Patent ID: 8007620

Claim:
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, wherein preheating said mold comprises preheating said mold to about 535 degrees Fahrenheit over about 15 minutes 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, 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 a 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; cooling said mold under controlled heat and pressure to form the composite material; and removing said composite material from said mold.