Hybrid hardened ballistic security door

Abstract

An innovative ballistic door is disclosed that is destined for use in schools, offices and building structures. The innovative door comprises a hybrid ballistic core, comprising at least two sections, wherein one section is a heavy impact resistant material rated to NIJ level III strength to resist rounds fired from high-powered rifles, as well as resisting breaches from explosive devices such as pipe bombs and the like. AR500 steel plate having a thickness of inch meets this requirement. The remaining sections of the innovative ballistic hybrid core comprise at least one lighter-weight ballistic sheet material, such as E Glass fiber composite sheet, which at least comply with the NIJ level IIIA standard. This E Glass material is ideally suited to resist the impact of a pipe bomb explosion. The novel ballistic core construction allows a compromise between protective and practical weight requirements. In addition, the innovative ballistic door provides for substantial anti-breach protection of the latch and lock mechanism and hinges.

Claims

1. A hybrid ballistic door, comprising: a high-impact resistant ballistic core having a front surface and a back surface, wherein the high-impact ballistic core comprises: a first high-impact resistant ballistic portion having an impact resistance corresponding to at least the NIJ Level III impact standard, the first high-impact resistant ballistic portion spanning the height of the hybrid ballistic door and a portion of the width and thickness of the hybrid ballistic door; and a second high-impact resistant ballistic portion having an impact resistance corresponding to at least the NIJ Level IIIA impact standard, said second high impact resistant ballistic portion being contiguous with the first high-impact resistant ballistic portion; and spanning substantially the remaining width of the hybrid ballistic door; and the first and second high-impact resistance ballistic portions having opposing edges that are positioned edge to edge to form the width of the hybrid ballistic door.

2. The hybrid ballistic door of claim 1, further comprising a vision window comprising a ballistic glass meeting having an impact resistance meeting at least the NIJ Level IIIA impact standard, wherein the vision window is disposed within the upper portion of the second high-impact resistant ballistic portion and displaced at least 20 inches laterally from the position of the latch, and displaced vertically at least 14 inches above the locking mechanism, so that the interior latch handle cannot be reached from outside the hybrid ballistic door in the event that the vision window is breached.

3. The hybrid ballistic door of claim 1, further comprising a ballistic fabric strip affixed to the front surface of the high-impact resistant ballistic core and spans the joint between the first and second high-impact ballistic core portions, said ballistic fabric strip having a length substantially equal to the length of the high-impact resistant ballistic core.

4. The hybrid ballistic door of claim 3, wherein the ballistic fabric is a flexible high-impact resistant woven material.

5. The hybrid ballistic door of claim 1, wherein the width portion comprises one vertical edge of the door, and wherein a locking mechanism is disposed therealong, the locking mechanism comprising an interior latch handle.

6. The hybrid ballistic door of claim 1, wherein the opposing edges of the first and second high-impact ballistic core portions form a joint, said second high-impact resistant ballistic portion spanning the height of the hybrid ballistic door and the remaining portion of the width of the hybrid ballistic door.

7. The hybrid ballistic door of claim 1, further comprising structural members girding the high-impact ballistic core and affixed to said high-impact ballistic core along the top and side edges, wherein adjacent structural members are affixed together so that the frame forms a substantially self-supporting rigid structure.

8. The hybrid ballistic door of claim 7, wherein said frame structural members are manufactured from a high-impact resistant ballistic material having an impact resistance corresponding to at least the NIJ Level IIIA standard.

9. The hybrid ballistic door of claim 1, wherein the high-impact ballistic core further comprises cutouts disposed within the first and second high-impact ballistic core portions to accommodate insertion of the locking mechanism and the vision window.

10. The hybrid ballistic door of claim 1, further comprising exterior sheets covering the front and rear faces of the high impact ballistic core, said exterior sheets having dimensions spanning substantially the height and substantially the width of the hybrid ballistic door.

11. The hybrid ballistic door of claim 10, wherein: the exterior sheets are fabricated from S-glass sheet; the exterior sheets comprise cutout portions having dimensions and positions coinciding with the positions and dimensions of the vision window and locking mechanism; or the exterior sheets are fabricated from wood veneer.

12. The hybrid ballistic door of claim 10, wherein the exterior sheets are fabricated from aluminum alloy.

13. The hybrid ballistic door of claim 12, wherein the aluminum alloy is selected from the group consisting of 6061-T6 and 7075-T6 aluminum plate.

14. The hybrid ballistic door of claim 1, wherein a high impact resistant ballistic armor plate is affixed on the front face of the hybrid ballistic door at a position corresponding to the position of the locking mechanism, and wherein the high-impact resistant ballistic plate is disposed over the body of the locking mechanism in such a way that the locking mechanism is covered by the high-impact resistant plate on the front face of the hybrid ballistic door.

15. The hybrid ballistic door of claim 14, wherein the high-impact resistant ballistic armor plate is fabricated from AR500 ballistic steel.

16. The hybrid ballistic door of claim 1, wherein a continuous articulating hinge is affixed to the outward vertical edge of the second high-impact resistant core portion of the hybrid ballistic door, the continuous articulating hinge spanning substantially the height of the hybrid ballistic door.

17. The hybrid ballistic door of claim 1, wherein the first high-impact resistant ballistic core portion is fabricated from AR500 steel plate.

18. The hybrid ballistic door of claim 1, wherein the second high-impact resistant ballistic core portion is fabricated from E Glass fiber composite sheet material.

19. The hybrid ballistic door of claim 1, wherein the ballistic glass of the window insert comprises an 11 layer stack comprising polycarbonate, urethane and heat-strengthened glass sheets, and wherein the ballistic glass withstands a breach attempt defined by a minimum of three minutes of rifle gunfire and strikes by a breaching tool.

20. A hybrid ballistic door system, comprising: a hybrid ballistic door, comprising: a high-impact resistant ballistic core having a front surface and a rear surface, comprising: a first high-impact resistant ballistic portion having an impact resistance corresponding to at least the NIJ Level III impact standard, wherein the first high-impact resistant ballistic portion spans the height of the hybrid ballistic door and a portion of the width of hybrid ballistic door, and wherein the width portion comprises one vertical edge of the door, and wherein a locking mechanism is disposed therealong; and a second high-impact resistant ballistic portion having an impact resistance corresponding to at least the NIJ Level IIIA impact standard, said second high impact resistant ballistic portion being contiguous with the first high-impact resistant ballistic portion, wherein opposing edges of the first and second high-impact ballistic core portions form a joint, and wherein the second high-impact resistant ballistic portion spans the height of the hybrid ballistic door and the remaining portion of the width of the hybrid ballistic door.

21. The hybrid door system of claim 20, further comprising a vision window comprising a ballistic glass meeting having an impact resistance meeting at least the NIJ Level IIIA impact standard, wherein the vision window is disposed within the upper portion of the second high-impact resistant ballistic portion and displaced at least 18 inches laterally from the locking mechanism.

22. The hybrid ballistic door system of claim 20, further comprising a black-out scroll, to unroll over the view window when the fixation is released so that the view window is obscured.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 Shows a frontal view of the pre-assembled innovative ballistic core preferred embodiment of the inventive ballistic door.

(2) FIG. 2 Shows a frontal view of the innovative ballistic core embodiment assembled.

(3) FIG. 3 Shows an exploded view of the assembly components of the inventive ballistic door, preferred embodiment.

(4) FIG. 4 Shows an installation of the inventive ballistic door in the wall of a room or office.

(5) FIG. 5 Shows a schematic diagram of the deleterious effect by the inventive ballistic door on the achievable shooting fan due to the restricted lines of fire in case of a breach of the door.

DETAILED DESCRIPTION

(6) FIG. 1 shows an embodiment of a pre-assembled hybrid ballistic door core 100, which comprises high impact-resistant section 101. In some embodiments, high impact-resistant section 101 comprising high impact steel meeting NIJ level III standards. In some embodiments, section 101 is disposed adjacently to a lighter weight high-impact section 102. In some embodiments, section 102 is an E Glass fiber composite sheet, having a lower breach threshold, for example, meeting NIJ level IIIA standards.

(7) In some embodiments, the use of the two types of ballistic materials in the hybrid core is a compromise between protection and weight requirements. It will be shown below that that configuration of the innovative hybrid core effectively restricts a shooting fan, as the ballistic glass core is on the right side of the door, thus greatly reducing the direct fire fan into the room. In the illustrated embodiment shown in FIG. 1, section 101 is disposed on the left of section 102 assuming a standard where the latch/lock is built into the left side of the door. However, the disposition of sections 101 and 102 may be equally reversed without consequence, depending on the desired configuration of the door. In some embodiments, latch cutout 103 is disposed on the left edge of steel section 101 to accommodate a latch/lock mechanism such as a mortise lock. In some embodiments, vision window inset 104 is disposed within E Glass fiber composite section 102. In some embodiments, vision window 104 is disposed in the upper portion of section 102.

(8) In some embodiments, vision window 104 is disposed at a distance from region 103. In some embodiments, the distance is longer than the length of a large man's arm extending through vision window 104. In some embodiments, the distance is longer than a man's arm extending from one side of the door to reach latch cutout 103, where it would be possible for a perpetrator to breach vision window 104 and unlock the door from the inside. As an example, an effective distance of approximately 30 inches (75 cm) from the bottom of window inset 104 to the center of region 103, which may exceed the length of an arm extending from window 104 attempting to reach the inside door latch.

(9) In some embodiments, section 101 comprises AR500 steel plate, however suitable materials are not limited to AR500 alloy steel plate, and other high-impact steel or other metal alloys that meet the NIJ level III standard at minimum are equally suitable. In some embodiments, E Glass section 102 meets the NIJ level IIIA standard. The NIJ standard requires that the material can substantially resist fire from handguns including 0.44 magnum rounds, including 15.55 g (240 gr) semi-jacketed hollow-point rounds, and 8 g (124 gr) full metal jacketed 9 mm rounds fired at velocities of 1400 ft/s or less, and but may not resist rounds fired from high-powered rifles.

(10) In some embodiments, section 101 substantially resists high-powered rifle fire. The combination of the two ballistic materials provides for a light- to medium-weight, highly impact-resistant core. For example, if inch (6 mm) thick AR500 plate is used, its unit weight per square foot is approximately 10 lbs/ft.sup.2 (50 kg/m.sup.2). For a 7/16 inch (11 mm) thick sheet of ballistic E Glass fiber composite sheet (NIJ level IIIA), the unit weight is approximately 4.8 lbs/ft.sup.2 (24 kg/m.sup.2), less than one half that of the AR500 plate. By way of example, a ballistic core may have overall dimensions of 34.5 inches82.375 inches.

(11) Again, by way of example, the AR500 plate may span 58% of the overall width of the core, and the remaining 42% is spanned by the ballistic E-glass fiber composite sheet would weigh approximately 154 lbs (70 kg), This is contrasted to a core weight of approximately 200 lbs (90.8 kg) if the core was completely composed of inch (6 mm) AR500 plate. By constructing the core from the steel plate and E Glass composite sheet, the weight of the door may be significantly reduced in comparison to a door built entirely from steel plate, thereby meeting door weight restrictions.

(12) FIG. 2 shows another embodiment of door core assembly 200, where the steel plate/E Glass fiber composite core members 101 and 102 are girded by frame comprising structural members 105 and 106, where the frame comprised of structural members 105 and 106 mechanically binds core members 101 and 102 together and forms a rigid core structure 200. By way of example, frame structural members 105 and 106 may be constructed from AR500 angle steel, which may meet NIJ level IIIA standards, fastened together with high hard security hardware.

(13) At the position of latch cutout 103, frame member 105 may be notched as shown in FIG. 2 to accommodate a lock such as a mortise lock. In some embodiments, core assembly 200 is completed with frame 107 surrounding window cutout 104. In some embodiments, Frame 107 holds the innovative ballistic window insert, which comprises a stack of laminated plastic sheets, according to some embodiments. However, the composition of the window insert is by no means limited to laminates. In some embodiments, other types of ballistic glass (inorganic), polymers and composites that at least meet NIJ level IIIA standards, are equally employed. If laminates are used, the composition of the sheets may comprise materials such as, but not limited to, polycarbonate sheets, combination of polycarbonate and silica-based glass sheets, polyester sheets, and combinations thereof.

(14) Other suitable materials are considered equivalent. In some embodiments, the ballistic window insert is an 11-layer polycarbonate laminate sheet stack, bonded by a transparent adhesive, such as a urethane-based liquid adhesive. Ballistic characteristics of this window assembly comprise no exit spall, meaning the innovative window insert will not spall glass splinters on the backside when struck by gunfire rounds. Additionally, the innovative window insert exhibits breach integrity, wherein the window resists blows with the butt of a rifle or handgun, a length of 24, a crow bar, etc., for at least 3 minutes, and will not collapse or break through. These ballistic characteristics substantially meet NIJ level IIIA standards.

(15) In FIG. 3, an exploded view of an embodiment of the finished innovative ballistic door 300 construction beyond the core level is shown, detailing the placement of the exterior sheets 301 and 302 over core 303, as well as the latch or lock mechanism 304. Exterior sheets 301 and 302 thus form a veneer, or skin, covering the innovative ballistic core 303. An example, exterior sheets 301 and 302 may be manufactured from aluminum aircraft plate, for example, from 6061-T6 and/or 7075-T6 aluminum plate. In addition, thin S-glass may be used, as well as high-strength wood veneer. The function of exterior sheets 301 and 302 is primarily to provide an aesthetic finish covering to the door, and no ballistic resistance may be required of the exterior sheets.

(16) Still referring to FIG. 3, an additional ballistic steel plate 305 is shown, whose function is to protect lock 305 from a gunfire or explosion breach. In some embodiments, lock 305 is a hi-hardened mortise lock. In some embodiments, the interface between the body of lock 304 and the steel portion of the innovative core may be relatively structurally weak and more vulnerable to a breach. In some embodiments, lock plate 305 overlaps the interface region by a substantial amount, as well as to cover and protect the lock body itself. In some embodiments, lock plate 305 meets NIJ level IIIA standards.

(17) As an example, lock plate 305 may be formed from 3/16-inch AR500 steel plate, extending at least 1 inch (2.5 cm) from the edge of the body of lock 304. In some embodiments, thicker plate is employed for greater protection. In other embodiments, Kevlar (e.g. Kevlar 745) and similar lightweight ballistic fabrics is added to further protect structurally weak interior regions of the inventive door. In some embodiments, lock plate 305 extends over the borders between the AR500 steel portion and E Glass fiber composite portion of the innovative core, the lock area and in corners of the frame.

(18) In FIG. 4, an installation embodiment 400 of ballistic hybrid door 401 is shown. The installation 400 also comprises wall 402, which may be of reinforced construction by a variety of suitable methods. Wall 402 may border an interior hallway, or may be an exterior wall. In some embodiments, wall 402 comprises cinder block brick. In some embodiments, the door casing or door frame is reinforced to meet NIJ level III standards. In some embodiments, ballistic hybrid door 401 comprises continuous hinge 403. In some embodiments, continuous hinge 403 is affixed to the articulating edge of the innovative ballistic door and attached to wall 402. In some embodiments, continuous hinge 403 is affixed to a reinforced door casing or hinge jamb. In some embodiments, continuous hinge 403 functions to provide integrity of the door-wall system by withstanding attack by gunfire or small bomb explosion.

(19) With conventional doors, a shooter may attempt to destroy the hinges to make a breach possible by destroying the integrity of the door-wall system. By use of continuous hinge 403, this method of breach is substantially thwarted. In some embodiments, lock plate 404, as described above, overlaps the door jamb to the access to the latch and/or deadbolt portion of the lock, and the relatively weak structure around it is protected to the bullet-proof level

(20) As described above, hybrid ballistic door 401 provides a restricted shooting fan for a shooter armed with weapon powerful enough to pierce through the weaker regions of the inventive door. In FIG. 5, an interior room 500 is represented schematically by the rectangular region protected by the hybrid ballistic door 501, shown schematically. In some embodiments, hybrid ballistic door 501 is further divided into both portions of the core, with the NIJ level III region on the left represented by segment 502, and the NIJ level IIIA region represented by region 503 on the right, where the two regions are separated by the thick line. Vision window is represented by region 504.

(21) Hypothetical lines of fire that would emanate from the exterior of the inventive door 501 are represented by the broken lines 505-508 in the figure. These lines of fire would be possible if the shooter successfully breaches vision window 504, and/or NIJ level IIIA region 503. It is understood that a breach of NIJ level III region 502 would not be possible, thus no fire would penetrate this region. Potential shooting fans are delineated between lines of fire 505 to 508. For example, a maximum shooting fan angle may be achieved if a shooter succeeds in firing through the right edge of door 501 into the room at an angle taken by line of fire 505. If the shooter fires at the door at a shallower angle, most likely the bullet will ricochet off and not penetrate. The shooter may shoot through the door from the inner edge of the NIJ level IIIA portion, and manage to penetrate at the angle taken by line of fire 508.

(22) Thus, a potential shooting fan is delineated, with angle between line of fire 505 and 507 representing the maximum shooting fan angle. Line of fire 506 may potentially arise if the shooter manages to breach vision window 504, and fires from the extreme right side of the window. Line of fire 507 also arises if the shooter shoots through the window, but is more likely than line of fire 506, engendering an even more restricted shooting fan. Hybrid ballistic door 501 provides the advantage that the shooter, not knowing beforehand the construction of hybrid ballistic door 501, would first attempt to breach vision window 504 and fire through it.

(23) The triangular region 509 on the left side of room 500 represents the safe region outside of the shooting fan. Region 509 is effectively a protected space, and occupants of the room would have time to take cover should a shoot attempt to breach the door. Even if the shooter successfully breaches the vision window, or manages to shoot through the NIJ level IIIA region 503, time would be needed to eventually breach through, giving the occupants time to take cover.

(24) In further embodiments, the instant ballistic door may be electrified for two different purposes. For example, doors used in common spaces in a school or college that have open access such as an administration office, a library, or a cafeteria, may remain unlocked when the door is closed, but will lock automatically on the press of a key fob which is the device used to put the school in alert and lockdown. By way of example, all staff members may carry a fob. Classroom doors may also be electrified with the capability to be opened remotely through software installed at law enforcement tactical work stations in coordination with a security team if there was a hostage situation in the classroom. The security team may then make entry into the class.

(25) While the disclosed embodiments describe preferred components, materials and configurations of the innovative ballistic door, it is understood by those skilled in the art that other embodiments may exist that are equivalent in purpose and function. Such embodiments that result in equivalent functionality do not depart from the scope and spirit of this innovation.