WO2006011903A2

WO2006011903A2 - Asymmetric composite materials

Info

Publication number: WO2006011903A2
Application number: PCT/US2004/043513
Authority: WO
Inventors: Tony Piscitelli
Original assignee: Tony Piscitelli
Priority date: 2004-06-29
Filing date: 2004-12-22
Publication date: 2006-02-02
Also published as: WO2006011903A3

Abstract

The present invention is directed to compositions and methods used to protect subjects from projectiles or explosion fragments in civilian and combat situations. More specifically, the invention relates to protecting subjects through the use of asymmetric composite materials.

Description

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Asymmetric Composite Materials

Field of the Invention

The present invention is directed to compositions and methods used to protect subjects from high velocity projectiles and explosion fragments in civilian and combat situations. More specifically, the invention relates to protecting subjects through the use of asymmetric laminated composite materials.

Background of the Invention

The present invention relates to asymmetric laminated composite materials capable of withstanding projectile and explosion fragment penetration.

Summary of the Invention

The present invention is directed to compositions and methods used to protect subjects from projectiles or explosion fragments. More specifically, the invention relates to protecting subjects through the use of asymmetric laminated composite materials and associated methods.

The presently disclosed compositions and methods are used to protect subjects from high velocity projectiles and explosion fragments in both civilian and combat situations.

More specifically, the invention relates to protecting subjects through the use of asymmetric laminated composite materials in a number of embodiments. For example, the composite materials of the present invention are used in windows, doors, curtain walls, face ADS-062904-PCT ²

masks, vests, flooring, helmets, tires, computer screens, television screens, housing, aircraft, shelters/bunkers, boats, security vehicles, buildings, automotive, sport arenas, guard shields. It is understood that these embodiments are exemplary, and should not be construed to be

exclusive or limiting of the invention.

All of these embodiments involve use of the present invention in a way that those of skill in the art can employ with modifications and applications that require a minimum of

difficulty.

Drawings

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings where:

Fig. 1 illustrates an angled view of a High Mobility Multipurpose Wheeled Vehicle (HMMWV) and associated composite panels according to a preferred embodiment of the invention.

Fig. 2 depicts typical engineer schematic drawings of elements of a MTRV vehicle, with associated installation areas of doors and windshield for the composite materials, with cross section drawings of the composite material, in frame, in a standard installation configuration.

Detailed Description and Embodiments of the Invention

While this invention is satisfied by embodiments in many different forms, there will herein be described preferred embodiments of the invention, with the understanding that the present disclosure is to be considered exemplary of the principles of the invention and is not ADS-062904-PCT ³

intended to limit the invention to the embodiments illustrated and described. The scope of the invention will be measured by the appended claims and their equivalents.

The present invention is directed to compositions and methods used to protect subjects from high velocity projectiles and explosion fragments in civilian and combat situations. More specifically, the invention relates to protecting subjects through the use of opaque and transparent asymmetric laminated composite materials.

"Asymmetric", as defined herein, is intended to describe either the layered or stacking of composite materials, wherein the thickness of one layer or stack in the composite material is variable, non-uniform, or different in relation to a plurality of other layers or stacks. The use of asymmetric intermediate materials is also contemplated (including the use of different substrate materials (e.g. glass and polycarbonate, or steel, ceramics and Kevlar, S Glass steel mesh)). For example, if a first layer or stack has a thickness of 1.5 mm, then at least one of the subsequent layers or stacks must be quantitatively different from the 1.5 mm thickness measurement of the first layer (e.g. 1.3, 1.4, 1.6., etc.) For clarification, a composite material may comprise a plurality of asymmetric layers, which in turn may comprise of a plurality of asymmetric or symmetric stacks.

For example, a composite material is considered that comprises a plurality of layers, in which the layers are asymmetric. It is further considered that these plurality of layers are further situated in a manner in which each asymmetric plurality of layers is laid one on top of the other so that the multiple plurality of layers form a thicker asymmetric stack. The multiple layers, and multiple stacks, are adhered together, with one or more layers situated as substrate, through the use of standard adhesives applied in any number of ways, or are bonded (laminated) together using conventional techniques and methods, including interlayers, that ADS-062904-PCT 4

are well known and widely documented in the art. Material bonding or curing procedures that utilize heat, compression, chemical reactions, radiation, and UV light are commonplace in the field (as communicated by the inventor). For one example, see the laminate manufacturing descriptions available in United States Patent 5,443,883, hereby incorporated by reference in its entirety. Through testing, it was determined that asymmetric composite materials are durable in terms of material ability to withstand projectile penetration (as indicted herein, and in private conversations with the inventor). For example, see the following Table 1.

Table 1, below, depicts the results of multiple tests on composite materials performed that illustrate the penetration resistance of a number of composite materials, when impacted by any number of projectiles, with composite weight and thickness. It should be pointed out that this table displays the penetration resistance of many composite materials, it does not illustrate the composites that were tested and failed to resist penetration. Such is the unpredictable nature of this embodiment of the present invention, which requires an enormous amount of experimentation to perfect. All testing described in this application either meets or exceeds all recognized and accepted testing parameters and guidelines presently being utilized. Consequently, the embodiments of the composite materials of the present invention have set new performance standards (see, specifically, Examples 1 and 2, infra).

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Table 1

₃1.01;inchθSa

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application are recognized, it is understood that these specifications are taught for exemplary purposes only, as many other embodiments are considered. For example, the invention may comprise any number of layers and stacks that are constructed using many different materials, with a variety of thickness, both of which will necessarily be dictated according to the exact objectives sought. For example, it is considered to be within the scope of this invention to construct composite materials with more then 3 layers, and no more then 20 layers, and with between 3 and no more then 15 stacks. In a preferred embodiment of the invention, it is considered the composite material would comprise between 3 to no more then 10 layers, and 1 to no more then 24 stacks. In a preferred embodiment of the invention, it is contemplated the composite material would comprise a thickness of between .5 inches to no more then 24 inches.

It will be intuitive to those of skill in the art that different materials are used in construction of the composite materials to suit the objectives sought. For example, a number of embodⁱments of the present invention relate to a composite material wherein the layers are constructed from plastics, glass, aluminum silicates, ionomer resins, metals, rubbers, rig_id aramid fiber materials, synthetic film, fabric, ceramics or combinations of these materials. For a sample illustration of a present embodiment, a three layer asymmetric composite comprising a sheet of glass, an ionomer resin interlayer, and a polycarbonate sheet are constructed using methods that are well known in the art. Additional layers are added to the partⁱcular composite, dictated by the objectives of the particular project. This three-layered stack can then be further bonded to one or more other asymmetric stacks, in a manner that ADS-062904-PCT 7

creates a durable composite, and further, eliminates spall (i.e. small flying glass shards), that are typically seen when normal glass materials are shattered. In one embodiment of the invention, the inventor has discovered a particular configuration of the above three materials that comprises no more then 1.5 inches thickness, and is capable of withstanding any penetration of 12 shots from a 7.62 mm M80 standard NATO rounds, with the grouping of shots spaced less then 3 inches apart. The composite is transparent, and resists spall. Further, upon increasing the thickness to 2 inches, the composite withstands penetration from a .50 caliber machine gun, while a composite thickness of 2.5 inches was sufficient to stop penetration from a .50 caliber armor-piercing round.

This list of materials herein is only exemplary, and should not be construed to be exclusive or limiting of the invention. For example, many other suitable materials, which are species of the aforementioned materials, exist. And any comprehensive lists of such are cumbersome and unnecessary for descriptive purposes. But as an example, while not intending to limit the invention, such a list of suitable materials may include polybenzoxazole (PBO), polybenzothiazole (PBT) polymers or related copolymers, thermoplastic polymers (polyethylene, polycarbonate, etc.), thermosetting polymers (vinyl ester, polyvinyl butyral (PVB), epoxy resins, polyvinyl urethanes, etc.), elastomers (polybutadiene, natural rubber, etc.).

Other preferred versions of the invention are also considered in constructing the asymmetric composite materials of the present invention utilizing a plurality of these suitable composite materials, but are not to be construed to be limited to any particular plurality of species. For example, a plurality of composite materials, that comprise plastics, annealed or treated glass (treated by chemicals, heat treated, tempered, low iron, solar), substantially pure ADS-062904-PCT 8

aluminum silicates, ionomer resins, metals, rubbers, rigid aramid fiber materials, ceramics, or combinations thereof are used in the construction of the opaque and transparent composites. AR 500 steel (high hardened), ionomer resins (sodium salts or potassium salts), that are available from E. I. du Pont de Nemours & Co., Wilmington, Del., under the product designations Surlyn® or by the Dow Company under the trademark Primacore® or like products. Opaque and clear ceramic materials, that are available from E. I. du Pont de Nemours & Co. under the trademark Torvex®, or like products, and rigid and flexible aramid

fibers, such as those sold under the trademark Kevlar®. Also, laminates referred to by the

trade names Sentryglas® and SentryGlas Plus® are manufactured by E. I. du Pont de

Nemours & Co. A plastic material referred to by the trade name Lexane® is manufactured by E. I. du Pont de Nemours & Co. Asymmetric composite materials are available from American Defense Systems, Long Beach, New York, under the product designation VistaSteel™ opaque and transparent composites.

A further embodiment of the present invention pertains to opaque and transparent composite materials that are capable of preventing penetration of high velocity projectiles, high velocity explosion fragments, or combinations thereof. The term "high velocity" as used herein, is intended to describe projectile velocities in the range from approximately 1500 to 9000 or more feet per second, as is typically demonstrated by various explosion fragments. "Explosion fragments", in the present context, are intended to encompass any type of high velocity projectiles whose velocity is generated by an explosion (e.g. including explosions caused by heat, pressure, electricity, compressed air, water, etc.). "High velocity projectiles" therefore includes both ballistic projectiles, such as bullets, and also shotgun scatter, bomb shrapnel, and metal or other type material fragments caused by large bombs, improvised ADS-062904-PCT ⁹

explosive devices (ED), blast mines, and hand grenades equivalent in force to an M67 fragmentation grenade detonated at a horizontal distance of 5 meters. It is contemplated that high velocity projectiles and explosion fragments can derive from any number of firearms or explosive devices. For example, a 7.62 x 39 x AP (steel core) bullet, manufactured at Plant 71 , 1986, and Plant 3, 1989, fired from an AK 47 (Rumania) rifle, number 155 H Comp B M107 No. D544, or metal shrapnel fragments from a detonation blast of a 155 mm shell.

A further embodiment of the present invention contemplates composite materials that are substantially transparent, or substantially opaque. The term "opaque", as defined herein, is intended to describe a material that fails to allow reasonable amounts of visibility when viewing through from one side of the stacked material to the other. Whereas the term "transparent", as defined herein, is intended to describe a substantially clear material that allows for a reasonable amount of visibility when viewing through from one side of the stacked material to the other. It is contemplated that either the transparent or opaque composites of the present invention may be tinted or colored. Generally speaking, the embodiment of the present invention pertaining to opaque composites comprises at least one layer of a metal material, while embodiments pertaining to transparent composite materials typically do not contain metal layers, but contain layers that allow for the passage of light. This allows for the utilization of transparent composites in embodiments where both blast mitigation and visual function are sought the be maintained, such as in vehicle windshields, building windows, etc.

In another embodiment of the present invention, opaque and transparent composite materials that are capable of being molded, shaped, bent, and deformed into a plurality of shapes for a number of utilizations are considered. For one example, an 'armoring' kit ADS-062904-PCT 10

comprising flat and curved asymmetric composite materials and custom design frame materials are considered for the assembly and use of protective safety barriers that protect subjects from projectiles or explosion fragments in civilian and combat situations. The composite materials are shaped in a variety of ways by subjecting them to heat, light, and pressure applied from a number of sources. The composite materials are attached to the custom design frame materials using materials and methods known in the art.

A protective safety barrier is comprised of asymmetric layers made from plastics, glass, aluminum silicates, ionomer resins, metals, rubbers, aramid fiber materials, or combinations thereof. The barrier may for used for installation to a motor vehicle, such as an instance where the vehicle has a body and one or more doors with outer metal surfaces, and said custom design frame material is secured to said outer surfaces using one or more frame fasteners. It is considered that in one embodiment of the invention, the custom design frame comprises material from at least one member of the group of plastics, glass, substantially pure aluminum silicates, ionomer resins, metals, rubbers, rigid aramid fiber materials, glazing or combinations thereof.

In one example, it is contemplated that utilization of opaque and transparent composites as a protective safety barrier in a motor vehicle, where the vehicle is a High Mobility Multipurpose Wheeled Vehicle (HMMWV). In one embodiment of the invention, the attachment of the protective safety barrier includes removing the glass and other components of the vehicle, and replacing the glass and several other components with the composite material, by attaching the custom design frame material, which houses the composite material, to the vehicle by use of a plurality of fasteners. The fasteners are made from a number of materials, including metal, plastic, rubber, composites, or any combination ADS-062904-PCT 11

thereof. The custom design frame fasteners may include, or be used in conjunction with, one or more screws, bolts, pins, shims, hinges, rivets, nails, dowels, clamps, sealants, and gaskets, for example. The fasteners are attached to the frame using materials and methods known in

the art.

A kit and method of use is further considered that comprises installing the contents of such kit, including the installation and use of a protective safety barrier. The kit and method comprise a protective asymmetric composite material, further comprising one or more opaque and transparent asymmetric layers, and a custom design frame material. The kit, in turn, is delivered, through one or more distribution modalities (e.g. air, water, land, etc.) to a particular geographic location (e.g. a combat zone or other installation site) in which the barrier is installed in any number of ways, as previously discussed. A means for assembling or installing the barrier in said location is also considered, and specifically, assembling or installing the barrier using the means for assembling or installing the barrier at the particular location. As contemplated, the means for assembling or installing a protective safety barrier may comprise any number of materials or procedures used in the assembling and installing of the kit materials to the appropriate use in the proper location. Therefore, the modality used to transfer the kit, as well as choice of the particular location involved, are both considered to be within the scope of the assembling and installing means, as are the machines (both computers, software, telephone, vehicles, and other apparatus), and equipment (e.g. tools, etc.), involved in the required assembly and installation of the kit components. In further embodiments of the present invention, vehicle measurements are recorded on any number of vehicle elements, and based on these measurements, engineering and architectural drawings are assembled, stored, and analyzed. These materials are used as specification readings for the particular kit, and are ADS-062904-PCT 12

further used in portions of the installation manual, that may or may not be included in the kit.

Kits are delivered according to a project schedule, which is generated according to the particular nuances of the project, as defined by communications between parties, private or government contracts, and specific project logistics. Quality control, including project testing, is also contemplated as a further embodiment of the present invention.

As is readily apparent from the foregoing description, the present invention lends itself to custom implementation regarding the specific logistic circumstances present, and particulars of any given location. The invention considers the flexible and customized nature of these circumstances. For example, in an example of another embodiment of the present invention, the barrier components of the kit are installed on any suitable vehicle, in combat or non-combat settings, including one or more seated HMMWV, MTVR, land rovers, jeeps, automobiles, ambulance, pick-up trucks, cranes, fuel tankers, tractor trailer trucks and cargo pulls. Any vehicle make and year are candidates for installation treatment (e.g. GMC, Chevy, etc.). The present invention is not to be construed to be limited to vehicles (as communicated in conversations with the inventor).

Buildings and other structures are also contemplated. For example, in another embodiment of the invention, fuel tanks, courts houses, police stations, military installations, or any number of terrorist targets, such as building where large numbers of people may live or work, are further contemplated for barrier installation treatment. The only requirement is that the composite materials and custom design frames be sized according to the particular vehicle or building elements sought to be protected by the composite. For example, in one embodiment, vehicle measurements are recorded on any number of vehicle elements, based on segment size, location, objectives, and functions of the element. That aspects that are ADS-062904-PCT 13

considered include vehicle size and weight, objectives of task, purported or building or vehicle use, structural integrity required, ease of installation, vehicle and barrier performance, transportability, schedule, location of installation, and visibility.

Examples of elements that are sized for installation treatment, including both the inside and outside surfaces, and internal contours, include windshields, side/rear windows, doors, walls, floor plates, pillars, body plates, blast panels, roof, ceiling, flooring, mats, pans, engine holds, etc.

Accordingly, this invention is not limited to the individual embodiments disclosed, but is intended to cover all modifications that are within the spirit and scope of the invention as defined by the appended claims. Further, the description of the specific embodiments of the invention fully reveal the general nature of the invention so that others can readily modify and/or adopt for various purposes such specific embodiments without departing from the general concept, and therefore such adaptations and modifications are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. All references and patents referred to are intended to be incorporated herein by reference.

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Illustrative Examples

While a number of embodiments of the invention are more fully illustrated by the following Examples, the Examples are supplied for illustrative purposes only, and are not intended as limitations on the scope of either the Specification or the Claims.

Example 1

Opaque Composite Material Blast Testing

Physical specifications of opaque composite material tested

Table 2

In order to test the capability of one embodiment of the present invention to withstand projectile and fragment penetration, a 12" x 12" opaque composite material test sample ADS-062904-PCT 15

having the dimensions described in Table 2 was installed in a metal frame at a height of approximately 5 feet. The sample was then subjected to six consecutive 7.62 x 39 x AP steel core shots from an AK 47 rifle, followed by being further subjected to the metal shrapnel fragments from a detonation blast of a 155 mm shell placed at the distance of approximately 33 feet from the opaque composite material. The composite material remained at a height of approximately 5 feet above the ground, while the 155 mm shell was detonated at a height of

approximately 8 feet above the ground.

Results of the multiple impacts on the opaque composite material tested

Table 3

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After impact of the high velocity explosion fragments with the composite material of Table 2, it was determined by visual inspection that the composite material was not penetrated by any of the 7 blasts. The impact of the six ballistic projectiles on the 12" x 12" opaque composite material test sample was determined. The impact of the seventh blast, which was a shrapnel bomb blast, was scattered across the surface of the material. But it was determined by post ballistic testing that a 1.5" x .75" inch explosion fragment was stopped, and did not penetrate the material. Surprisingly, no spall was detected.

Example 2

Transparent Composite Material Blast Testing

Physical specifications of transparent composite material tested

Table 4

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In order to test the capability of one embodiment of the present invention to withstand projectile and fragment penetration, a 12" x 12" opaque composite material test sample having the dimensions described in Table 4 was installed in a metal frame at a height of approximately 5 feet. The sample was then subjected to three consecutive 7.62 x 39 x AP steel core shots from an AK 47 rifle, followed by being further subjected to the metal shrapnel fragments from a detonation blast of a 155 mm shell placed at the distance of approximately 33 feet from the opaque composite material. The composite material remained at a height of approximately 5 feet above the ground, while the 155 mm shell was detonated at a height of approximately 8 feet above the ground.

Results of the multiple impacts on the transparent composite material tested

Table 5

After impact of the high velocity explosion fragments with the composite material of Table 4, it was determined by visual inspection that the composite material was not penetrated by any of the 4 blasts. The impact of the six ballistic projectiles on the 12" x 12" opaque laminated ADS-062904-PCT 18

composite material test sample was determined. The impact of the forth blast, which was a shrapnel bomb blast, was scattered across the surface of the material. But it was determined by post ballistic testing that a 1.5" x .75" inch explosion fragment was stopped, and did not penetrate the material. Again, no spall was detected.

Claims

ADS-062904-PCT 19CLAIMSWhat is claimed:

1. A composite material comprising a plurality of layers, wherein said layers are asymmetric.

2. A composite material of Claim 1 , further comprising a plurality of asymmetric

stacks.

3. A composite material according to Clam 1 , wherein said layers comprise at least one member of the group of plastics, glass, substantially pure aluminum silicates, ionomer resins, metals, rubbers, rigid aramid fiber materials, or combinations thereof.

4. As composite material according to Claim 3, that is capable of preventing penetration by one or more high velocity projectiles.

5. A composite material according to Clam 2 that is substantially transparent.

6. A composite material according to Clam 2 that is substantially opaque.

7. A composite material according to Claim 2 that is capable of being molded, shaped, bent, deformed, and washed.

8. A protective safety barrier, comprising one or more asymmetric layers and a custom design frame material.

9. A method used to protect subjects from projectiles or explosion fragments in civilian and combat situations, comprising the protective safety glass barrier according to Claim 8.

10. A protective safety barrier of Claim 8, wherein said layers comprise at least one ADS-062904-PCT 20

member of the group of plastics, glass, substantially pure aluminum silicates, ionomer resins, metals, rubbers, rigid aramid fiber materials, or combinations

thereof.

11. A protective safety barrier of Claim 8, wherein said custom design frame material comprises at least one member of the group of plastics, glass, substantially pure aluminum silicates, ionomer resins, metals, rubbers, rigid aramid fiber materials, glazing or combinations thereof.

12. A protective safety barrier according to Clam 8, that is substantially transparent.

13. A protective safety barrier according to Clam 8, that is substantially opaque.

14. A protective safety barrier of Claim 8, comprising asymmetric layers and custom design frame material for installation to a motor vehicle, wherein said vehicle has a body and one or more doors with outer metal surfaces, and said custom design frame material is secured to said outer surfaces using one or more fasteners.

15. A protective safety barrier according to Claim 14, wherein said motor vehicle is a High Mobility Multipurpose Wheeled Vehicle (HMMWV).

16. A protective safety barrier of Claim 14 that is capable of preventing penetration from at least one member of the group comprising high velocity projectiles, high velocity explosion fragments, or combinations thereof.

17. A method for installing the protective safety barrier according to Claim 12 wherein said custom design frame material includes a fastener means.

18. A kit for constructing a protective safety barrier, comprising: a) providing: i) a protective asymmetric composite material comprising one or more asymmetric layers; ii) a custom design frame material; iii) a geographic location in ADS-062904-PCT 21

which to assemble said barrier; and iii) a means for assembling said barrier in said location; and b) assembling said barrier using said means for assembling at said location.