WO2017049274A1

WO2017049274A1 - Flexible adhesive ballistic shield

Info

Publication number: WO2017049274A1
Application number: PCT/US2016/052449
Authority: WO
Inventors: Scott R. WHITAKER
Original assignee: Whitaker Scott R
Priority date: 2015-09-17
Filing date: 2016-09-19
Publication date: 2017-03-23

Abstract

A flexible and malleable ballistic panel having an adhesive surface for bonding the ballistic shield to a substrate, the ballistic shield including 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 bonding butyl rubber material, 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. The base layer of the 'ballistic shield is attached to the- inner surface of the substrate to provide a reinforced substrate that improves the resistance to penetration of the reinforced substrate by a ballistic projectile.

Description

FLEXIBLE ADHESIVE 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 armor by major disassembly and reassembly.

[0003] A similar problem exists in architectural 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 (and malleable) and adhesive ballistic shield or panel that includes one or more, and preferably a plurality of, layers of flexible, taskified rubber material, and one or more, and preferably a plurality of, layers of a ballistic fabric, positioned between layers of the flexible, taskified rubber material.

[0006] The present invention utilizes thin, alternating layers of certain aramid and ultra- high-molecuiar-weight polyethylene (UHMWPE) fibers, or other ballistic fabric, and of a tenacious bonding agent that can include a synthetic viscoelastie polymer, which is termed a bonding rubber material. The bonding rubber material can include either a butyl rubber comprising polyisobutene or a copolymer of i&obutylene and tsoprene, or an acrylic rubber. When the flexible and malleable adhesive ballistic shield or panel is applied by bonding or adhesion to a surface of a substrate, and typically a rigid or inflexible substrate, such as an automobile or vehicle body panel, wood, a construction wall or surface, etc., the resistance of the substrate to projectile penetration is significantly and dramatically increased.

[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 wall or other substrate of a vehicle or a construction structure, including a vehicle side wall or any type of construction substrate or structure, presumably because the ballistic fabric has not been fastened adequately to the substrate or structure to keep the ballistic fabric from moving, and therefore limiting its ability to capture the projectile. The bonding rubber material provides fast and secure adhesion of the ballistic panel or shield to me 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 (mat is, without the alternating layers of the flexible, tackified rubber) 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 layers of the bonding rubber material that attach the ballistic shield to the substrate and to the alternating layers of ballistic fabric significantly contributes to the "catching" of the projectile. The combination of the bonding rubber material layers and the ballistic fabric layers reduces or limits the deformation (and resulting penetration) of the ballistic shield, and of the original substrate (the vehicle panel or structural substrate) to which the ballistic shield has been adhesively applied.

[0009] The present invention provides a flexible and adhesive ballistic shield, haying an adhesive surface for bonding the ballistic shield to a substrate. The ballistic shield can include at least a base layer of a bonding robber material and at least a first layer of a ballistic fabric material disposed on an outer-facing surface of die base layer of bonding rubber material Additional layers of ballistic fabric material can be applied with layers of the rubber material disposed therebetween. The bonding rubber material can comprise a butyl rubber selected from the group consisting of polyisobutene, a copolymer of isobutylene and isoprene, and a combination thereof The bonding rubber material can also comprise an acrylic rubber.

[0010] The bonding rubber material can further comprises a plasticizer or a tackifying agent, carbon black, and a filler material.

[0011] The present invention provides a flexible ballistic shield having an adhesive surface for bonding the ballistic shield to a substrate, the ballistic shield comprising at least a base layer of a bonding butyl rubber material and at least a first layer of a ballistic fabric material disposed on an outer-facing surface of the base layer of bonding butyl rubber material, the inner- facing surface of the base layer providing the adhesive surface of the ballistic shield, the bonding butyl rubber material comprising: a butyl rubber selected from the group consisting of polyisobutene, a copolymer of isobutylene and isoprene, and a combination thereof, for attaching the ballistic shield to a substrate of a vehicle or structure.

[0012] As used herein, an inner layer or an inner-facing surface of a layer refers to the direction or position of a surface or layer towards the base layer of the bonding rubber material that attaches the ballistic shield to the substrate or structure, while an outer layer or outermost layer, or outer surface or outermost surface, of a layer refers to me direction or position of a surface or layer that is remote (or most remote) or away from the base layer of the bonding rubber material.

[0013] The bonding rubber material includes a cross linked acrylic or a cross-linked butyl rubber that provides cohesive properties to maintain the integrity of the adhesive or attachment of the bonding rubber material with the ballistic fabric layers, to reduce and minimize the separation of the layers when subjected to the forces of the high-velocity projectiles. A butyl rubber can include butyl rubber comprising a polyisobutene or a copolymer of isobutylene and isoprene, or an acrylic rubber. The butyl rubber can include a cross-linked butyl rubber material The butyl rubber or the acrylic rubber can comprise about 5% to about 60%, including about 10% to about 40%, and further including about 10% to about 20%, of the bonding rubber material. |00ί4] The bonding rubber material also includes a tackifying agent and/or a plasticizer that provides flexibility, tack, adhesion, and extends the life of these properties in the layers of the bonding rubber material, so that the applied ballistic shield maintains its performance over lime. Non-limiting examples including a polybutene, a polypropene, a paraffinic oil, a petrolatum_* a phthalate, arid a One or more resins selected form the group consisting of a polyterpene, a terpene-phenoHc, a blocked-phenolic, a modified rosin or rosin ester, a cumarone- indene resin, a styrene resin, and a Irydrocarbon resin. The tackifier and/or plasticizer should be compatible with the butyl rubber or acrylic rubber material. Preferred tackifiers and/or piasticizers are a polybutene, a hydrocarbon resin, a phenolic resin, or a combination thereof. The kind and quantity of tackifiers used should be chosen to provide adequate adhesion and plasticity across the anticipated range of temperatures to which the adhesive wilt be exposed. The tackifier and/or plasticizer agent can comprise about 10% to about 40%, including about 15% to about 30%, and further Including about 20% to about 30%, of the bonding rubber material.

[0015] The bonding rubber material can also include one or more reinforcing or filler agents. Examples include a finery divided carbon, such as carbon black, aluminum hydrate, clays, hydrafed silicas, calcium silicates, siUcoahiminates, magnesium oxide, magnesium carbonate, mica, lime, and talc. The reinforcing or filler agents can comprise about 20% to about 80%, including about 40% to about 70%, and further including about 50% to about 60%, of the bonding rubber material. The carbon black can comprise about 5% to about 30%, including about 20% to about 25%, of the bonding rubber material.

[0016] The ballistic shield can include at least two layers of the bonding rubber material, including the base layer and a second layer, with the first layer of ballistic fabric material disposed between the at least two layers of the bonding rubber material, and including a second layer of ballistic fabric material disposed on an outer surface of the second layer of bonding rubber material. The ballistic shield can further including one Or more additional layers of bonding rubber material, and one or more additional layers of ballistic fabric material, disposed between successive layers of the bonding rubber material. The ballistic shield can further including a handling fabric layer disposed on an outer surface of an outermost layer of bonding rubber material. The ballistic shield can further including a reieasable protective layer on an inner-most surface of the base layer of bonding rubber material, to protect such inner-most surface of the base layer from particulate contamination prior to use of the flexible ballistic shield. The ballistic materiel 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®, Dyneerna^, and other aramid fiber. The ballistic fabric provide flexibility and improved handling and use of the flexible ballistic shield.

|jO017] The present invention also provides a method of applying a flexible 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 inner-facing surface of the base layer of bonding rubber material of the ballistic shield to an inside surface of a wall or structure; and (Hi) applying pressure to the outer surface of the ballistic shield sufficient to adhere die ballistic shield to the wall or structure surface. Heat can also be applied to the adhesively-applied ballistic shield or to the inside surface of the wall or structure, to improve adherence of the butyl rubber layer to the wall or structure, and further improve penetration of the bonding rubber material into the ballistic fabrics.

[0018] The present invention also provides a flexible ballistic panel having an adhesive surface for bonding the ballistic shield to a substrate, the ballistic shield comprising a laminate of a plurality of ballistic-resistant layers comprising ballistic fabric, each the ballistic-resistant layers having a first inner-facing surface and a second outer-facing surface, and a plurality of bonding layers comprising a bonding rubber material, each bonding layer having a first inner- facing surface directed toward the substrate and a second outer-facing surface directed away from the substrate, at least one of the bonding rubber material layers being an inner-most layer of the laminates, and each ballistic-resistant layer having a bonding rubber material layer therebetween. The ballistic fabric can be a woven ballistic material. The bonding layer typically consists essentially of a bonding butyl rubber material comprising: a butyl rubber selected from the group consisting of polyisobutene, a copolymer of isobutylene and isoprene, and a combination thereof; a plasticizer Or a tackifying agent; carbon black; and a filler material. An outmost layer is a fabric including a ballistic fabric or a non-ballistic handling fabric.

[0019] 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 fabric material, b. providing a plurality of bonding layers comprising a bonding rubber material, c, forming a stack comprising alternating layers of the ballistic-resistant layers and the bonding rubber material layers, and d. applying pressure and Optionally heat 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.

[0020] 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 fabric material, b. providing a plurality of bonding rubber material layers comprising a bonding butyl rubber material comprising: a butyl rubber selected from the group consisting of polyisobutenc, a copolymer of isobutylene and isoprene, and a combination thereof; a plasticizer or a tackifying agent; carbon black; and a filler material, c. forming a stack comprising alternating layers of the ballistic-resistant layers and the bonding rubber material layers, and d. applying pressure to the stack to adhere the plurality of bonding rubber material layers to the plurality of ballistic-resistant layers.

[0021] The present invention further includes a method of baliisticly-reinforcing a substrate on a human-occupancy side of the substrate, comprising the steps of: a) providing a substrate having an inner surface that feces 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 provide 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.

[0022] 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

[0023] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee. [0024] Figure 1 shows a ballistic panel having an innermost bonding layer and a ballistic- resistant layer.

[0025] Figure 2 shows a ballistic panel having two bonding layers including ah innermost bonding layer, and two ballistic-resistant layers between the bonding layers.

[0026] Figure 3 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.

[0027] Figure 4 shows a ballistic panel having three bonding layers including an innermost bonding layer, and three ballistic-resistant layers between the bonding layers.

[0028] Figure 5 shows a ballistic panel having four bonding layers including an innermost bonding layer, and four ballistic-resistant layers between the bonding layers.

[0029] Figure 6 shows a ballistic panel haying five bonding layers including an. innermost bonding layer, and five ballistic-resistant layers between the bonding layers.

[0030] Figure 7 shows the ballistic panel of Figure 2 bonded to the inner surface of a substrate.

[0031] 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.

[0032] Figures 8A and 8B show a 20 gauge steel panel shot with both 9 mm projectiles and 38 caliper projectiles.

[0033] Figures 9A and 9B show a 20 gauge steel panel shot with both 45 caliper projectile and 38 caliper projectiles.

[0034] Figures 10A through IOC show a 20 gauge steel panel with a layer of butyl and PE UD Fabric 170 shot with 9 ram projectiles and 38 caliper projectiles,

[0035] Figures 11 A through 11 £ show a 20 gauge steel panel two layers of butyl and PE UD Fabric 170 shot with both 9 mm and 38 caliper projectiles.

[0036] 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.

[0037] Figures 13A and 13B show a 20 gauge steel panel a layer of butyl and PE UD Fabric 140 shot with 9 mm projectiles. [0038] Figures 14A and 14B shows a 20 gauge steel panel with two layers of butyl and PE UD Fabric 140 shot with 9 ram projectiles.

[0039] Figures 15 A, 1 SB and .15C show a 20 gauge steel panel with three layers of butyl and PE UD Fabric 140 shot with 9 ram projectiles.

[0040] Figures 16A and MB show a 20 gauge steel panel with one layer of butyl and

Kevlar® 29 Denier 1500 shot with 9 mm projectiles.

[0041] 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.

[0042] 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.

[0043] 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.

[0044] Figures 20A and 20B show a 20 gauge steel panel with two layers of butyl and Kevlar® 29 Denier 3000 shot with 9 ram projectiles.

[0045] 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.

[0046] 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.

[0047] 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.

[0048] 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.

[0049] Figures 25A and 25B show a 20 gauge steel panel with one layer of butyl and Dyneema® shot with 9 mm projectiles.

[0050] Figures 26A and 26B show a 20 gauge steel panel with two layers of butyl and Dyneema® shot with 9 mm projectiles.

[0051] Figures 27A through 27C show a 20 gauge steel panel with three layers of butyl and Dyneema® shot with 9 mm projectiles.

[0052] Figures 28A and 28B show a 20 gauge steel panel with three layers of butyl and Dyneema® shot with 45 caliper projectiles. [0053] Figures 29A and 29B show a 20 gauge steel panel with four layers of butyl and Dyneema® shot with 45 caliper projectiles.

[0054] Figures 30A and 30B show a 20 gauge steel panel with five layers of butyl and Dyneerna® shot with 45 caliper projectiles.

[0055] Figures 31 A and 31 B show a 20 gauge steel panel with one layer of butyl and PH

UD 35 fabric shot with 9 ram projectiles.

[0056] Figures 32A and 32B show a 20 gauge steel panel with two layers of butyl and PE

UD 35 shot with 9 mm projectiles.

[0057] 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

[0058] 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.

[0059] 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 die 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. The bonding rubber 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 bonding rubber material are tenaciously adhered to the back-side (the side opposite the side of projectile penetration) of the substrate through the tackified, flexible bonding rubber material, thereby using the structural integrity of the substrate itself to hold the ballistic fabrics in place and in lamination, even though the substrate or structure is riot "backing up" the ballistic shield.

[0060] The bonding material is preferably selected from butyl rubber and polyisobutylene. The bonding materials provide adhesion, cohesion, viscosity, density, elasticity, formabihty and deformability, at a minimal thickness and weight, when layered with the ballistic layers. Typical bonding layer thickness is from about 0.5 ram 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 I mm, and up to about 4 mm.

[0061] The braiding rubber material has a tensile strength, an elongation, a modulus at 300% elongation, a modulus at failure, a shear strength, and a peel strength sufficient to adhere to the substrate or structure, to resist delamination from the substrate and the ballistic fabric, as applied and under most all environmental conditions, and under the force of ballistic projectiles.

[0062] Tensile strength refers to the maximum stress (force per unit area) that a specimen of adhesive material can withstand before rapturing. Elongation measures the relative increase in length of a specimen of material at the point of rupture. The modulus at 300% elongation is the force required to stretch a sample of die adhesive to an elongation of 300% divided by the elongation of the sample expressed as a decimal rather than as a percentage. The modulus at failure is the tensile strength divided by the elongation. The bonding rubber material can be compounded to have a tensile strength of at least 50 psi, and more preferably at least 60 psi; an elongation of at least 600%, and more preferably of at least 800%, and even preferably more than 1000%; a modulus at 300% elongation of less than 12_* preferably of at most 8; and a modulus at failure of less man 20, preferably of at most 16.

[0063] The adhesive composition also preferably has a peel strength of at least 2 pounds per inch and a sheer strength of at least 15 psi. The shear strength and peel strength relate to the ability of the adhesive to adhere to a substrate or structure.

[0064] 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. [0065] Figure 7 shows the ballistic panel 70 of Figure 2 having two ballistic layers 75 and 76, which is formed into a ballistic shield SO having an innermost butyl layer 71 that adheres to the inside surface 86 (opposite the expected projectile: penetration side) of the substrate 84.

[0066] 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 KevkrSD and Dyneema$D, and others, and high impact plastic layers, including ultra-high-molecular-weight polyethylene (UHMWPE, UHMW), and UHMWPE containing carbon nanotubes, and combinations thereof.

[0067] 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 a silicon, a polycarbamate, or a polyolefin, including polyethylene. The ballistic panel can be made by forming a stack of alternating layers of the ballistic fabric material and ihe bonding rubber material layer, 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.

[0068] 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. The tackiness and flowability of the bonding rubber material can penetration of the fabric material and flow between and around individual the fibers of the ballistic fabric. The penetration of the bonding rubber material into the ballistic fiber may be substantially complete, in which at least about 90% of the fibers in the ballistic fabric are contacted by the bonding rubber material, or a majority of the fibers in ballistic fabric are contacted by the bonding rubber material, or as few as about 10% or less of the fibers in the ballistic fabric are contacted by the bonding rubber material. The extent of the wet out is influenced by the specific fiber of the ballistic fabric, and the pressure and temperature applied to the stack of alternating layers of the ballistic fabric material and the bonding rubber material layers. Typically the butyl or acrylic rubber material will not run or flow out from the ballistic fabrics unless dissolved in a solvent.

[0069] When formed, at least one of the outer-most layers is the butyl or acrylic rubber material. For manufacture and transport of the panels, a release layer of a plastic film placed over the outer-rnost 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.

[0070] When applying the ballistic panel to the surface of a substrate, the surface of the substrate should be carefully cleaning of dirt, debris, and liquids, and in particular removing any traces of oily material, to improve adherence of the bonding rubber material panels, and thus the ballistic performance of ballistic shield panels. Surface preparation of the substrate includes cleaning, degreasing, oil stripping, and roughing of the surface including sanding.

EXAMPLES

[0071] Ballistic panels were made by alternating layers of a bonding butyl rubber material and ballistic fabrics. The ballistic fabrics included an aramid fiber fabric (Kevlar®) and an ultra-high molecular weight polyethylene fiber fabric (Dyneema®), and UD Fabric of various denier (fabric weights). The composition of the bonding butyl rubber material is shown in Table A. 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.

[0072] Figures 8A-33B show the conditions and results of the tests.

[0073] 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.

[0074] Figure 8B shows the back surface of the 20 gauge steel panel of Figure 8A.

[0075] 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.

[0076] Figure 9B shows the back surface of the 20 gauge steel panel of Figure 9A.

[0077] Figure 10A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with its baek covered with one (1) layer of butyl and one (1) layer of PE UP 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 projeciilefs) into the front surface.

[0078] Figures 1 OB and IOC show the back surface of the 20 gauge steel panel of Figure 10A. The back layer appears to show a Mure 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.

[0079] Figure 11 A 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 bury! and two (2) layers of PE UD Fabric 170. The panel was shot from 30 feet with both 9 mm projectile^) and 38 caliper projectiles) into the front surface.

[0080] Figures 11 B, 11C, 1 ID and HE show the back surface of the 20 gauge steel panel of Figure 11 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.

[0081] 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 projectiles) into the front surface.

[0082] 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.

[0083] 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 (! ) 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 Qiangiun (China). The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0084] Figure 13B shows the back surface of the 20 gauge steel panel of Figure 13 A.

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

[0085] 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 projectiles) into the front surface.

[0086] Figure 14B shows the back surface of the 20 gauge steel panel of Figure 14A.

[0087] Figure 15 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 Fabric 140. The panel was shot from 30 feet with 9 mm projectile(s) into the front surface.

[0088] Figure 15B shows the back surface of the 20 gauge steel panel of Figure ISA. 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 14G shows that the bullet dropped out of the bottom of the panel.

[0089] 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 (I) layer of Kevlar® 29 Denier 1500, an aramid fabric with a density of 200 gm/m². This fabric adhered to the butyl layer very well. The panel was shot from 30 feet with 9 mm projectiles) into the front surface. [0090] Figure 16B shows the back surface of the: 20 gauge steel panel of Figure 16 A. 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 die bullet to pass through

[0091] 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.

[0092] Figure 17B shows die back surface of the 20 gauge steel panel of Figure 17 A. 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.

[0093] 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 projectHe(s) into the front surface.

[0094] Figure 18B shows the back surface of the 20 gatige steel panel of Figure ISA.

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

[0095] 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 pxojectile(s) into front surface.

[0096] 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).

[0097] Figure 20 A 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.

[0098] 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. [0099] 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 pf Kevlar® 29 Denier 3000. The panel was shot from 30 feet with 9 mm projectile(s) into die front surface.

[00100] Figure 21B 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.

[00101] Figure 22A 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 Keviar® 29 Denier 3000. The panel was shot from 30 feet with 45 caliper projectUe(s) into the front surface.

[00102] 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.

[00103] 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 projectiie(s) into the front surface.

[00104] 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.

[00105] Figure 24 A 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.

[00106] Figure 24B shows the back surface of the 20 gauge steel panel of Figure 24A. The bullets were completely stopped.

[00107] Figure 25 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 (I) layer of butyl and one (!) 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 trim projectile(s) into front surface.

[00108] 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 die fabric, and windowing. [00109] Figure 26Λ 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 Pyneerna® having a density of 290 gm/m². The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[00110] 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.

[00111] Figure 27 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 Dyneema® having a density of 290 gm/m². The panel was shot from 30 feet with 9 mm projectiles) into front surface.

[00112] 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.

[00113] 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/m². The panel was shot from 30 feet with 45 caliper projectile(s) into front surface.

[00114] 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.

[00115] 6igure 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 Dyneerna® having a density of 290 gm/m². The panel was shot from 30 feet with 45 caliper projectiles) into front surface.

[00116] Figure 29B shows the back surface of the 20 gauge steel panel of Figure 29 A. The bullets penetrated through all layers of the fabric. There were no broken fibers, though a windowing effect. [00117] Figure 3ΘΛ 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 Dyneenu# having a density of 290 gm/m². The panel was shot from 30 feet with 45 caliper projecttle(s) into front surface.

[00118] Figure 30B shows the hack surface of the 20 gauge steel panel of Figure 30A. The bullets penetrated through all layers of the fabric. There was a windowing effect.

[00119] 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 *Ή+Τ\ with a density of 135 gm/m². The panel was shot from 30 feet with 9 mm projectile(s) into front surface.

[00120] Figure 31B 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.

[00121] Figure 32A shows the front surface of a test panel, a 6 inch x 9 inch 20 gauge steel panel, with i ts 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 projectiles) into front surface.

[00122] 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.

[00123] Figure 33A 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.

[00124] Figure 33B shows the back surface of the 20 gauge steel panel of Figure 33A. The back layer showed delarnination and poor adhesion with this sample, with the bullets penetrating through every layer. The fabric separated from the butyl.

Claims

I claim: t. A flexible ballistic shield having an adhesive surface for bonding the ballistic shield to a substrate, the ballistic shield comprising at least a base layer of a bonding butyl rubber material and at least a first layer of a ballistic fabric material disposed on an outer-facing surface of the base layer of bonding butyl rubber material, the inner-facing surface of the base layer providing the adhesive surface of die ballistic shield, the bonding butyl rubber material comprising: a butyl rubber selected from the group consisting of poiyisobutene, a copolymer of isobutylene and isoprene, and a combination thereof, for attaching the ballistic shield to a substrate of a vehicle or structure.

2. The ballistic shield according to Claim 1, die bonding butyl rubber material further comprising a plasticizer or a tacfctfying agent.

3. The ballistic shield according to Claim 2 wherein the bonding butyl rubber material further comprises carbon black and a filler material.

4. The ballistic shield according to Claim 3 including at least two layers of the bonding butyl rubber material, including the base layer and a second layer, with the first layer of ballistic fabric material disposed between the at least two layers of the bonding butyl rubber material, and including a second layer of ballistic fabric material disposed on an outer surface of the second layer of bonding butyl rubber material.

5. The ballistic shield according to Claim 4 further including one or more additional layers of bonding butyl rubber material, and one or more additional layers of ballistic fabric material, disposed between successive layers of the bonding butyl rubber material.

6. The ballistic shield according to Claim 3, further including a handling fabric layer disposed on an outer surface of an outermost layer of butyl rubber.

7. The ballistic shield according to Claim 3, further including a releasable protective layer on the inner-lacing surface of the base layer of bonding butyl robber material, to protect the inner-facing surface of the base layer from particulate contamination prior to use of die flexible ballistic shield.

8. The ballistic shield according to Claim 3 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.

9. A method of applying a flexible ballistic shield to the inside surface if a resilient wall or structure, comprising the steps of:

(i) providing a flexible ballistic shield according to Claim I;

(ii) attaching the inner-facing adhesive surface of the base layer of bonding butyl rubber material of the ballistic shield to an inside surface of a wall or structure; and

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

10. The method according to Claim 9 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.

11. The method according to Claim 9 wherein heat is applied to the applied flexible ballistic shield or to the inside surface of the wall or structure, prior to the step (iii) of applying pressure, to improve adhesion of the base layer of bonding butyl rubber material to the wall, and the further penetration of bonding butyl rubber material into the layers of the ballistic fabric.

12. A flexible ballistic panel having an adhesive surface for bonding the ballistic shield to a substrate, the ballistic shield comprising a laminate of a plurality of ballistic-resistant layers comprising ballistic fabric, each the ballistic-resistant layers having a first inner-facing surface and second outer-facing surface, and a plurality of bonding layers comprising a bonding rubber material, each bonding layer having a first inner-facing surface directed toward the substrate and a second outer-facing surface directed away from the substrate, at least one of the bonding rubber material layers being an inner-most layer of the laminate, and each bailistio-resistant layer having a bonding rubber material layer therebetween.

13. The flexible ballistic panel according to Claim 12 wherein the ballistic fabric comprises a woven ballistic fabric.

14. The flexible ballistic panel according to Claim 12 wherein the bonding rubber material layer consists essentially of a bonding butyl rubber material comprising: a butyl rubber selected from the group consisting of polyisobutene, a copolymer of isobutylene and isoprene, and a combination thereof; a plasticizer or a tacki tying agent; carbon black; and a filler material.

15. The flexible ballistic panel according to Claim 12 wherein an outermost layer is a fabric material.

16. The flexible ballistic panel according to Claim 12 wherein the ballistic fabric is selected from the group consisting of nylon, aramid, ultra-high-molecular-weight polyethylene (UHMWPE), cotton, or blends thereof.

17. Λ method of making a ballistic panel comprising the steps of:

a. providing a plurality of ballistic-resistant layers comprising ballistic fabric material,

b. providing a plurality of bonding rubber material layers comprising a bonding butyl rubber material comprising: a butyl rubber selected from the group consisting of polyisobutene, a copolymer of isobutylene and isoprene, and a combination thereof; a plasticizer or a tackifying agent; carbon black; and a filler material,

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

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

18. The method according to Claim 17 wherein an inner-most layer of the stack of the ballistic-resistant layers and the bonding rubber material layers is one of the bonding rubber material layers, and a release layer material is disposed on an inner-facing surface of the innermost bonding rubber material layer.

19. The method according to Claim 17 wherein at least 1 psi pressure is applied to the stack, and further including applying heat to the stack before or while applying pressure.

20. A method of ballisticly-reinforcmg 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 according to Claim 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.