U.S. patent application number 11/454492 was filed with the patent office on 2007-05-24 for formed-container armor structure and methodology.
This patent application is currently assigned to High Impact Technology, L.L.C.. Invention is credited to Russell A. Monk, Thomas S. Ohnstad.
Application Number | 20070113729 11/454492 |
Document ID | / |
Family ID | 38052219 |
Filed Date | 2007-05-24 |
United States Patent
Application |
20070113729 |
Kind Code |
A1 |
Monk; Russell A. ; et
al. |
May 24, 2007 |
Formed-container armor structure and methodology
Abstract
A method for forming a ballistic-impact armor structure (and a
resulting structure) having a defined, precision-shaped outside
configuration, where the method which results in the structure
includes the steps of (a) precision-creating a hollow container
having the defined outside configuration, (b) introducing ballistic
armor-content material into the interior of the container, (c)
positionally stabilizing the introduced armor-content material, and
(d) unifying the armor-content material with the container.
Inventors: |
Monk; Russell A.; (Salem,
OR) ; Ohnstad; Thomas S.; (Salem, OR) |
Correspondence
Address: |
ROBERT D. VARITZ, P.C.
4915 SE 33RD PLACE
PORTLAND
OR
97202
US
|
Assignee: |
High Impact Technology,
L.L.C.
|
Family ID: |
38052219 |
Appl. No.: |
11/454492 |
Filed: |
June 16, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60691509 |
Jun 16, 2005 |
|
|
|
Current U.S.
Class: |
89/36.02 ;
89/917 |
Current CPC
Class: |
F41H 5/0435
20130101 |
Class at
Publication: |
089/036.02 |
International
Class: |
F41H 5/02 20060101
F41H005/02 |
Claims
1. A method for forming a ballistic-impact armor structure having a
defined, precision-shaped outside configuration comprising
precision-creating a hollow container having the defined outside
configuration, introducing ballistic armor-content material into
the interior of the container, positionally stabilizing the
introduced armor-content material, and unifying the armor-content
material with the container.
2. The method of claim 1, wherein the armor structure as a whole
possesses a linear ballistic-response directionality with respect
to an impacting object, and lies generally in a plane which crosses
the line associated with the mentioned directionality.
3. The method of claim 1, wherein the armor structure as a whole
possesses a linear ballistic-response directionality with respect
to an impacting object, with the container having been created to
include an outwardly exposed strike face which crosses the line
associated with the mentioned directionality.
4. The method of claim 1, wherein the armor structure is intended
to have a complementary utility fit within a preselected reception
space, and said precision-creating is carried out in a manner
whereby the outside configuration of the container complementarily
fits such space.
5. The method of claim 1, wherein said precision-creating is
carried out in a manner giving at least a preselected portion of
the outer configuration of the container a predetermined faux
appearance.
6. The method of claim 5, wherein the predetermined faux appearance
results from an actual, three-dimensional, precision-created
surface structure.
7. The method of claim 1, wherein said precision-creating is
implemented by precision-roto-molding the container as a closed
continuum, and which further comprises thereafter (a) providing an
access opening in the continuum, and (b) implementing said
introducing via inserting the armor-content material through that
opening.
8. The method of claim 7, wherein said providing involves
returnably removing a portion of the continuum.
9. The method of claim 1 which further comprises, during said
precision-creating, introducing independent, relationship hardware
so as to result in a precision-created container which is joined
to, and which makes outwardly accessible, that hardware.
10. A ballistic-impact armor structure which is formed in
accordance with the methodology of claim 1.
11. A ballistic-impact armor structure which is formed in
accordance with the methodology of claim 9.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to currently co-pending
U.S. Provisional Patent Application Serial No. 60/691,509, filed
Jun. 16, 2005, for "Formed-Container Armor Structure and
Methodology". The entire disclosure content of that provisional
application is hereby incorporated herein by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] This invention pertains to ballistic-impact armor
structure--specifically precision-formed-container armor
structure--and to methodology for making such structure.
[0003] In today's world, there is much emphasis on, and apparent,
or at least perceived, need for, armoring various spaces, things,
vehicles, etc., for protection against the threat and reality of a
ballistic, or related, attack. There are many associated
environments where this is desired, and variously, there are strong
interests in achieving successful armoring while at the same time
doing so: (a) in relatively light-weight, non-bulky fashion; (b) in
a manner which results in a structure that precision-form-fits in
relation to a to-be-protected space, i.e., a complementary
fit-situation; (c) in ways which disguise the presence of armor,
either (1) to deflect attention from the fact that something is
being guarded, or (2) to create an esthetically pleasing,
faux-appearance, "non-announcement" of the presence of armor, or
(3) both of these things; or (d) in other ways which make the
placement of armor more user-friendly and acceptable.
[0004] It is also desirable to accomplish some or all of these
things in manners which are simple, versatile, easily deliverable
and installable, and relatively inexpensive in all aspects.
[0005] The present invention addresses all of these important
considerations in a unique methodologic and structural way which is
based upon the known, and otherwise used (i.e., in other settings),
practice of precision rotational molding, or roto-molding.
[0006] Roto-molding is a process/practice which employs a special
kind of motion-based molding machinery, or machine, utilizing a
pre-formed, precision mold, and associating this mold appropriately
with loading, heating, and cooling zones. In such a practice, and
if desired, several molds may be placed in a roto-molding machine
at the same time. Typically, pre-measured plastic resin of
selectable character is loaded into a mold, and the mold is moved
into an oven where it is slowly rotated on both vertical and
horizontal axes. Resin introduced into the mold before passing of
the mold into the oven, and once heated in the oven, melts and
sticks to the hot mold interior surface, coating every part of that
surface very evenly. The mold continues to rotate during a
subsequent cooling cycle, and as a consequence, each molded
component achieves an even wall thickness, resulting, in accordance
with a specific important feature and practice of the present
invention, in a hollow, initially continuous-walled container
(i.e., a continuum) having a specific, precision outside shape and
surface characteristic.
[0007] This process, i.e., the roto-molding process, enables
economical precision molding of controlled material, controlled
shape, controlled continuous wall thickness, and controlled outside
surface texture and configuration, unitary, hollow, container-like
structures, or containers, which can then, in accordance with
further practice of the invention, be filled with ballistic armor
material, called armor-content material, which is then suitably
stabilized within the hollow interior of the container.
[0008] These important features of the methodology and resulting
structure of the invention, and how they address ultimately all of
the armoring considerations expressed earlier herein, will now be
more fully presented as the detailed descriptions thereof which
follow below are read in conjunction with the accompanying
drawings.
DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a simplified, isometric, broad-facial illustration
of a generally rectangular, hollow-container, ballistic-impact
armor panel, or armor structure, made in accordance with a
preferred practice of the present invention.
[0010] FIG. 2 is an enlarged, fragmentary, partly broken-away, and
somewhat more detailed, schematic edge view of the panel of FIG. 1
with a post-roto-molding, replaceable, removable end portion shown
in two different positions. Removal and replacement of this end
portion exposes and closes an access opening which accommodates
filling of the hollow interior of the roto-molded container with
interior armor material, here shown to include stabilized,
generally parallel-planar layers of somewhat different-constituent
armoring elements (armor-content material).
[0011] FIG. 3 is an enlarged, fragmentary detail, with portions
broken away, taken generally in the region bracketed by curved
arrows 3-3 in FIG. 2.
[0012] FIG. 4 is a simplified side view of a military vehicle,
wherein panel-like, precision-formed and complementarily shaped
armor structure, made in accordance with the present invention, is
installed both in a door, and in a side-panel area, on the side of
this vehicle which faces the viewer in FIG. 4.
[0013] FIG. 5 in an enlarged, removed, fragmentary detail of one of
the armor panels installed in the vehicle of FIG. 4, illustrating
generally how auxiliary, outside-accessible hardware, such as
attaching hardware, may be molded into the wall of the
hollow-container structure portion of the present invention. Such
hardware is also referred to herein as independent, relationship
hardware--the term "relationship" being employed to indicate that
such hardware establishes, for example, an appropriate attaching
relationship for securing a structure (made by practice of the
present invention) to selected, external "receiving structure".
[0014] FIG. 6 is somewhat like FIG. 1--showing a panel-like armor
structure having a quite different perimetral shape.
[0015] FIG. 7 is a fragmentary photo-illustration of armor
structure made in accordance with the invention having a container
which has been roto-molded to possess a ballistic-impact strike
face formed with three-dimensional, precision-molded surface
structure giving the predetermined faux appearance of a stone
wall.
[0016] FIG. 8 is a simplified, schematic view of armor structure
including a decidedly non-rectilinear outside shape.
[0017] In FIGS. 5, 6 and 8, in relation to FIGS. 1-3, inclusive,
common reference characters are employed to identify generally like
structures, like parts thereof, and associated illustration
elements.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Beginning with FIG. 1-3, inclusive, a generally planar,
panel-like, ballistic-impact armor structure 10 made in accordance
with a preferred practice of the present invention is shown. Panel
10, lying generally in a plane 10a (the plane of FIG. 1) includes a
hollow-interior, generally rectilinear container 12 having a wall
12a which was initially formed as an uninterrupted,
closed-container continuum, by precision roto-molding, out of a
selected plastic resin material in accordance with conventional
roto-molding technique(s), as generally described earlier herein.
While different wall thicknesses may be created as desired in
container 12, wall 12a herein has a thickness of about 1/8-inches.
A representative typical range of suitable wall thicknesses, in
accordance with practice of the present invention, is from about
1/8-inches to about 3/16-inches.
[0019] Container 12 may, of course, be formed of any suitable
roto-molding material, and may be shaped/configured in a highly
precision-controlled manner, versatilely and completely by user
selection, by pre-formation (in any convention fashion) of an
appropriate roto-molding mode. With respect to this mold,
dimensions, outside surface texture and "topography", and other
features may be designed to be whatever is desired by a user.
[0020] This versatility and user selectability are what enable the
making, according to the invention, of a jacketing formed container
which can be form-fit complementarily in any one of a number of
different user selectable spaces, and which can possess the
"outside" esthetic/disguising characteristics which may be
desired.
[0021] Container 12 herein is formed of cross-linked polyethylene.
Other very suitable plastic resin materials selectable for use in
the construction of a container, such as container 12, may include
polyethylene, polypropylene, and high-density polyethylene. A
typical molding time for forming such a container might be about
30-minutes. As will become apparent, roto-molding of container 12
to finish with what, at least initially, is a completely continuous
(i.e., a continuum) wall 12a, is beneficial to ultimate container
integrity, and of course to the economy of container manufacture as
well.
[0022] Container 12, which lies essentially in previously mentioned
plane 10a has a hollow interior 12b which is filled, as will
shortly be explained, with internal ballistic armor-content
material 14 (still to be described) which is introduced into this
interior through any suitable form of access opening, such as an
opening created by careful returnable removal of a portion of the
originally formed container, such as the portion shown generally at
12c. Container portion 12c has been appropriately divided from the
remainder of the container, along a parting line 12d formed, for
example, by sawing. With portion 12c removed, line 12d effectively
defines the mentioned access opening to the interior of the
container.
[0023] After initial preparation of hollow container 12 by
roto-molding, and after an appropriate portion, such as portion 12c
shown in FIGS. 1 and 2, of the container has been removed,
preferably returnably, by careful sawing (or otherwise severing) to
expose the inside of the container, insertion and installation of
armor material 14, via opening 12d may take place generally as
indicated (very schematically in FIG. 2) by curved arrow 15. Such
insertion, of course, takes place with container portion 12c moved
out of the way, as is generally indicated by double-headed curved
arrow 17, to a suitably displaced position, such as that shown
generally in dashed lines at 12c in FIG. 2.
[0024] Inserted armor-content material, in a structure like panel
structure 10, is preferably placed in a manner so that it generally
occupies one or more planes, which plane or planes lie(s)
substantially parallel to previously mentioned plane 10a. In the
specific panel armor structure 10 which is illustrated herein,
several such layers of armor-content material are illustrated,
including two layers 16 of side-by-side-adjacent, rectangular,
ceramic tiles 16a, and a plurality of layers, such as layers 18,
formed of aramid-fibre material.
[0025] Other materials which may be employed include various highly
hardened steels, plastic armor sheets, ceramic composites,
compressed fibreglas, or other appropriate armor materials of
otherwise conventional construction.
[0026] These inserted and installed layers of armor-content
material are organized in such a fashion that structure 10 has what
is referred to herein as a linear, ballistic-impact response
directionality which is illustrated by arrow 20 in FIGS. 1, 2 and
3--i.e., the direction in which the structure is preferably
oriented to receive any ballistic impact. The "line" of arrow 20 is
the line of ballistic-response directionality herein. In container
12 of structure 10, tiles 16a are located more closely adjacent the
"impact-intended" side (the so-called strike-face side 12e) of the
container than are aramid-fibre layers 18. Strike-face side, or
strike face, 12e (which, in container 12, is generally planar)
extends across the directionality line of arrow 20.
[0027] The layer, or layers, of inserted and installed
armor-content material are suitably stabilized on the inside of
container 12, with stabilizing material herein shown at 22. In
structure 10, material 22 takes the form preferably of a poured-in
high-elastomeric material, such as the product known as TUFF
STUFF.RTM. FR made by Rhino Linings USA, Inc. in San Diego,
Calif.
[0028] Other stabilizing materials which may be used if desired
include expanded urethane foam, or appropriately driven-in wedges
of a material, such as a urethane material. Such a wedge is shown
very schematically in dashed lines at 24 in FIG. 2.
[0029] Following full installation and appropriate stabilizing of
armor-content material 14, removed container portion 12c, in the
particular practice of the invention now being described, is
restored and returned to a position closing off the interior of the
container. It is appropriately secured in its returned condition
through gluing or heat welding, or in any other appropriate manner.
One consideration in this context is that this "removed portion"
may be re-anchored in position through an appropriate adhesive
which offers the opportunity for later removal for internal
panel-structure repairs following a damaging ballistic event.
[0030] Describing briefly another container "reclosing" approach,
it is entirely acceptable to return "opened" container 12 to a
fully re-enclosed condition by closing off the installation opening
in the container with an appropriate cap structure which may not be
the portion of the container removed initially to expose the
container's interior.
[0031] As was mentioned earlier, the roto-molding process which is
employed to create container 12 in structure 10 offers a great deal
of versatility and selectability in terms of shape and outside
surface quality. For example, and turning attention for a moment to
FIG. 4 in the drawings, here, shown generally at 26 is a military
vehicle wherein several panels made in accordance with practice of
the present invention have been form-fittingly roto-molded, at
least with respect to their containers, for complementary fitment
in predefined spaces (preselected reception spaces) existing in
this vehicle. For example, a generally rectangular, panel-like
armor structure 28 (seen in dash-dot lines) has been installed
form-fittingly, i.e., complementarily, in a preselected reception
door space 30 which exists within a passenger door panel 32 located
on the side of vehicle 26 that faces the viewer in FIG. 4. The fit
which exists between structure 28 and space 30 is referred to
herein as a complementary utility fit.
[0032] Similarly, two somewhat differently perimetrally shaped,
container-formed panel-like armor structures, shown by dash-dot
lines 34, 36, are complementarily fitted into a receiving space (or
spaces) firnished in the near side of vehicle 26 in FIG. 4 in the
region immediately behind door panel 32. Structures 34, 36, which
are shown vertically next adjacent one another as illustrated by
dash-triple dot line 38, may, if desired, be formed (i.e.,
roto-molded) simply as a single structural unit.
[0033] As was also mentioned earlier, and turning attention now
specifically to FIG. 5 in the drawings, a container-formed armor
structure, like structure 10, may be formed in such as fashion
that, during roto-molding of its container, appropriate externally
exposed hardware, such as the attaching hardware shown generally at
40 in FIG. 5, may be molded into the container wall, such as into
container wall 12a, to be exposed through a wall opening, such as
the wall opening shown at 12a.sub.1 in FIG. 5. Attaching structure
40 may be appropriately provided with anchoring structure, such as
that shown at 40a, which becomes embedded within the material
forming the container wall.
[0034] Such hardware, of any category, may be installed to
facilitate securing of an armor structure in place (i.e., to
facilitate an attaching "relationship" with external structure),
such as might be required with respect to the several-panel
installations shown in FIG. 4 in vehicle 26. As was mentioned
earlier herein, this hardware, which, strictly speaking, is
independent of a roto-molded container, per se, is also referred to
herein as independent, relationship hardware.
[0035] FIG. 6 shows yet another panel-like armor structure 10
having a still quite different perimetral outline. Reference
numerals are employed in FIG. 6, in a manner whereby structural
components, and associated features, that are like those described
with respect to FIGS. 1-3, inclusive, are commonly/similarly
labeled. Those generally skilled in the relevant art will
appreciate that FIG. 6 is essentially self-explanatory.
[0036] Turning to FIG. 7 in the drawings, here, shown generally at
42, is a panel-like, ballistic-impact armor structure whose strike
face 42a has been roto-molded to simulate the appearance of a stone
wall, including the "faux-appearance" look of mortared-together
"stone elements", such as those shown at 42. FIG. 7 thus provides a
very clear illustration of the capability of the present invention,
in its practice, to enable outside surface formation in a manner
providing an aesthetic and/or otherwise disguising
appearance--readily enabled during, and as a consequence of, the
versatile roto-molding approach toward the making of the formed
container portion of the armor structure of the present
invention.
[0037] FIG. 8 in the drawings, also employing a reference-character
scheme like that used in FIGS. 1-3, inclusive, shows a distinctly
non-rectilinear, non panel-like armor structure 10 with a specially
compoundly-curvedly-shaped, roto-molded container 12 filled with
appropriate armor-content material 14. As stated with respect to
FIG. 6 above, FIG. 8 is also essentially self-explanatory.
[0038] From what has been presented above, it will be apparent that
one way of describing the methodology of the present invention is
to characterize it as featuring a method for forming a
ballistic-impact armor structure having a defined, precision shaped
outside configuration, with this method including the steps of (a)
precision-creating a hollow container having the desired, defined
outside configuration, (b) introducing ballistic armor-content
material into the interior of the created container, (c)
positionally stabilizing the introduced armor-content material, and
(d) unifying the armor-content material with the container.
[0039] This methodology may be further viewed as one wherein the
mentioned precision-creating step is implemented by
precision-roto-molding the container as a closed continuum, and
thereafter, in terms of carrying out the introducing step, (1)
first providing an access opening in the container continuum, and
then (2) implementing the armor-content introducing step, per se,
by inserting the armor-content material through that access
opening.
[0040] Thus, a unique formed-container armor structure, and an
appropriate roto-molding methodology for container formation, have
been illustrated and described herein. They have been described and
illustrated in a manner which clearly demonstrates the ability of
the present invention to meet all of the special and important
considerations and concerns/desires of the current state of the art
with respect to furnishing armor structure of the type discussed
earlier and above herein. Formed-container structures may be
created in a very wide variety of sizes, configurations and surface
qualities to meet a very side range of needs.
[0041] The preferred roto-molding container-forming process is, as
described, a precision process which enables the construction of
armor structures, in accordance with the present invention,
designed to form-fit complementarily in a wide variety of
differently shaped receiving spaces. Roto-molding offers, in the
setting of the present invention, numerous design advantages over
other container-forming processes. The roto-molding process, for
example, has a number of inherent design strengths, such as
consistent wall thickness and strong outside corners that are
virtually stress free. If additional strength is required, for
example in a container to be employed in the present invention,
appropriate reinforcing ribs can be designed into such a container.
Additives to help make a container weather resistant, flame
retardant, or static free can be specified. As suggested, or
hinted-at, above, inserts, and other things, such as threads,
handles, minor undercuts, flat surfaces that eliminate draft angles
or fine surface detail can all be part of a container's design.
[0042] Different specific arrangements and materials may be
employed for specific armor structure components (armor-content
materials) which are inserted into the interior of the proposed,
roto-molded formed container, with these installed armor components
stabilized in any one of a number of different suitable ways. If
desired, an originally created access opening provided to the
interior of the once (i.e., initially) continuous-walled container
may be closed in such a fashion that the container may be reopened
later if desired to perform internal repairs after a damaging
ballistic event. Armor structures constructed in accordance with
the invention are preferably made with a ballistic impact
directionality as mentioned.
[0043] Accordingly, while a preferred embodiment of, and manner of
practicing, the present invention has been presented herein, and
several variations and modifications have been suggested, it is
appreciated that many variations and modifications, other than
those specifically pointed out herein, may be made without
departing from the spirit of the invention.
* * * * *