GB2420096A - Moulding of camouflage object - Google Patents

Abstract

A process of moulding a precursor 5 on to a film 2, whereby film 2 is possibly a camouflage film having a plurality of components already thereon, involves involving placing film 2 in to a mould 1A, 1B, inserting a mouldable precursor 5 also in to the mould and then moulding the precursor 5 on to the film 2 allowing it to adhere thereon, possibly thereby forming a camouflaged object. Prior to this process, camouflage film 2 may have attached components to protect against detection. It may also comprises a rough surface, achieved by prior embossing, within mould 1A, 1B or by the provision of aluminium oxide or other metal particles on the surface. Film 2 may comprise at least one of Nylon, butyl rubber, co-polyesters, polypropylene, polyethylene terephthalate, polybutylene terephthalate, PVC, PTFE, Kevlar (RTM), Tedlar (RTM) or polyolefins. The mouldable precursor 5 may comprise a resin, carbon fibre or co-polyester. The surface layer of film may also optionally be applied by digital printing.

Description

PROCESS FOR FORMING CAMOUFLAGED OBJECT

The present invention relates to a process for forming a camouflaged object, and in particular to a process for forming an object protected against detection by a plurality of sensing methods.

Camouflage patterns are commonly painted on to structures. Painting patterns has the disadvantage that it is time-consuming to create the camouflage pattern using multiple colours for each installation. Furthermore, paints have the limitation that it is difficult to incorporate additional components to provide protection against detection by a wide spectral range of radiation.

Coverings providing camouflage capability are well known in the field of camouflage. Such coverings include nets for throwing over objects to be hidden, magnetic plates for attaching to objects such as vehicles, and sheets which can be adhered to objects, either temporarily or permanently.

Coverings of these types can be convenient in situations requiring rapid application of camouflage to objects, for example when troops or equipment are moving or being set up in a new location. For instance, a vehicle might be moving from a city environment (generally grey in colour) to a desert environment (generally yellow-brown in colour), and different camouflage equipment would be desirable to allow the vehicle to remain undetected while it moves between the different environments. In such a situation, a temporary covering which can be quickly deployed would be appropriate.

However, the above types of camouflage covering can have the disadvantages of being ill-suited to long-term use, since they can be damaged by exposure to extreme climatic conditions such as heat or rain, and of being unable to remain attached to the objects they are intended to cover in conditions such as storms or high winds.

It is therefore desirable to provide a pre-patterned camouflage covering which can be more securely fixed to an object to be protected.

According to a first aspect of the present invention there is provided a process comprising: placing a camouflage film into a mould, the film comprising a plurality of components, each such component providing protection of the film against detection by a different sensing method; inserting a mouldable precursor into the mould; moulding the precursor in the mould so as to shape it and cause it to adhere to the film, thereby forming a camouflaged object.

The process of the invention thus enables objects to be made comprising integrated protective coverings which can be durable and which are securely attached to the object.

The film could suitably comprise an adhesive layer on one of its outer surfaces for adhering to the precursor in the mould. In this way the film can readily be secured to the precursor.

The components of the camouflage film could suitably provide protection against detection using one or more of: visible light; near infra-red; far infra- red; and radar. Techniques using these wavelengths of radiation are commonly used for detecting objects, so it is desirable to provide protection against them.

At least a part of the camouflaged object may be provided with a rough surface. This can act to reduce glint and glare from the object, thus making it harder to detect. The rough surface could be achieved by embossing a surface of the camouflage film prior to placing the film in the mould, by providing a surface roughness in the mould, or by providing particles in the camouflage film. Suitable particles for this purpose are aluminium oxide (A1203) or metal particles.

The camouflage film could be provided with a non-reflective coating. This would assist in making the film undetectable by visible means.

Suitable materials for the camouflage film include one or more of: polypropylene; polyethylene terephthalate; polybutylene terephthalate; Nylon 6; Nylon 66; butyl rubber; co-polyesters; low density polyethylene; KevlarL1?-i Tedlariyo(efin; PTFE; and PVC. These materials generally have high durability and are therefore well suited to this application. PVC is generally an unsuitable material for use in such applications since it tends to absorb chemical agents. However, if covered with a nuclearbiological-chemical (NBC) barrier coating, it can conveniently be used as a camouflage film in embodiments of the present invention.

The camouflage film may be provided with an anti-slip surface. This would allow personnel to climb onto objects protected by such a film, such as vehicles. The anti-slip surface could be achieved by providing particles of aluminium oxide in the film. Alternatively or in addition, the antislip surface could comprise rubber. The surface could also be provided with indentations or protrusions to give non-slip characteristics.

The camouflage film could suitably comprise phase change materials. These could enable a camouflages object to absorb heat. They would be of particular use in hot-spots such as areas surrounding an engine of a vehicle.

Aerogel could be included to achieve a similar purpose.

A surface layer of the camouflage film could be applied by digital printing.

This is beneficial since it can allow the film to be printed with a pattern whose repeat length is not limited by the size of the rollers used in the printing process. Patterns can therefore be produced which are harder to detect than repeating patterns.

Suitable materials for the precursor include resins and carbon fibre. These can be tough and durable and are therefore suitable for this application. Co- polyesters can also suitably be used.

According to a second aspect of the present invention there is provided a camouflaged object formed by one or more of the methods described above.

The present invention will now be described by way of example with reference to the accompanying drawing, in which: Figure 1 shows a process for forming a camouflaged object.

Figure IA shows an initial stage of a process in accordance with an embodiment of the present invention. A camouflage film 2 is placed on a receiving surface of the base of a mould IA. In certain embodiments the film 2 has an adhesive outer surface 3, shown in the exploded section of Figure IA.

Figure lB shows the same mould in a nearly-closed configuration, with the upper part of the mould lB lowered towards the base IA. An inlet 4 is provided in a side of the mould, through which liquids 5 can be passed for insertion into the mould. For example, a resin 5 could be inserted through the inlet 4 so as to fill a space within the mould. The resin 5 is then heated to a temperature suitable for curing the resin. In this way, a solid component is formed as shown in Figure IC, the component having a body 5 made of resin and an integral camouflage film 2.

Examples of objects or components which could suitably be produced by the process of the present invention include parts of tanks or body parts of other vehicles.

Instead of a liquid precursor being inserted into the mould, a deformable solid substrate such as a plastics material which softens on heating could be used.

In this case, it may be preferable to provide an adhesive layer 3 on the camouflage film 2 to ensure a strong bond between the film and the substrate 5. Such adhesive layers could suitably be heat-activated. They could comprise wet-type adhesives or dry laminates (for example of a dry polyeurethane material which is heat fused). An adhesive could suitably be sprayed onto the surface of the camouflage film. Other suitable types of adhesive and methods of application will be understood by those skilled in the art to fall within the scope of the invention.

Heat or pressure or a combination of both could be applied to the precursor and the film within the mould to achieve (i) a component of the desired shape and/or (ii) a strong adhesion between the film and the precursor.

It is envisaged that camouflage films of the type generally known from copending application PCT/USO3/12474 (WO 03/091652) could be used in embodiments of the present invention. The films could suitably provide protection against detection by one or more of the following techniques: visible observation; near-infra-red observation (typically about 650-1 400nm wavelength); far infra-red observation (typically about 3-5im and about 8- 14j.xm); and radar (typically at 94GHz band, or 2-18GHz). Radar protection could be achieved by providing a surface which reflects radar or by providing a material which absorbs appropriate wavelengths. It will be understood that components in the camouflage film could be provided to protect against other types of detection.

Examples of materials that can protect against detection by various means are disclosed in PCT/USO3/12474. Such materials may be incorporated in the camouflage film 2 of embodiments of the present invention by means of blending into the film during production of the film, or layering into or on to components of the film.

A coloured pattern is preferably applied to an outer surface 6 of the camouflage film to provide protection against visible detection. The colours are preferably varied depending upon the specific application of the end product. For example, a tank part to be used in a desert environment would be formed from a film having a yellow-brown printed pattern. Digital printing is a particularly preferred technique for applying colours for camouflage application. Additives or other means can be used to provide a non-slip outer surface 6 of the film 2.

It can be desirable for articles used in situations where camouflage is required to have high durability to NBC materials, and to be easily cleanable of such materials. Thus, the precursor material introduced into the mould and/or the materials used to form the camouflage film could be resistant to NBC contaminants. Such materials could suitably conform to the United States specifications Ml L-C-64 159, Ml L-C-46 1 68D or Ml L-C53039A which govern chemical agent resistant coating (CARC) requirements.

The precursor to which the film is applied could be a plastics material, most conveniently a thermoplastic material. The material could be a composite material, for instance a material having a resin matrix reinforced with fibres such as carbon fibres. The material could be an armou red material.

There are several possible ways of forming the moulded camouflaged article.

In each case a precursor of the structural part of the article is placed against the film in a mould and moulded to shape under conditions that cause the film to adhere to the precursor or structural part of the article when the process is complete. The conditions used will depend on the properties of the precursor and the film.

1. In the case of a malleable precursor, pressure can be applied to the precursor by means of the mould so as to force it against the film and form it to shape. If the film can adhere to the precursor under pressure alone then no heat needs to be applied. Alternatively, if for example the film has heat activated adhesive on it, heat may be applied so as to cause it to adhere.

2. In the case of a precursor that can be shaped under heat (e.g. a thermoplastic sheet that can be pressed to a desired shape, or thermoplastic particles that can be fused together in a desired shape, or thermoplastic liquid that can be set in a desired shape) heat may be applied to the mould to permit the shaping to take place. The heat (with or without pressure applied by the mould) may also activate adhesive that adheres the film to the precursor or may cause the film to fuse to the precursor. In the case of a liquid precursor the adhesion of the film to the substrate will occur when the precursor becomes solid on cooling of the mould.

3. In the case of a thermosetting precursor (e.g. a precursor comprising a thermosetting resin), the precursor can be laid or poured into the mould, and the mould heated to cause it to set. The heat (with or without pressure applied by the mould) may also activate adhesive that adheres the film to the substrate or may cause the film to fuse to the substrate.

Once a camouflage object formed by means of the process of the present invention has been used for a period of time, it may become necessary to repair the camouflage film. To achieve this, patches of replacement camouflage film could be applied over damaged areas by means of a roller, If a heat-activated adhesive is used, a heated roller could be employed to apply the replacement film.

The applicant hereby discloses in isolation each individual feature described herein and any combination of two or more such features, to the extent that such features or combinations are capable of being carried out based on the present specification as a whole in the light of the common general knowledge of a person skilled in the art, irrespective of whether such features or combinations of features solve any problems disclosed herein, and without limitation to the scope of the claims. The applicant indicates that aspects of the present invention may consist of any such individual feature or combination of features. In view of the foregoing description it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention.

Claims (23)

1. A process comprising: placing a camouflage film into a mould, the film comprising a plurality of components, each such component providing protection of the film against detection by a different sensing method; inserting a mouldable precursor into the mould; moulding the precursor in the mould so as to shape it and cause it to adhere to the film, thereby forming a camouflaged object.

2. A process as claimed in claim 1 wherein the film comprises an adhesive layer on an outer surface thereof for adhering to the precursor in the mould.

3. A process as claimed in claim 1 or claim 2 wherein the components of the camouflage film provide protection against detection using one or more of: visible light; near infra-red; far infra-red; and radar.

4. A process as claimed in any preceding claim wherein at least a part of the camouflaged object is provided with a rough surface.

5. A process as claimed in claim 4 wherein the rough surface is achieved by embossing a surface of the camouflage film prior to placing the film in the mould.

6. A process as claimed in claim 4 or claim 5 wherein the rough surface is achieved by providing a surface roughness in the mould, thereby enabling the surface roughness to be transferred to the camouflage film during the said process.

7. A process as claimed in any of claims 4 to 6 wherein the rough surface is achieved by providing particles in the camouflage film.

8. A process as claimed in claim 7 wherein the particles comprise aluminium oxide.

9. A process as claimed in claim 7 or claim 8 wherein the particles comprise a metal.

1O.A process as claimed in any preceding claim wherein the camouflage film has a non-reflective coating.

11.A process as claimed in any preceding claim wherein the camouflage film comprises at least one of: polypropylene; polyethylene terephthalate; polybutylene terephthalate; Nylon 6; Nylon 66; butyl rubber; copolyesters; low density polyethylene; KevlarWedlarfriv) polyolefin; PTFE; and PVC.

12.A process as claimed in any preceding claim wherein the camouflage film has an anti-slip surface.

13.A process as claimed in claim 12 wherein the anti-slip surface is achieved by providing particles of aluminium oxide in the film.

14.A process as claimed in claim 12 or claim 13 wherein the anti-slip surface comprises rubber.

15.A process as claimed in any of claims 12 to 14 wherein the anti-flip surface has indentations or protrusions.

16.A process as claimed in any preceding claim wherein the camouflage film comprises phase change materials.

17.A process as claimed in any preceding claim wherein the camouflage film comprises aerogel.

18.A process as claimed in any preceding claim wherein a surface layer of the camouflage film is applied by digital printing.

19.A process as claimed in any preceding claim wherein the mouldable precursor comprises a resin.

20.A process as claimed in any preceding claim wherein the mouldable precursor comprises carbon fibre.

21.A process as claimed in any preceding claim wherein the mouldable precursor comprises a co-polyester.

22.A process substantially as described herein with reference to the accompanying drawings.

23.A camouflaged object formed by the method of any of claims I to 21.