WO2014197084A2

WO2014197084A2 - Ballistic shield

Info

Publication number: WO2014197084A2
Application number: PCT/US2014/027906
Authority: WO
Inventors: Scott R. WHITAKER
Original assignee: Whitaker Scott R
Priority date: 2013-03-15
Filing date: 2014-03-14
Publication date: 2014-12-11
Also published as: MX2015012924A; WO2014197084A3; EP2972061B1; US10302401B2; CN105121995B; CA2906928C; CA2906928A1; CN105121995A; US20140260937A1; EP2972061A2

Abstract

A flexible and malleable ballistic panel comprising a laminate of a plurality of ballistic- resistant layers comprising ballistic material, each the ballistic-resistant layer having a first inner surface and second outer surface, and a plurality of bonding layers comprising butyl rubber, each bonding layer having a first inner surface and second outer surface, at least one of the bonding layer being an inner-most layer of the laminate, and each ballistic-resistant layer having a bonding layer therebetween.

Description

BALLISTIC SHIELD

FIELD OF THE INVENTION

[0001] The present invention relates to a ballistic panel.

BACKGROUND OF THE INVENTION

[0002] Bullet-proofing materials are known and have been used to protect vehicles, facilities, equipment and personnel. Armor for resisting gunfire or explosions is very difficult, heavy and takes a lot of time and planning to install. Soldiers and security officers in the field often find themselves utilizing stock, civilian vehicles or inadequately armored vehicles offering little to no protection. Most armoring has to be built into the vehicle as it is produced at the factory or weeks of adapting armour by major disassembly and reassembly.

[0003] A similar problem exists in architectual situations. Because of the complexity and time involved, armoring is often not installed. This invention allows anyone with minimal mechanical skills to apply a bullet resistant material very quickly and easily. A stock vehicle (including a new, used, leased or rented one) can receive armoring into the doors, floor, side panels and roof within hours and without highly skilled personnel.

[0004] US Patent 5,531,500, issued to Podvin, describes bullet-proofing panel for attachment to the exterior door surfaces of a police cruiser or the like, the panel having an outer polymeric skin having a contour corresponding to the contour of the sheet metal of the vehicle's doors. The polymeric skin member when affixed to the outer sheet metal panels of the vehicle's doors defines a predetermined space or pocket therebetween which contains a barrier member, preferably a woven KEVLAR® material, capable of stopping bullets from practically all handguns. Because the outer polymeric skin can be shaped to follow the contours of the original vehicle and painted to match, the bullet-proof panel does not detract from the overall ornamental appearance of the vehicle.

SUMMARY OF THE INVENTION

[0005] The present invention provides a flexible or malleable ballistic shield or panel that includes one or more layers of butyl rubber and one or more layers of a ballistic fabric. [0006] The present invention utilizes thin, alternating layers of certain aramid and ultra- high-molecular-weight polyethylene (UHMWPE) fibers, or other ballistic fabric, and a tenacious bonding agent that can include a synthetic viscoelastic polymer, such as polyisobutene or butyl rubber. When the flexible or malleable ballistic shield or panel is applied to a substrate (an automobile or vehicle body panels, wood, construction wall or surface, etc.), the resistance of the substrate to projectile penetration is significantly and dramatically increases.

[0007] Aramid fabric is known to be used in bullet proofing when it has a backing material (i.e., a human body), but have not proven to be effective inside of a vehicle or any structure, presumably because the fabric has not been fastened adequately to the substrate to keep the ballistic fabric from moving and therefore capturing the projectile. The bonding material must insure fast and secure adhesion of the panel or shield to the inside surface of the substrate or structure (the inside surface being that surface of the substrate or structure that is on the human-occupancy side). The amount and thickness of the ballistic fiber material alone that is needed to stop a projectile is believed to be 3 to 10 times the amount of such ballistic fiber material when comprised in the ballistic shield or panel of the present invention.

[0008] The adhesion, cohesion and elasticity of the bonding material that attaches to the substrate and to the alternating layers of ballistic fabric significantly contributes to the "catching" of the projectile.

[0009] The present invention provides a flexible and adhesive ballistic shield. The ballistic shield can include at least base layer of a butyl rubber and at least a first layer of a ballistic material disposed on an outer surface of the base layer of butyl rubber. Additional layers of ballistic material can be applied with layers of butyl rubber disposed therebetween. The ballistic shield can include at least two layers of the butyl rubber, including the base layer and a second layer, with the first layer of ballistic material disposed between the at least two layers of the butyl rubber, and including a second layer of ballistic material disposed on an outer surface of the second layer of butyl rubber. The ballistic shield can further including one or more additional layers of butyl rubber, and one or more additional layers of ballistic material, disposed between successive layers of the butyl rubber. The ballistic shield can further including a handling fabric layer disposed on an outer surface of an outermost layer of butyl rubber. The ballistic shield can further including a releasable protective layer on an inner-most surface of the base layer of butyl rubber, to protect the inner-most surface of the base layer of butyl rubber from particulate contamination prior to use of the flexible ballistic shield. The ballistic material can be is a ballistic fabric, including a ballistic fabric made from ballistic fibers selected from the group consisting of aramid fibers and ultra-high-molecular-weight polyethylene (UHMWPE) fibers, and including Kevlar®, Dyneema®, and other aramid fiber. The ballistic fabric provide flexibility and improved handling and use of the flexible ballistic shield.

[0010] The present invention also provides a method of applying a bullet-proof ballistic shield to the inside surface of a resilient or rigid wall or structure, comprising the steps of: (i) providing a ballistic shield or a flexible ballistic shield according to any embodiment of the invention; (ii) attaching an inside surface of the base layer of butyl rubber of the ballistic shield or flexible ballistic shield to an inside surface of a wall or structure; and (iii) applying pressure to the outer surface of the ballistic shield sufficient to adhere the ballistic shield to the wall or structure surface. Heat can also be applied to improve adherence of the butyl rubber layer to the wall or structure, and penetration of the butyl rubber into the ballistic fabrics.

[0011] The present invention also provides a flexible ballistic panel comprising a laminate of a plurality of ballistic-resistant layers comprising ballistic material, each the ballistic- resistant layers having a first inner surface and second outer surface, and a plurality of bonding layers comprising butyl rubber, each bonding layer having a first inner surface and second outer surface, at least one of the bonding layers being an inner-most layer of the laminate, and each ballistic-resistant layer having a bonding layer therebetween. The ballistic material can be a woven ballistic material. The bonding layer typically consists essentially of butyl rubber. An outmost layer is a fabric, including a ballistic fabric or a non-ballistic handling fabric.

[0012] The present invention also provides a method of making a ballistic panel comprising the steps of: a. providing a plurality of ballistic-resistant layers comprising ballistic material, b. providing a plurality of bonding layers comprising butyl rubber, c. forming a stack comprising alternating layers of the ballistic-resistant layers and the bonding layers, d. and applying optional heat and pressure to the stack to and adhere the plurality of bonding layers to the plurality of ballistic-resistant layers. An end-most bonding layer can be covered by a release layer material for handling purposes.

[0013] The present invention further includes a method of ballisticly-reinforcing a substrate on a human-occupancy side of the substrate, comprising the steps of: a) providing a substrate having an inner surface that faces a defined human-occupancy side; b) providing a flexible ballistic shield according to any embodiment of the present invention; c) attaching adhesively the base layer of the flexible ballistic shield to the inner surface of the substrate to provided a reinforced substrate, wherein the adhesive attachment of the flexible ballistic shield improves the resistance to penetration of the reinforced substrate by a ballistic projectile.

[0014] In an example of the invention, a laminated ballistic panel applied to a 20 gauge- thick steel panel successfully stopped 9 mm bullets with complete success, with no penetration. In another example, a laminated ballistic panel applied to a 20 gauge-thick steel panel stopped a 45 caliber bullet with no penetration.

BRIEF DESCRIPTION OF THE FIGURES

[0015] Figure 1 shows a ballistic panel having an innermost bonding layer and a ballistic- resistant layer.

[0016] Figure 2 shows a ballistic panel having two bonding layers including an innermost bonding layer, and two ballistic-resistant layers between the bonding layers.

[0017] Figure 2 shows a ballistic panel having two bonding layers including an innermost bonding layer, a ballistic-resistant layers between the bonding layers, and an outermost handling fabric layer.

[0018] Figure 4 shows a ballistic panel having three bonding layers including an innermost bonding layer, and three ballistic-resistant layers between the bonding layers.

[0019] Figure 5 shows a ballistic panel having four bonding layers including an innermost bonding layer, and four ballistic-resistant layers between the bonding layers.

[0020] Figure 6 shows a ballistic panel having five bonding layers including an innermost bonding layer, and five ballistic-resistant layers between the bonding layers.

[0021] Figure 7 shows the ballistic panel of Figure 2 bonded to the inner surface of a substrate.

[0022] Figures 8A- 33b show test results for various ballistic panels made by alternating layers of a butyl rubber and ballistic fabrics, adhered to steel plating, fired from a distance of 30 feet using different caliper firearms.

[0023] Figures 8 A and 8B show a 20 gauge steel panel shot with both 9 mm projectiles and 38 caliper projectiles. [0024] Figures 9A and 9B show a 20 gauge steel panel shot with both 45 caliper projectile and 38 caliper projectiles.

[0025] Figures 10A through IOC show a 20 gauge steel panel with a layer of butyl and

PE UD Fabric 170 shot with 9 mm projectiles and 38 caliper projectiles.

[0026] Figures 11A through 1 IE show a 20 gauge steel panel two layers of butyl and PE

UD Fabric 170 shot with both 9 mm and 38 caliper projectiles.

[0027] Figures 12A through 12D show a 20 gauge steel panel with three layers of butyl and PE UD Fabric 170 shot with both 9 mm and 38 caliper projectiles.

[0028] Figures 13A and 13B show a 20 gauge steel panel a layer of butyl and PE UD

Fabric 140 shot with 9 mm projectiles.

[0029] Figures 14A and 14B shows a 20 gauge steel panel with two layers of butyl and

PE UD Fabric 140 shot with 9 mm projectiles.

[0030] Figures 15A and 15B show a 20 gauge steel panel with three layers of butyl and

PE UD Fabric 140 shot with 9 mm projectiles.

[0031] Figures 16A and 16B show a 20 gauge steel panel with one layer of butyl and

Kevlar® 29 Denier 1500 shot with 9 mm projectiles.

[0032] Figures 17A and 17B show a 20 gauge steel panel with two layers of butyl and

Kevlar® 29 Denier 1500 shot with 9 mm projectiles.

[0033] Figures 18A and 18B show a 20 gauge steel panel with three layers of butyl and

Kevlar® 29 Denier 1500 shot with 9 mm projectiles.

[0034] Figures 19A and 19B show a 20 gauge steel panel with one layer of butyl and

Kevlar® 29 Denier 3000 shot with 9 mm projectiles.

[0035] Figures 20A and 20B show a 20 gauge steel panel with two layers of butyl and

Kevlar® 29 Denier 3000 shot with 9 mm projectiles.

[0036] Figures 21 A and 21B show a 20 gauge steel panel with three layers of butyl and

Kevlar® 29 Denier 3000 shot with 9 mm projectiles.

[0037] Figures 22A and 22B show a 20 gauge steel panel with three layers of butyl and

Kevlar® 29 Denier 3000 shot with 45 caliper projectiles.

[0038] Figures 23A and 23B show a 20 gauge steel panel with four layers of butyl and

Kevlar® 29 Denier 3000 shot with 45 caliper projectiles. [0039] Figures 24A and 24B show a 20 gauge steel panel with five layers of butyl and

Kevlar® 29 Denier 3000 shot with 45 caliper projectiles.

[0040] Figures 25A and 25B show a 20 gauge steel panel with one layer of butyl and

Dyneema® shot with 9 mm projectiles.

[0041] Figures 26A and 26B show a 20 gauge steel panel with two layers of butyl and

Dyneema® shot with 9 mm projectiles.

[0042] Figures 27A through 27C show a 20 gauge steel panel with three layers of butyl and Dyneema® shot with 9 mm projectiles.

[0043] Figures 28A and 28B show a 20 gauge steel panel with three layers of butyl and

Dyneema® shot with 45 caliper projectiles.

[0044] Figures 29A and 29B show a 20 gauge steel panel with four layers of butyl and

Dyneema® shot with 45 caliper projectiles.

[0045] Figures 30A and 30B show a 20 gauge steel panel with five layers of butyl and

Dyneema® shot with 45 caliper projectiles.

[0046] Figures 31A and 3 IB show a 20 gauge steel panel with one layer of butyl and PE

UD 35 fabric shot with 9 mm projectiles.

[0047] Figures 32A and 32B show a 20 gauge steel panel with two layers of butyl and PE

UD 35 shot with 9 mm projectiles.

[0048] Figures 33A and 33B show a 20 gauge steel panel with three layers of butyl and

PE UD 35 shot with 9 mm projectiles.

DETAILED DESCRIPTION OF THE INVENTION

[0049] There is well established wide spread use of peel and stick sound deadener by automotive shops and do-it-yourself (DIY) consumers that suggest to the inventor the feasibility of a similarly applied product having armor and ballistic materials.

[0050] A small projectile at a high velocity is one of the most difficult to stop.

Bulletproof vests protect human bodies from the penetration of bullets, using ballistic fabrics of woven material that can catch the projectile. A much smaller projectile, or a sharpened object, can penetrate such vests because the tip can penetrate between the woven fibers. A bulletproof vest does function by using the human body behind the vest to absorb the blunt force trauma of the bullet, because there the ballistic fabric itself cannot oppose the force of the projectile, and the ballistic fabric itself is forced out of the path of the projectile unless supported or provided with structural integrity.

[0051] The bonding material used to bond together the aramid fabric layers, and to adhere the ballistic shield panels to the substrate significantly impacts the ballistic performance. The alternating layers of ballistic fabric and butyl rubber are tenaciously adhered to the back-side (the side opposite the side of projectile penetration) of the substrate through the butyl bonding material, thereby using the structural integrity of the substrate itself to hold the ballistic fabrics in place and in lamination, even though not "backing up" the shield.

[0052] The bonding material is selected from butyl rubber and polyisobutylene. The bonding materials provide adhesion, cohesion, viscosity, density, elasticity, formability and deformability, at a minimal thickness and weight, when layered with the ballistic layers. Typical bonding layer thickness is from about 0.5 mm and thicker, including at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, and at least about 5 mm, and up to about 10 mm, including up to about 8 mm, up to about 6 mm, up to about 1 mm, and up to about 4 mm.

[0053] Figure 1 shows a ballistic panel 10 having a single ballistic layer, including an innermost layer of butyl rubber 11 and a layer of ballistic fabric 15. Figure 2 shows a ballistic panel 20 having two ballistic layers, including an innermost layer of butyl rubber 21 and a second butyl layer 22 sandwiched between two ballistic fabric layers 25 and 26. Figure 3 shows a ballistic panel 30 having a single ballistic layer 35 and a handling fabric layer 8, with an innermost layer of butyl rubber 31 and a second butyl layer 32 sandwiched between the ballistic fabric layer 35 and the handling fabric layer 8, which can be a non-ballistic fabric. Figures 4-6 show ballistic panel laminates have three, four, and five layers each of the ballistic fabrics and butyl rubber.

[0054] Figure 7 shows the ballistic panel 70 of Figure 2 having two ballistic layers 75 and 76, which is formed into a ballistic shield 80 having an innermost butyl layer 71 that adheres to the inside surface 86 (opposite the expected projectile penetration side) of the substrate 84.

[0055] The alternating layers of ballistic materials can be selected of any material that can be bonded together in a laminate by the bonding layers, and can include sheets of metals including steel, stainless steel, aluminum, and others, sheets of carbon fiber fabrics and materials, and ballistic fabrics including aramid fabrics including Kevlar® and Dyneema®, and others, and high impact plastic layers, including ultra-high-molecular-weight polyethylene (UHMWPE, UHMW), and UHMWPE containing carbon nanotubes, and combinations thereof.

[0056] Another feature of the claimed invention is a flexible and malleable ballistic panel that can be formed to any panel shape for adhesion to a substrate of a wide variety of shapes. The adhesive, cohesive and elastic qualities of the bonding material provide flexibility to the panel, and an effective adhesive surface that adheres tenaciously to metal, wood and other substrate surfaces. Use of release layers produces an effective "peel and stick", quick and easy application, and a highly effective projectile resistant barrier. Non-limiting examples of release layers are films of polyolefin, including polyethylene.

[0057] The ballistic panel can be made by forming a stack of alternating layers of the ballistic material and the bonding layer, typically butyl rubber, and applying pressure to the stack transverse to the stack surface to cause the bonding layers to adhere by penetration of the bonding material into the fabric and threads ballistic material. The pressure can be applied to speed and aid the depth of penetration, typically at least about 1 psi. Heat can also be applied, before or during the pressure, to further aid penetration. Typically butyl rubber will not run unless dissolved. When formed, at least one of the outer-most layers is butyl rubber. For manufacture and transport of the panels, a release layer of a plastic film placed over the outermost butyl layer prevents dust, dirt and other contaminants from adhering to the butyl surface, and from the tackiness of the butyl rubber from contacting hands, packaging and other surfaces. The process can be batch or continuous stacking, heating pressurizing and packaging.

[0058] When applying the ballistic panel to the surface of a substrate, carefully cleaning the surface of the substrate of dirt, debris, and liquids, and in particular removing any traces of oily material, improves adherence of the butyl rubber panels, and thus the ballistic performance of panels. Surface preparation of the substrate includes cleaning, degreasing, oil stripping, and roughing of the surface including sanding.

EXAMPLES

[0059] Ballistic panels were made by alternating layers of a butyl rubber (also containing carbon black, which has no beneficial impact on the bonding performance) and ballistic fabrics. The ballistic fabrics included Kevlar® and Dyneema®, and UD Fabric of various denier (fabric weights). The panels were adhered to 20 gauge steel panels (6 inch x 9 inch) with heat and pressure treatment, and fixed mounted. Bullets of various caliber and power were fired from a distance of 30 feet at the mounted panels, including 9 mm, 38 caliper, and 45 caliper firearms, and the results noted.

[0060] Figures 8A-33B show the conditions and results of the tests.

[0061] Figure 8A shows the front surface of a 20 gauge steel panel shot from 30 feet with both 9 mm projectiles and 38 caliper projectiles into the front surface.

[0062] Figure 8B shows the back surface of the 20 gauge steel panel of Figure 8A.

[0063] Figure 9A shows the front surface of a 20 gauge steel panel shot from 30 feet with both 45 caliper projectile and 38 caliper projectiles passing through the front surface.

[0064] Figure 9B shows the back surface of the 20 gauge steel panel of Figure 9A.

[0065] Figure 10A shows the front surface of a test panel, a 6 inch x 9 inch 20 steel panel, with its back covered with one (1) layer of butyl and one (1) layer of PE UD Fabric 170, which is a rayon/polyester with a density of 170 gm/m² and a yarn count of 32-43, made by Qianglun (China). The panel was shot from 30 feet with both 9 mm projectile(s) and 38 caliper projectile(s) into the front surface.

[0066] Figures 10B and I OC show the back surface of the 20 gauge steel panel of Figure

10A. The back layer appears to show a failure of adhesion, with delamination of the fabric. The projectiles appear to show a can-opening effect on the metal plate that did not cut the fabric, but the fabric failed in a straight-across, perfectly straight horizontal line.

[0067] Figure 11A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with two (2) layers of butyl and two (2) layers of PE UD Fabric 170. The panel was shot from 30 feet with both 9 mm projectile(s) and 38 caliper projectile(s) into the front surface.

[0068] Figures 1 IB, 1 1C, 1 ID and 1 IE show the back surface of the 20 gauge steel panel of Figure 1 1 A. The back layer appears to show delamination of the fabric. The projectiles appear to show a can-opening effect on the metal plate that ripped the fabric, but the fabric had no horizontal tearing.

[0069] Figure 12A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with three (3) layers of butyl and three (3) layers of PE UD Fabric 170. The panel was shot from 30 feet with both 9 mm projectile(s) and 38 caliper projectile(s) into the front surface.

[0070] Figures 12B, 12C, and 12D show the back surface of the 20 gauge steel panel of

Figure 12A. The back layer appears to show delamination of the fabric with horizontal tearing. The projectiles appear to show a can-opening effect on the metal plate.

[0071] Figure 13A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with one (1) layer of butyl and one (1) layer of PE UD Fabric 140, which is a rayon/polyester with a density of 140 gm/m and a yarn count of 32-42, made by Qianglun (China). The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0072] Figure 13B shows the back surface of the 20 gauge steel panel of Figure 13A.

The back layer appears to show the start of delamination of the fabric with a perfect hole in the fabric.

[0073] Figure 14A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with two (2) layers of butyl and two (2) layers of PE UD Fabric

140. The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0074] Figure 14B shows the back surface of the 20 gauge steel panel of Figure 14 A.

[0075] Figure 15A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with three (3) layers of butyl and three (3) layers of PE UD Fabric 140. The panel was shot from 30 feet with 9 mm projectile(s) into the front surface. [0076] Figure 15B shows the back surface of the 20 gauge steel panel of Figure 15 A.

The back layer appears to show a can-opening effect on the metal plate, and the start of delamination of the fabric, but not penetration of the third layer. Figure 14C shows that the bullet dropped out of the bottom of the panel.

[0077] Figure 16A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with one (1) layer of butyl and one (1) layer of Kevlar® 29 Denier 1500, an aramid fabric with a density of 200 gm/m . This fabric adhered to the butyl layer very well. The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0078] Figure 16B shows the back surface of the 20 gauge steel panel of Figure 16A.

The back layer appears to show a can-opening effect on the metal plate, and the bullet penetrating through every layer, with windowing of the fabric, which is the separation between the threads of the woven fabric that allows the bullet to pass through

[0079] Figure 17A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with two (2) layers of butyl and two (2) layers of Kevlar® 29 Denier 1500. The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0080] Figure 17B shows the back surface of the 20 gauge steel panel of Figure 17A.

The back layer appears to show a can-opening effect on the metal plate, and the bullet penetrating through every layer, with windowing of the fabric.

[0081] Figure 18A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back c8overed with three (3) layers of butyl and three (3) layers of Kevlar® 29 Denier 1500. The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0082] Figure 18B shows the back surface of the 20 gauge steel panel of Figure 18A.

[0083] Figure 19A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with one (1) layer of butyl and one (1) layer of Kevlar® 29 Denier 3000. This fabric adhered to the butyl layer very well. The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[0084] Figure 19B shows the back surface of the 20 gauge steel panel of Figure 19A.

The back layer appears to show a can-opening effect on the metal plate, and the bullet penetrating through every layer, with windowing of the fabric, and bubbling of the adhesive (butyl).

[0085] Figure 20A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with two (2) layers of butyl and two (2) layers of Kevlar® 29 Denier 3000. The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0086] Figure 20B shows the back surface of the 20 gauge steel panel of Figure 20A.

The back layer appears to show a can-opening effect on the metal plate, but the bullet failed to penetrate any of the layers, with some small mushrooming-type separation between the fabric and the butyl. The result was deemed a complete success.

[0087] Figure 21 A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with three (3) layers of butyl and three (3) layers of Kevlar® 29 Denier 3000. The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0088] Figure 21 B shows the back surface of the 20 gauge steel panel of Figure 21 A.

The back layer does not show a can-opening effect on the metal plate. The bullet hit in one place, made a hairline crack to start can opening, but did not penetrate. There was no mushrooming-type effect on the fabric of the butyl. The result was a complete success.

[0089] Figure 22 A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with three (3) layers of butyl and three (3) layers of Kevlar® 29 Denier 3000. The panel was shot from 30 feet with 45 caliper projectile(s) into the front surface.

[0090] Figure 22B shows the back surface of the 20 gauge steel panel of Figure 22A.

The bullets penetrated all layers. There was windowing of the fabric. [0091] Figure 23A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with four (4) layers of butyl and four (4) layers of Kevlar® 29 Denier 3000. The panel was shot from 30 feet with 45 caliper projectile(s) into the front surface.

[0092] Figure 23B shows the back surface of the 20 gauge steel panel of Figure 23A.

The bullets were completely stopped. There was mushrooming-type effect on the back, with separation of the layers material due to oils on the metal panel.

[0093] Figure 24A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with five (5) layers of butyl and five (5) layers of Kevlar® 29 Denier 3000. The panel was shot from 30 feet with 45 caliper projectile(s) into the front surface.

[0094] Figure 24B shows the back surface of the 20 gauge steel panel of Figure 24A.

The bullets were completely stopped.

[0095] Figure 25A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with one (1) layer of butyl and one (1) layer of Dyneema® having a density of 290 gm/m². This fabric adhered to the butyl layer very well. The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[0096] Figure 25B shows the back surface of the 20 gauge steel panel of Figure 25A.

The back layer appears to show a can-opening effect on the metal plate, and the bullet penetrating through every layer, with delamination of the fabric, and windowing.

[0097] Figure 26A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with two (2) layers of butyl and two (2) layers of Dyneema® having a density of 290 gm/m . The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[0098] Figure 26B shows the back surface of the 20 gauge steel panel of Figure 26A.

The back layer appears to show a can-opening effect on the metal plate, and the bullet penetrating through every layer, with hardly any delamination of the fabric, and windowing of the fabric with some broken threads in the weave. [0099] Figure 27A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with three (3) layers of butyl and three (3) layers of Dyneema® having a density of 290 gm/m². The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[00100] Figures 27B and 27C show the back surface of the 20 gauge steel panel of Figure 27A. The back layer appears to show a can-opening effect on the metal plate, though the bullet did not penetrate through any layer of the fabric. There was no delamination, though there was a mushrooming effect where the bullet stopped.

[00101] Figure 28A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with three (3) layers of butyl and three (3) layers of Dyneema® having a density of 290 gm/m . The panel was shot from 30 feet with 45 caliper projectile(s) into front surface.

[00102] Figure 28B shows the back surface of the 20 gauge steel panel of Figure 28A. The back layer appears to show a can-opening effect on the metal plate, with the bullets penetrating through all layers of the fabric. There were broken fibers.

[00103] Figure 29A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with four (4) layers of butyl and four (4) layers of Dyneema® having a density of 290 gm/m . The panel was shot from 30 feet with 45 caliper projectile(s) into front surface.

[00104] Figure 29B shows the back surface of the 20 gauge steel panel of Figure 29A. The bullets penetrated through all layers of the fabric. There were no broken fibers, though a windowing effect.

[00105] Figure 30A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with five (5) layers of butyl and five (5) layers of Dyneema® having a density of 290 gm/m . The panel was shot from 30 feet with 45 caliper projectile(s) into front surface.

[00106] Figure 30B shows the back surface of the 20 gauge steel panel of Figure 30A. The bullets penetrated through all layers of the fabric. There was a windowing effect. [00107] Figure 31 A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with one (1) layer of butyl and one (1) layer of PE UD 135 fabric under the brand "H+T", with a density of 135 gm/m². The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[00108] Figure 3 IB shows the back surface of the 20 gauge steel panel of Figure 31 A. The back layer appears to show a can-opening effect on the metal plate, and the bullet penetrating through every layer, with separation of the fabric layers, with strands still attached to the butyl layer.

[00109] Figure 32A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with two (2) layers of butyl and two (2) layers of PE UD 135. The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[00110] Figure 32B shows the back surface of the 20 gauge steel panel of Figure 32A. The back layer appears to show a can-opening effect on the metal plate, and the bullet penetrating through every layer, with delamination.

[00111] Figure 33 A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its back covered with three (3) layers of butyl and three (3) layers of PE UD 135. The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[00112] Figure 33B shows the back surface of the 20 gauge steel panel of Figure 33A. The back layer showed delamination and poor adhesion with this sample, with the bullets penetrating through every layer. The fabric separated from the butyl.

Claims

I claim:

1. A ballistic shield comprising at least base layer of a butyl rubber and at least a first layer of a ballistic material disposed on an outer surface of the base layer of butyl rubber.

2. The ballistic shield according to Claim 1 including at least two layers of the butyl rubber, including the base layer and a second layer, with the first layer of ballistic material disposed between the at least two layers of the butyl rubber, and including a second layer of ballistic material disposed on an outer surface of the second layer of butyl rubber

3. The ballistic shield according to Claim 2 further including one or more additional layers of butyl rubber, and one or more additional layers of ballistic material, disposed between successive layers of the butyl rubber.

4. The ballistic shield according to any of Claims 1 -3, further including a handling fabric layer disposed on an outer surface of an outermost layer of butyl rubber.

5. The ballistic shield according to any of Claims 1-4, further including a releasable protective layer on an inner-most surface of the base layer of butyl rubber, to protect the innermost surface of the base layer of butyl rubber from particulate contamination prior to use of the flexible ballistic shield.

6. The ballistic shield according to any of Claims 1-5 wherein the ballistic material is a ballistic fabric.

7. The ballistic shield according to Claim 6 wherein the ballistic fabric is made from ballistic fibers selected from the group consisting of aramid fibers and ultra-high-molecular- weight polyethylene (UHMWPE) fibers.

8. The ballistic shield according to Claim 7 wherein the ballistic fabric or fiber is selected from the group consisting of Kevlar®, Dyneema®, and aramid fiber.

9. The ballistic shield according to any of Claims 6-8 wherein the ballistic shield is a flexible ballistic shield.

10. A method of applying a bullet-proof ballistic shield to the inside surface if a resilient wall or structure, comprising the steps of:

(i) providing a ballistic shield according to any of Claims 1-9;

(ii) attaching an inside surface of the base layer of butyl rubber of the ballistic shield to an inside surface of a wall or structure; and

(iii) applying pressure to the outer surface of the ballistic shield sufficient to adhere the flexible ballistic shield to the inside surface of the wall or structure.

1 1. The method according to Claim 10 wherein prior to the steps (ii) of attaching, the inside surface of the wall or structure is cleaned of dirt, dust, or other foreign particulate matter including oily material.

12. The method according to any of Claims 10 and 1 1 wherein heat is applied to the applied ballistic shield prior to the step (iii) of applying pressure, to improve adhesion of the base layer of butyl rubber to the wall, and the penetration of butyl rubber material from the layers of butyl rubber layers into the layers of the ballistic fabric.

13. A flexible ballistic panel comprising a laminate of a plurality of ballistic-resistant layers comprising ballistic material, each the ballistic-resistant layers having a first inner surface and second outer surface, and a plurality of bonding layers comprising butyl rubber, each bonding layer having a first inner surface and second outer surface, at least one of the bonding layer being an inner-most layer of the laminate, and each ballistic-resistant layer having a bonding layer therebetween.

14. The flexible ballistic panel according to Claim 13 wherein the ballistic material comprises a woven ballistic material.

15. The flexible ballistic panel according to Claim 13 wherein the bonding layer consists essentially of butyl rubber.

16. The flexible ballistic panel according to any of Claims 13-15 wherein the outermost layer is a fabric material.

17. The flexible ballistic panel according to any of Claims 13-16 wherein the ballistic material is a fabric material is selected from the group consisting of nylon, aramid, cotton, or blends thereof.

18. A method of making a ballistic panel comprising the steps of:

a. providing a plurality of ballistic-resistant layers comprising ballistic material, b. providing a plurality of bonding layers comprising butyl rubber,

c. forming a stack comprising alternating layers of the ballistic-resistant layers and the bonding layers, and

d. applying pressure to the stack to and adhere the plurality of bonding layers to the plurality of ballistic-resistant layers.

19. The method according to Claim 18 wherein an end-most layer of the stack of the ballistic-resistant layers and the bonding layers is one of the bonding layers, and a release layer material is disposed on an outermost surface of the end-most layer.

20. The method according to Claim 18 wherein at least 1 psi pressure is applied to the stack.

21. The method according to Claim 18 further including applying heat to the stack before or while applying pressure.

22. A method of ballisticly-reinforcing a substrate on a human-occupancy side of the substrate, comprising the steps of:

a) providing a substrate having an inner surface that faces a defined human-occupancy side; b) providing a flexible ballistic shield selected from the group consisting of the ballistic shield of any of Claims 1-9 and the flexible ballistic shield of any of Claims 13-17;

c) attaching adhesively the base layer of the ballistic shield to the inner surface of the substrate to provided a reinforced substrate,

wherein the adhesive attachment of the ballistic shield improves the resistance to penetration of the reinforced substrate by a ballistic projectile.