WO1989001959A1 - Masco i - Google Patents

Abstract

A new system of armor, blast protection, and fire resistance for the protection and safety of politicians, executives, diplomats, etc., by the use of a MASCO I vehicle that will save extensive costs in production, maintenance, and fuel usage. Masco I will also serve to insure greater protection from varied forms of attack from almost any distance and at all angles. It also affords the added advantage of being able to protect any size/shape vehicle which is not currently affordable or reasonable to armor. Also, this type of car is not armored due to the increased weight incurred when using conventional armor systems.

Description

MASCO 1

Background — Field of Invention:

This invention relates to composite armor; (though actually a completely fiberglass armor) especially to armor capabilities associated with items that provide small to medium caliber (See Figure 3) protection. Therefore, it is possible to offer more effective ballistic capabilities while providing considerable cost (See Figure 1) and weight reduction (See Figure 2) and at the same time have both blast and fire retardant ability. Background — Description of Prior Art

In the world of political officials, corporate executives, law enforcement, and other people requiring protection, it is necessary to turn to the armor and ballistic composite industry to find heretofore adequate security measures that may insure one's safety in certain situations.

Each of the aforementioned groups has specific requirements based on its exposure to threatening situations.

Up to this point, there has been limited, if not restricted, availability of protection devices, systems, and products.

One type of protection implements the use of steel; at this level it is known as T-l armor. T-l is the rating of the hardness of steel. It has been found to be the best suited metal to defeat small to medium caliber (See Figure 3) weapons to date, and as far as this applicant can determine, it at best offers only moderate protection. Because of the weight constraints (it weighs about 20-30 pounds per square foot (11.25-13.5 kgs. per sq. meter) (See Figure 2)) and the difficulty of working it, it is not the best form of protection available. Therefore, use of this armor in the automotive industry until now has been a very costly and restrictive process, due to required to deliver the necessary power to handle the added weight in armor protected limousines. T-l also requires the use of special heavy-duty tires to carry the extra 6-8,000 pounds (2,700-3,600 kgs.) added to the car, the fabricating of special brackets and attaching points in anything that is armor protected thereby demanding extensive and costly labor to accomplish a minimum of protection in these vehicles. Through research and study of this type of vehicle I have learned that armor is placed only in the back doors and back fenders thereby providing minimal protection to the back seat passenger. This procedure leaves the driver and the engine/drive train very vulnerable to most forms of attack. The price of this type of armored vehicle is estimated to be in the range of 1-1.8 million dollars (See Figure 1). It is important to note that armor plated limousines offer limited heat resistance and blast protection.

A second type of ballistic protection has been the implementation of "Kevlar 29". However, this has the same cost constraints due to the fact that Kevlar 29 sells for approximately $4,000.00 per roll and achieves best ballistic protection in a soft form. Therefore, a weight problem is incurred because the material has no structural integrity and must be added to the existing metal structure. Another constraint is that the need for special equipment to use this type of product drastically increases production costs. Kevlar 29 is also seldom used as a form of ballistic protection in vehicles because it minimal protection due to the lack of covered areas in the rear doors and rear fenders. Kevlar 29 inserts do not offer any significant blast protection or fire resistance since the outside metal is not protected.

Another product is Owens-Corning*s S-2 glass which is called a ballistic glass. Also available, through Allied Fibers, is a product known as Spectra R. Both materials, though highly useful, have a common problem of very little being known about them; and of the companies aware of their existence, there remain many misunderstandings of the material's capabilities. Each product has the problem of being costly to use, therefore, most companies do not use them.. These products are used with a standard polyester resin or a vinylester resin that has a heat protection of only about 250 F (121 C) which offers minimal heat resistance or blast protection.

Also, as an alternative, the use of light and medium duty steel with plywood as a filler is a fairly common practice. This too can be very restrictive because armored cars, to date, carry the weight of a tank, which is not cost effective in the transportation field due to fuel consumption, tire wear, etc. The composite, as demonstrated by previous robbery attempts, affords neither fire nor blast resistance. Host users of ballistic products would find it desirable to lessen the weight by at least 50% and reduce the cost considerably (See Figure 1) to achieve the same, if not 90 more, effective ballistic protection. One would gain the added benefit of blast protection and fire retardantion as well as increased safety using a MASCO I vehicle.

Objects and Advantages:

I. Accordingly we claim the following as our objects and 95 advantages of the invention:

To provide extensive, if not maximum protection against small to medium caliber (See Figure 3) weapons as well as blast protection, by implementing the use of a complete MASCO I body. To provide protection to the 100driver/passenger as well as all major components of the vehicle against almost any type of attack.

XI. In addition we claim the following objects and advantages of the invention:

To reduce the cost of protection offered in the armor

105 market by the use of standard E-glass which is approximately 25% the cost of ballistic glass (Kevlar 29, S-2, Spectra R) . Using the MASCO I formula it is not required to have any special equipment for the production of products, therefore, anyone generally experienced with

110 the production and use of a standard fiberglass product has the talents or skills necessary to effectively work with such a formula due to the simplistic nature of chemicals used in the glass industry. It is not required to change the stock/supply of most fiberglass production

115 shops, therefore, it is feasible to produce ballistically capable parts from the same mold used to manufacture replacements for the metal parts — for about the cost of metal parts. The cost of MASCO 1 is about $25.00 per square foot for a 3/8 inch (.953 cm) laminate that would

120 produce about the same results as a 1/2 inch (1.27 cm) of T-l armor which costs about $50. - $55. per square foot without the necessary labor required for production. Additionally, considering the weight reduction obtained, there would be no reason for the extensive, and expensive,

125 modifications to the chassis and engine systems that are presently required to offer protection. The reduction of cost afforded using MASCO 1 would be between 50-75% of the III. In addition we claim the following objects and advantages of the invention:

130 Weight Reduction Advantages:

The resultant advantages from the reduction of weight (25% minimum reduction) would be increased gas mileage, reduction of tire and chassis wear, and the increased ability to transport the vehicle without the need of

135 special weight bearing equipment. In turn, it is feasible to envision a light assault vehicle at a later date. This also enables executives and political officials to have built a very sound and dependable^', as well as ballistically protected, sports car without losing the

140 "sports car" effect because, as it stands,, to protect such a car is almost impossible while retaining the speed and handling attributed to sports cars.

IV. In addition we claim the following objects and advantages of the invention:

145 The implementation of a MASCO I vehicle will greatly increase the safety and protection offered in armor plated ballistic vehicles. At the present time, any armor plated limousine can be defeated by the use of explosive attacks from above and below, or incendiary attacks from

150 any angle. From what this applicant can determine as a material can be above 4,000 F (2,204 C) . We have tested the material using a cutting torch and have not been able to defeat a piece of 3/8 inch (.95 cm) MASCO I material within a reasonable time period. The safety protection 155 referred to earlier in this section is due to the fact that in an accident fires that often result will have little effect on MASCO I vehicles. Therefore, the occupants of said vehicle will be better protected.

V. In addition we claim the following objects and 160 advantages of this invention:

With the use of existing armor in the event of an attack on a vehicle, typically the vehicle is considered a total loss because the repair of such a vehicle is costly due to the amount of time, money, and services required to repair

165 or replace damaged parts. In the use of a MASCO I vehicle the repair of the vehicle would be a simple task. This would be accomplished by: 1) using power tools to remove remaining shells in the vehicle; 2) grinding or cuting out the surrounding area of fiberglass and re-fusing new

170 fiberglass into place; 3) re-applying the outside Gelcoat; 4) sanding and painting according to paint manufacturer's recoaaaendations.

Readers will find further verification of all claims, objects, and advantages of the MASCO I formula of armor

175 protection through the ensuing formula and process. MASCO I Formula and Process

VI. This section is designed to describe for the reader the process and the formula needed to manufacture the MASCO I system of armor protection. The companies referenced here for supply of needed products are only a

180 recommendation. All chemicals are available through various fiberglass and chemical suppliers. The order in which this formula is listed herein is an essential part of the successful use of the formula, variations from its procedure could be hazardous to the worker and surrounding

185 area. Do not change the sequence! it would be best if lamination is done at a temperature of 59-64 F (15-18 C) .

1 Gallon (3.78 liters) Resin Solution Hetron FR 992 (P. 10-14) - (Ashland Chemicals, 6608 East 26th St., Los Angeles, CA) 190 .35 ounces (10 Grams) N,N Di ethylaniline (P. 15-16) (Reichhold Corp., Los Angeles, CA)

.945 ounces (27 Grams) 6% Cobalt Naphthenate (Atlas Chemical, Commerce St., San Diego, CA) 7 ounces (200 Grams) Antimony (III) Oxide (P. 17-18) 195 .175 ounces (5 Grams) Methyl Ethyl Ketone Peroxide Solution Hi-Point 90 (P. 19-22) (Atlas Chemicals, Commerce St., San Diego, CA)

1.5 Quarts (1.425 liters) Gelcoat (Ferro-FRP Coatings, 5309 South District Blvd., Los Angeles, CA)

200 ι. Take base Hetron FR 992 resin solution and add N,N Di ethylaniline; fold until completely mixed.

2. Blend in Cobalt Naphthenate (6%) until resin solution blends to a purple cast. Do not leave chunks of Cobalt floating. Cobalt will appear to be a black film floating

205 on surface.

3. Blend in Antimony (III) Oxide. The resin should take on a pink color. Blend until completely smooth with uniform consistency. Do not leave dry (III) Oxide floating.

210 4. Divide resin into two containers of equal parts.

5. Next we need to move to the mold. The mold should already be waxed with a mold release wax (which is common in the industry) .

6. Take 1 quart (.95 liters) Gelcoat (this is a common 215 plastic coating used to give a uniform and smooth outside surface. It has the same basic structure as a resin and is sprayed/brushed into the mold.) Add 1 quart (.95 liters) MASCO I resin, blend until it reaches an even consistency. Mix in .07 ounces (2 grams) catalyst 220 (Hi-Point 90)for each quart of resin and .07 ounces (2 grams) catalyst(Hi-Point 90) for each quart of Gelcoat. (This is to be sprayed using a pressure pot or brushed. lacquer thinner of a higher grade depending on air pressure. NOTE: Air pressure used is dependent on shop 225 conditions and equipment.)

7. Allow material to cure in mold for approximately 2 hours. Gelcoat should be hard but tacky to allow adhesion of the resin and fiberglass reinforcement.

8. At this time, one needs approximately 10 pieces of 230 pre-cut bi-directional ATex pieces. (See Figure 4) .

9. Take 1/2 gallon (.475 liters) resin, blend in .0875 ounces (2.5 grams) catalyst per 1/2 gallon (.475 liters).

10. With the use of all natural bristle brushes, apply thick but even coat of MASCO I resin, then add 1 layer

235 ATex bi-directional fiberglass material.

11. Apply another coat of MASCO I resin making sure to use enough resin to facilitate saturation of fiberglass material.

12. By use of various sizes and shapes of bubble chasers, 240 (Figure 5; this is a commonly used piece of equipment in the fiberglass industry) roll out all air that forms pockets in the fiberglass. Air bubbles will form weak spots if not controlled.

13. Repeat steps 10 through 12 making sure to observe ²⁴⁵ each step until all 10 layers of ATex are used. (Mix more resin according to above stated directions if needed.)

14. Mix the single quart (.95 liters) of resin remaining from original gallon (3.8 liters) and 1/2 quart (.475 liters) of Gelcoat. Brush/spray this on the fiberglass

250 laminated part and allow to dry for approximately 2 hours at 70 F (21 C) . If possible, best temperature to facilitate drying is 75-81 . F (24-27 C) (CAUTION - This lamination due to chemical process achieves extremely high temperatures — DO NOT TOUCH) .

Claims

255 we claim the masco I fiberglass armor system is the only system that uses a vinylester base resin solution to fuse atex fiberglass material together for ballistic armor that is not only light weight, structurally sound, fire, chemical, solvent, base, and blast resistant, but simple

260 to make, all that is required to produce masco I is one gallon 3.78 liters hetron fr 992 vinylester resin solution, .35 ounces 10 grams n,n -dimethylaniline thoroughly mixed in resin solution, .945 ounces 27 grams cobalt naphthenate 6%, thoroughly mixed in resin solution,

2657 ounces 200 grams antimony III oxide thoroughly mixed in resin solution, .175 ounces 5 grams mek peroxide thoroughly mixed just prior to application, the amount of chemicals combined in resin are activated to cause high heat to resemble a ceramic product that will protect to a

270 ballistic threat level of III a, also, in the fusion of this material the structural integrity is increased greatly to resemble the strength properties of steel to deter blast attacks with one added Advantage, that being, that it is more heat resistant as well as more than 40%

275 lighter than that of steel as well as being a minimum of 50% more cost effective and much easier to work with.