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WO2011123474A1 - Panneau isolé structurel balistique - Google Patents

Panneau isolé structurel balistique Download PDF

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Publication number
WO2011123474A1
WO2011123474A1 PCT/US2011/030399 US2011030399W WO2011123474A1 WO 2011123474 A1 WO2011123474 A1 WO 2011123474A1 US 2011030399 W US2011030399 W US 2011030399W WO 2011123474 A1 WO2011123474 A1 WO 2011123474A1
Authority
WO
WIPO (PCT)
Prior art keywords
spall
ballistic
section
panel
skin
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2011/030399
Other languages
English (en)
Inventor
Jeff Mason
Patrick Redfern
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Lcoa Composites Inc
Original Assignee
Lcoa Composites Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Lcoa Composites Inc filed Critical Lcoa Composites Inc
Publication of WO2011123474A1 publication Critical patent/WO2011123474A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

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    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • F41H5/0414—Layered armour containing ceramic material
    • F41H5/0428—Ceramic layers in combination with additional layers made of fibres, fabrics or plastics
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    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/045—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
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    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B13/12—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H9/00—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate
    • E04H9/04—Buildings, groups of buildings or shelters adapted to withstand or provide protection against abnormal external influences, e.g. war-like action, earthquake or extreme climate against air-raid or other war-like actions
    • E04H9/10—Independent shelters; Arrangement of independent splinter-proof walls
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Definitions

  • the disclosure relates to composite panels, structural insulated panels and similar materials having ballistic and blast-proof properties.
  • Example embodiments described herein have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the inventions expressed by the claims, some of the advantageous features will now be summarized.
  • a ballistic panel comprises: a strike face, a first spall section, a structural insulated panel, a second spall section, and at least one decorative skin disposed on the strike face or the second spall section, wherein the first spall section is disposed on a first side of the structural insulated panel and the second spall section is disposed on a second side of the structural insulated panel.
  • a method of slowing a projectile comprising: providing a ballistic panel comprising a strike face configured to engage a spall section, a first spall section configured to engage a structural insulated panel, a structural insulated panel, a second spall section, and at least one decorative skin disposed on the strike face or the second spall section, absorbing an initial impact of the projectile, tumbling the projectile in the structural insulated panel, and slowing the projectile in the second spall section.
  • a ballistic panel comprises: a strike face, a first spall section, a structural insulated panel, a second spall section, wherein the first spall section is disposed on a first side of the structural insulated panel and the second spall section is disposed on a second side of the structural insulated panel.
  • FIGS. 1-8 of the drawings in which like numbers refer to like features unless indicated otherwise.
  • FIG. 1 depicts a schematic view of an example of a ballistic panel system.
  • FIG. 2 depicts an exploded view of an example composite ballistic structural insulated panel.
  • FIG. 3 illustrates an exploded view of another example composite ballistic structural insulated panel or "BSIP" incorporating a combined strike face and first spall section.
  • FIG. 4 shows an exploded view of yet another example composite ballistic structural insulated panel incorporating a hybrid spall layer.
  • FIG. 5 illustrates an exploded view of yet another example composite ballistic structural insulated panel incorporating a hybrid spall layer.
  • FIG. 6 depicts an exploded view of yet another example composite ballistic structural insulated panel.
  • FIG. 7 depicts an illustration of an example of a method of manufacturing a ballistic structural insulated panel.
  • FIG. 8 depicts a chart demonstrating three example layups of ballistic structural insulated panels and three comparative example layups of ballistic panels.
  • FIG. 9 shows a table illustrating and comparing V 50 testing data of the examples and comparative examples of FIG. 8.
  • Composite ballistic panels can comprise ballistic materials that include high strength fibers, steel and ceramic.
  • Structural insulated panels or "SIPs” are a composite building material. Generally they consist of an insulating layer of foam sandwiched between two layers of structural material. SIPs provide insulation and protection to a structure with a tighter building envelope. SIPs may be used as floor, wall, or roof of a structure. SIPs may be used in the construction of living units such as permanent or temporary housing, mobile units such as cars, or aerospace vehicles such as planes or helicopters.
  • structural insulated panel or “structurally insulated panel” or “SIP” are broadly interpreted herein and comprise, without limitation, their customary and ordinary meaning as well as any and all panels that consist of an insulating layer sandwiched between at least two layers of structural material.
  • SIPs may be used for a variety of applications, but are generally used as a composite building material. As a building material, SIPs may be used as exterior wall, roof, floors, and foundation systems. However, SIPs may also be used in other applications such as aerospace, armored vehicles, military, police, civilian, medical, and applications where improved safety and protection are desired.
  • SIPs generally comprise an inner insulating layer that may include any suitable material such as polymer foam.
  • the core of a SIP may be expanded polystyrene, extruded polystyrene or rigid polyurethane.
  • the core of a SIP may comprise a non-polymer foam insulation such as sand, metal, ceramic, solid polymer resin, or air.
  • One or more outer layers of an SIP may include steel, aluminum, cement board, fiber-reinforced plastic, or magnesium oxide.
  • Outer layers of a SIP may also comprise a material such as metal, plywood, cement or oriented strand board.
  • a SIP is incorporated as part of a building or structure as it is constructed, and supports the building. However, in other embodiments, a SIP may be installed into an existing structure.
  • strike face is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art (i.e., it is not to be limited to a special or customized meaning) and includes, without limitation, the entire thickness of the outermost layer of a ballistic panel.
  • the strike face may be covered with a decorative layer.
  • a strike face may be flat, planar, convex, concave, multi-faceted, undulating, distressed, smooth— or it may have a different geometry.
  • a strike face may be formed of any suitable material. Useful example materials include those that are hardened; for example, they can be harder than the rest of the composite layers.
  • a strike face may be made of various hardened metals such as aluminum or steel.
  • a strike face may also be formed of a ceramic material such as alumina, silicon carbide, boron carbide, and the like or a combination of materials.
  • a strike face may also be formed of a high resin content composite. Hybrids or combinations of any of these and similar materials are also useful.
  • the general purpose of the strike face in a ballistic panel may be to flatten and slow down an incoming projectile, thereby allowing other materials in the panel to assist in absorbing and dispersing the energy from the projectile.
  • a strike face may consist of several plies (e.g., layers) of materials or a strike face may only consist of one ply (e.g., layer) of material.
  • a strike face may comprise a hybrid panel comprising more than one different type of material.
  • spall section or "spall layer” is a broad term and is to be given its ordinary and customary meaning to a person of ordinary skill in the art (i.e., it is not to be limited to a special or customized meaning) and includes, without limitation, one or more layers in which a projectile and/or projectile debris may distribute.
  • a projectile When a projectile contacts a target, the projectile may generally maintain its shape or pieces of the projectile may be broken off as a result of impact.
  • a spall section may absorb energy provided by a projectile or spall and it may redistribute the spall upon its entry into the spall section.
  • a spall section may function as a net for incoming projectile or debris.
  • a spall section may be formed of any suitable material including, but not limited to: woven or unidirectional fibers including E-glass, R-glass, S-glass, fiberglass, aramid, ultra-high molecular weight polyethylene (“UHMWPE”) or a polypropylene fiber utilizing thermoplastic or thermoset resin systems.
  • woven or unidirectional fibers including E-glass, R-glass, S-glass, fiberglass, aramid, ultra-high molecular weight polyethylene (“UHMWPE”) or a polypropylene fiber utilizing thermoplastic or thermoset resin systems.
  • UHMWPE ultra-high molecular weight polyethylene
  • Common fiberglass types include E-glass (alumino-borosilicate glass with less than 1 wt% alkali oxides, mainly used for glass-reinforced plastics), R-glass (alumino silicate glass without MgO and CaO with high mechanical requirements), and S- glass (alumino silicate glass without CaO but with high MgO content with high tensile strength).
  • Aramid fibers are a class of heat-resistant and strong synthetic fibers in which the fiber-forming substance is a long-chain synthetic polyamide in which at least 85% of the amide linkages, (-CO-NH-) are attached directly to two aromatic rings.
  • Aramid fibers are often used in aerospace and military applications, such as for ballistic rated body armor fabric, vehicle armor composites, and ballistic shields.
  • Well-known aramid fibers are sold under the trademarks KEVLAR, TWARON and K-FLEX.
  • UHMWPE fibers are known for their strength and abrasion resistance, and are commonly used in ballistic protection and defense applications.
  • resin which can be any of the following: petroleum-free phenolic resin, standard phenolic resin, polyvinyl butyral (PVB) phenolic resin, polyethylene thermoplastic resin, polypropylene thermoplastic resin, polyester thermoset resin, and epoxy thermoset resin.
  • a spall layer or section may comprise one or more layers.
  • a spall layer or section may also comprise a hybrid layer consisting of at least two different types of materials selected that may absorb energy provided by a projectile or spall and it may redistribute the spall upon entry into the spall section.
  • a spall layer or section may consist of several plies of materials or a spall layer or section may only consist of one ply of material.
  • decorative ballistic skin or “decorative outer skin” is defined broadly to mean a decorative layer comprised of a material such as PAPERSTONE® that gives an aesthetically pleasing appearance, but still maintains favorable ballistic properties when subjected to ballistics testing.
  • PAPERSTONE® is a composite material that is made from 100% post-consumer recycled paper manufactured by PanelTech Products, Inc. (Hoquiam, WA). It consists of a petroleum-free phenolic resin (or “green resin”) impregnated paper product that when laminated under heat and pressure, becomes a hard consolidated laminate. It is non-porous and comes in a variety of colors.
  • a decorative phenolic ballistic skin may be disposed on the portion of a ballistic structural insulated panel facing the potential direction of the ballistic or blast threat. According to some embodiments, a decorative skin may not provide significant ballistic properties and may perform a more decorative function.
  • the term "decorative interior skin” may be broadly defined to mean a material that gives an aesthetically pleasing appearance and may include phenolic PAPERSTONE® material, a thermoplastic, a thin textured material, or wood.
  • a decorative phenolic ballistic skin may be disposed on the portion of a ballistic structural insulated panel facing the interior of an enclosure and provide a decorative finish to the interior of the structure, improved fire resistance characteristics, or anti-viral wall protection.
  • a decorative skin may not provide significant ballistic properties and may perform a more decorative function; nevertheless, some layers and/or materials can include both decorative and protective (e.g., ballistic) properties.
  • skin is broadly interpreted herein and comprise, without limitation, any generally thin layer of material that engages at least one other layer of material within.
  • a skin may serve to protect the layer or layers it engages from damage or debris, and a skin may supply an aesthetically pleasing effect. While it may be implied that a skin is a thinner layer, according to some embodiments, a skin may have a greater thickness than a layer not labeled as a skin.
  • projectile is used broadly to mean any type of material propelled towards the ballistic panel: the objects or items propelled through the environment— often at great speed— from which protection may be sought.
  • projectiles may include bullets, ordnance, shrapnel, knives, glass shards, materials that may be fragmented and violently displaced by an explosion, portions of exploding armaments, metal slugs, and the like.
  • a projectile may also include debris from explosion caused by vandalism, civil unrest, pranks, fireworks, bombs, pipe-bombs, or other means of entering any structure.
  • a projectile may stay in one piece as it enters the BSIP, or it may break into fragments (e.g., as it enters the ballistic structural insulated panel.
  • a ballistic panel is illustrated that can have multiple layers (e.g., a first face layer 10, a function layer 20, and a second face layer 30).
  • This generalized example demonstrates some aspects of the inventions herein described, although often the functions described here can be combined (for example, a functional layer can also be aesthetic or provide other characteristics desirable in a face layer).
  • a projectile can enter the BSIP through first face layer 10, only to be slowed, stopped, redirected, deformed, fragmented, dispersed, deflected, (or some combination thereof), etc. by a function layer 20.
  • a function layer can include dynamic materials that harden or otherwise change in a useful manner when they are stressed or otherwise subject to force or pressure.
  • two general steps may be performed. Within the function layer 20, the projectile and any projectile debris may be dispersed. The function layer 20 may also slow and/or rotate the projectile and any projectile debris. These two steps may be performed in the above mentioned order. They may also be performed simultaneously within the function layer 20. The steps may be performed in the reverse order as disclosed above.
  • FIG. 2 illustrates a ballistic structural insulated panel (“BSIP") 100.
  • the BSIP comprises a first ballistic zone 110, a second ballistic zone 120, and a third ballistic zone 130.
  • the first ballistic zone 110 faces outer threat area X.
  • the second ballistic zone 120 engages the first ballistic zone 110.
  • the third ballistic zone 130 engages the second ballistic zone 120.
  • the third ballistic zone 130 faces an interior I, which can be decorative.
  • the layers and zones described here are not always present in all advantageous embodiments.
  • a BSIP can still be effective although it may not always have a separate decorative interior skin.
  • the functional layers may themselves be so aesthetically pleasing that no additional interior layer is deemed desirable.
  • the first ballistic zone 110 can comprise three layers.
  • Decorative outer ballistic skin 111 engages outer threat area X.
  • Strike face 112 engages outer ballistic skin 111.
  • First spall section 113 engages strike face 112.
  • the second ballistic zone 120 comprises SIP 121.
  • SIP 121 engages first spall section 113.
  • SIP 121 comprises three layers, first SIP skin layer 122, core layer 123, and second SIP skin layer 124 as shown.
  • First SIP skin layer 122 engages core layer 123.
  • Second SIP skin layer 124 engages core layer 123.
  • Third ballistic zone 130 comprises at least two layers and engages second ballistic zone 120 at second SIP skin layer 124.
  • Third ballistic zone 130 comprises second spall layer 131.
  • Second spall layer 131 engages decorative interior skin 140.
  • the third ballistic zone 130 may comprise one or more layers, and these layers may comprise one or more spall layers.
  • Decorative interior skin 140 engages interior I.
  • Decorative interior skin 140 may exhibit some favorable ballistics properties or it may serve a more decorative function.
  • an additional layer of adhesive adheres the aforementioned layers to one another within the BSIP.
  • adhesive is only incorporated between selected layers.
  • adhesive may be inserted to improve adherence between two layers that lack interfacial compatibility.
  • the same type of adhesive may be used to all layer incorporating adhesive.
  • no adhesive may be used at all.
  • Adhesives utilized may include thermoplastic films, methyl methacrylate, epoxy resin, or other suitable adhesive systems.
  • BSIP 100 is shown as having a flat, planar surface, other embodiments are contemplated in which BSIP 100 may have concave and/or convex contours and/or sides that may coincide with specific wall, door etc. conformations to which the BSIP 100 may be applied.
  • First ballistic zone 110 may be designed to absorb the initial impact of a projectile and to flatten it as it enters the BSIP. By flattening the projectile, the projectile affects a broader cross sectional area of the BSIP that can distribute the energy over a greater surface area. Most of the energy absorption in first ballistic zone 110 may occur upon impact of the projectile with strike face 112 and through utilizing the strength of the material used in first spall section 113.
  • the first spall section 113 comprises a sacrificial layer such as, for example, one or more plies of woven E-Glass. By incorporating a less expensive sacrificial layer, cost of a BSIP panel may be reduced since the layer may be sacrificial and serve, in part, to absorb energy from the projectile and/or projectile debris upon entering the spall section 113.
  • Second ballistic zone 120 may be designed to cause the projectile to tumble if it enters into this section including SIP 121. Tumbling is broadly defined as the free movement and/or rotation of a projectile, fragment, or other high velocity product of the ballistic event. Because the core 123 of the SIP 121 has less tensile strength than the first spall layer 123, the projectile will undergo the tumbling effect.
  • the second ballistic zone 120 may utilize the air space, void, and/or less dense space contained within the SIP to allow the projectile to tumble and yaw, and thus create a larger profile to the second spall section 131. The tumble effect also allows a greater cross section of the projectile to enter into the third ballistic zone 130.
  • the third ballistic zone 130 may be designed to stop the forward movement of the projectile by utilizing the tensile strength of the fibers in the material used in this zone during the stretching of the fiber to absorb the last of the energy of the projectile.
  • a higher performing material such as aramid fibers or oriented polyethylene fibers in thermoplastic or thermoset polymer resin may be utilized for the high tensile strength of the fibers in the resin matrix.
  • the third ballistic zone 130 may prevent backside deformation of the BSIP by absorbing the energy of the projectile and debris and ceasing their movement through the BSIP before it would start to exit the panel.
  • Outer threat area X generally refers to the area outside of a space being protected by the BSIP. Outer threat area X may be outdoors (for example, the exterior surface of a police station in a volatile inner-city or a military's forward operating base), or outer threat area X may be indoors (for example, the interior surface of a shooting gallery or explosives laboratory). Interior I refers to another side of the BSIP distinct from outer threat area X. In general, in an embodiment it may be assumed that a projectile will enter into the BSIP from outer threat area X, directly first contacting decorative outer ballistic skin 111 as shown by arrow P. A person or object to be protected by the BSIP panel may be positioned on interior I instead of outer threat area X.
  • a projectile following the path P will be slowed or stopped in a more satisfactory fashion than a projectile following the opposite path, entering the BSIP through interior I (not illustrated).
  • the ability of the BSIP to slow or stop a projectile is equivalent, whether the projectile enters the BSIP from outer threat area X or interior I.
  • Decorative outer ballistic skin 111 may comprise any suitable material and may comprise a material that gives an aesthetically pleasing appearance, but still maintains favorable ballistic properties when subjected to ballistics testing.
  • a useful material that can meet this description is PAPERSTONE®.
  • PAPERSTONE® is a composite material that is made from 100% post-consumer recycled paper manufactured by PanelTech Products, Inc. (Hoquiam, WA). It consists of a petroleum-free phenolic resin (or "green resin”) impregnated paper product that when laminated under heat and pressure, becomes a hard consolidated laminate.
  • Other suitable materials for decorative outer ballistic skin 111 may include various thermoplastics and thermoset polymers, reinforced polymers, gypsum, stone, wood, brick, ceramic, or metal.
  • the type of decorative coating may be selected based on the application in which the panel is used. Thus a material may be selected that fits the desired appearance of the exterior using the BSIP 100.
  • the decorative outer ballistic skin 111 also incorporates favorable ballistic properties. In other embodiments, the outer ballistic skin 111 employs little to no ballistic properties.
  • Strike face 112 may comprise any suitable material that may assist in absorbing the energy of an incoming projectile.
  • the strike face 112 may also affect the trajectory of an incoming projectile or fragments of projectile.
  • a strike face may be made of such materials including, but not limited to: metals such as aluminum or steel, ceramic such as alumina, silicon carbide, boron carbide, or other such suitable materials, etc.
  • First spall section 113 may also comprise any suitable material that may further assist in flattening and slowing a projectile.
  • suitable materials for the first spall section 113 include, without limitation: woven or uni-directional E-glass, R-glass, S-glass, Aramid (such as K-Flex® H provided by TechFiber), UHMWPE (such as Dyneema® provided by DSM) or a polypropylene fiber (such as InnegraTM S or I-Flex provided by Tech Fiber) utilizing thermoplastic or thermoset resin systems.
  • first spall section 113 may be a hybrid of two or more of the spall materials.
  • the first spall section may be considered a sacrificial layer since it functions to absorb much of the initial energy of a projectile and debris entering the BSIP.
  • the first spall section may comprise a less expensive material such as woven E-glass.
  • a strike face may be omitted, and the first spall section 113 may act alone as the strike face. In other embodiments where the strike face is omitted, the first spall section 113 may act as a strike face in combination with the outer decorative skin 11 1.
  • FIG. 2 One embodiment illustrating such configuration is shown in FIG. 2.
  • SIP 121 may be comprised of at least two SIP outer skins 122,124 and core 123.
  • Outer SIP skins 122, 124 may be comprised by any such suitable material as steel, aluminum, cement board, fiber-reinforced plastic, or magnesium oxide.
  • SIP skins 122, 124 may be rigid. In some embodiments the outer SIP skins 122, 124 are made of the same material. In other embodiments, the outer SIP skins 122, 124 are made of different materials.
  • the core 123 may comprise polymer foam such as expanded polystyrene, extruded polystyrene, or rigid polyurethane.
  • the SIP 121 may only have one outer SIP skin and engage one spall layer, or it may have no outer SIP skins and directly engage both spall layers on either side of the SIP.
  • An example of a SIP may be a GreenixTM panel from SIP Supply.
  • Second spall section 131 may also comprise any suitable material that may further assist in flattening and slowing the projectile.
  • suitable materials for the second spall section 131 include, without limitation: woven or uni-directional E-glass, R-glass, S-glass, Aramid, ultra-high molecular weight polyethylene (“UHMWPE") (such as Dyneema® provided by DSM), or a polypropylene fiber (such as InnegraTM S or I-Flex provided by Tech Fiber) utilizing thermoplastic or thermoset resin systems.
  • UHMWPE ultra-high molecular weight polyethylene
  • One or more material comprising second spall section 131 may include fibers and include a high tensile strength material.
  • second spall section may be a hybrid of two or more of the spall materials.
  • Second spall section 131 may prevent backside deformation of the BSIP by absorbing the energy of the projectile and debris and ceasing their movement through the BSIP before it would start to exit the panel or contact a decorative interior skin(if provided).
  • Decorative interior skin 140 may comprise any suitable material such as phenolic PAPERSTONE® material, a thermoplastic, gypsum, stone, a thin textured material, or wood.
  • the inner decorative layer faces an indoors area I, such as the inside of a house or the inside of a plane. Thus a material may be selected that fits the desired appearance of the room using the BSIP 100.
  • the inner decorative layer 140 also incorporates favorable ballistic properties. In other embodiments, the decorative interior skin 140 employs little to no ballistic properties.
  • An exterior decorative skin may have a suitable thickness of 0.008-0.080 inches.
  • an exterior decorative skin may have a thickness of 0.016-0.072 inches, 0.016-0.064 inches, 0.024-0.064 inches 0.040-0.064 inches, or any other suitable thickness.
  • the strike face may comprise a total thickness of 0.10-1.50 inches. According to other embodiments, the strike face may measure a suitable thickness such as 0.150-1.25 inches, 0.150-1.0 inches, 0.150-0.75 inches, 0.150-0.50 inches, 0.150-0.25 inches, or any other suitable thickness.
  • a first spall section may have a total thickness of 0.035-1.0 inches. According to other embodiments, the first spall section may be a suitable thickness such as 0.040-0.750 inches, 0.040-0.670 inches, 0.035-0.060 inches, 0.190-0.240 inches, 0.640-0.690 inches, or any other suitable thickness.
  • a SIP may comprise a total thickness of 2.0-6.0 inches. According to some embodiments, the SIP may comprise a total thickness of 2.0-5.0 inches, 2.0-4.6 inches, 2.5-4.6 inches, or any other suitable thickness.
  • a second spall section may have a total thickness of 0.260-1.0 inches.
  • the second spall section may measure a suitable thickness such as 0.040-0.750 inches, 0.040-0.670 inches, 0.240-0.310 inches, 0.280-0.320 inches, 0.630-0.690 inches, or any other suitable thickness.
  • a decorative interior skin if provided, may have a suitable thickness of 0.008-0.080 inches.
  • an inner decorative layer may have a thickness of 0.016-0.072 inches, 0.016-0.064 inches, 0.024-0.064 inches 0.040-0.064 inches, or any other suitable thickness.
  • the total thickness of a BSIP may comprise 2.5-8.0 inches in thickness.
  • the thickness of a BSIP may comprise 2.0-7.5 inches, 2.0- 7.0 inches, 2.0-6.0 inches, 2.0-5.0 inches, 2.0-4.0 inches, or any other suitable thickness.
  • the dimensions of a BSIP may be uniform for ease of installation, and may be manufactured with a length by width dimension of 22 inches by 96 inches to 48 inches by 96 inches or any other suitable dimensions.
  • BSIP 100 is shown as a flat, planar surface, other embodiments are contemplated in which BSIP 100 may have geometries that may better protect a given target.
  • BSIP 100 may have geometries that may better protect a given target.
  • one or more spall section may be disposed at an angle to better slow a projectile entering the BSIP.
  • one or more plies of material comprising any of the layers may be disposed at a 0 / 90 orientation.
  • the adjacent layers or adjacent sections are disposed at a 0 / 90 orientation.
  • the BSIP comprises a first ballistic zone 210, a second ballistic zone 220, and a third ballistic zone 230.
  • the first ballistic zone 210 faces outer threat X.
  • the second ballistic zone 220 engages the first ballistic zone 210.
  • the third ballistic zone 230 engages the second ballistic zone 220.
  • the third ballistic zone 230 faces an interior I.
  • FIG. 3 illustrates an embodiment with a first ballistic zone 210 that comprises only two layers.
  • Decorative outer skin 211 engages outer threat side X.
  • First spall section 212 engages decorative outer skin 211.
  • Decorative outer skin 211 may exhibit some favorable ballistics properties or it may serve a more decorative function.
  • Second ballistic zone 220 comprises SIP 221.
  • SIP 221 engages first spall section 213.
  • SIP 221 comprises three layers, first SIP skin layer 222, core layer 223, and second SIP skin layer 224 as shown.
  • First SIP skin layer 222 engages core layer 223.
  • Second SIP skin layer 224 engages core layer 223.
  • Third ballistic zone 230 comprises two layers and engages second ballistic zone 220 at second SIP skin layer 224.
  • Third ballistic zone 230 comprises second spall layer 231.
  • Second spall layer 231 engages decorative interior skin 240.
  • Decorative interior skin 240 may exhibit some favorable ballistics properties or it may serve a more decorative function.
  • the BSIP comprises a first ballistic zone 310, a second ballistic zone 320, and a third ballistic zone 330.
  • the first ballistic zone 310 faces outer threat X.
  • the second ballistic zone 320 engages the first ballistic zone 310.
  • the third ballistic zone 330 engages the second ballistic zone 320.
  • the third ballistic zone 330 faces an interior I.
  • first ballistic zone 310 comprises four layers.
  • Decorative outer skin 311 engages outer threat side X.
  • Strike face 312 engages decorative outer ballistic skin 311.
  • the first spall section may comprise at least two first hybrid layers 313a and 313b.
  • First spall hybrid layer 313a engages strike face 312.
  • Second spall hybrid layer 313b engages first spall hybrid layer 313a.
  • Decorative outer skin 311 may exhibit some favorable ballistics properties or it may serve a more decorative function.
  • First spall hybrid layer 313a and second spall hybrid layer 313b may comprise one spall layer material each, or they may comprise multiple different layers.
  • An appropriate material may be selected to achieve desired cost of the BSIP materials, weight, and blast performance.
  • Second ballistic zone 320 comprises SIP 321.
  • SIP 321 engages second spall hybrid layer 313b.
  • SIP 321 comprises three layers, first SIP skin layer 322, core layer 323, and second SIP skin layer 324 as shown.
  • First SIP skin layer 322 engages core layer 323.
  • Second SIP skin layer 324 engages core layer 323.
  • third ballistic zone 330 comprises two layers and engages second ballistic zone 320 at second SIP skin layer 324.
  • Third ballistic zone 330 comprises second spall layer 331.
  • Second spall layer 331 engages decorative interior skin 340.
  • Second spall layer 331 engages decorative interior skin 340.
  • the third ballistic zone 330 may comprise one or more layers, and these layers may comprise one or more spall layers.
  • Decorative interior skin 340 engages interior I.
  • Decorative interior skin 340 may exhibit some favorable ballistics properties or it may serve a more decorative function.
  • FIG. 5 illustrates an embodiment of a composite multilayer ballistic structural insulated panel 400.
  • the BSIP comprises a first ballistic zone 410, a second ballistic zone 420, and a third ballistic zone 430.
  • the first ballistic zone 410 faces outer threat X.
  • the second ballistic zone 420 engages the first ballistic zone 410.
  • the third ballistic zone 430 engages the second ballistic zone 420.
  • the third ballistic zone 430 faces an interior I.
  • first ballistic zone 410 comprises three layers.
  • Decorative outer ballistic skin 41 1 engages outer threat side X.
  • Strike face 412 engages decorative outer ballistic skin 411.
  • First spall layer 413 engages strike face 412.
  • Decorative outer skin 411 may exhibit some favorable ballistics properties or it may serve a more decorative function.
  • Second ballistic zone 420 comprises SIP 421.
  • SIP 421 engages first spall layer 413.
  • SIP 421 comprises three layers, first SIP skin layer 422, core layer 423, and second SIP skin layer 424 as shown.
  • First SIP skin layer 422 engages core layer 423.
  • Second SIP skin layer 424 engages core layer 423.
  • third ballistic zone 430 comprises three layers and engages second ballistic zone 420 at second SIP skin layer 424.
  • Third ballistic zone 430 comprises second spall section comprising second spall hybrid layers 431a, 431b and decorative interior skin 440.
  • the second spall section may comprise at least two first hybrid layers 431a and 431b.
  • First spall hybrid layer 431a engages second SIP skin layer 424.
  • Second spall hybrid layer 431b engages first spall hybrid layer 431a.
  • Second spall hybrid layer 431b engages decorative interior skin 440.
  • Decorative interior skin 440 engages interior I.
  • Decorative interior skin 440 may exhibit some favorable ballistics properties or it may serve a more decorative function.
  • FIG. 6 illustrates an embodiment of a composite multilayer ballistic structural insulated panel 500.
  • the BSIP comprises a first ballistic zone 510, a second ballistic zone 520, and a third ballistic zone 530.
  • the first ballistic zone 510 faces outer threat X.
  • the second ballistic zone 520 engages the first ballistic zone 510.
  • the third ballistic zone 530 engages the second ballistic zone 520.
  • first ballistic zone 510 comprises only two layers. Strike face 512 engages outer threat side X. First spall section 513 engages strike face 512.
  • Second ballistic zone 520 comprises SIP 521.
  • SIP 521 engages first spall section 513.
  • SIP 521 comprises three layers, first SIP skin layer 522, core layer 523, and second SIP skin layer 524 as shown.
  • First SIP skin layer 522 engages core layer 523.
  • Second SIP skin layer 524 engages core layer 523.
  • Third ballistic zone 530 comprises one layer and engages second ballistic zone 520 at second SIP skin layer 524.
  • Third ballistic zone 530 comprises second spall layer 531.
  • Second spall layer 531 engages second SIP skin layer 524.
  • a nonlimiting method for manufacturing a BSIP is described herewith.
  • the manufacturing of the BSIP occurs in several steps.
  • a SIP panel is manufactured by a SIP manufacturer and purchased as commercial item as is.
  • One example of such SIP is the GreenixTM Polyurethane Panel provided by SIP Supply.
  • a BSIP as illustrated, for example, in FIG. 2 may be manufactured in one to three lamination steps depending on the embodiment and referred to as the Exterior Panel. Panels may be laminated using heat and pressure in a either a hydraulic lamination process or autoclave consolidation process to adhere the layers comprising the first ballistic zone and the second ballistic zone together. Individual layers of a BSIP may be adhered to each other using the resin system inherent as the resin matrix in the material, or with a separate adhesive system.
  • the adhesive system may comprise a suitable adhesive such as thermoplastic films, methyl methacrylate, epoxy resin, or other suitable adhesive systems such as Nolax thermoplastic films, methyl methacrylate by Devcon, and epoxy adhesives resins by Daubert or others.
  • the second interior panel portion of a BSIP comprising the third ballistic zone are laminated in one to three steps depending on the embodiment and referred to as the Interior Panel.
  • Panels are laminated used heat and pressure in a either a hydraulic lamination process or autoclave consolidation process. Individual portions of the panel may be adhered to each other using the resin system inherent as the resin matrix in the material or as a separate adhesive system.
  • the Interior and Exterior panels are laminated and cut to size, they are adhered to the SIP using a variety of adhesives depending on the SIP Skin material.
  • the adhesive system may comprise a suitable adhesive such as thermoplastic films, methyl methacrylate, epoxy resin, or other suitable adhesive systems.
  • the Interior and Exterior panels are adhered to the SIP simultaneously. In other embodiments, the Interior and Exterior panels are adhered to the SIP one at a time.
  • the Interior and Exterior panels are adhered to the SIP by a cleating system 600.
  • a first set of cleats 601a, 601b is attached to both the Exterior 615 and Interior (not illustrated) faces of the SIP panel 610.
  • a second cleat or cleats is attached to an Interior panel (not illustrated).
  • a third cleat or cleats 602a, 602b is attached to an Exterior panel 620. The cleats are then interlocked to one another, thus attaching the Interior and Exterior panels to the SIP and forming the BSIP.
  • the BSIP is formed by mechanical means such as screws, fasteners, braces, plastic skins, and the like.
  • the Interior and Exterior panels, once formed individually, may be mechanically attached by mechanical means.
  • BSIP panels may be performed alone, or any combination of the steps above may be performed to form a BSIP panel.
  • an Interior panel may be mounted on an interior-facing face of a SIP by a cleating system, while the Exterior panel may be mounted on the exterior-facing face of a SIP by an adhesive system.
  • BSIPs Once BSIPs are produced, they may be installed into various applications to provide ballistic protection. According to an embodiment, the BSIP may be held together within a structure by a suitable adhesive system or a cleating system or a mechanical method using suitable fasteners and the like.
  • BSIP panels may be incorporated into permanent, semi-permanent, or temporary structures.
  • BSIP panels may be utilized for a rapidly deployable solution for a temporary structure and/or a solution for a temporary structure that may be rapidly taken down that also incorporate ballistic properties.
  • a structure built with a BSIP panel such as those described in this application may be deployed via helicopter or DROPS vehicle and assembled with one simple hand tool.
  • the V50 Ballistic Test for Armor is a common method for determining the relative performance of a given material.
  • an initial shot is fired and the velocity of the projectile is recorded in compliance with factors of the specification such as distance of muzzle to target and muzzle to velocity measuring device. If the shot penetrates the material, a second shot is taken after adjusting the amount of powder in the casing to produce a slightly lower velocity. If the shot is stopped by the material, powder is increased for the second shot to produce a slightly higher velocity. This procedure is repeated until a tight range of velocities are recorded, some with penetration, some without.
  • V50 velocity an indication of a velocity at which 50% of the projectiles fired at this speed would penetrate and 50% would be stopped.
  • Examples 1-3 and Comparative Examples 1-3 are described below and descriptions and properties of the Examples and Comparative Examples are illustrated in FIG. 8.
  • Example 1 utilized the configuration disclosed by FIG. 5 and incorporated 8 plies of a decorative material, a 4 mm thick ceramic strike face, and 2 plies of E-Glass spall layer on the front exterior face of a SIP panel. Adhered to the back side of the SIP panel was a hybrid spall layer of 13 plies of 0/90 oriented polypropylene fibers (InnegraTM S from Tech Fiber) and 28 plies of 0/90 aramid fibers (TechFiber) in polyethylene resin matrices. Two plies of a decorative material formed the interior decorative layer of the BSIP.
  • Example 1 exhibited an areal density of 5.5 pounds per square foot ("psf '). Surprisingly, Example 1 demonstrated a V 50 of 3310 feet per second (“fps").
  • Comparative Example 1 utilized the configuration disclosed by Example 1, but without the SIP panel.
  • LC-1330 incorporated 8 plies of a decorative material, a 4 mm thick ceramic strike face, 2 plies of E-Glass spall layers, a hybrid spall liner of 13 plies of 0/90 oriented polypropylene fibers (InnegraTM S from Tech Fiber) and 28 plies of 0/90 aramid fibers (TechFiber) in polyethylene resin matrices.
  • Two plies of a decorative material formed the interior decorative layer of the panel.
  • Comparative Example 1 exhibited an areal density of 5.5 psf. Comparative Example 1 demonstrated a V 5 o of 2183 fps.
  • Example 2 (LC-1 104) utilized the configuration disclosed by FIG. 2 and incorporated 8 plies of a decorative material, a 4 mm thick ceramic strike face, and 10 plies of woven roving E-glass in a phenolic resin matrix as a spall layer on the exterior face of a SIP panel. Adhered to the back side of the SIP panel was a second spall layer of 15 plies of woven roving E-glass in a phenolic resin matrix. Two plies of a decorative material formed the interior decorative layer of the BSIP.
  • Example 2 exhibited an areal density of 9.3 psf. Surprisingly, Example 2 demonstrated a V 50 of 3666 fps.
  • Comparative Example 2 (LC-1328) utilized the configuration disclosed by Example 2, but without the SIP panel. Comparative Example 2 incorporated 8 plies of a decorative material, a 4 mm thick ceramic strike face, and 25 plies of woven roving E-glass in a phenolic resin matrix as a spall layer. Two plies of a decorative material formed the interior decorative layer of the panel. [0097] Comparative Example 2 exhibited an areal density of 9.3 psf. Comparative Example 2 demonstrated a V 50 of 2420 fps.
  • Example 3 utilized the configuration disclosed by FIG. 3 and incorporated 8 plies of a decorative material and 33 plies of woven roving E-glass in a phenolic resin matrix as a combined strike face and spall layer on the exterior face of a SIP panel. Adhered to the back side of the SIP panel was a second spall layer of 32 plies of woven roving E-glass in a phenolic resin matrix. Two plies of a decorative material formed the interior decorative layer of the BSIP. The incorporation of several plies of E-glass may beneficially reduce the cost of the BSIP system by 40-50%.
  • Example 3 exhibited an areal density of 14.7 psf. Surprisingly, Example 3 demonstrated a V 50 of 3643 fps.
  • Comparative Example 3 (LC-1329) utilized the configuration disclosed by Example 3, but without the SIP panel. Comparative Example 3 incorporated 8 plies of a decorative material and 65 plies of woven roving E-glass in a phenolic resin matrix as a spall layer. Two plies of a decorative material formed the interior decorative layer of the panel.
  • Comparative Example 3 exhibited an areal density of 14.7 psf. Comparative Example 3 demonstrated a V 50 of 2983 fps.

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  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Architecture (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Engineering & Computer Science (AREA)
  • Wood Science & Technology (AREA)
  • Business, Economics & Management (AREA)
  • Textile Engineering (AREA)
  • Emergency Management (AREA)
  • Environmental & Geological Engineering (AREA)
  • Civil Engineering (AREA)
  • Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)

Abstract

Un ou plusieurs modes de réalisation de la présente invention concernent un panneau isolé structurel doté de propriétés balistiques améliorées, et concernent également des procédés pour l'utiliser.
PCT/US2011/030399 2010-03-29 2011-03-29 Panneau isolé structurel balistique Ceased WO2011123474A1 (fr)

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