U.S. patent application number 12/920497 was filed with the patent office on 2011-01-13 for transportable modular system permitting isolation of assets.
Invention is credited to Nicholas Boone, Toney K. Cummins, James L. Davis, Bartley P. Durst, Andrew B. Edwards, Jason D. Edwards, Jerry C. Edwards, William F. Heard, Carol F. Johnson, Pamela G. Kinnebrew, Reed Mosher, Robert A. Pilgrim, Michael J. Roth, Shane H. Sanford, Thomas R. Slawson, Ryan Stinson.
Application Number | 20110005695 12/920497 |
Document ID | / |
Family ID | 41065758 |
Filed Date | 2011-01-13 |
United States Patent
Application |
20110005695 |
Kind Code |
A1 |
Boone; Nicholas ; et
al. |
January 13, 2011 |
Transportable Modular System Permitting Isolation of Assets
Abstract
A system comprising inexpensive composite panels and a
configuration that holds them, all components of which are man
portable. Select embodiments protect assets against external force
and impacts from airborne projectiles. An open box-like stackable
frame module holds thin panels along a longitudinal axis of the
frame. Multiple frames a reconnected to construct a protective
barrier, such as a wall. The panels may be formulated of a very
high strength portland cement-based concrete with one side, both
sides, or both sides and all edges, covered with elastic material,
the combination of which significantly reduces penetration of
projectiles. A panel may be covered with specially formulated
elastic material comprising multiple layers, each layer of a
different type or thickness of elastic material. The elastic
material may include reinforcing material such as fabric woven from
available COTS high-strength fibers. The panels may be fabricated
using basic means available in rural locations. A method of
installing is also provided.
Inventors: |
Boone; Nicholas; (Vicksburg,
MS) ; Durst; Bartley P.; (Clinton, MS) ;
Cummins; Toney K.; (Vicksburg, MS) ; Kinnebrew;
Pamela G.; (Vicksburg, MS) ; Heard; William F.;
(Clinton, MS) ; Slawson; Thomas R.; (Vicksburg,
MS) ; Roth; Michael J.; (Raymond, MS) ;
Stinson; Ryan; (Prairieville, LA) ; Mosher; Reed;
(Vicksburg, MS) ; Davis; James L.; (Vicksburg,
MS) ; Johnson; Carol F.; (Vicksburg, MS) ;
Edwards; Jerry C.; (Huntsville, AL) ; Edwards; Andrew
B.; (Toney, AL) ; Edwards; Jason D.;
(Meridianville, AL) ; Sanford; Shane H.;
(Franklin, TN) ; Pilgrim; Robert A.; (Benton,
KY) |
Correspondence
Address: |
Albuquerque Engineer District;ATTN: CESPA-OC
4101 Jefferson Pl. NE
Albuquerque
NM
87109-3434
US
|
Family ID: |
41065758 |
Appl. No.: |
12/920497 |
Filed: |
March 2, 2009 |
PCT Filed: |
March 2, 2009 |
PCT NO: |
PCT/US09/35703 |
371 Date: |
September 1, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61033061 |
Mar 3, 2008 |
|
|
|
Current U.S.
Class: |
160/377 ;
160/379; 160/405 |
Current CPC
Class: |
F41H 5/04 20130101; F41H
5/013 20130101; F41H 5/0414 20130101; E04H 9/04 20130101 |
Class at
Publication: |
160/377 ;
160/379; 160/405 |
International
Class: |
E04C 2/38 20060101
E04C002/38; E04B 1/343 20060101 E04B001/343 |
Goverment Interests
STATEMENT OF GOVERNMENT INTEREST
[0002] Under paragraph 1(a) of Executive Order 10096, the
conditions under which this invention was made entitle the
Government of the United States, as represented by the Secretary of
the Army, to an undivided interest therein on any patent granted
thereon by the United States. Research supporting at least part of
the work described herein was accomplished with the United States
Gypsum Company under a Cooperative Research and Development
Agreement, CRADA-05-GSL-04, dated 20 May 2005. This and related
patents are available for licensing to qualified licensees. Please
contact Phillip Stewart at 601 634-4113.
Claims
1. A configuration providing isolation of assets, comprising: a
quadrilateral frame module with an open top and an open bottom,
comprising: one each mount of a first type at each of four corners
of said module establishing extremities of said top, one each mount
of a second type at each of said four corners establishing
extremities of said bottom, wherein said mount of a first type is
connectable to said mount of a second type on another said module
to permit vertical stacking of said frame modules, and wherein said
mount of a first type is connectable to an abutted said mount of a
first type to permit horizontal connection of said frame modules
one to another; a pair of cross members in compression on each of
said four sides of said frame module, each said cross member
establishing a diagonal connection between a said first type of
mount and a said second type of mount, wherein each said cross
member of said pair is pivotally joined at the center to the other
said cross member of said pair, and wherein each said cross member
is pivotally joined to one said mount of a first type and one said
mount of a second type to allow pivoting of said pair of cross
members in a plane parallel to said side containing said pair of
cross members; and at least first and second members in tension on
each said side, ends of one first member in tension attached
horizontally to each said mount of a first type in each said side
and ends of one second member in tension attached horizontally to
each said mount of a second type in each said side; at least one
pair of z-bars comprising integral open channels facing opposite
directions and raised slots at each end on one side for indexing
said z-bar to said module, each said z-bar incorporating an
adjustable tensioner at each end, wherein said z-bars are affixed
along at least a first side of said frame module, each end of a
first z-bar of said pair affixed to one of two said mounts of a
first type at the extremities of the top of said first side and
each end of a second z-bar of said pair affixed to two said mounts
of a second type at the extremities of the bottom of said first
side; four leveling pads indexed to each bottom corner of said
module via at least one first type of rod in each said pad that
mates with an opening in said mount of a second type, wherein each
said pad is in operable communication both with at least one each
said mount of a second type and a surface upon which said pads
rest; and wherein said second type of mount is connectable to said
leveling pad when said second type of mount is employed in modules
that are a base of said configuration, and wherein said pads may
accommodate up to at least three said mounts of a second type;
panels having a length, width and depth; wherein said panels are
mounted on at least one said side of said configuration in each
said pair of z-bars to provide said isolation.
2. The configuration of claim 1 in which said leveling pads are
adjustable at least in height.
3. The configuration of claim 2 in which said pads further
comprise: a bottom plate configured to accept a non-threaded end of
a second type of rod having a threaded portion; a top plate
configured to accept said threaded portion of said rod of a second
type in a matching threaded bearing in the center of said top
plate; wherein said rod is in operable communication with said
bottom plate and said top plate and configured to be rotated and
moved in relation to said top plate using a COTS tool for adjusting
the height of said module.
4. The configuration of claim 1 in which all components of said
configuration are man transportable and at least some said
components comprise at least steel having at least a corrosion
resistant finish.
5. The configuration of claim 1 in which the length, width and
height of said frame modules are equal.
6. The configuration of claim 1 in which said z-bars comprise
integral first and second open rectangular channels, the open
portion of a first said channel facing to said top and the open
portion of a second said channel facing to said bottom of said
configuration, said channels incorporating open ends, said z-bars
much longer in length than either width or depth.
7. The configuration of claim 1 in which said panels are
quadrilateral in dimension, wherein said length and said width are
much greater than said depth.
8. The configuration of claim 1, said panels further having a
pre-specified resistance to penetration, wherein said panels having
a pre-specified resistance to penetration provide protection of
assets from physical damage due to dynamic force.
9. The configuration of claim 1 in which said members in tension
comprise wires, wherein for each said module, four said wires are
employed with said mounts of a first type and four said wires are
employed with said mounts of a second type.
10. The configuration of claim 1 in which said panels are installed
on two opposing sides of said configuration.
11. The configuration of claim 1 comprising panels that overlap on
at least one said side as installed in said z-bars.
12. The configuration of claim 1 in which said cross members have a
quadrilateral cross section.
13. The configuration of claim 1, said frame modules foldable to
facilitate storage and transport.
14. A method for isolating assets via a modular configuration,
comprising: a) providing and unfolding a quadrilateral frame module
with an open top and an open bottom, comprising: one each mount of
a first type at each of four corners of said module establishing
extremities of said top, one each mount of a second type at each of
said four corners establishing extremities of said bottom, wherein
said mount of a first type is connectable to said mount of a second
type on another said module to permit vertical stacking of said
frame modules, and wherein said mount of a first type is
connectable to an abutted said mount of a first type to permit
horizontal connection of said frame modules one to another; a pair
of cross members in compression on each of said four sides of said
frame module, each said cross member establishing a diagonal
connection between a said first type of mount and a said second
type of mount, wherein each said cross member of said pair is
pivotally joined at the center to the other said cross member of
said pair, and wherein each said cross member is pivotally joined
to one said mount of a first type and one said mount of a second
type to allow pivoting of said pair of cross members in a plane
parallel to said side containing said pair of cross members; and at
least first and second members in tension on each said side, ends
of one first member in tension attached horizontally to each said
mount of a first type in each said side and ends of one second
member in tension attached horizontally to each said mount of a
second type in each said side; b) providing at least one pair of
z-bars comprising integral open channels facing opposite directions
and raised slots at each end on one side for indexing said z-bar to
said module, each said z-bar incorporating an adjustable tensioner
at each end, affixing said z-bars along at least a first side of
said frame module by indexing each end of a first z-bar of said
pair to one of two said mounts of a first type at the extremities
of the top of said first side and indexing each end of a second
z-bar of said pair to two said mounts of a second type at the
extremities of the bottom of said first side; c) providing four
leveling pads; d) placing said pads on a level surface spaced to
approximate the spacing of the four corners of a said frame module;
e) indexing each said pad to each bottom corner of a first said
module via at least one first type of rod incorporated in each said
pad that mates with an opening in said mount of a second type,
wherein each said pad is in operable communication both with at
least one each said mount of a second type and a surface upon which
said pads rest; and wherein said second type of mount is
connectable to said leveling pad when said second type of mount is
employed in modules that are a base of said configuration, and
wherein said pads may accommodate up to at least three said mounts
of a second type; f) providing two additional said pads per a
second and each succeeding said frame module to be connected to
existing installed said modules to comprise said modular
configuration, each said addition of said second and succeeding
frame modules comprising: 1) repeating steps (a) and (b); 2)
placing said two pads on a level surface, spaced to approximate the
spacing of two of the four corners of an additional said frame
module to be abutted to said installed frame module; 3) indexing
each of two said pads employed in installing said installed frame
module to each mount of a second type on the side of said
additional frame module abutting said first frame module and in a
similar manner indexing said additional two pads to remaining said
mounts of a second type on said additional frame module; 4)
adjusting the height of said leveling pads now associated with said
additional frame module to permit connection of said mounts of a
first type on the abutting sides of said installed and additional
frame modules to be connected together and approximately level; 5)
providing panels having a length, width and depth; 6) mounting said
panels on at least one said side of said configuration in each said
pair of z-bars in each said frame module incorporated in said
configuration as a base of said configuration; 7) checking openings
between installed panels, 8) re-adjusting the height of said
installed modules to minimize any said openings above a
pre-specified value; 9) setting tension of said adjustable
tensioners to a pre-specified value; and g) repeating steps a)-f)
until a pre-specified length of said configuration is
established.
15. The method of claim 14 further comprising installing said
panels on two opposing sides of said configuration.
16. The method of claim 14 further comprising installing overlapped
said panels on at least one said side of said configuration.
17. The method of claim 14 connecting said mounts of a first type
via fitting rivet heads on a first abutting said frame module to
rivet slots on a second abutting said frame module.
18. The method of claim 14 stacking additional said frame modules
directly upon first installed said modules to increase the height
of said configuration, further comprising. a) providing and
unfolding at least one said quadrilateral frame module; b)
selecting said at least one pair of said z-bars; c) indexing a
first said z-bar along at least a first side of said frame module,
affixing each end of said first z-bar of said pair to one of two
said mounts of a first type at the extremities of the top of said
first side and affixing each end of a second said z-bar of said
pair to two said mounts of a second type at the extremities of the
bottom of said first side; d) indexing each said mount of a first
type on said installed frame modules to a below corresponding said
mount of a second type on said additional stacked frame module via
said at least one first type of rod; e) adjusting the height of
said leveling pads now associated with abutting said stacked frame
modules to permit approximately level connection of said mounts of
a first type on the abutting sides of said stacked frame modules;
f) selecting said panels; g) mounting said panels on at least one
said side of said stacked frame modules; h) checking openings
between all said installed panels, i) re-adjusting the height of
said installed frame modules to minimize any said openings above a
pre-specified value; j) setting tension of said adjustable
tensioners of said z-bars affixed to said stacked frame modules to
a pre-specified value; and k) repeating steps (a)-(j) until a
pre-specified length of said configuration is established.
19. The method of claim 18 further comprising installing said
panels on two opposing sides of said stacked frame modules.
20. The method of claim 18 further comprising installing overlapped
said panels on at least one said side of said stacked frame
modules.
Description
RELATED APPLICATIONS
[0001] This application is filed as a national stage under U.S.C.
.sctn.371, of International Application No. PCT/US09/35,703, filed
Mar. 2, 2009, which claims the benefit under 35 U.S.C.
.sctn.119(e)(1) of U.S. Provisional Patent Application Ser. No.
61/033,061, Transportable Modular System Permitting Isolation of
Assets, filed Mar. 3, 2008, both incorporated herein by reference.
This application is also related to U.S. Provisional Patent
Application No. 61/033,240, Method of Manufacturing Cement Based
Armor Panels filed Mar. 3, 2008; U.S. patent application Ser. No.
12/394,448 filed Feb. 27, 2009 which claims the benefit under 35
U.S.C. .sctn.119(e)(1) of U.S. Provisional Patent Application No.
61/033,212, A Self-Leveling Cementitious Composition with
Controlled Rate of Strength Development and Ultra-High Compressive
Strength upon Hardening and Articles Made from Same filed Mar. 3,
2008; U.S. patent application Ser. No. 12/394,396, which claims the
benefit under 35 U.S.C. .sctn.119(e)(1) of U.S. Provisional Patent
Application No. 61/033,264, Cement Based Laminated Armor Panels;
U.S. patent Ser. No. 12/394,564 filed Feb. 27, 2009 which claims
the benefit under 35 U.S.C. .sctn.119(e)(1) of U.S. Provisional
Patent Application No. 61/033,258, Cement Based Armor Panel System,
filed Mar. 3, 2008; and International Application No.
PCT/US09/35,707, filed Mar. 2, 2009, which claims the benefit under
35 U.S.C. .sctn.119(e)(1) of International Application No.
PCT/US09/35,707, filed Mar. 2, 2009, which claims t he benefit of
U.S. Provisional Patent Application Ser. No. 61/033,059,
Transportable Modular Configuration for Holding Panels, filed Mar.
3, 2008, all the above incorporated herein by reference.
BACKGROUND
[0003] It is important to protect both material and personnel from
catastrophe, especially in cases where the probability of
occurrence is greater than the norm. Conventionally, both temporary
and permanent means may be used for this purpose, depending on the
scenario. For example, a permanent military facility may best be
protected by a permanent configuration, whereas a mobile field unit
would best be served by a temporary, but not necessarily less
effective, configuration. Conventionally, protection against
manmade catastrophe, such as occurs in war zones, has been provided
with large bulky concrete structures or earthen embankments that
require heavy equipment to produce, whether temporary or permanent.
Needs for protective structure may include barriers to prevent
personnel access, vehicular intrusion, or even line-of-site access
in the case of a sniper, as well as protective enclosures for
emergency response personnel or revetments for high value assets.
Because of constraints such as geography, response time,
availability of both material and heavy equipment, and the like,
select embodiments of the present invention that provide good
protection for both personnel and valued assets are of value for
protection of both military and community assets.
[0004] To protect personnel and resources, military organizations
use a variety of protective materials ranging from soil cover to
expensive, high-performance, lightweight ballistic ceramics. A need
exists for an inexpensive blast and fragmentation barrier for
large-area applications, such as forward facilities, installation
and structure perimeters, and both interior and exterior protective
upgrades. Certain applications call for panels that may be emplaced
on robust platforms, both the modular platform sections and panels
being of sufficiently light weight to be man portable.
[0005] Select embodiments of the panels of the present invention
have excellent energy absorbing capacity against blast and
ballistic penetration forces. This capacity is often described as
toughness, a term also associated with the tensile strength of
concrete. Select embodiments of the panels of the present invention
obtain their strength and toughness qualities through engineering
of the type and quantity of component materials.
[0006] When combined with an elastic outer layer, the core of
select embodiments of the panels of the present invention reduces
fragment velocities as compared to existing core materials that
cost more, weigh more, and require greater thickness to achieve the
same kinetic energy reduction. Cost is reduced by employing high
performance concrete materials as a core. Use of multi-dimensional,
discrete and continuous fibers of various material compositions
distributed throughout the core matrix optimizes strength and
toughness. Coating or covering the inexpensive core with a tough
pliable material provides the necessary "toughness" to dampen or
completely eliminate through penetration of fragments and debris
from an event such as a hurricane, nearby explosion or even
penetration by munitions.
[0007] Select embodiments of both the panels and the box-shaped
platform modules of the present invention are man portable.
Systems, such as walls, employing select embodiments of the present
invention are designed to replace existing systems that are
heavier, e.g., those that employ thicker panels comprising
materials conventionally used for protection from ballistic
sources. Because some existing systems are made from exotic
materials, such as ceramics, they are also more expensive than
embodiments of the present invention.
[0008] A need also exists for inexpensive protective cladding with
superior resistance to wind damage, including penetration of debris
generated by natural forces, such as tornadoes and hurricanes.
Although select embodiments of the present invention may be used as
ballistic armor, connectors, protective construction,
blast-resistant panels, protection against fragmenting munitions,
vehicle up-armoring, forced entry resistant structural elements,
other applications include strengthening of building components
such as walls, floors and ceilings. Because select embodiments of
the panels of the present invention have high strength and
toughness, they are suitable for use in new construction of
residential housing as structural members that are resistant to the
natural forces and debris impact of tornadoes and hurricanes and in
commercial security situations such as the construction of bank
vaults and armor protective enclosures.
BRIEF DESCRIPTION OF DRAWINGS
[0009] FIG. 1 is a perspective view of components of panels of a
first generic embodiment of the panels that may be used with
embodiments of the present invention.
[0010] FIG. 2 is a perspective view of components of panels of a
second generic embodiment of the panels that may be used with
embodiments of the present invention.
[0011] FIG. 3 is a perspective view of components of panels of a
third generic embodiment of the present invention and a perspective
view of a resultant generic embodiment of the panels that may be
used with embodiments of the present invention.
[0012] FIG. 4 is a perspective view of components of panels of a
fourth generic embodiment of the panels that may be used with
embodiments of the present invention.
[0013] FIG. 5A is a perspective view of components of panels of a
fifth generic embodiment of the present invention and a perspective
view of a resultant generic embodiment of panels as may be used
with the present invention comprising these components.
[0014] FIG. 5B is a perspective view of the components of FIG. 5A
in an alternate resultant generic embodiment of panels as may be
used with the present invention comprising these components.
[0015] FIG. 5C is an end view through a cross section of two
alternative geometries of an outer covering of the resultant
generic embodiment of panels of the present invention as is
represented in FIG. 5A.
[0016] FIG. 6 is a longitudinal side elevation view of a single
box-shaped platform and single installed panel thereon that may be
employed in embodiments of the present invention.
[0017] FIG. 7 is a top plan view of the single box-shaped platform
of FIG. 6 that may be employed in embodiments of the present
invention.
[0018] FIG. 8 is a top plan view of a bottom plate connector, as
well as elevation views of the two vertical outer sides of the
connector that may be employed in embodiments of the present
invention, one of four such bottom plate connectors on each of the
box-shaped platform modules of FIG. 6.
[0019] FIG. 9 is a top plan view of a top plate connector, as well
as elevation views of the two vertical outer sides of the connector
that may be employed in embodiments of the present invention, one
of four such top plate connectors on each of the box-shaped
platform modules of FIG. 6.
[0020] FIG. 10 illustrates how a corner is formed using box-shaped
platforms and panels of embodiments of the present invention.
[0021] FIG. 11 shows detail of an adjustment unit that may be used
with embodiments of the present invention to adjust height of
individual box-shaped platform modules to match modules connected
therewith.
[0022] FIG. 12 shows plan and edge views of a "z-bar" employed to
hold panels onto individual platform modules that may be used in
embodiments of the present invention.
[0023] FIG. 13 is a perspective of the basic structure of a
box-shaped platform module expanded for installation of panels, to
include z-bars, compression and members in tension and top and
bottom mounts that may be used with embodiments of the present
invention.
[0024] FIG. 14 is a perspective of the basic structure of a
platform module collapsed for transportation or storage without
z-bars and members in tension that may be used with embodiments of
the present invention.
[0025] FIG. 15 is an elevation view of a longitudinal side of a
box-shaped wall comprising three long by two high interconnected
box-shaped platform modules that may be employed in embodiments of
the present invention, and a single installed panel thereon for
illustration purposes only.
[0026] FIG. 16 shows plan and elevation views of a strap that may
be employed to constrain the z-bars in the box-shaped platform
modules of an embodiment of the present invention after
installation of the panels in the z-bars.
DETAILED DESCRIPTION
[0027] Select embodiments of the present invention comprise
transportable components for fortifying an area. Select embodiments
of the present invention include opaque blast and projectile
resistant panels and rectangular box-shaped platform modules for
holding the panels in order to provide a secure perimeter. The
panels are resistant to sudden impulses such as may occur with
explosions or impact with projectiles and also shield what they are
protecting from view of possible adversaries.
[0028] In select embodiments of the present invention, a
transportable configuration provides protection for assets. Main
components of select embodiments of the present invention comprise
an open stackable frame of a length greater than or equal to the
width, the width in turn less than or equal to the height. A frame
comprises four sides, eight corners and an open top and bottom. In
select embodiments of the present invention the frame comprises:
mounts at each of its eight corners, four of the mounts being of a
first type and located at the top of the frame and four of the
mounts being of a second type and located at the bottom of the
frame such that the first and second types are able to be
interlocked via suitable means to permit vertical stacking as well
as horizontal connection of the frames one to another; a pair of
cross members in compression on each side of the frame, such that
each cross member of a pair is pivotally joined at the center to
the other cross member of the pair thereby allowing pivoting of the
pair of cross members in one plane, and such that each cross member
is also pivotally joined to one top mount of a first type and one
bottom mount of a second type thereby allowing pivoting of the
connected pair of cross members in one plane; and two or more
members in tension on each side of the frame, a first member in
tension attached to the top mounts of a first type and a second
member in tension attached to a bottom mounts of a second type;
pairs of z-bars to be affixed, in one embodiment, along a first
longitudinal side of the frame, ends of one of the z-bars affixed
to the top mounts of a first type and ends of the second z-bar of a
pair affixed to two bottom mounts of a second type; tensioning
means for securing the ends of the z-bars to the top and bottom
mounts; four height adjustable bases, on which rest the bottom
mounts of a second type; and panels, preferably quadrilateral,
having a length and width either of which is much greater than the
depth of a panel, the panels having a pre-specified resistance to
blast and penetration by airborne projectiles such that when the
panels are mounted in the z-bars on the frame the combination
provides physical protection of assets on the side of the
configuration away from the origination of any blast and airborne
projectiles.
[0029] In select embodiments of the present invention, third and
fourth z-bars are mounted on the longitudinal side of the frame
opposite the longitudinal side on which the first two z-bars are
mounted. These z-bars accommodate mounting optional panels on the
"back" side (the side away from the origin of external hazards) of
the frame.
[0030] In select embodiments of the present invention, the cross
members are of tubular construction and further comprise means for
pivotally connecting each cross member of a pair of cross members
at the respective approximate center of each cross member. For
example, the means for pivotally connecting may be a bushed rivet
or clevis pin. In select embodiments of the present invention the
cross members are metal tubes having a quadrilateral cross section,
e.g., a square or rectangular cross section.
[0031] In select embodiments of the present invention, the members
in tension are braided wires affixed to the plates horizontally,
e.g., via rivets through holes in the plates and end loops on the
braided wire from one top plate to another top plate and from one
bottom plate to another bottom plate, all on the same frame
module.
[0032] In select embodiments of the present invention, the z-bars
are formed from sheet metal and incorporate means for positioning
them on the frame and tensioning means for attaching the z-bars to
the appropriate mounts, i.e., to top mounts for bottom z-bars and
vice versa.
[0033] In select embodiments of the present invention, the
configuration mounts are formed from sheet metal and further
comprise: means for positioning the z-bars to the frame, for
example an "external slot," and means for attaching the tensioning
means for connecting the z-bars to the mounts, e.g., a strap with
hook on one end and a tightening ratchet on the other end; means
for connecting to the first and second members in tension, e.g.,
slots or holes to which a wire may be affixed via a rivet or the
like; channels for positioning the cross members at the mounts,
e.g., vertical tabs incorporating attachment holes, the tabs
affixed by suitable means such as "tack welding" to the base of the
mounts; and means for connecting each end of the cross members in
the channels, e.g., bushed pins such as clevis pins or the
like.
[0034] In select embodiments of the present invention, the
adjustable bases comprise: a first mount for affixing the mounts of
a second type, the mount incorporating a first threaded collar
approximately centered in the first mount; a threaded rod
incorporating means for moving, such as an affixed hex nut, the
threaded rod in the first threaded collar to raise and lower the
first mount; and a second reinforced mount incorporating a second
collar for receiving the threaded rod, so that the threaded rod may
be turned via the means for moving to adjust the height of the
adjustable base to facilitate interconnecting a frame module to
adjoining frame modules.
[0035] In select embodiments of the present invention, the
quadrilateral panels comprise a core of very high strength concrete
having elastic material bonded to at least one side, the side
defined by the length and the width of the quadrilateral panel, the
depth or thickness of the panel much less than either the length or
width. In select embodiments of the present invention, the
quadrilateral panel incorporates elastic material bonded to both
its sides. In select embodiments of the present invention, the
quadrilateral panels incorporate elastic material bonded to the
outside of the quadrilateral panel. In select embodiments of the
present invention the elastic material completely encapsulates the
panel.
[0036] In select embodiments of the present invention, the
quadrilateral panels further comprise means for suspending them
from the frame, e.g., grommets, tabs and the like.
[0037] In select embodiments of the present invention, the frames
employ four or more connection pins, such as steel bar stock of
circular cross section with both ends chamfered to facilitate
insertion of the pins, to affix each bottom mount of a second type
to each adjustable base as well as to affix vertically stacked
frames to those below.
[0038] In select embodiments of the present invention, a method of
installing a transportable configuration that provides protection
for assets, comprises: providing an open stackable frame having a
length greater than or equal to a width that is less than or equal
to a height, four sides, and eight corners, the frame comprising:
mounts at each of the eight corners of the frame, such that a first
four mounts are of a first type located at the top of the frame and
a second four mounts are of a second type located at the bottom of
the frame, a pair of cross members in compression on each side of
the frame, such that each cross member of a pair is pivotally
joined at the center to the other cross member of the pair to allow
pivoting of the pair of cross members in one plane, and such that
each cross member is pivotally joined to one top mount of a first
type and one bottom mount of a second type so as to allow pivoting
of the pair of cross members in one plane; and two or more members
in tension on each side of the frame, tension provided from a
member such as a braided wire, a first member in tension attached
to the top mounts and a second tension member attached to the
bottom mounts. The method further provides z-bars, the z-bars
affixed along a longitudinal side of the frame, ends of a first
z-bar affixed to two top mounts and ends of a second z-bar affixed
to two bottom mounts; providing tensioning means in a vertical
plane, such as braided wires adjustable for amount of tension,
connectable to each end of the z-bars; providing adjustable bases
such that each base supports a bottom mount for one or two frames
depending on the position of the frames in a final protective wall;
providing four or more connection pins for affixing each frame to
the four adjustable bases; and providing quadrilateral panels
having a pre-specified resistance to blast and penetration by
airborne projectiles; transporting said configuration to a location
having assets requiring physical protection and unloading the
configuration from its transporting means, such as a truck. The
method further comprises completing the following steps to result
in a protective wall for the assets: a) arranging the adjustable
bases on the desired substrate, e.g., the ground, to permit
placement of the frames thereon and adjusting the bases to be about
six turns from bottoming out; b) leveling the adjustable bases with
respect to the substrate; c) placing a first frame on four
adjustable bases; d) connecting the frame to its adjustable bases
with four connection pins; e) further arranging two adjustable
bases for holding one side of an initially adjoining frame to the
originally placed frame, leveling the two adjustable bases, placing
the adjoining frame on the two adjustable bases common to the
initially placed frame and the two further arranged adjustable
bases; f) connecting the adjoining frame to the adjustable bases on
the one side common to the initially placed frame; g) connecting
the adjoining frame to the two further arranged adjustable bases;
h) leveling the initially placed frame by adjusting the adjustable
bases to facilitate joining the initially placed frame and the
adjoining frames at the top mounts; i) connecting the initially
placed frame and the adjoining frames at adjoining top mounts; j)
along the length of the frame, attaching a z-bar at the top of each
installed frame and a second z-bar at the bottom of each installed
frame; k) employing the tensioning means at the ends of each z-bar,
securing the z-bars to the frame; l) inserting the quadrilateral
panels between the top and bottom z-bars along the length of each
installed frame; and m) repeating steps a) through l) treating each
added frame as an initially added frame until a pre-specified
length of said protective wall is attained.
[0039] In select embodiments of the present invention, the method
of installation further comprises installing third and fourth
z-bars on the side of the frame opposite that on which the first
and second z-bars are installed, installing the third and fourth
z-bars in a manner identical to that of installing the first and
second z-bars; and inserting quadrilateral panels between the third
and fourth z-bars along the length of each installed frame.
[0040] In select embodiments of the present invention, the method
of installation further comprises: a) stacking a frame module above
each frame module of an initially installed protective wall, b)
attaching each bottom mount of the added frame module to a
corresponding top mount of the initially installed frame module
using a connection pin per connection; c) as necessary, further
leveling the adjustable bases with respect to the substrate to
facilitate joining each stacked frame module to an adjoining
stacked frame module at the respective top mounts; d) connecting
the stacked frame modules at adjoining top mounts, e.g., via a
rivet and slot arrangement; e) along one side of the length of the
stacked frame module, attaching a z-bar at the top of each
installed stacked frame module; f) employing the tensioning means
at the ends of each newly installed z-bar, securing the newly
installed z-bars to the stacked frame module; g) inserting
quadrilateral panels between the originally installed top z-bar of
the bottom layer of frame modules and the newly installed z-bars of
the top layer of frame modules along the length of each installed
stacked frame module until the pre-specified length of the
protective wall is attained at the increased height resultant from
adding the stacked frame modules.
[0041] In select embodiments of the present invention, the method
of installation further comprises: installing an additional z-bar
on the top of the side of the stacked frame module opposite that on
which the newly installed top z-bar is installed, installing the
additional top z-bars in a manner identical to that of installing
the newly installed top z-bars; and inserting quadrilateral panels
between the initially installed top and the newly installed top
z-bars along the "back" length of each installed stacked frame
module.
[0042] In select embodiments of the panels of the present
invention, inexpensive impact-resistant composite structures
incorporate a core of an improved very high strength concrete
(VHSC) and an external "skin" of elastic material. The skin may be
applied to one or more sides of the structure or completely cover a
structure, e.g., a rectangular panel could be covered on both sides
and all four edges. Materials that form a composite structure of an
embodiment of the present invention may include a core of a
cementitious material such as COR-TUF.TM. (a high-performance VHSC)
coupled with reinforced polymer-based facings placed on one or more
sides of the VHSC core or completely enveloping the core. Note that
VHSC is an accepted descriptor in the profession for high
performance concrete. COR-TUF.TM. and methods for producing it are
described in U.S. Pat. No. 7,744,690 B2 to Durst et al. (hereafter
the '690 patent), issued Jun. 29, 2010, incorporated herein by
reference. Further, the elastic material for covering the panels
may be of the type described in United States patent publication
2009/000430 A1, Reinforced Elastomeric Configuration Tailored to
Meet a User's Requirements for Protecting a Structure and a
Structure Comprised Thereof published Jan. 1, 2009 (hereafter the
'430 publication), incorporated herein by reference. Methods for
applying the elastomeric material to a panel are also provided in
the '430 publication.
[0043] Refer to FIG. 1 detailing major components of a panel 100
that may be employed in select embodiments of the present
invention. In select embodiments of the present invention, a thin
rectangular core 101 of length, L, width, W, and thickness, T, much
less than either L or W, comprising a VHSC concrete such as
COR-TUF.TM., has sheets 102, 103 of flexible or elastic (hereafter
elastic) material affixed to each side 104 of the core 101. The
elastic material may be in the form of sheets 102, 103, thin
membranes, laminates and the like or "flowed on" a side 104 of the
core 101 by spraying, rolling, brushing, troweling or the like.
Multiple layers, such as thin membranes built up into a laminate,
and the like, may be employed as the sheets 102, 103 of elastic
material on any side of the core 101, each layer placed in
accordance with manufacture's instructions to insure proper
adhesion of the resultant sheets 102, 103 of elastic material to
the core 101. Multiple layers of fluid elastic material that
solidifies upon curing may be applied to build up a veneer (sheet)
102, 103 of elastic material of appropriate thickness upon final
cure. Each application coat of fluid material is applied in
accordance with manufacture's instructions to insure proper curing
and adhesion of the sheets 102, 103 of elastic material to the core
101. For select embodiments of the present invention employing
elastic material in the form of sheets 102, 103 of elastic
material, to include such as thin membranes alone or thin membranes
built into laminates, an adhesive may be applied to either or both
the sheets 102, 103 of elastic material and the sides 104 of the
core 101 in compliance with the manufacturer's instructions for the
elastic material used for the sheets 102, 103 of elastic material
and the adhesive. Sheets 102, 103 of elastic material, to include
such as thin membranes and laminates thereof may be provided with a
"peel and stick" type of adhesive that may permit ready adhesion of
sheets 102, 103 of elastic material to a side 104 of the core 101
prepared in accordance with the manufacturer of the "peel and
stick" type adhesive. In select embodiments of the present
invention, the edges 107 of the core 101 need not be covered by the
sheets 102, 103 of elastic material in order to achieve a desired
level of performance.
[0044] Refer to FIG. 2 depicting the core 101 of FIG. 1. In select
embodiments of the present invention only one side of the core 101
has a sheet 102 of elastic material adhered thereto. The type of
elastic material used in the sheet 102 and method of application
may be any of the types and methods used for the "double-sided"
example of FIG. 1. Again, for select embodiments of the present
invention, the edges 107 of the core 101 need not be covered by the
single sheet 102 of elastic material in order to achieve a desired
level of performance.
[0045] Refer to FIG. 3 in which the same core 101 is shown as in
FIGS. 1 and 2. In select embodiments of the present invention both
sides 104 and all four edges 107 of the core 101 have a sheet 102,
103 of elastic material adhered thereto. The type of elastic
material used for the sheets 102, 103 of elastic material and
method of application may be any of the types and methods used for
the "double-sided" example of FIG. 1. Further, in select
embodiments of the present invention, the elastic material
incorporated in the sheets 102, 103 of elastic material may be
reinforced with one or more "webs" 302, 303 of woven or un-woven
reinforcement material. In select embodiments of the present
invention, the webs 302, 303 of reinforcement material may comprise
fabric incorporating polymer fibers. In select embodiments of the
present invention, the webs 302, 303 of reinforcement material may
comprise fabric incorporating polymer "strands" arranged in a
matrix such that one set of strands runs at a "bias" (i.e.,
non-parallel) to the length, L, and the intersecting set of strands
runs at a bias to the width, W, of the core 101. In select
embodiments of the present invention, the finished "encapsulated"
panel 306 has edges 307 that are also covered with sheets 102, 103
of elastic material that incorporate webs 302, 303 of reinforcement
material.
[0046] Refer to FIG. 4 in which the same core 101 is shown as in
FIGS. 1-3. In select embodiments of the present invention, the core
101 has one or more reinforcement layers 402, 403 externally added
to the sheets 102, 103 of elastic material adhered to both sides
104 of the core 101. The type of elastic material in the sheets
102, 103 and method of application may be any of the types and
methods used for the "double-sided" example of FIG. 1. In select
embodiments of the present invention, the material of the
reinforcement layers 402, 403 may comprise fabric incorporating
polymer "strands" arranged in a matrix such that one set of strands
runs parallel to the length, L, and the intersecting set of strands
runs parallel to the width, W, of the core 101. Again, for select
embodiments of the present invention the edges 107 of the core 101
need not be covered by the sheets 102, 103 of reinforced elastic
material in order to achieve a desired level of performance.
[0047] Refer to FIG. 5A in which the same core 101 is shown as in
FIGS. 1-4. In select embodiments of the present invention both
sides 104 of the core 101 have sheets 102, 103 of an elastic
material adhered thereto. However, the edges of the sheets 102, 103
of elastic material are allowed to overlap far enough to be joined
together to create a "border" in which grommets 504 may be inserted
for ease in hanging the resultant encapsulated panel 501. The type
of elastic material in the sheets 102, 103 and method of
application may be any of the types and methods used for the
"double-sided" example of FIG. 1. Further, in select embodiments of
the present invention, the elastic material in the sheets 102, 103
may be reinforced with one or more webs 502, 503 of woven or
un-woven reinforcement material similar to that of FIG. 3. In
select embodiments of the present invention, the web 502, 503 of
reinforcement material may comprise fabric incorporating polymer
fibers. In select embodiments of the present invention, the web
502, 503 of reinforcement material may comprise fabric
incorporating polymer "strands" arranged in a matrix such that one
set of strands runs at a "bias" (i.e., non-parallel) to the length,
L, and the intersecting set of strands runs at a bias to the width,
W, of the core 101. In select embodiments of the present invention
incorporating a border as shown in the encapsulated panel 501, the
web 502, 503 of reinforcement material may comprise fabric
incorporating polymer "strands" arranged in a matrix that runs as
shown in FIG. 4. Refer to FIG. 5B. In select embodiments of the
present invention, loops (tabs) 506 may be sewn into the borders of
the encapsulated panel 505 as an alternative to grommets 504.
[0048] Refer to FIG. 5C in which two configurations of attaching
the overlapped edges of the sheets 102, 103 of elastic material of
FIG. 5A are shown. On the viewer's left is shown the two sheets
102, 103 of elastic material as reinforced by webs 502, 503 of
reinforcement material, being joined at the middle of the depth, d,
of the resultant encapsulated panel 501. On the viewer's right is
shown two un-reinforced sheets 102, 103 of elastic materials being
joined in the same plane as one sheet 103 of elastic materials,
i.e., at one side of the resultant panel 501. This latter
configuration would facilitate the resultant panel 501 lying
flatter against the surface to which it is mounted since the
mounting item (e.g., an eyehook) would not need to protrude as far
from the mounting surface to engage grommets 504.
[0049] In select embodiments of the present invention, sheets 102,
103 of elastic materials used for the "skin" of the composite may
comprise a spun para-aramid fiber, e.g., KEVLAR.RTM., ballistic
grade E-glass, commercial E-glass, S2-glass, polypropylene
thermoplastic sheet, polyurethane/polyurea-blended sheet,
polyurethane films (with or without reinforcement), fiberglass,
carbon fiber, metal mesh/grid fiber reinforced plastic (FRP), and
the like. Where more than one layer of skin is applied as a sheet
102, 103, e.g., as a laminate, the layers may be of the same
material and same thickness, same material different thicknesses,
different materials of the same thickness or different materials of
different thicknesses. Further, individual layers may be a
composite of different material, e.g., a laminate of FRP and carbon
fiber. The selection of materials depends on the amount of
protection required and may also be subject to a cost/benefit
constraint. The core 101 may comprise variants of hard armor
material produced from high performance concretes, ceramics,
quarried stone, various architectural armors, plastics and the
like. To keep costs in line, portland cement-based VHSC's, such as
COR-TUF.TM., are preferred.
[0050] In select embodiments of the present invention, a core 101
is prepared to accept one or more outer sheets 102, 103 of an
elastic material, such as a polymer, by applying a compatible
adhesive, such as an epoxy, to the sides 104 and to the surface of
the sheets 102, 103 of elastic material, such as solid sheets of
polymer, and mating the surfaces of the sheets 102, 103 to that of
the surfaces of the sides 104 in accordance with the instructions
of the adhesive manufacturer. In select embodiments of the present
invention, the sheets 102, 103 may be attached via applying
pressure to the back (top) surface of the sheets 102, 103 of
elastic material. In select embodiments of the present invention,
if the sheet 102, 103 of elastic material is applied in fluid form
prior to curing to a flexible solid, e.g., either sprayed, brushed,
trowelled or rolled on, the bonding mechanism is generally the
fluid form of the elastic material itself, such as a sprayable
polymer, and no adhesive is necessary. In select embodiments of the
present invention, a "laid-up" composite panel 306 is then allowed
to cure in accordance with the instructions of the manufacturer of
the material used to create the flexible solid sheets 102, 103 of
elastic material.
[0051] In select embodiments of the present invention, the core 101
is a very high-strength, high-toughness cement-based material,
e.g., a VHSC, that is very efficient at absorbing or reducing the
kinetic energy of any impacting object, such as a fragment
projected from a blast or deposited by wind.
[0052] In select embodiments of the present invention, one or more
sheets 102, 103 of elastic material, such as a polymer sheet, trap
impacting objects thereby increasing protection from airborne
fragments as compared to the trapping capacity available from use
of the core 101 alone. A sheet 102, 103 of elastic material, e.g.,
a polymer sheet, on the non-impact side (inside) 104 of a panel 306
provides added resistance to punching shear in the core 101.
Additionally, facing a core 101 with a high tensile strength (high
"toughness") membrane on the impact side (outside) 104, further
enhances the performance of the panel 306.
[0053] Select embodiments of the present invention may be employed
in building construction products such as roofing tiles, wall
panels, floor tiles, hurricane and tornado resistant structural
elements, forced entry resistant structural elements and the
like.
[0054] The ability to choose among many polymer materials for an
appropriate sheet 102, 103 of elastic material makes various
embodiments of the present invention suitable for use in a variety
of military, first responder, commercial, industrial and consumer
applications.
Example I
[0055] Select embodiments of the panel of the present invention
include a panel 306 having a core 101 comprising a portland
cement-based composite material, such as COR-TUF.TM., that is
completely encapsulated in a sheet 102, 103 of thermoplastic
material bonded to the core 101 through application of heat and
pressure. Because of the combined properties of the thermoplastic
material and the COR-TUF.TM., select embodiments of the present
invention are capable of blunting sharp edges of shrapnel resultant
from an explosion. This blunting flattens airborne debris (or
shrapnel) as it penetrates the core 101, thereby slowing it while
decreasing the depth of penetration. Select embodiments of the
present invention provide a composite panel 306 that has the
compressive strength of high-performance concrete coupled with the
additional capacity (toughness) to trap at least some impacting
fragments in the encapsulation layers of the sheet 102, 103 of
elastic material applied to both the impact (outside) side 104 and
non-impact (inside) side 104 of the panel 306.
[0056] In select embodiments of the present invention, using
COR-TUF.TM. as the core 101 of a panel 501 such as that of FIG. 5A,
the core 101 is prepared according to any of the methods described
in the '690 patent and cured. The cured COR-TUF.TM. core 101 is
covered with sheets 102, 103 of thermoplastic (elastic) material,
approximately 0.1-0.2 in. (2.5-5 mm) thick, cut so that the sheets
102, 103 overlap the core 101 by approximately three inches on each
edge 107.
[0057] With the sheets 102, 103 of thermoplastic material placed
beneath and over the core 101 the sheets 102, 103 are welded to
each other through one of the following processes. While heat is
applied to the sheets 102, 103 of thermoplastic material,
mechanical pressure such as from weights, applied pressure or other
clamping technique, is applied to the top and bottom edges of the
sheets 102, 103 to melt the thermoplastic material of the sheets
102, 103 and to fuse the edges of the sheets 102, 103 of
thermoplastic material together providing a completely encapsulated
core 101 resulting in a panel such as the panel 501 of FIG. 5.
[0058] In select embodiments of the present invention a vacuum
assist, coupled with the heating of the sheets 102, 103 of elastic
material, may be used to withdraw any air from inside the confines
of the two facing layers and draw the sheets 102, 103 of elastic
material to the core 101 to thermally weld one sheet 102 of
thermoplastic material to another sheet 103 of thermoplastic
material.
[0059] Alternatively, in select embodiments of the present
invention, a mechanical mold (not shown separately) may be
employed. The mold may consist of top and bottom forms that are
three inches larger on all sides than the core 101, and deep enough
to surround the core 101 with resin (not shown separately) to a
depth of about 0.20 inches. In select embodiments of the present
invention, a resin incorporating reinforcing polymer fibers is
injected around the core 101 in a manner similar to an injection
molding process.
[0060] Alternatively, in select embodiments of the present
invention, an adhesive may be applied to the internal side of the
top and bottom sheets 102, 103 of elastic material and mechanical
pressure applied to them to "weld" the sheets 102, 103 of elastic
material around the core 101. This process bonds the outer sheets
102, 103 of elastic material to themselves and the core 101 as an
alternative to a thermal welding process.
[0061] These processes are particularly suitable for making
inexpensive thin panels 501 for use as armor. If the sheets 102,
103 of elastic material are impermeable to moisture, the core 101
will not gain any moisture after sealing the elastic material of
the sheets 102, 103. This is important in areas where any freezing
water in a porous concrete core 101 may cause cracking or if the
core 101 is reinforced with steel that may corrode upon
introduction of moisture.
[0062] In select embodiments of the present invention, panels 306,
501 made from these processes may be produced in size and thickness
to accommodate man-portability. These man-portable panels 306, 501
may be configured for attaching to a structural framework to
produce a protective system for mitigation of blast and
fragmentation effects. Further, resistance to dynamic pressure
forces makes these embodiments suitable as a panel to resist
collateral damage due to hurricanes and tornadoes.
Example II
[0063] Select embodiments of the panels of the present invention
comprise a core 101 of a high-performance concrete such as
COR-TUF.TM. coupled with an elastomeric "skin" consisting of a
blend of polyurethane and polyurea that hardens to a tough, elastic
sheet (coating) 102, 103 bonded to the core 101.
[0064] The polyurethane/polyurea sheet (coating) 102, 103 is
applied to the core 101 by suitable means, such as a pressure
driven spray gun. The sheet (coating) 102, 103 is applied at
ambient temperature by means of multiple passes to build up a sheet
thickness of about 1/16 to 11/2 inches (1.5 mm-38 mm). For select
embodiments of the present invention, the sheet (coating) 102, 103
dries to the touch within 30 seconds and achieves full strength
within 24 hours of application.
[0065] The bonding of the sheet (coating) 102, 103 of elastic
material to the core 101 reduces or eliminates spalling of debris
and strike-face chipping by confining fragments behind the sheet
(coating) 102, 103 at the front and back faces of resultant panels
306. The resultant panel 306 reduces or eliminates hazards from
shock; fragments, projectiles and debris that may strike the panel
306; and reduces or eliminates injuries associated with flying
objects. Equipping the panel 306 with sheets (coatings) 102, 103 of
this type also minimizes the tendency towards forward momentum of
the panel 306 that would accompany ejection of material on the
impact side (outside) 104 of the panel 306. Further, the integrity
of a significant thickness (greater than 3/4'') of a
polyurethane/polyurea sheet (coating) 102, 103 has been found to be
better than that achieved by adhesively laminating multiple thin
polymer sheets 102, 103.
Example III
[0066] Select embodiments of the present invention comprise a core
101 of a high-performance concrete, such as COR-TUF.TM., coupled
with an applied elastomeric sheet (skin) 102, 103 comprising a
blend of polyurethane and polyurea material augmented with an
aramid reinforcing layer 302, 303 that is embedded into the blend
before the mix hardens to a tough, elastic sheet (coating) 102, 103
bonded to the core 101.
[0067] In select embodiments of the present invention, the aramid
component comprises strands of the aramid woven into a reinforcing
fabric 302, 303. The reinforcing fabric 302, 303 may be composed of
one type or a combination of types of strands oriented at various
angles to the long axis, L, of the core 101, e.g. oriented as a
matrix of fibers, one set at 90.degree. to another to form a matrix
(checkerboard), one axis of the matrix aligned along the length, L,
of the core 101. In select embodiments of the present invention, an
alternate alignment aligns the same matrix as above and aligns it
at a 45.degree. angle (i.e., "on a bias") to the length, L, of the
core 101. In select embodiments of the present invention, the
reinforcing fabric 302, 303 is cut to the desired size to fit one
or more sides 104 of the core 101 and affixed to the sides 104
before a spray-on elastomer is applied to cure as an elastic sheet
102, 103. The reinforcing fabric 302, 303 may be affixed to both
the front and back sides 104 of the core 101 or cut to completely
enclose the core 101 as shown in the encapsulated panel 306.
[0068] As in Example II, in select embodiments of the present
invention, a polyurethane/polyurea material is applied and cured as
a sheet (coating) 102, 103 to an aramid covered core 101 by
suitable means, such as a pressure driven spray gun. The
polyurethane/polyurea material is applied to the core 101 at
ambient temperature and pressure and by means of multiple passes to
build up a thickness of about 1/16 to 11/2 inches (1.5 mm-38 mm).
The polyurethane/polyurea material dries to the touch within 30
seconds and achieves full strength within 24 hours of application.
The polyurethane/polyurea material may be applied to one side 104
of the core 101, both sides 104 of the core 101, or both sides 104
and all four edges 107 of the core 101 to fully encapsulate the
core 101 as shown in the panel 306.
[0069] In select embodiments of the present invention, the
polyurethane/polyurea material saturates the threads of the
reinforcement cloth 302, 303, e.g., aramid strands, and penetrates
to the sides 104 and covered edges 307 of the core 101. The bonding
of the polyurethane/polyurea material to the reinforcement cloth
302, 303 and the core 101 produces a sheet 102, 103 of elastic
material that reduces spalling of debris from the front and back
sides 104 of the core 101 as well as the covered edges 307. An
aramid reinforcement cloth 302, 303 provides an increase of tensile
strength (toughness) in the resultant composite panel 306.
[0070] The use of aramid as the reinforcement cloth 302, 303 adds a
level of flexural failure resistance (toughness) to the resultant
panel 306 when under load from a blast. Availability of aramid
cloth 302, 303 woven at custom orientations allows a user to
specify axis-specific material properties that are beneficial to
enhancing the structural capacities of the resultant panels 306.
The additional expense of the aramid employed in the reinforcement
cloth 302, 303 may limit the use of these panels 306 to fragile or
high-value targets.
Example IV
[0071] Select embodiments of the present invention comprise a core
101 of a high-performance concrete such as COR-TUF.TM. coupled with
a facing of a thin elastomeric sheet (membrane) 102, 103 on one or
both sides 104 of the core 101. The elastomeric sheet (membrane)
102, 103 may contain embedded reinforcement 302, 303 in a grid or
mesh configuration that may be oriented in various geometries
(compare FIG. 3 to FIG. 4) to establish desired performance
characteristics for specific applications.
[0072] In select embodiments of the present invention, the
thin-film elastomeric sheets (membranes) 102, 103 may comprise
polymer resin systems of the type: polyurethane, polyurea,
polyethylene, polypropylene, commercial elastomeric polymers, and
combinations thereof. The thickness of the applied elastomeric
membrane 102, 103 may be varied between about 20 mils to 0.5 inches
(0.5-12.5 mm). In select embodiments of the present invention, a
thin-film sheet (membrane) 102, 103 is affixed to a core 101 by
means of an adhesive compatible with both the material of the core
101 and the thin-film sheet (membrane) 102, 103.
[0073] In select embodiments of the present invention, the sheet
(membrane) 102, 103 may be reinforced. Reinforcement cloth 302, 303
may be provided in grid or mesh configuration and embedded into the
sheet (membrane) 102, 103 of elastic material as shown in FIGS. 3,
4 and 5A. In select embodiments of the present invention, the
reinforcement cloth 302, 303 may be adhered separately (not shown
separately) between the core 101 and the elastomeric sheet
(membrane) 102, 103. The reinforcement cloth (matrix) 302, 303 may
be of the following types: spun para-aramid fiber (e.g.,
KEVLAR.RTM.), fiberglass, carbon fiber, polypropylene, nylon,
polyethylene, commercially available geo-grid materials,
commercially available geo-fabric materials, metallic grids,
metallic meshes, metallic membranes, combinations thereof, and the
like. The reinforcement cloth 302, 303 may be oriented as a matrix
(grid or mesh) of fibers, one set of fibers at 90.degree. to
another to form a matrix (grid or mesh), one axis of the matrix
aligned along the length, L, of the core 101, as shown in FIG. 4.
In select embodiments of the present invention, an alternate
alignment aligns the same matrix at an angle less than 90.degree.
as shown in FIG. 3, e.g., a 45.degree. angle (i.e., "on a bias") to
the length, L, of the core 101.
[0074] The bonding of the thin film elastomeric sheets (membranes)
102, 103 to the core 101 reduces spalling of debris from the front
and back sides 104 and edges 107 of the core 101. A resultant panel
306 reduces or eliminates hazards from shock; fragments,
projectiles and debris that may strike the panel 306; and reduces
or eliminates injuries associated with airborne objects that impact
the panel 306. Equipping the panel 306 with thin film sheets
(membranes) 102, 103 of this type also minimizes the tendency
towards forward momentum of the panel 306 that would accompany
ejection of material from an impact side 104 of the panel 306.
[0075] Further, select embodiments of the present invention
employing adhered thin film sheets (membranes) 102, 103 have the
potential for manufacture in remote or austere locations using a
minimal amount of specialized equipment. This may significantly
reduce cost, including transportation, where the panels 306 are to
be used near the site of fabrication.
Example V
[0076] Select embodiments of the present invention comprise a core
101 of a high-performance concrete such as COR-TUF.TM. backed with
layers of polymer sheets 102, 103 and fiber reinforcement 302, 303
as in FIG. 3, for example. In select embodiments of the present
invention, the reinforced polymer sheets 102, 302, 103, 303 may
employ components comprising at least: spun para-aramid fiber
(e.g., KEVLAR.RTM.), ballistic grade E-glass, commercial E-glass,
S2-glass, polypropylene thermoplastic sheet, polyurethane/polyurea
blended sheet, polyurethane films, fiberglass, carbon fiber, metal
mesh fiber reinforced plastic (FRP), grid FRP, combinations
thereof, and the like.
[0077] In select embodiments of the present invention, the
reinforced polymer sheets 102, 302, 103, 303 may be pre-fabricated
sheets or be provided in a package of reinforcement fabric webs
302, 303 and a polymer in fluid form for local application, such as
brush-on, trowel-on or spray-on formulations. In select embodiments
of the present invention, the reinforcement cloth 302, 303 may be
either a self-contained layer of woven material that may be
sandwiched between layers of polymer sheets 102, 103 or a woven
mesh that is embedded in a thermoplastic polymer (resin) system
that is sprayed, brushed or troweled over the mesh, thus
encapsulating the strands of the mesh. The reinforcement cloth 302,
303 may be oriented as a matrix (grid or mesh) of fibers, one fiber
set at 90.degree. to another to form a matrix (grid or mesh), one
axis of the matrix aligned along the length, L, of the core 101. In
select embodiments of the present invention, an alternate alignment
aligns the same matrix on a bias to the length, L, of the core 101
as discussed above.
[0078] In select embodiments of the present invention, polymer
sheets 102, 103 are bonded to the back (non-impact) side 104 of the
core 101 to provide toughness and spall protection. In select
embodiments of the present invention, both the back and front sides
104 of the core 101 may incorporate polymer sheets 102, 103. The
same type and thickness of polymer sheet 102, 103 need not be used
on the front side 104 as the back side 104 and either or both sides
104 may incorporate reinforcement cloth 302, 303 in the polymer
sheets 102, 103 as the user's application dictates. Select
embodiments of the present invention provide a modular panel 306
that allows tailoring protection levels to user needs and
flexibility in applied configurations and geometry.
[0079] Further, select embodiments of the present invention
employing adhered, brushed, sprayed-on, or troweled-on polymer
coatings (sheets) 102, 103 have the potential for manufacture in
remote or austere locations using a minimal amount of specialized
equipment. This may significantly reduce cost, including
transportation, for panels 306 to be used in the vicinity of their
fabrication.
Example VI
[0080] Select embodiments of the present invention comprise a core
101 of a high-performance armor material, e.g., COR-TUF.TM.,
coupled with reinforcement of rigid, yet elastic, polymer sheets
102, 103 on one or both sides 104 of the core 101. The polymer
sheets 102, 103 may be any rigid, yet elastic, composite comprising
a suitable binder/hardener and material of the type comprising:
spun para-aramid fibers (e.g., KEVLAR.RTM.), ballistic grade
E-glass, commercial E-glass, S2-glass, polypropylene thermoplastic
sheet, polyurethane/polyurea blended sheet, polyurethane films
(with or without reinforcement), fiberglass, carbon fiber
reinforced plastic (FRP), metal mesh FRP, combinations thereof, and
the like. The component materials used in these embodiments of the
present invention obtain strength and toughness qualities by
appropriate choice of the type and quantity of component materials,
balancing cost with the required performance in each
application.
[0081] In select embodiments of the present invention, the core 101
may comprise any of various hard armor materials such as that
produced from high performance concretes including VHSCs, ceramics,
quarried stone or various architectural armors. In select
embodiments of the present invention, once fabricated, the sides
104 of the core 101 are prepared to accept a sheet 102, 103
comprising a rigid, yet elastic, outer layer of polymer material by
applying a compatible adhesive to the applicable sides 104 of the
core 101 that will be bonded to the sheets 102, 103 of rigid, yet
elastic, polymer material. In select embodiments of the present
invention, adhesive is also applied to the inner surface (not shown
separately) of the sheets 102, 103 of rigid, yet elastic, polymer
material. Following the adhesive manufacturer's recommended
procedures, the core 101 and the sheets 102, 103 of rigid, yet
elastic, polymer material are mated and pressure applied to the
outer surface of the sheets 102, 103 of rigid, yet elastic, polymer
material as provided for in the adhesive manufacturer's
instructions for use.
[0082] In select embodiments of the present invention, the
multi-part rigid, yet elastic, sheets 102, 103 allow a user to
tailor configurations for specific applications while optimizing a
cost/performance ratio. These embodiments have excellent toughness
to resist blast and ballistic penetration forces.
Example VII
[0083] Select embodiments of the present invention comprise a core
101 of a high-performance armor material, e.g., COR-TUF.TM.,
coupled with one or more combinations of polymer sheets (layers)
102, 103 with or without reinforcement 302, 303 added to one or
more sides 104 of the core 101. For example, a polymer sheet
(coating) 102, 103 that is sprayed on a core 101 may be
supplemented with a rigid, yet elastic, polymer sheet 102, 103 that
sandwiches a reinforcement mesh 302, 303 between the rigid, yet
elastic, polymer sheet 102, 103 and the sprayed on sheet (coating)
102, 103 for enhanced protection. In select embodiments of the
present invention, an alternative may be the use of multiple thin
flexible polymer sheets (membranes) 102, 103 with a reinforcement
mesh 302, 303 between each layer on one side 104 of the core 101 to
improve penetration and blast resistance of a core 101 having but a
single sheet (membrane) 102, 103 or rigid, yet elastic, polymer
sheet 102, 103 on that one side 104. In select embodiments of the
present invention, an alternative embodiment sprays a coating of a
polyurethane and polyurea to create a sheet (coating) 102, 103 on a
core 101 having existing elastic sheets (membranes) 102, 103 or
rigid, yet elastic, polymer sheets 102, 103 already affixed in
order to seal out moisture from the edges 107, to make it easier to
handle by reducing sharp edges 107, and to further enhance
resistance to blast and fragment penetration.
Example VIII
[0084] Select embodiments of the present invention comprise one or
more cores 101 of a high-performance armor material, e.g.,
COR-TUF.TM., each core 101 coupled with one or more polymer sheets
(layers) 102, 103 with or without reinforcement cloth 302, 303
added to one or more sides 104 of each core 101. For example, a
polymer sheet (coating) 102, 103 that is sprayed on one or more
sides 104 of one or more of the cores 101 may be supplemented with
a rigid, yet elastic, polymer sheet 102, 103 that sandwiches a
reinforcement cloth mesh 302, 303 between the rigid, yet elastic,
polymer sheet 102, 103 and the sprayed on sheet (coating) 102, 103
for enhanced protection. In select embodiments of the present
invention, an alternative embodiment may use multiple elastic thin
polymer sheets (membranes) 102, 103 with a reinforcement cloth mesh
302, 303 between each two thin polymer sheets (membranes) 102, 103
and the one or more faces 104 of one or more cores 101 to improve
penetration and blast resistance of those cores 101 having a single
membrane 102, 103 or rigid, yet elastic, polymer sheet 102, 103 on
those faces 104. Another alternative may involve spray coating a
polyurethane and polyurea coating 102, 103 on one or more cores 101
having existing elastic membranes 102, 103 or rigid, yet elastic,
polymer sheets 102, 103 already affixed to seal out moisture from
the edges 107, to make it easier to handle by eliminating sharp
edges 107, and to further enhance resistance to blast and fragment
penetration.
[0085] Refer to FIG. 6 depicting, for clarity only, an elevation
view of a single box-shaped base platform unit 600 and single panel
100 installed thereon as may be employed in select embodiments of
the present invention. In select embodiments of the present
invention, the frame module 1400 (FIG. 14) for holding the panels
100 comprises a number of tubular cross members 603, pairs of which
are "movably arranged" in an "X" pattern (see FIG. 13) on each of
the base platform unit's four sides to comprise a basic "backbone"
in compression. Pairs of wires 602, such as braided wires, parallel
to the respective side on which they are placed and located at the
top and bottom of each side of the frame module 1400, provide
tension between each end of each pair of parallel sides of the
frame module 1400 to hold the frame module 1400 in position for
accepting the panels 100. The cross members 603 are "movably"
(loosely) pinned to permit limited pivoting on the pins (not shown
separately) affixing the cross members 603 to the bottom 606 and
top 607 plates and are joined in the center by joining means 604,
such as a contained rod or a clevis pin, where each pair of cross
members 603 cross along a side. The joining means 604 permit
pivoting of the cross members 603 in the plane of the respective
sides of the frame module 1400. Connection at the ends of each
cross member 603 is by suitable means, such as clevis pins or
rivets, the cross members 603 fitting in two slots 808 (FIG. 8)
perpendicular one to the other, at the bottom 606 and top 607
plates that comprise the corners of the "foldable" portion (frame
module 1400) of the base platform unit 600. Likewise, the pairs of
wires 602 on each of the four sides of the frame module 1400 are
connected perpendicular to and between each of the parallel sides
by end connectors fitted to holes 805 in 811, 911 (FIGS. 8 and 9)
in each of the top 607 and bottom 606 plates, respectively. Note
that in select embodiments of the present invention the top tabs
911 may be used for z-bars 601 that provide a top support for
bottom panels 100 and a bottom support for panels 100 placed on
"stacked" frame modules 1400. Together with the adjustable bases
605 on which the basic frame module 1400 rests at each of four
corners of the base frame module 1400, the panels 100 when mounted
in z-bars 601 fitted to mounting tabs 809 at the top 607 and bottom
606 plates, respectively, of the longitudinal sides of length, L,
provide the degree of physical protection specified by a user. The
adjustable bases 605 comprise a top (or bearing) plate 605A, a
bottom (or support) plate 605B, an adjusting through bolt 605C and
necessary internal assemblies to support and permit one-handed
adjustment of the height, h (FIG. 11), of the adjustable base 605.
In select embodiments of the present invention, the top and bottom
z-bars 601 for each frame module 1400 may be further secured by
straps 1600 (FIG. 16) that are tensioned at each end by tensioning
means, such as ratchets 1601, affixed to holes 804 (FIGS. 8, 9) in
the bottom 606 and top 607 plates, respectively, at the time of
installation as further explained below. In select embodiments of
the present invention, the frame module 1400 is configured such
that it may be disassembled and "collapsed" for transport as shown
in FIG. 14, as discussed further below. The dimensions of length,
L, width, W (FIG. 7), and height, H, are chosen to permit frame
modules 1400 of select embodiments of the present invention to be
carried and assembled without the use of lifting machinery.
[0086] Refer to FIG. 7, a top view, shown for clarity, of the base
platform unit 600 of FIG. 6 that may be employed in embodiments of
the present invention. The top z-bars 601 are evident along the
length, L, of the base platform unit 600 as fitted onto tabs 809
(FIG. 8) parallel to the length, L, and along the "outside" edge of
the top plates 607. Note that, although not evident in this view, a
second set of z-bars 601 runs along the bottom of each of the front
and back sides, L. Also evident in FIG. 7, are the top tensioning
wires 602 as readily seen running parallel to the width, W, of the
base platform unit 600. Note that, although not evident in this
view, a second set of tensioning wires 602 runs along the bottom of
each of the four sides, L and W and the top of sides, L. Note also
that, in select embodiments of the present invention, the z-bars
601 do not extend to the end of the sides, L, although the emplaced
panels 100 may since the z-bars 601 have open ends. In select
embodiments of the present invention, multiple panels 100 may be
emplaced one upon the other in the slots of the z-bars 601 (that
are made sufficiently deep to accommodate multiple "stacked"
panels) to create a greater thickness, preferably in such a manner
that the overlaying panels 100 cover the intersection between
panels 100 in the layer below. In select embodiments of the present
invention, a different thickness (either panel type or the total
overlaid number of panels 100) may be used on each side, L,
depending on a user's requirements.
[0087] Refer to FIG. 8, a top view A of a bottom plate 606, as well
as elevation views B, C of the two outer sides of the bottom plate
606 that may be employed in embodiments of the present invention,
one of four such bottom plates 606 on the frame module 1400. In the
top view A, the opening 807 is for a pin (not shown separately) to
both align and join the bottom plate 606 to either an adjustable
base 605 or a top plate 607, the latter when extending the height
of an installation of frame modules 1400. Also shown are openings
804 in the base 810 of the bottom plate 606 that may be used for
affixing the end 1602 (FIG. 16) of a tension adjustment strap 1600
from a z-bar 601 to the bottom plate 606. The base 810 of the
bottom plate 606 is shown with a channel 808 for securing at right
angles one to the other two of the cross members 603 therein by
means of pins (not shown separately) through holes 806 in the sides
of the channel 808 as seen in the elevation views B, C. The pins
are loosely fitted, permitting the pivoting of the cross members
603 in the plane of the securing tabs 811, i.e., along the edge of
the frame module 1400 in which the cross member 603 lies. For the
bottom plates 606, the tabs 809 are "folded" from the base plate in
the same direction as the securing tabs 811 for affixing the cross
members 603 and the tension wires 602. The connection tabs 809 may
also serve as connection tabs for the z-bars 601 and are shown most
clearly on the opposing corners of the outer edges of the base 810
of the bottom plate 606 as seen in the elevation views B, C. In
select embodiments of the present invention, the tabs 809 are
presented on both of the outer sides of the base 810 of the bottom
plate 606 to permit the installation of frame modules 1400 at right
angles to one another.
[0088] Refer to FIG. 9, a top view A of a top plate 607, as well as
elevation views B, C of the two outer sides of the top plate 607
that may be employed in embodiments of the present invention, one
of four such top plates 607 on the frame module 1400. In select
embodiments of the present invention, although similar to the
bottom plates 606 with respect to all aspects including the two
tabs 907 arising from the base 910, the top plates have connection
tabs 911 on the opposite side of the base 910 from the two tabs
907. This arrangement facilitates mating the bottom 606 and top 607
plates to permit vertical stacking of the frame modules 1400. The
top plates 607 also incorporate a rivet 905 and slot 906
arrangement in the two vertical tabs 907. The rivet 905 and slot
906 arrangement is provided for securing individual frame modules
1400 one to another at their respective tops, vertical tabs 907 of
top plates 607 on one end of each of the top plates 607 having a
slot 906 and on the other end of the top plate 607 having a rivet
905. The orientation of the rivet 905 and slot 906 arrangement of
the top plates 607 is reversed at opposite ends of the frame module
1400 to permit connection of adjacent frame modules 1400. That is,
in select embodiments of the present invention, the top plates 607
are specifically configured to fit to the bottom plates 606 so as
to permit "stacking" of the frame modules 1400 to make a high
protective barrier, an example of which is shown in FIG. 15 stacked
two high.
[0089] Refer to FIG. 10, shown for clarity only, a cross section
taken through the bottom of the corners of three adjacent frame
modules 1400. FIG. 10 depicts a top view of the three bottom plates
606. FIG. 10 illustrates how in select embodiments of the present
invention a corner is formed using three frame modules 1400, only
two of which are shown with a panel 100 installed in the z-bars
601. Note the threaded adjustment rod 605C shown to indicate the
position of the adjustable base 605 in relation to the three bottom
plates 606 as installed in base platform units 600.
[0090] Refer to FIG. 11, an elevation view of an adjustable base
unit 605 that may be used with embodiments of the present invention
to adjust the height of individual frame modules 1400 to match
frame modules 1400 connected therewith as base platform units 600.
In select embodiments of the present invention, a threaded rod 605C
with an appropriate end nut (not shown separately) for applying a
socket wrench or the like, is threaded through a threaded collar
1101 in a rest plate 605A on which a corner of a frame module 1400
rests. The support base 605B for the adjustable base unit 605 is of
the same general dimensions as the rest plate 605A, further
including a collar 1103 reinforced via a ramped configuration 1102,
the collar 1103 for receiving and supporting the threaded rod
605C.
[0091] Refer to FIG. 12 showing top and end 601A views of a z-bar
601 employed to hold panels 100 onto individual frame modules 1400
as may be used in embodiments of the present invention. Note the
slot configurations 1201 added to the z-bars 601 for affixing the
z-bars 601 to the tabs 809, 907 along the length, L, at the bottom
and top of frame modules 1400, respectively.
[0092] Refer to FIG. 13, a perspective of the basic structure of a
frame module 1400 expanded for installation of z-bars 601 and
panels 100 (not shown separately in FIG. 13), to include z-bars
601, compression 603 and members in tension 602 and top 607 and
bottom 606 plates (connectors) that may be used with embodiments of
the present invention. Note that, in select embodiments of the
present invention, z-bars 601, and consequently panels 100, may be
installed only on one longitudinal side, L, in some applications.
Further, double thicknesses of panels 100, i.e., panels placed one
on top of the other, may be installed in the z-bars 601 on one
side, L, while a single panel is installed in the z-bars 601 on the
opposing side, L, in select embodiments. Normally, no z-bars 601
and thus, no panels 100 are installed along the width, W, of the
frame modules 1400. Rather, the configuration of FIG. 10 is used to
change direction of the resultant barrier.
[0093] Refer to FIG. 14, as depicted for clarity only, a
perspective of the basic structure of a frame module 1400 collapsed
for transportation or storage, without z-bars 601 and members in
tension (wires) 602, as may be used in select embodiments of the
present invention. The necessity for "loose" fittings of the pins
in the top 607 and bottom 606 plates as well as at the "tie" pin
604 (FIG. 6) at the mid-connection of cross members 603 in each
side of the frame module 1400 is evident from FIG. 14, a frame
module 1400 collapsed for storage or transport.
[0094] Refer to FIG. 15, an elevation view of one side of a
"protective" wall 1500 comprised of box-shaped frame modules 1400
of select embodiments of the present invention. The section of wall
1500 comprises three long by two high interconnected frame modules
1400 and a single installed panel 100 thereon for illustration
purposes only. Note that the bottom of each base platform unit 600
is "secured" to its neighbor by a common adjustable base unit 605
while the tab 905 and slot 906 arrangement available at the top
plate 607 of each frame module 1400 secures the individual frame
modules 1400 to each other at their respective tops.
[0095] Refer to FIG. 16, top A and elevation B views of a strap
1600 that may be employed to tighten a wire (not shown separately)
used to constrain the z-bars 601 as installed with inserted panels
100 in the frame modules 1400 of an embodiment of the present
invention. The strap 1600 comprises a hook 1602 at one end for
inserting in holes 804 in the top 607 or bottom 606 plates as
appropriate and a ratchet 1601 at the other end for tensioning the
wire (not shown separately) attached to the strap and one of the
holes 804 in the top 607 or bottom 606 plate as appropriate. In
select embodiments of the present invention, the wire attached to
the strap 1600 is "pre-attached" one to each end of a z-bar 601 to
facilitate shipping and installation of the z-bars 601 on the frame
modules 1400.
[0096] In select embodiments of the present invention all modules
(components) used in constructing a protective wall or enclosure
are "man portable," i.e., no specialized mechanical equipment is
required for handling, packaging for transport, or installing the
components into a finished protective configuration.
[0097] The abstract of the disclosure is provided to comply with
the rules requiring an abstract that will allow a searcher to
quickly ascertain the subject matter of the technical disclosure of
any patent issued from this disclosure. 37 CFR .sctn.1.72(b). Any
advantages and benefits described may not apply to all embodiments
of the invention.
[0098] While the invention has been described in terms of some of
its embodiments, those skilled in the art will recognize that the
invention can be practiced with modifications within the spirit and
scope of the appended claims. For example, although the system is
described in specific examples for use in protecting assets, it may
be used for any type of portable structure where physical or visual
restriction or even noise suppression is desired. Thus select
embodiments of the present invention may be useful in such diverse
applications as mining, logging, construction, outdoor concerts,
parades, and the like. In the claims, means-plus-function clauses
are intended to cover the structures described herein as performing
the recited function and not only structural equivalents, but also
equivalent structures. Thus, although a nail and a screw may not be
structural equivalents in that a nail employs a cylindrical surface
to secure wooden parts together, whereas a screw employs a helical
surface, in the environment of fastening wooden parts, a nail and a
screw may be equivalent structures. Thus, it is intended that all
matter contained in the foregoing description or shown in the
accompanying drawings shall be interpreted as illustrative rather
than limiting, and the invention should be defined only in
accordance with the following claims and their equivalents.
* * * * *