Abstract:
An aviation laminate includes an intumescent backer sheet covered by a decorative sheet. The aviation laminate is generally fire-resistant, may be structural, and may be used to construct various components within an aircraft cabin that may be held to government/regulatory fire mitigation requirements.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This patent application claims priority to India Patent Application Serial No. 3684/DEL/2015 filed Nov. 10, 2015, the entire contents of which is incorporated herein by reference. 
       BACKGROUND 
       [0002]    The present disclosure relates to laminates and, more particularly, to a fire-resistant aviation laminate used for interior cabin components in the aviation industry. 
         [0003]    Traditional veneer systems used in aircraft interiors must undergo chemical treatment to meet fire resistant requirements of various government agencies. Known processes of treating the veneers is vary labor intensive and the effectiveness varies. Moreover, known treatment methods may not yield consistent results and some veneers may require retreatment. Yet further, known fire retardant solutions used in the chemical treatments may discolor the veneer and/or are not environmentally friendly. Alternative fire-resistant and/or chemical friendly materials for use in an aircraft cabin is desirable. 
       SUMMARY 
       [0004]    An aviation laminate according to one, non-limiting, embodiment of the present disclosure includes an intumescent backer sheet; and a decorative sheet engaged to the intumescent backer sheet. 
         [0005]    Additionally to the foregoing embodiment, the intumescent backer sheet is a polymer matrix infused with an intumescent material. 
         [0006]    In the alternative or additionally thereto, in the foregoing embodiment, the intumescent backer sheet is made of mineral fiber, exfoliating graphite and an organic binder. 
         [0007]    In the alternative or additionally thereto, in the foregoing embodiment, the intumescent backer sheet is made of at least an expandable graphite. 
         [0008]    In the alternative or additionally thereto, in the foregoing embodiment, the aviation laminate includes an adhesive layer for securing the intumescent backer sheet to the decorative sheet. 
         [0009]    In the alternative or additionally thereto, in the foregoing embodiment, the adhesive layer includes a pressure sensitive adhesive. 
         [0010]    In the alternative or additionally thereto, in the foregoing embodiment, the adhesive layer is one of an epoxy, a phenolic based adhesive, and a polyurethane based adhesive. 
         [0011]    In the alternative or additionally thereto, in the foregoing embodiment, the decorative sheet is a plastic sheet. 
         [0012]    In the alternative or additionally thereto, in the foregoing embodiment, the decorative sheet is a wood veneer. 
         [0013]    In the alternative or additionally thereto, in the foregoing embodiment, the wood veneer is between about 0.015 to 0.022 inches thick. 
         [0014]    In the alternative or additionally thereto, in the foregoing embodiment, the aviation laminate at least in-part forms a bulkhead. 
         [0015]    In the alternative or additionally thereto, in the foregoing embodiment, the aviation laminate at least in-part forms a cabin door. 
         [0016]    In the alternative or additionally thereto, in the foregoing embodiment, the aviation laminate at least in-part forms a cabin table top. 
         [0017]    In the alternative or additionally thereto, in the foregoing embodiment, the aviation laminate at least in-part forms interior cabinetry. 
         [0018]    An aircraft according to another, non-limiting, embodiment includes an interior cabin including cabinetry including an aviation laminate having an intumescent backer sheet and a decorative sheet engaged to the intumescent backer sheet, and wherein the laminate is fire and burn resistant. 
         [0019]    Additionally to the foregoing embodiment, the intumescent backer sheet is made of mineral fiber, exfoliating graphite and an organic binder. 
         [0020]    In the alternative or additionally thereto, in the foregoing embodiment, the intumescent backer sheet is made of at least an expandable graphite. 
         [0021]    In the alternative or additionally thereto, in the foregoing embodiment, the intumescent backer sheet is pressure bonded to the decorative sheet. 
         [0022]    In the alternative or additionally thereto, in the foregoing embodiment, the decorative sheet is a wood veneer. 
         [0023]    In the alternative or additionally thereto, in the foregoing embodiment, the wood veneer is between about 0.015 to 0.022 inches thick. 
         [0024]    The foregoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated otherwise. These features and elements as well as the operation thereof will become more apparent in light of the following description and the accompanying drawings. However, it should be understood that the following description and drawings are intended to be exemplary in nature and non-limiting. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]    Various features will become apparent to those skilled in the art from the following detailed description of the disclosed non-limiting embodiments. The drawings that accompany the detailed description can be briefly described as follows: 
           [0026]      FIG. 1  is a perspective view of an interior cabin of an aircraft utilizing the fire-resistant aviation laminate of the present disclosure; and 
           [0027]      FIG. 2  is a perspective cross section of the aviation laminate. 
       
    
    
     DETAILED DESCRIPTION 
       [0028]    Referring to  FIGS. 1 and 2 , an exemplary embodiment of an interior cabin  20  of an aircraft  22  is illustrated. The aircraft  22  may be any variety of aircrafts including helicopters and airplanes that may be designed in accordance with government regulations pertaining to the propagation of cabin fire and burn characteristics of interior cabin components. In accordance with the present disclosure, the cabin components are substantially made of an aviation laminate  24 . The components may include, but are not limited to, interior cabinetry  26 , bulkheads  28  (e.g., decorative walls), doors  30 , table tops  32 , credenzas  34  and other components that may include decorative surfaces. 
         [0029]    The aviation laminate  24  includes an intumescent backer sheet  26  and an external sheet  38  that may include a decorative or finish surface  40 . The intumescent backer sheet  26  may be rigid and structurally supportive and generally swells up (e.g., about twenty to forty times initial volume) when exposed to extreme heat, and thereby may prevent further propagation of fire. Furthermore, the intumescent feature of the backer sheet  26  not only functions as a fire stop, but may be fire resistant (i.e., fireproof) so as not to contribute toward fueling a fire. The intumescent backer sheet  26  may be made of a polymer matrix (e.g., epoxies, poly vinyl ester, or phenolic) infused with intumescent material. The intumescent backer sheet  26  may also be made of a polymer infused material such as a glass fiber, and/or made of a mineral fiber, exfoliating graphite and an organic binder. More generally, the intumescent backer sheet  26  may be made at least in-part of an expandable graphite. 
         [0030]    The external sheet  38  may be decorative and generally seen by the naked eye. Non-limiting examples of the external sheet  38  may include decorative wood veneers, plastic materials having an appealing color and/or pattern, and various forms of paints or coatings. For the example of wood veneers, the veneer may not include intumescent qualities, and instead may be sufficiently thin so as not to contribute toward fire propagation. As one example, the exposed face veneer may be between 0.015 to 0.022 inches in thickness. It is further contemplated and understood that the external sheet  38  may also include intumescent qualities. 
         [0031]    The decorative external sheet  38  may be bonded to the intumescent backer sheet  26  by an adhesive layer  42 . The adhesive layer  42  may be a dry film adhesive (e.g., phenolic, epoxies, hot melt polyamide or polyurethane), a pressure sensitive adhesive, or any other variety of adhesives generally known in the art. It is further contemplated and understood that the external sheet  38  may be pressure bonded to the intumescent backer sheet  26  without the need for an adhesive layer  42 . 
         [0032]    The aviation laminate  24  and the various cabin components substantially made of the laminate  24  are substantially fire-resistant. In contrast, more traditional cabin components typically made of wood backers (e.g., plywood) are not fire-resistant, or to facilitate passing of government/regulatory flammability tests, the plywood must undergo time consuming salt-based treatments. The overall weight with respect to volume and/or strength of the laminate  24  may be substantially less than more traditional materials, which is particularly advantageous for the aviation industry. The overall thickness of the laminate  24  may be substantially less than more traditional materials, which is also advantageous for the aviation industry. 
         [0033]    The laminate  24  may be planar and, during manufacturing of the various cabin components, may be cut to appropriate sizes and shapes. Alternatively, the laminate  24  may have a substantially consistent thickness, however, is formed to a desired three dimensional shape during the manufacturing process of the laminate  24  itself to conform to a particular cabin component shape or need. 
         [0034]    While the present disclosure is described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the spirit and scope of the present disclosure. In addition, various modifications may be applied to adapt the teachings of the present disclosure to particular situations, applications, and/or materials, without departing from the essential scope thereof. The present disclosure is thus not limited to the particular examples disclosed herein, but includes all embodiments falling within the scope of the appended claims.