BALLISTIC PROECTION SYSTEM AND METHOD THEREFOR

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is related to U.S. Pat. No. 11,788,819, entitled “Ballistic Protection System and Method Therefor,” which was issued on Oct. 17, 2023, in the name of the inventor herein and which, in turn, is a continuation of U.S. Pat. No. 11,243,051, entitled “Ballistic Protection System and Method Therefor,” which was issued on Feb. 8, 2022, in the name of the inventor herein.

TECHNICAL FIELD

The present application relates generally to an armor systems, devices and methods, and more specifically, to ballistic protection systems, devices, and related methods that utilize engineered thermoplastics containing carbon additives and which may have geometrical shape designs to deflect projectiles in order to increase yaw and decrease penetration.

BACKGROUND

Armor has been used for years in order to protect personnel and equipment from damage due to projectiles. More specifically, body armor has become an essential piece of safety equipment to protect military personnel, police, and security personnel as well as private citizens against various dangerous threats such as penetrating attacks by weapons, slashing, bludgeoning, etc.

Presently, there are several different types of body armor. For example, there are different types of body armor to provide protection against attacks using cutting tools or weapons such as knives, swords, axes, broken bottles, and the like, commonly referred to as edge blade protection devices/systems. Others may be designed to provide protection against objects like long nails, needles, ice picks, screwdrivers, stilettos and the like, commonly referred to as spike protection devices/systems. However, ballistic protection is the most common type of body armor and is generally referred to as “bulletproof vest” and/or “bullet resistant armor,” as these types of body armor provide resistance to projectiles/bullets.

In traditional body armor ballistic protection systems, the quality of the system is directly correlated to the outcome of the individual (e.g., from as little as a soft bruise to blunt force trauma to a bullet wound to death). The type of bullets resisted is generally based on the categorized level of the armor.

Ballistic protection armor can be categorized as Handgun 1, Handgun 2 (HG1, HGH2). HG1 and HG2 armors are designed to offer protection against most of the commonly available handgun threats such as 9 mm, 0.357 magnum, and 0.44 magnum firearms. Ballistic vests at these levels use soft materials like Kevlar and Spectra, which are strong and can trap and slow bullets to a complete stop.

Higher ballistic armor of Rifle 1, Rifle 2, and Rifle 3, (RF1, RF2, RF3) are designed to provide protection against large, high-velocity bullets such as from rifles and submachine guns. Body armor at these levels is in the form of hard rigid ballistic plates. The ballistic plates are generally incorporated into the vests or plate carriers. The ballistic plates are designed to stop rounds both from penetrating soft body armor and entering the body as well as protecting the users from blunt trauma associated with the dissipation of the high energy generated by a round striking the body.

Typically, ballistic plates vary in size, material, and design with each offering trade-offs regarding performance, weight, and other factors. Some may be made of steel or hardened steel or aluminum which are generally relatively effective at stopping projectiles and are relatively inexpensive but are relatively heavy and can be uncomfortable to wear for long periods of time. Other ballistic plates/protection systems are made of multiple compressed sheets of fiber such as polyethylene that are designed to cause the bullet to become trapped within the layers. This design requires a sufficient number of woven and/or laminated fiber layers so as to prevent the projectile from penetrating all the way through the layers. This design offers a lighter weight relative to steel but is more expensive and involves a more complicated manufacturing process. Another material that is in common use for ballistic plates is a ceramic or glass plates that are compressed together and are designed to cause the projectile to disintegrate or deform upon impact. This design also offers a weight advantage over the heavy steel plates, however, once impacted, that area of the ceramic is generally no longer effective and offers no secondary protection from a second projectile impacting the same area.

The National Institute of Justice (NIJ) armor testing protocols identify, for testing, a very specific and limited range of existing projectiles. Current NIJ standards for RIFLE 1 (RF1) are specific to non-armor piercing bullets/projectiles. RIFLE 2 (RF2) specifies certain armor piercing projectiles. RIFLE 3 (RF3) specifies additional armor piercing projectiles. In order to achieve these varying NIJ standards, the Armor Manufacturing industry has limited materials to choose from. Additionally, there have been no recent innovations in materials science. The key components currently relied upon to achieve RF2 and RF3 are ceramic and steel as disclosed above. However, these materials may each have limitations.

Steel has been utilized in the manufacturing of personal body armor rifle plates for the better part of 30 years to achieve NIJ RF1, RF2, and RF3. The manufacturer of steel plates would simply make them thicker to achieve higher threat protection. The primary disadvantage of steel is its overall weight in comparison to modern polymers. Impacts to steel plates are known to allow dangerous shrapnel ricochet off the plate causing soft tissue damage. Additionally the mass of the projectile is not contained within the plate, allowing for redirection into vital areas. Further, heat treatment is a vital step in the process of steel plate manufacturing. Inconsistent heat treatment processes can compromise the effectiveness of a steel product.

The body armor industry has been utilizing various ceramic products in the making of hard armor products for approximately 30 years. A ceramic plate/tile is generally a thin sheet of material, approximately 0.125-0.30″ in thickness There are difficulties involved when using ceramic tiles in the manufacturing process of hard armor. Ceramic tiles placed on the face of these ballistic products are fragile and can break easily during the manufacturing process. In addition, ceramics can also be compromised, cracked or broken during the normal day-to-day use of this equipment over its expected 5-year service life.

The other disadvantage to using ceramics in the manufacturing of hard armor, is that during NIJ certification, the testing protocol requires that the hard armor ceramic plate be dropped from a specified height. It is also required that a specified amount of weight be attached to the back side of the item being tested. The hard armor is then intentionally dropped onto a hard surface. This usually results in the ceramic-faced armor cracking and breaking into individual pieces. This usually creates additional problems with continued testing. Further, inherent to the design properties of ceramics, a large area of ceramic ballistic material is sacrificed in order to defeat the specified bullet/projectile. This limits the overall effective area of the ceramic product.

Compressed sheets of fiber such as polyethylene also have certain disadvantages. For examples, a body armor vest containing multiple layers/sheets of polyethylene fibers should be able to stop conventional hand-gun bullets but if one wants to stop a high-powered rifle bullet (800 m/s or more), one may need something more than layers of polyethylene fibers. Polyethylene fibers'effectiveness relies not only on the strength of the fibers, but also on its ability to flex. So, even when the polyethylene fiber vest can stop the bullet, that does not mean the wearer will avoid injury. Blunt trauma, in which the bullet presses the protective material back into the body before it is stopped, can break bones, disrupt organs and kill.

Further, the weaves of polyethylene fibers are varied, the tighter and more complex the weave, the more expensive the armor but the more effective it is in preventing injury.

In all of the aforementioned, plate designs, regardless of plate configuration and material, the ballistic protection systems employ essentially a “plate” design, that is, a relatively flat configuration designed to prevent a bullet from penetrating the plate. Current ballistic plate designs focus on preventing the bullet from penetrating the ballistic plate the way an arrow would penetrate a target. However, projectiles come in various shapes and sizes (i.e. calibers). Bullets are also available in a wide range of configurations to include armor piercing, hollow point and ball. Bullets are also fired at a range of velocities which affect the plate configurations.

Therefore, it would be desirable to provide a ballistic protection system and method that overcomes the problems discussed above. The ballistic protection system and method would offer maximum protection regardless of the bullet configuration and velocity of the projectile. The ballistic protection system and method would be able to redirect and stop projectiles regardless of their configuration and velocity in order to maximize the protection to an individual wearing the ballistic protection system. The ballistic protection system and method would be able to guide and stop projectiles. The present disclosure addresses the above-mentioned problems as well as providing other, related advantages.

SUMMARY

In accordance with one embodiment of the present invention, a ballistic panel providing ballistic protection is disclosed. The ballistic panel has at least one plate. The at least one plate is formed of engineered thermoplastics containing carbon additives.

In accordance with another embodiment of the present invention, a ballistic panel providing ballistic protection is disclosed. The ballistic panel has at least one plate, wherein the at least one plate is formed by injection molding of mixtures of engineered thermoplastics containing carbon additives.

BRIEF DESCRIPTION OF THE DRAWINGS

The present application is further detailed with respect to the following drawings. These figures are not intended to limit the scope of the present application, but rather, illustrate certain attributes thereof. In the descriptions that follow, like parts are marked throughout the specification and drawings with the same numerals, respectively. The drawing figures are not necessarily drawn to scale and certain figures can be shown in exaggerated or generalized form in the interest of clarity and conciseness. The disclosure itself, however, as well as a preferred mode of use and further objectives and advantages thereof, can be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is an elevated perspective view of an exemplary ballistic protection system, in accordance with one aspect of the present disclosure;

FIG. 2 is a front view of the ballistic protection system of FIG. 1, in accordance with one aspect of the present disclosure;

FIG. 3 is an exploded perspective view of an exemplary ballistic protection system, in accordance with one aspect of the present disclosure;

FIG. 4 is an elevated perspective view of the exemplary ballistic protection system of FIG. 3, in accordance with one aspect of the present disclosure; and

FIG. 5 is a front view of the exemplary ballistic protection system of FIG. 3, in accordance with one aspect of the present disclosure.

DESCRIPTION OF THE APPLICATION

The description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the disclosure and is not intended to represent the only forms in which the present disclosure can be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the disclosure in connection with the illustrated embodiments. It is to be understood, however, that the same or equivalent functions and sequences may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of this disclosure.

Embodiments of the exemplary ballistic protection device, system, and method (hereinafter device) employ one or more sheets of thermoplastic material containing carbon additives. The sheets of thermoplastic material may be formed to have re-direction (Non-Linear) technology designed to cause additional surface area of a projectile to make contact with the ballistic protection device. The exemplary ballistic protection device generally comprises a plate that has an exterior (i.e. projectile facing) surface that is comprised of geometrical shaped protrusions utilized to cause more of the surface area of the projectile to come into contact with the plate. The geometrical shaped protrusions may cause the projectile to begin to yaw or be deflected and/or redirected, the result is that an increasing amount of the surface of the projectile is placed into contact with the ballistic protection device. The more surface area of the plate that is able to contact the surface area of the projectile, the more blunt force trauma energy can be dispersed and the more effective that ballistic protection device can be in serving its primary function, preventing a projectile from penetrating and otherwise causing damage to the person or object on the other side.

Referring to FIG. 1, one exemplary embodiment of a ballistic protection device 10 (hereinafter device 10) may be seen. The device 10 may be comprised of a plate 12 having an exterior facing surface 12A and an interior facing surface 12B. The interior facing surface 12B may be the surface closest to a body of a wearer of the device 10.

The plate 12 may be formed of one or more thermoplastic sheets having carbon additives and/or carbon fiber (hereinafter carbon additives) reinforcements. The thermoplastic sheets may be formed using high temperature and pressure to melt the thermoplastic and fuse the carbon additives within the matrix. For example, the plate 12 may be formed by injection molding, extrusion, or through various other methods of thermoforming.

During the manufacturing process, various blends of engineered thermoplastics containing carbon additives may be created to meet the desired ballistic protection requested. The plate 12 may also be formed in varying thicknesses to achieve specified ballistic protection. The plate 12 formed of thermoplastic sheets having carbon additives may have similar properties and similar compressive strength as ceramic plates currently being used. However, the plate 12 formed of thermoplastic sheets having carbon additives may be more flexible and lighter weight than the ceramic plates.

The plate 12 may be placed in varying positions throughout hard armor products during manufacturing to achieve additional ballistic protection. For example, the plate 12 may be placed on existing ballistic shields/vest to achieve additional ballistic protection. Alternatively, the plate 12 may be used in place of other ballistic materials that may be more difficult and costly to produce. For example, the plate 12 may be used in place of metal or ceramic plates on existing ballistic shields/vest, armored vehicles, and other similar applications. The plate 12 may also be formed in sizes to form walls for a safe room or other similar applications.

During the manufacturing process, the plate 12 may be formed with smooth surfaces. Alternatively, different geometric shapes may be formed on the plate 12. As may be seen in FIG. 1, the plate 12 may have a plurality of channels 14 formed therein. In the present embodiment, the plate 12 may have a plurality of channels 14A formed on the exterior facing surface 12A. In the embodiment shown, the channels 14A may be shown run an entire height (vertically) along the exterior facing surface 12A of the plate 12. However, this is shown as one embodiment and the channels 14A may run vertically, horizontally, in a curved pattern, or in other designs. Each channel 14A may be formed of a pair of side walls 14A′. In the embodiment shown, the side walls 14A′ of each channel 14 may be slanted so that the channel 14A may be “V” shaped. Each channel 14A may run parallel to an adjacent channel 14A to form an undulating triangular wave configuration of channels 14A along the exterior facing surface 12A of the plate 12.

Each channel 14A may have a corresponding channel 14B formed on the interior facing surface 12B of the plate 12. The channel 14B may be formed directly below and may run parallel to the corresponding channel 14A located directly above. Each channel 14B may be formed of a pair of side walls 14B′. In the embodiment shown, the side walls 14B′ of each channel 14 may be slanted so that the channel 14B may be “V” shaped. Each channel 14B may run parallel to an adjacent channel 14B to form an undulating triangular wave configuration of channels 14B along the interior facing surface 12B of the plate 12. In accordance with one embodiment, the channels 14A formed on the exterior facing surface 12A and the corresponding channels 14B formed on the interior facing surface 12B may be formed having the same depth and width. Thus, the undulating triangular wave configuration formed by channels 14A and the undulating triangular wave configuration formed by the channels 14B may have the same frequency.

The channels 14A formed on the exterior facing surface 12A and the corresponding channels 14B formed on the interior facing surface 12B may form a plurality of three-dimensional polyhedron 16. Each polyhedron 16 may run the entire length of the plate 12. In the present embodiment, each polyhedron 16 may be a hexahedron. More specifically the polyhedron 16 may be a trigonal trapezohedron and run parallel to an adjacent trigonal trapezohedron. In accordance with one embodiment, each polyhedron 16 may be formed so that the sides 14A′ and 14B′ are all equal in length and angles thereby forming cubic polyhedron 16.

The undulating triangular wave configuration of channels 14A and 14B may cause the projectile to yaw or be deflected and/or redirected, the result is that an increasing amount of a surface of the projectile may be placed into contact with the plate 12. The more surface area of the plate 12 that is able to contact the surface area of the projectile, the more blunt force trauma energy that may be dispersed and the more effective that device 10 may be in serving its primary function, preventing a projectile from penetrating and otherwise causing damage to the wearer or object on the other side of the plate 12. It should be noted that the angle and depth of the “V” shaped channels 14A and 14B may vary depending on the type of projectile that the plate 12 is designed to stop.

Referring to FIGS. 1-5, another example of the ballistic protection device 20 (hereinafter device 20) may be disclosed. In this embodiment, the device 20 may be formed of a plurality of plates 12. Each plate 12 may be layered and positioned against an exterior facing surface 12A or an interior facing surface 12B of an adjacent plate 12. The layering of plates 12 may increase the stopping capability and reduce blunt force trauma caused by a projectile due to the thickness of the layered plates 12 as well as the configuration of the plates 12 which may cause the projectile to yaw or be deflected and/or redirected, the result being that an increasing amount of a surface of the projectile may be placed into contact with the plates 12.

In the present embodiment, each plate 12 may have a differing undulating triangular wave configuration formed by the channels 14. Having differing undulating triangular wave configurations formed by the channels 14 may cause the projectile to yaw or be deflected and/or redirected more if the projectile moves through a first plate 12 to the next since the next plate 12 would have a different undulating triangular wave configuration of channels 14, Thus, as stated above, this may result in an increasing amount of a surface of the projectile may be placed into contact with the plates 12.

In the present embodiment, the density of the triangular wave configuration formed by the “V” shaped channels 14A and/or 14B may decrease as the plates 12 move closer to the wearer. In the present embodiment, the device 20 may have four (4) different plates 12. The first plate 12-1 may have a same configuration as the plate 12 shown in FIG. 1. In this embodiment, the first plate 12-1, which may be located furthest from the wear, may have channels 14A-1 formed on the exterior facing surface 12A-1 and corresponding channels 14B-1 formed on the interior facing surface 12B-1. The triangular wave configurations formed by the channels 14A-1 and corresponding channels 14B-1 may have the same frequency/density and form a plurality of polyhedrons 16-1. In accordance with one embodiment, the polyhedrons 16-1 may be hexahedron hexahedrons and, more specifically, may be diamond shaped prisms.

The second plate 12-2 may be located directly behind the first plate 12-1. The second plate 12-2 may have channels 14A-2 formed on the exterior facing surface 12A-2. The channels 14A-2 may form a triangular wave configuration having the same frequency/density as the triangular wave configuration formed by the channels 14B-1 formed on interior facing surface 12B-1. Thus, the bottom section 16-1B of the polyhedrons 16-1 may fit within a corresponding channel 14A-2 formed on the exterior facing surface 12A-2 of the second plate 12-2. The triangular wave configurations of the channels 14B-2 formed on the interior facing surface 12B-2 may have a frequency/density that is less than that of the channel 14A-2. Thus, the plurality of polyhedrons 16-2 formed by the channels 14A-2 formed on the exterior facing surface 12A-2 and the channels 14B-2 formed on the interior facing surface 12B-2 may be a plurality of trapezoidal prisms 16-2 in shape wherein the upper portions of the trapezoidal prisms 16-2 formed by the sidewalls side walls 14A′-2 may be at a steeper angle than the sidewalls side walls 14B′-2 forming the bottom portions of the trapezoidal prisms 16-2.

The third plate 12-3 may be located directly behind the second plate 12-2. The third plate 12-3 may have channels 14A-3 formed on the exterior facing surface 12A-3. The channels 14A-3 may form a triangular wave configuration having the same frequency/density as the triangular wave configuration formed by the channels 14B-2 formed on interior facing surface 12B-2. Thus, the bottom section 16-2B of the polyhedrons 16-2 may fit within a corresponding channel 14A-3 formed on the exterior facing surface 12A-3 of the third plate 12-3. The triangular wave configurations of the channels 14B-3 formed on the interior facing surface 12B-3 may have a frequency/density that is the same as that of the channels 14A-3. Thus, the triangular wave configurations formed by the channels 14A-3 and corresponding channels 14B-3 may have the same frequency/density and form a plurality of polyhedrons 16-3. In accordance with one embodiment, the polyhedrons 16-3 may be hexahedron hexahedrons and, more specifically, may be diamond shaped prisms. However, the diamond shaped prisms of the polyhedrons 16-3 may be wider than that of the diamond shaped prisms of the polyhedrons 16-1.

The fourth plate 12-4 may be located directly behind the third plate 12-3. The fourth plate 12-4 may have channels 14A-4 formed on the exterior facing surface 12A-3. The channels 14A-4 may form a triangular wave configuration having the same frequency/density as the triangular wave configuration formed by the channels 14B-3 formed on interior facing surface 12B-2. Thus, the bottom section 16-3B of the polyhedrons 16-3 may fit within a corresponding channel 14A-4 formed on the exterior facing surface 12A-4 of the fourth plate 12-4. The interior facing surface 12B-4 of the fourth plate 12-4 may be flat. As the interior facing surface 12B-4 of the fourth plate 12-4 may be closest to the user, having a flat surface may be more comfortable to the user.

The foregoing description is illustrative of particular embodiments of the application but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the application.