Ballistic resistant laminate panel

Abstract

A ballistic resistant, fragmentation debris capture laminate panel is comprised of one or more ballistic resistant and containment materials that have been laminated together with one or more thermoplastic resin substrates such as polycarbonate and/or PETG. The ballistic resistant, fragmentation debris capture laminate panel can be manufactured with a variety of ballistic resistant and containment materials, by autoclave or hot press methods, and include decorative and/or image bearing appearance. Specifically, a ballistic resistant laminate, fragmentation debris capture panel of the present invention can be manufactured to include materials, such as aramid fiber sheet, ballistic ceramic products, and/or metal fabric sheet, or combination thereof, to meet one or several ballistic resistant standards and fragmentation debris capture ratings selected by the user for a specific building, construction or structural application.

Claims

1. A ballistic resistant, fragmentation debris capture laminate panel having a plurality of layers comprising: at least one thermoplastic resin sheet wherein the at least one thermoplastic resin sheet is PETG, at least one additional ballistic resistant material wherein the at least one additional ballistic resistant material is selected from the group consisting of a thermoplastic resin sheet, a metal fabric, a ballistic ceramic material, and an aramid fiber sheet, wherein the ballistic resistant, fragmentation debris capture laminate panel satisfies at least one ballistic resistance rating from at least one ballistic standard selected from the group consisting of standards ASTM F-1233, DIN EN 1063, HPW-TP 0500.02, MIL-662F 1997, NIJ 0108.01, and UL 752, and wherein the at least one ballistic resistance rating is selected from ratings applicable to ammunition selected from the group 7.62, 5.56 and 30.06.

2. A ballistic resistant, fragmentation debris capture laminate panel of claim 1 wherein the at least one additional ballistic resistant material is a first metal fabric.

3. A ballistic resistant, fragmentation debris capture laminate panel of claim 2 wherein the metal fabric is a coiled wire mesh possessing a weave of between 3/32 inches (0.2 cm) and inches (1.6 cm) and wire in corresponding gauges of between 20 and 15 (diameters of between 0.0318 (0.8 mm) and 0.08 (2.0 mm)).

4. A ballistic resistant, fragmentation debris capture laminate panel of claim 2 wherein the at least one additional ballistic resistant material further comprises at least a second or more additional metal fabric oriented in a plane parallel to the first and having an orientation wherein the weave is the same as the orientation of the weave of the first metal fabric.

5. A ballistic resistant, fragmentation debris capture laminate panel of claim 1 wherein the at least one additional ballistic resistant material is a thermoplastic resin architectural panel having a decorative element.

6. A ballistic resistant, fragmentation debris capture laminate panel of claim 2 wherein the at least one additional ballistic resistant materials further comprises at least a second or more metal fabric oriented in a plane parallel to the first and having an orientation wherein the weave is rotated between 1 and 90 degrees in relation to the weave of the first metal fabric.

7. A ballistic resistant, fragmentation debris capture laminate panel of claim 1 wherein at least a first thermoplastic resin sheet, the at least one additional ballistic resistant material, and a second thermoplastic resin sheet are bonded to form a module.

8. A ballistic resistant, fragmentation debris capture laminate panel of claim 7 having a plurality of modules.

9. A ballistic resistant, fragmentation debris capture laminate panel of claim 8 wherein the at least one additional ballistic resistant material of a module is a metal fabric, wherein the metal fabric is a coiled wire mesh.

10. A ballistic resistant, fragmentation debris capture laminate panel of claim 9 wherein the panel comprises the following layers: a first 0.6 cm polycarbonate sheet, a series of six modules wherein the first and second thermoplastic resin sheet of each module is PETG, and wherein in the first, third and fifth modules the additional ballistic resistant material is a coiled wire mesh, and wherein in the second, fourth and sixth modules the additional ballistic resistant material is an aramid fiber, and a second 0.6 cm polycarbonate sheet, and wherein the panel is selected to satisfy at least one ballistic resistance rating of the 7.62, 5.56 and 30.06 ammunition ballistic standards from the group of ballistic resistance ratings consisting of: for 7.62 the following: NIJ 018.01 Type III, EURO DIN EN 1063 BR6 7.62 X 51 NATO, ASTM F1233 7.62 NATO, HPW-TP 0500.02 D 7.62 X 51, UL 752 Level 5, and UL 752 Level 8, for 5.56: EURO DIN EN 1063 BR5 5.56 X 45 NATO AP, and UL 752 Level 7, and for 30.06: NIJ 018.01 Type IV, UL 752 Level 4, and UL 752 Level 9.

11. A ballistic resistant, fragmentation debris capture laminate panel of claim 9 wherein the panel comprises a first 1.3 cm polycarbonate sheet, a series of at least two modules, and a second 1.3 cm polycarbonate sheet, wherein the first and second thermoplastic resin of each module is PETG, wherein the at least one additional ballistic resistant material of a module is two coiled wire mesh, namely a first coiled wire mesh and a second coiled wire mesh.

12. A ballistic resistant, fragmentation debris capture laminate panel of claim 11 wherein the panel comprises a first 1.3 cm polycarbonate sheet, a series of four modules, namely a first module, a second module, a third module and a fourth module, and a second 1.3 cm polycarbonate sheet, wherein the first and second thermoplastic resin of each module is PETG, wherein the at least one additional ballistic resistant material of the first module is two coiled wire mesh, namely a first coiled wire mesh and a second coiled wire mesh, wherein in the second module and fourth module, the second coiled wire mesh is oriented at an angle between 1 and 90 degrees offset from the orientation of the first coiled wire mesh, and wherein the panel is selected to satisfy at least one ballistic resistance rating of the 7.62 and 30.06 ammunition ballistic standards from the group of ballistic resistance ratings consisting of: for 7.62 the following: NIJ 018.01 Type III, EURO DIN EN 1063 BR6 7.62 X 51 NATO, ASTM F1233 7.62 NATO, HPW-TP 0500.02 D 7.62 X 51, UL 752 Level 5, and UL 752 Level 8, and for 30.06: NIJ 018.01 Type IV, UL 752 Level 4, and UL 752 Level 9.

13. A ballistic resistant, fragmentation debris capture laminate panel of claim 11 wherein the panel comprises a first 1.3 cm polycarbonate sheet, a series of four modules, namely a first module, a second module, a third module and a fourth module, and a second 1.3 cm polycarbonate sheet, wherein the first and second thermoplastic resin of each module is PETG, wherein the at least one additional ballistic resistant material of a first module is two coiled wire mesh, namely a first coiled wire mesh and a second coiled wire mesh, wherein in the second module and fourth module, the second coiled wire mesh is oriented 45 degrees offset from the orientation of the first coiled wire mesh, and wherein the panel is selected to satisfy at least one ballistic resistance rating of the 7.62 and 30.06 ammunition ballistic standards from the group of ballistic resistance ratings consisting of: for 7.62 the following: NIJ 018.01 Type III, EURO DIN EN 1063 BR6 7.62 X 51 NATO, ASTM F1233 7.62 NATO, HPW-TP 0500.02 D 7.62 X 51, UL 752 Level 5, and UL 752 Level 8, and for 30.06: NIJ 018.01 Type IV, UL 752 Level 4, and UL 752 Level 9.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention is better understood with reference to the accompanying drawings and detailed description wherein:

(2) FIG. 1 is a cross-section view of a block of the ballistic resistant laminate panel in the form of a metal fabric module as described in detail as Example 1 below.

(3) FIG. 2 is a cross-section view of a block of the ballistic resistant laminate panel in the form of a metal fabric module as described in detail as Example 2 below.

(4) FIG. 3 shows a partially separated perspective view of a ballistic resistant laminate panel of the present invention described in detail as Example 3 below.

(5) FIG. 4 shows a partially separated perspective view of a ballistic resistant laminate panel of the present invention described in detail as Example 4 below.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

(6) The preferred embodiment of the present invention is disclosed herein and in the accompanying drawings. It comprises a ballistic resistant laminated material formed of a first polycarbonate exterior sheet, laminated together with at least one layer of metal fabric, and a second polycarbonate exterior sheet, the entire structure bonded together without the use of any bonding catalyst by applying heat to create a mechanical bond between the exterior polycarbonate sheets and the interior metal fabric, under environmental conditions of heat, pressure and vacuum known to those skilled in the art.

(7) The metal fabric, preferably a coiled wire mesh having a weave of between 3/32 inches (0.2 cm) and inches (1.6 cm) and wire in corresponding gauges of between 20 and 15 (diameters of between 0.0318 (0.8 mm) and 0.08 (2.0 mm)), respectively. The wires are preferably made of steel, which may optionally be treated with an alternative finish. Examples of alternative steel finishes include copper cladding, galvanizing, nylon coating, and aluminum coating. Further coiled wire may be of stainless steel, titanium, brass, nickel, copper or aluminum. Wires of these non-steel materials may be particularly useful in customizing the appearance of the finished product.

(8) The number of metal fabric layers, and the orientation of their weave relative to one another, may be selected independent of one another to obtain a finished product meeting specific performance criteria according to the MIL, Euro, ASTM, HP White, UL or NIJ standards, or customized to a special custom user-specified standard. It is preferable that the metal fabric be of the coiled wire mesh type, as it has proven to have superior ability to deflect a bullet and facilitate bullet capture within the material. Further, a selection of one or more optional additional ballistic resistant materials may be added to the laminate panel. Such optional additional ballistic resistant materials may be selected from the group of thermoplastic resin sheets, aramid sheet modules, and decorative layers to meet user-selected performance specifications and aesthetic design criteria.

EXAMPLES

(9) The following example is presented to illustrate the invention and should not be construed to limit the scope of the invention.

(10) 1. Single Metal Fabric Modules

(11) A preferred embodiment of the present ballistic resistant laminate panel of the present invention is disclosed by FIG. 1. In this example, the first layer of the laminate is a first polycarbonate sheet (a) with a thickness of one-half inch () (1.3 cm). The second layer is a metal fabric layer (b) wherein the metal fabric is coiled wire mesh. The third layer is a second polycarbonate sheet (a) of one-half inch () (1.3 cm) thickness. A panel of the present example, comprising two thermoplastic resin layers encapsulating a dissimilar ballistic resistant material, is what is called a module. In this example the dissimilar ballistic resistant material is a metal fabric, so this module is, more particularly, a metal fabric module (c). This exemplary lay-up results in a metal fabric module (c) having a thickness of approximately one inch (1) (2.5 cm), and a V50 rating of 1250 m/s.

(12) This same lay-up, substituting thicker polycarbonate sheets (a) results in metal fabric module (c) having a thickness of 1.5 (3.8 cm) overall and a V50 of 1650 m/s with respect to a 1 oz. (28.4 g) 0.12 gauge slug. By substituting still thicker polycarbonate sheets (a) the metal fabric module (c) having a thickness of 3.5 (8.9 cm) has a V50 rating of 3200 m/s.

(13) 2. Double Metal Fabric Module

(14) In a preferred embodiment of the present invention, a ballistic resistant laminate panel was constructed to meet the NIJ Type IV and armor piercing ratings which material comprised a first polycarbonate sheet (a), a first and second metal fabric layers (b), (b) with the second metal fabric sheet (b) in a plane adjacent to the first metal fabric sheet (b) but having an orientation rotated 90 degrees from the orientation of the first metal fabric sheet (b), and a second polycarbonate sheet (a) laminated as follows: a (0.6 cm) polycarbonate sheet (a); a first coiled wire mesh (b); a second coiled wire mesh (b); and a (0.6 cm) polycarbonate sheet (a).

(15) In a variant of this preferred embodiment, wherein the metal fabric is coiled wire mesh, the metal fabric layers (b) and (b) are compressed so that they become nested together, whether in parallel or rotated orientation, reducing the overall finished thickness of the ballistic resistant laminate panel, and imparting an increase in ballistic resistant, fragmentation debris capture properties to the module, more particularly the double metal fabric module (c).

(16) 3. Divided Double Metal Fabric Module with Image

(17) Another preferred embodiment of the ballistic resistant, fragmentation debris capture laminate panel (p) was constructed to meet the NIJ Type IV and armor piercing ratings which material comprised two polycarbonate layers and two metal fabric layers, and laminated and decorated as follows: (0.6 cm) polycarbonate sheet, unadorned (a); A first coiled wire mesh (b); (0.6 cm) PETG sheet (d); A second coiled wire mesh (b); (1.3 cm) polycarbonate sheet (a), on which is printed an image (e) of a building faade segment.

(18) Preferred embodiments of the type disclosed by this example 3 were tested against NIJ 0108.01 Type III; UL 752 Levels 7 and 8; Euro DIN EN 1063 BR5, BR6, and BR7; and ASTM-F-1233 7.62 NATO ballistic resistant standards.

(19) Another variation of the preferred embodiment of the ballistic resistant, fragmentation debris capture laminate panel in a divided double metal fabric configuration may optionally be achieved by laminating, with the addition of a layer of TPU between them, two metal fabric modules (c) of FIG. 1 as described in Example 1 above.

(20) 4. Combination Ballistic Resistant Laminate Panel

(21) A generic sample lay-up of the ballistic resistant laminate panel (p) of the present invention is disclosed by FIG. 4, as follows: a first polycarbonate sheet (a); a TPU membrane (f); a metal fabric module (c); a TPU membrane (f); an aramid sheet module (g); a TPU membrane (f); and a decorative thermoplastic layer (h).

(22) The decorative thermoplastic layer may be any compatible thermoplastic sheet decorated with an image or comprising a decorative thermoplastic panel further comprising compatible films, sheets, or decorative interlayers.

(23) 5. Material Comprising Alternating Metal Fabric and Aramid Sheet Modules

(24) Following the above stated principles, a ballistic resistant, fragmentation debris capture laminate panel was constructed to meet the NIJ Type IV, HP White HP Level E and ASTM 30.06 AP standards. This panel comprised a first polycarbonate sheet (a), three pairs of alternating metal fabric (c) and aramid sheet modules (g) wherein the thermoplastic resin in each module was PETG, and having a final layer of a second polycarbonate sheet (a). The polycarbonate sheets and modules were separated by a bonding layer of TPU (f), laminated as follows: (0.6 cm) polycarbonate sheet (a) 0.050 (1.3 mm) TPU membrane (f) metal fabric module (c) 0.050 (1.3 mm) TPU membrane (f) aramid sheet module (c) 0.050 (1.3 mm) TPU membrane (f) metal fabric module (c) 0.050 (1.3 mm) TPU membrane (f) aramid sheet module (c) 0.050 (1.3 mm) TPU membrane (f) metal fabric module (c) 0.050 (1.3 mm) TPU membrane (f) aramid sheet module (c) 0.050 (1.3 mm) TPU membrane (f) (1.3 cm) polycarbonate sheet (a)

(25) 6. Thermoplastic Resin Ballistic Resistant Laminate Panel

(26) A ballistic resistant, fragmentation debris capture laminate panel of the present invention was constructed of thermoplastic ballistic resistant materials to meet the NIJ Type I rating which panel comprised a first polycarbonate sheet (a), a TPU bonding membrane (f), a second polycarbonate sheet (a), a second TPU bonding membrane (f), and a third polycarbonate sheet.

(27) It will be recognized that these examples are illustrative only, and not intended in any way to limit the possible embodiments of the present invention, which are limited only by the desired protective performance characteristics, and visual design requirements, and budget of the user.