Patent Publication Number: US-2015068691-A1

Title: Multilayer aircraft shade material

Description:
FIELD OF THE DISCLOSURE 
     This invention relates to aircraft shade materials and assemblies useful in aircraft or other vehicles. 
     BACKGROUND 
     Flexible window shades in vehicles such as aircraft, buses, ships, and the like need to remain durable while subjected to repeated use and extreme environmental conditions including thermal, chemical, moisture, solvent, passenger contact, and ultraviolet (UV) exposure. Accordingly, aircraft shade materials may find utility in various vehicles including aircrafts, buses, ships and the like. 
     SUMMARY 
     In various aspects, multilayer materials are provided. In some aspects, a multilayer material comprises a first layer formed from a thermoplastic elastomeric material, a second layer formed from a fabric and secured to a first side of the first layer, and a third layer formed from a fabric secured to a second side of the first layer. 
     In another aspect there is provided a window shade, comprising a handle, a roller, and a multilayer material, comprising a first layer formed from a thermoplastic elastomeric material, a second layer formed from a fabric and secured to a first side of the first layer, and a third layer formed from a fabric secured to a second side of the first layer. 
     In another aspect there is provided a window assembly, comprising a fitting, a window, and a window shade assembly comprising a frame and a window shade, comprising a handle a roller and a multilayer material comprising a first layer formed from a thermoplastic elastomeric material, a second layer formed from a fabric and secured to a first side of the first layer, and a third layer formed from a fabric secured to a second side of the first layer. 
     In another aspect there is provided a method to make a multilayer material comprising applying a primer to at least a first side of a first sheet of polyester fabric, applying a primer to at least a first side of a second sheet of polyester fabric, calendaring a thermoplastic elastomer onto a first side of the polyester fabric, and curing the multilayer material. 
     The features, functions and advantages discussed herein can be achieved independently in various aspects described herein or may be combined in yet other aspects, further details of which can be seen with reference to the following description and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The detailed description is described with reference to the accompanying figures. 
         FIGS. 1-3  are schematic illustrations of multilayer materials in accordance with some aspects. 
         FIG. 4  is a flowchart illustrating operations in a method to make a multilayer material in accordance with some aspects. 
         FIG. 5  is a schematic, exploded view of a window shade assembly in accordance with some aspects. 
         FIG. 6  is a schematic, exploded view of a window assembly in accordance with some aspects. 
         FIG. 7  is a schematic view of an aircraft in accordance with some aspects. 
     
    
    
     DETAILED DESCRIPTION 
     Described herein are examples of multilayer materials, window shade and window assemblies comprising multilayer materials, vehicles comprising such assemblies, and methods to make multilayer materials. In the following description, numerous specific details are set forth to provide a thorough understanding of various aspects. However, it will be understood by those skilled in the art that the various aspects may be practiced without the specific details. In other instances, well-known methods, procedures, components, and circuits have not been illustrated or described in detail so as not to obscure the particular aspects. 
       FIGS. 1-3  are schematic illustrations of multilayer materials  100  in accordance with some aspects. Referring first to  FIG. 1 , in some aspects a multilayer material  100  may comprise a first layer  110  formed from a thermoplastic elastomeric material, a second layer  120 A formed from a fabric and secured to a first side of the first layer  110 , and a third layer  120 B formed from a fabric secured to a second side of the first layer  110 . 
     In some aspects the first layer  110  comprises at least one of a silicone material such as CS5093-01, which is a silicone rubber commercially available from Seal Science, Inc. of California, USA), a rubber material such as styrene butadiene rubber sheet commercially available from Rubber Cal of California, USA), a polyisoprene material (such as Cariflex™ polyisoprene rubber commercially available from Kraton of Texas, USA), a polyolefin material such as Clysar® high abuse film commercially available from Clysar® of Iowa, USA, a polyamide material such as cast PA 6 films commercially available from Impex Global, LLC of Texas, USA, a polyimide material such as Kapton® commercially available from DuPont, a copolyestermaterial such as Eastar™ copolyester 6763 commercially available from Eastman Chemical, a fluoroelastomer material such as Viton® films commercially available from DuPont or DaiEl T-530 film commercially available from Daiken Industries, Ltd., of Japan or a urethane material such as 3M™ Polyurethane film tapes or Elastollan® resin from BASF Corporation of Germany, and may be formed to a thickness that measures about 0.1 thousandths of an inch (mils) to about 12 mils. First layer  110  may be doped with a material such as a carbon black material or other dye in a quantity sufficient to render the first layer  110  opaque to visible light. Further, in some aspects the first layer  110  comprises a flame retardant material. Examples of suitable flame retardant materials include at least one of a brominated polymer such as Saytex® flame retardant materials commercially available from Albemarle of Louisiana, USA, a hydrated metal oxide such as Magnifin flame retardants commercially available from Albemarle or Hymod™ products from Huber Engineered Materials of Georgia, USA, ammonium polyphosphate such as Exolit AP products commercially available from Clariant of Switzerland, phosphorus polyols such as Exolit OP products commercially available from Clariant of Switzerland), red phosphorus, or a polyphosphinate (such as Exolit OP products from Clariant of Switzerland). 
     In some aspects the second layer  120 A and the third layer  120 B comprise at least one of a fiberglass material, a polyester material, a polyimide material, a polyarylate material, a semi-aromatic polyamide fiber, a polybenzimidazole fiber, a modified acrylic fiber, and a metal oxide fiber material. Second layer  120 A and third layer  120 B may also be coated with a flame retardant material or may be formed from a material that is inherently flame retardant. Examples of materials suitable for use in second layer  120 A and  120 B include Vectran™ fibers commercially available from Kuraray Co., Ltd, of Osaka, Japan, Nomex® fibers commercially available from DuPont of Wilmington, Del., USA, PBI® fibers commercially available from PBI Performance Products, Inc. of Charlotte, N.C., USA, Protex® fibers commercially available from Kaneka Corporation of Osaka, Japan, or a woven fiber commercially available from Vector Systems of Holmen, Wis., USA. Other examples may include hydrated inorganic materials that release water vapor at high temperatures to reduce heat (i.e., endothermic materials), or halogenated retardants that act to interrupt the burn cycle (i.e., gas phase retardants), or finally char inducing materials (i.e., intumescents) that generate a char barrier between a substrate and a heat source. 
     In some aspects the multilayer material  100  may comprise two or more layers of a thermoplastic elastomeric material. Referring to  FIG. 2 , the multilayer material  100  comprises a fourth layer  110 B secured adjacent the first layer  110 A. In some aspects the fourth layer  110 B is formed from a thermoplastic elastomeric material and comprises a carbon black material in a quantity sufficient to render the fourth layer  110 B opaque to visible light. The first layer may comprise a material such as Titanium dioxide. In the aspect depicted in  FIG. 2  the first layer  110 A may be formed to a thickness of about 0.1 thousandths of an inch (mils) to about 12 mils and the fourth layer  110 B may be formed to a thickness of about 0.1 thousandths of an inch (mils) to about 12 mils. 
     Referring to  FIG. 3 , in some aspects a fifth layer formed from a fabric material may be interposed between the first layer  110 A and the fourth layer  110 B. 
       FIG. 4  is a flowchart illustrating operations in a method to make a multilayer material in accordance with some aspects. Referring to  FIG. 4 , at operation  410  a primer is applied to at least a first side of a first sheet of fabric and at operation  415  a primer is applied to at least a first side of a second sheet of fabric. Examples of suitable primers include Chemlok® 607 and Chemlok® 608 commercially available from the Lord Corporation of Cary, N.C., USA and PR-2260 primer commercially available from Dow Chemical of Midland, Mich., USA. The primer may be blended with a solvent such as naptha. 
     At operation  420  a thermoplastic elastomer is calendered to a first fabric sheet and second fabric sheet. In some aspects the thermoplastic elastomer base compound may be cold mixed on roll mill with a peroxide curing agent and the first fabric sheet and second fabric sheet may be passed through the calendar rollers at 1.8 pph and to a specified thickness (e.g., 5 mil). 
     At operation  425  the multilayer material is cured. In some aspects the material may be cured in a heat-cure press at a pressure that measures between about 20 pounds per square inch and about 60 pounds per square inch at a temperature that measures between about 200 degrees Fahrenheit and about 280 degrees Fahrenheit for a time period that measures between about 5 minutes and about 30 minutes. 
     At operation  430  the multilayer material is subjected to a post-cure heating to burn off an residual catalyst materials. In some aspects the material may be heated to a temperature that measures between about 250 degrees Fahrenheit and 350 degrees Fahrenheit for a time period that measures between about 1 hours and 10 hours. 
     In some aspects a multilayer material as described with reference to  FIGS. 1-3  may be incorporated into a window shade.  FIG. 5  is a schematic, exploded view of a window shade assembly  500  in accordance with some aspects. Referring to  FIG. 5 , in some aspects window shade assembly  500  comprises a frame  510  which defines a window  514 . Frame  510  may be formed from a suitably rigid material, e.g., a metal or a plastic, and comprises tracks  512 A,  512 B, which may be referred to collectively here by reference numeral  512 , and a receptacle  516 . 
     A window shade  520  comprises a handle  522 , tabs  524 A and  524 B, which may be referred to collectively herein by reference numeral  524 , a roller  526 , and a multilayer material  100  connected to handle  522  and to roller  526 . Multilayer material  100  may be dimensioned to cover the window  514 . 
     Window assembly  500  may further comprise a cover  530  which receives roller  526  and covers receptacle  516 . 
     Window shade  500  may be assembled by sliding tabs  524  into tracks  512  and fitting roller  526  into cover  530 , then coupling the cover over the receptacle  516  such that the roller  520  is housed in the receptacle  516  and cover  530 . 
     In some aspects a window shade assembly  500  may be incorporated into a window assembly.  FIG. 6  is a schematic, exploded view of a window assembly  600  in accordance with some aspects. Referring to  FIG. 6 , in some aspects a window assembly  600  comprises a shroud  610 , a mounting base  615 , a window shade assembly  500 , a transparent pane  620  and an isolator assembly  625 . Window assembly  600  may be secured together using fasteners such as screws or bolts or via interference fit features on mating surfaces. In use, isolator assembly  625  may interface with the frame of a vehicle, e.g., an aircraft, bus, ship, or the like. 
       FIG. 7  is a schematic illustration of an aircraft  700  in which a window shade assembly  500  may be installed, according to aspects Referring to  FIG. 7 , the airplane  700  may be a commercial airline, cargo plane, or small passenger plane. The airplane  700  may comprise a body  710  which defines an interior cabin, one or more wings  720  and one or more engines  630 . The particular design of the aircraft  700  is not critical. 
     Reference in the specification to “one aspect” or “some aspects” means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least an implementation. The appearances of the phrase “in one aspect” in various places in the specification may or may not be all referring to the same aspect. 
     Also, in the description and claims, the terms “coupled” and “connected,” along with their derivatives, may be used. In some aspects of the invention, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may mean that two or more elements are in direct physical or electrical contact. However, “coupled” may also mean that two or more elements may not be in direct contact with each other, but may still cooperate or interact with each other. 
     Although aspects have been described in language specific to structural features and/or methodological acts, it is to be understood that claimed subject matter may not be limited to the specific features or acts described. Rather, the specific features and acts are disclosed as sample forms of implementing the claimed subject matter.