Translucent, flame resistant composite materials

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.

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.