto an entire top surface of said melted polyphenylsulfone substrate material within said calendar roll stack, said weaved glass fiber layer comprising a plurality of long glass fibers.
28. A method for forming a composite material for use in translucent, flame-resistant components, the method comprising:
introducing a first layer of a polyphenylsulfone substrate material to a mold;
introducing a fibrous material onto an entire top surface of said polyphenylsulfone substrate material within said mold, said fibrous material comprising a plurality of long glass fibers;
introducing a second layer of said polyphenylsulfone substrate material to a mold such that said fibrous material is sandwiched between said first layer and said second layer;
preheating said mold to a first temperature to soften said first layer and said second layer;
laminating said fibrous material to said first layer and said second layer such that said plurality of long glass fibers are substantially encapsulated within said polyphenylsulfone substrate material while substantially preventing said first layer and said second layer from outgassing;
cooling said mold under controlled heat and pressure to form the composite material; and
removing said composite material from said mold.
29. The method of claim 28 , wherein introducing a fibrous material comprises introducing a plurality of unidirectional long glass fibers onto an entire top surface of said polyphenylsulfone substrate material within said mold.
30. The method of claim 28 , wherein introducing a fibrous material comprises introducing a weaved glass fiber layer onto an entire top surface of said polyphenylsulfone substrate material within said mold, said weaved glass fiber layer comprising a plurality of long glass fibers.
31. The method of claim 28 , wherein preheating said mold comprises preheating said mold to about 535 degrees Fahrenheit over about 15 minutes to soften said polyphenylsulfone substrate material.
32. The method of claim 31 , wherein laminating said fibrous material to said polyphenylsulfone substrate material comprises:
holding said mold at about 535 degrees Fahrenheit for 0 minutes to about 55 minutes;
increasing said pressure of said mold at 0 minutes to about 15 pounds per square inch part pressure;
holding said mold at about 15 pounds per square inch part pressure between about 0 minutes and about 5 minutes;
increasing said pressure from about 15 pounds per square inch part pressure to about 50 pounds per square inch part pressure at 5 minutes;
holding said mold at about 50 pounds per square inch part pressure between about 5 minutes and about 27 minutes;
increasing said pressure from about 50 pounds per square inch part pressure to about 100 pounds per square inch part pressure at 27 minutes;
holding said mold at about 100 pounds per square inch part pressure between about 27 minutes and about 47 minutes;
increasing said pressure from about 100 pounds per square inch part pressure to about 200 pounds per square inch part pressure at 47 minutes; and
holding said mold at about 200 pounds per square inch part pressure between about 47 minutes and about 55 minutes.
33. The method of claim 32 , wherein cooling said mold comprises:
slowly cooling said mold from about 535 degrees Fahrenheit to about 235 degrees Fahrenheit at 200 pounds per square inch part pressure at a cooling rate of about 5 degrees Fahrenheit per minute; and
further cooling said mold to about 150 degrees Fahrenheit at about 100 pounds per square inch part pressure.
34. A method for forming a translucent, flame resistant component for use in the cabin area of a commercial aircraft, the method comprising:
forming a composite material, said composite material comprising a polyphenylsulfone substrate material substantially encapsulating a plurality of long glass fibers, wherein said composite material has an average allowable heat release not to exceed a 65/65 standard; and
post processing said composite material to form the translucent, flame resistant component.
35. The method of claim 34 , wherein said translucent, flame resistant component is selected from the group consisting of a countertop, a cabinet enclosure, a tray table, a backlit lighted sign, an illuminating window panel, a window bezel, a class divider, a privacy partition, a backlit ceiling panel, a direct lighting ceiling panel, a backlit control panel, a lighted door, a lighted door latch, a doorway lining, a proximity light, a stow bin door, a privacy curtain, a translucent door handle, a translucent amenities cabinet, a translucent sink deck a doorway liner, a stow bin latch handle, and a lighted phone.
36. The method of claim 34 , wherein forming a composite material comprises:
introducing a layer of polyphenylsulfone substrate material to a mold;
introducing a fibrous material onto an entire top surface of said polyphenylsulfone substrate material within said mold, said fibrous material comprising a plurality of long glass fibers;
preheating said mold to a first temperature to soften said polyphenylsulfone substrate material;
laminating said fibrous material to said polyphenylsulfone substrate material such that said plurality of long glass fibers are substantially encapsulated within said polyphenylsulfone substrate material while substantially preventing said polyphenylsulfone substrate from outgassing;
cooling said mold under controlled heat and pressure to form the composite material; and
removing said composite material from said mold.
37. The method of claim 34 , wherein forming a composite material comprises:
introducing a first layer of a polyphenylsulfone substrate material to a mold;
introducing a fibrous material onto an entire top surface of said polyphenylsulfone substrate material within said mold, said fibrous material comprising a plurality of long glass fibers;
introducing a second layer of said polyphenylsulfone substrate material to a mold such that said fibrous material is sandwiched between said first layer and said second layer;
preheating said mold to a first temperature to soften said first layer and said second layer;
laminating said fibrous material to said first layer and said second layer such that said plurality of long glass fibers are substantially encapsulated within said polyphenylsulfone substrate material while substantially preventing said first layer and said second layer from outgassing;
cooling said mold under controlled heat and pressure to form the composite material; and
removing said composite material from said mold.
38. The method of claim 34 , wherein forming a composite material comprises:
introducing a polyphenylsulfone substrate material to an extruder;
melting said polyphenylsulfone substrate material within said extruder;
introducing said melted polyphenylsulfone substrate material to a calendar roll stack;
introducing a fibrous material layer onto a top surface of said first portion within said calendar roll stack, said fibrous substrate material layer comprising a plurality of long glass fibers;
pressing said fibrous substrate material layer within said melted polyphenylsulfone substrate material within said calendar roll stack to form the composite material such that said plurality of long glass fibers are substantially encapsulated within said melted polyphenylsulfone substrate material; and
removing the composite material from the calendar roll stack.
39. The method of claim 34 , wherein post processing said composite material is selected from the group consisting of cutting said composite material to a desired shape and size, thermoforming said composite material to a desired shape and size, and bending said composite material to a desired shape and size.
40. The three-layer composite material of claim 16 , wherein said plurality of long glass fibers comprises a plurality of unidirectional long glass fibers.
Priority Applications (5)
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PCT/US2004/038242 WO2005065944A1 (en) | 2003-12-24 | 2004-11-10 | Translucent, flame resistant composite material |
EP04817829.7A EP1704050B1 (en) | 2003-12-24 | 2004-11-10 | Translucent, flame resistant composite materials |
US12/577,618 US8007620B2 (en) | 2003-12-24 | 2009-10-12 | Translucent, flame resistant composite materials |
US13/048,704 US20120156440A1 (en) | 2003-12-24 | 2011-03-15 | Translucent, Flame Resistant Composite Materials |
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US10/707,612 US20050142968A1 (en) | 2003-12-24 | 2003-12-24 | Translucent, flame resistant composite materials |
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US20080166544A1 (en) * | 2007-01-10 | 2008-07-10 | Airbus Deutschland Gmbh | Rear-Illuminable Aircraft Interior Component |
US8277070B1 (en) | 2009-11-17 | 2012-10-02 | Crafted Countertops, Inc. | Counter with border lighting |
US9797074B1 (en) * | 2017-02-02 | 2017-10-24 | Douglas J. Bailey | Flexible translucent to transparent fireproof composite material |
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FR2960902B1 (en) * | 2010-06-08 | 2015-04-24 | Baumert Technologies | FIRE-CUTTING DOOR BLOCK HAS ONE OR TWO PIVOTING DOORS (S) |
JP6535167B2 (en) * | 2015-01-21 | 2019-06-26 | 三菱航空機株式会社 | Aircraft and fuselage cooling structure |
DE102017215369A1 (en) * | 2017-09-01 | 2019-03-07 | Benecke-Kaliko Ag | Translucent multi-layer composite film |
GB2569151B (en) * | 2017-12-07 | 2021-01-27 | Jaguar Land Rover Ltd | Reformable article |
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US20040219855A1 (en) * | 2003-05-02 | 2004-11-04 | Tsotsis Thomas K. | Highly porous interlayers to toughen liquid-molded fabric-based composites |
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US20080166544A1 (en) * | 2007-01-10 | 2008-07-10 | Airbus Deutschland Gmbh | Rear-Illuminable Aircraft Interior Component |
US8501311B2 (en) * | 2007-01-10 | 2013-08-06 | Airbus Deutschland Gmbh | Rear-illuminable aircraft interior component |
US8277070B1 (en) | 2009-11-17 | 2012-10-02 | Crafted Countertops, Inc. | Counter with border lighting |
US9797074B1 (en) * | 2017-02-02 | 2017-10-24 | Douglas J. Bailey | Flexible translucent to transparent fireproof composite material |
US10125439B2 (en) | 2017-02-02 | 2018-11-13 | Douglas J. Bailey | Flexible translucent to transparent fireproof composite material |
US10695795B2 (en) | 2017-02-02 | 2020-06-30 | Fire Curtains, Inc. | Method of producing a composite panel |
Also Published As
Publication number | Publication date |
---|---|
US20100059900A1 (en) | 2010-03-11 |
US8007620B2 (en) | 2011-08-30 |
EP1704050A1 (en) | 2006-09-27 |
EP1704050B1 (en) | 2016-05-25 |
WO2005065944A1 (en) | 2005-07-21 |
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