Patent ID: 8530043

Claim:
A multi-layer composite laminate composition comprising: a substrate layer and an overlay layer that are both bonded to at least one adjacent layer in a multi-layer composite laminate composition; the substrate layer being a thermoformable material having a material formulation that includes a polycarbonate homopolymer or copolymer; the overlay layer being a thermoformable material having a material formulation that includes an ingredient selected from the group consisting of PVC, PVC alloy, acrylic, polyurethane, acrylonitrile butadiene styrene, and combinations thereof; the multi-layer composite laminate composition having the following performance characteristics; flammability: the composite laminate being compliant with FAR 25-853(a)(1)(i)60-second vertical burn, wherein 60-second vertical burn average burn length does not exceed 6 inches, average after flame time does not exceed 15 seconds and average after flame drip time does not exceed 3 seconds; flammability: the composite laminate being compliant with FARQ25-853(a)(1)(ii) of 12-second vertical burn, wherein 12-second vertical burn average burn length does not exceed 8 inches, average after flame time does not exceed 15 seconds and average after-flame drip time does not exceed 5 seconds; specific optical smoke density: using an NBS smoke chamber, the average peak smoke density within 4-minute is equal to or less than 200 as regulated by FAR 25-853(d); specific optical smoke density: using an NBS smoke chamber, the average peak composite-material smoke density within 4-minute is equal to or less than 150 as regulated by airbus ABD0031/ATS1000; toxicity of burning gas: composite-material smoke extracted from NBS smoke chamber and measured by Draeger tube has an average concentration (in parts per million, ppm) of the following gas components: HF<100 ppm, HCI<150 ppm, HCN<150 ppm, SO2/H2S<100 ppm, NO/NO2<100 ppm, and CO<1000 ppm; heat release and heat release rate: as measured by OSU heat release tester, the total 2-minute heat release and heat release rate does not exceed 65KW-min/m2 and 65 KW/m2, respectively regulated by FAR 25-853(d); wherein the number of layers within the composition is two, the first layer being a substrate layer having a material formulation that includes a polycarbonate-polyester; and the second layer being an overlay layer having a material formulation that includes an ingredient selected from the group consisting of polyvinyl chloride, polyvinyl chloride alloy, acrylic, polyurethane, acrylonitrile butadiene styrene, and combinations thereof; and wherein the substrate layer has a material formulation comprising poly(oxycarbonyloxy-1,4-phenylene-isopropylidine) polycarbonate.