Thermoformable/polycarbonate/woven glass cloth composites
AssigneeGeneral Electric Company
InventorsMichael G. Minnick, Daniel E. Floryan
Life of this patent
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Abstract
Thermoformable composites comprised of polycarbonate/woven glass cloth and methods for their preparation are provided which have good flammability characteristics and physical properties and are suitable for use in aircraft interiors.
Claims17
A flame-resistant and smoke-resistant aircraft interior component, comprising at least 50 wt % of a woven glass cloth and up to 50 wt % of a flame-retardant matrix material which comprises a flame-retardant polycarbonate resin.
A flame-resistant, vacuum-thermoformed, non-planar composite having at least one glossy surface finish comprising at least 50 wt % knitted woven glass cloth and up to 50 wt % of a flame-retardant matrix material which comprises flame-retardant polycarbonate resin, wherein samples of said composite show a heat release rate of less than 65 kW/min/m.sup.2 for the first two minutes and a peak release of less than 65 kW/m.sup.2 within the first five minutes upon application of 3.5 watts/cm.sup.2 of radiant heat, as determined by ASTM E906.
A flame-resistant, planar composite having a thickness of from 4 to 60 mils, which comprises at least 50 wt % knitted woven glass cloth in three plies and up to 50 wt % of a flame-retardant polycarbonate matrix material, wherein said planar composite:
- (a) shows a heat release rate of less than 65 kW/min/m.sup.2 for the first two minutes and a peak release of less than 65 kW/m.sup.2 within the first five minutes upon application of 3.5 watts/cm.sup.2 of radiant heat, as determined by ASTM E906;
- (b) shows a specific optical smoke density of less than 200 as determined by ASTM E662, after 4 minutes upon ignition in an NBS smoke chamber;
- (c) does not burn-through upon exposure for 5 minutes to a flame 6" from the surface, as determined by FAR 25, Appendix F (Part III, 1990);
- (d) is self-extinguishing upon vertical exposure to a Bunsen burner flame for 60 seconds, as determined by FAR, Appendix F (Part IV, 1990),
- (e) has emissions of <500 ppm HCl, <150 ppm HCN, <100 ppm SO.sub.x, <200 ppm HF, <3500 CO, and <100 ppm NO.sub.x upon ignition;
- (f) has flexural strength >3.5M (L) and >3.0M (C);
- and
- (g) shows flexural modulus >1.76 MM (L) and >1.16 MM (C).
A process for producing a flame-resistant, thermoformable composite by melt impregnating 2-4 sheets of fiber-reinforcement cloth with polycarbonate from layers thereof under heat and pressure, the improvements which comprise utilizing (a) at least 50 wt % knitted woven glass cloth, (b) flame-retardant polycarbonate copolymers, and (c) at least one core layer of non-flame-retardant thermoplastic in forming the composite.
A process for producing a flame-resistant, thermoformable composite for aircraft interior components by melt impregnating 2-4 sheets of knitted woven glass cloth with flame-retardant polycarbonate, the improvement which comprises utilizing a continuous press at temperatures below 250.degree. C.
Dependencies are inferred from the claim text.