Ballistic resistant fabrications

Abstract

The present invention claims a shield which is larger than 72 square inches in area and which is at least semi-rigid; not able to be easily bent with common hand or foot pressure. The invention further claims a shield which is composed of at least two layers of steel-belted tire tread material, in which preferably whole tread sections, which may have some rubber removed, in each layer are abutted and in which adjacent layers have seams which are offset or aligned at different angles. The tire tread layers may be separated by at least one layer of a penetration and/or force resistant or absorbing or dampening material. The interior layers may be substantially flat or not, and the shield itself may be substantially flat or not. The strike face of the shield is covered with a layer of fabric material. The shield may be covered with materials which enhance performance or create an aesthetic appearance.

Description

BACKGROUND OF THE INVENTION

[0001] 3. Field of the Invention

[0002] This invention relates generally to construction fabrications and more specifically to a fabrication constructed chiefly of recycled tires and other materials designed to provide protection from ballistic projectiles, explosive forces, and other hazards.

[0003] 4. Discussion of Related Art

[0004] Construction elements are typically designed to support some type of building or structure. They are not designed strongly enough to resist excessive forces and/or stresses due to the additional cost associated with such designs.

[0005] There are times in which additional protection is required. For example, in hurricane prone areas it would be advantageous to have a structure which can withstand high-speed winds and the impact of projectiles thrown by the high speed winds.

[0006] In violence prone areas, anti-ballistic panels or fabrications capable of protecting against projectiles fired from small-to-heavy arms would be useful. In addition, fabrications which would protect residents from explosions have obvious safety advantages over many currently used construction materials.

[0007] There currently are anti-ballistic fabrications available; however, these have their shortcomings. Many of these types of fabrications are very expensive so as to prohibit use in construction.

[0008] Others are designed for a single use and shatter upon receiving an impact. After taking a single `hit`, they are not capable of providing any additional protection. In many uses, there will be multiple ballistic objects impacting the fabrications. Therefore, these would not be suitable for use as construction materials.

[0009] Currently there is a need for anti-ballistic fabrications which may be used in construction which have the capability to deflect numerous ballistic objects and are economical to produce.

SUMMARY OF THE INVENTION

[0010] The present invention may be embodied as a ballistic-resistant shield having a plurality of layers comprising: [0011] a at least two layers of tire tread material; [0012] b a strike face consisting of a fabric layer; [0013] c. at least one sheet of high tensile strength material within the composite structure designed to catch a projectile and deform to dissipate its kinetic energy and to absorb pressure forces.

[0014] The shield may also include interstitial materials such as metals, fabrics, ceramics, gels, foams, and other penetration or force-resisting substances. Since tire tread material can be obtained from used tires at little cost, these can be made cheaply. Also, since the materials use deformable materials and a different mechanism for dissipating kinetic energy, they are able to protect against repeated impacts, unlike many prior art ballistic-resistant fabrications.

[0015] It is also envisioned that these shields may include metal reinforcements, interstitial materials as described above, and additional layers of deformable materials and ballistic-resistant sheeting. This results in a very efficient, protective shield which may be produced at a low cost thereby make them feasible for use as construction materials. Now it is possible to protect objects which are secure and protected from both human threats as well as the threats of nature.

OBJECTS OF THE INVENTION

[0016] Accordingly, a primary object of the present invention is to provide a novel ballistic-resistant shield which is manufactured from used tires in combination with other ballistic-resistant materials.

[0017] Another object of the invention is to provide the above novel ballistic-resistant shield which includes a matrix formed by portions of material obtained from discarded vehicle tires in conjunction with other ballistic-resistant materials. The construction materials are combined in layers to form a composite fabrication. The layers may be combined in a loose fashion or may be bonded together either partially or completely so that a finished composite product is produced which will be resistant to penetration by moving objects and forces.

[0018] Other objects and advantages will become apparent from reading the following detailed description of the invention wherein reference is made to the accompanying drawings.

ADDITIONAL DESCRIPTION OF THE INVENTION

Definition of "Shield"

[0019] As used in this document, the word "Shield" implies: 1. An object which is larger than 72 square inches in surface area and protects against penetration by projectiles and/or pressures; and 2. A device which is considered to be at least semi-rigid to the extent that it cannot be easily bent by common hand or foot pressure.

Size of the Invention

[0020] The present invention is distinguished from prior art by several characteristics. The size of the shield and its tire tread subcomponents is specified, the minimum number of layers of the subcomponents is unique to this application, the level of rigidity related to force absorption is distinguishable from prior art, and other composition variables related to penetration and force absorptive materials are listed and are considered unique to this invention. The present invention is distinguished from prior art in that the intended size of the shield is larger than other similar claimed inventions. VAZ (U.S. Pat. No. 5,979,081) and. Soni (US 2003/0209822) claim a device sized of approximately that of a shoe sole. And Falone, et al. (U.S. Pat. No. 6,652,398) describes a vibration grip cover for the handle of an implement. These described uses are clearly distinguishable from the present invention when viewed in light of the definition of the word "Shield", above. Vaz claims in the first sentence of his Abstract "A boot having an improved blast and fragment resistant vulcanized rubber boot sole (13) for protection against large anti-personnel mines is described". Soni describes in the Title of his patent "Recycling of used automobile tires in to shoe soles". Falone, et al. describes in the title of his patent "Vibration dampening cover for the handle of an implement". The present invention describes a shield which is larger than 72 square inches in area, greater than the size of even the largest shoe sole or handle of an implement. The size of the claimed invention is greater than the size of the devices described by Vaz, Soni and Falone, et al. and is clearly distinguished as a different and separate application of the materials used and therefore the intent of use. The portion of the tire tread utilized in the Soni invention and possibly anticipated by Vaz is a piece of tire sidewall or tread carcass which is cut to approximately the size of a shoe sole or, as Falone et al. teaches, small strips which can be formed into an implement handle. The present invention does not utilize the tire sidewall, as described in Soni, but utilizes most of or the entire used tire tread section in which the steel belt portion is largely uncut and intact. Multiple entire tire tread steel belt sections are used in the present invention in which multiple tread sections have been abutted into a layer to form a shield which is greater than 72 square inches, or the size of a typical shoe sole.

Shape of the Tire Tread Components and Finished Shield

[0021] The present invention is comprised of used tire tread sections containing the steel belts and rubber which are composited with other materials to form the finished shield. The steel belts are largely intact and are minimally cut to facilitate lying substantially flat, or to be formed into that of a shaped shield. The shape associated with tire treads which have been thusly processed is that of a rectangle with typical dimensions of approximately 6-8 inches wide by at least 48 inches long, or that of a fairly exaggerated rectangle having substantially perpendicular corners and substantially parallel sides. These pieces of tire tread are then abutted side-by-side and end-to-end to form a shield which may be any size in area but which will always be larger than 72 square inches in total. Individual tire treads used in the present invention may be smaller than the 72 square inch areal dimension in instances where they are used to fill gaps which would occur near the edges of panels where the whole tire tread does not extend to the edge of the shield, but the overall area of the finished panel will be a minimum of 72 square inches and the preferred embodiment is to use the largest pieces of tread practicable in order to minimize the number of internal seams. Multiple Layers of Tire Treads in Combination with Other Materials The present invention is further distinguished from the above described art in that multiple layers of substantially whole tire tread sections, which have been abutted, have been composited into a shield. The composition of the shield utilizes these multiple layers, in which subsequent layers of tire tread sections are oriented at an angle which differs from adjacent layers, or where the seams of abutted tire tread sections are offset to minimize cross-sectional weaknesses due to aligning seams within the composite structure, to maximize the potential for protecting against penetration or pressure forces. Neither Soni nor Falone, et al. teaches the use of multiple layers of multiple whole tire tread sections abutted and aligned to minimize resistance to penetration by objects or forces. Also, the present invention specifies the use of tire tread layers in association with other layers, in the size of a shield greater than 72 square inches in area, which is used as a penetration and/or pressure resistant device. Winkner et al. (U.S. Pat. No. 3,371,604) teaches a blast mat which is comprised of used tire tread sections but does not anticipate the use of other penetration and/or force-resistant materials in conjunction with a composite structure. Cunn (U.S. Pat. No. 3,648,613) teaches a bomb blanket which is flexible and is constructed from multiple layers of ballistic-resistant fabric (column 2, lines 15-65), but would not be able to utilize tire tread sections due to the lack of a certain level of flexibility inherent in the material; flexibility of which is crucial to the operation of his invention by the action of the venturi effect and apertures which aid in promoting a "puckering" of the device to contain shrapnel and blast gasses.

Level of Rigidity of Composite Structure

[0022] The present invention is further distinguished from prior art in that the proposed composite structure is designed to exhibit a level of rigidity which is different from described art. Although common art includes the formation of blast-resistant mats formed from used tire casings (Winkner et al., U.S. Pat. No. 3,371,604; column 1, lines 25-40), none describe the formation of a semi-rigid composite structure made from multiple layers of tire tread sections abutted and joined to layers of high tensile strength fabric or other penetration and/or force resistant materials. Cunn (U.S. Pat. No. 3,648,613) describes a bomb blanket which is constructed from "a plurality of layers of ballistic cloth" (Abstract), he makes no mention of a composite structure which is composed of multiple layers of tire tread sections which are abutted, aligned at different angles, and used in conjunction with ballistic or force resistant fabrics or other materials. Additionally, Cunn describes a device which is flexible enough to be easily "puckered" around a detonated explosive device as "The effectiveness of the blanket is due to the downward flexure or puckering of the corners of the blanket about the bomb as the bomb explodes so as to reduce the lateral blast effect and to prevent the spread of shrapnel, such puckering being primarily attributable to the partial vacuum or venturi effect created on the underside of the blanket in the central region thereof as the gas released by an explosion vents through the apertures. The effect is enhanced by limiting the number of layers of ballistic cloth which extend the full dimension of the blanket so as to allow the corners of the blanket to more readily flex downwardly to enclose about the bomb. The effect is further enhanced by tightening an adjustable strap arrangement to initially set the blanket in a puckered state about the bomb prior to explosion." (Abstract). The above description specifically denotes a device which is designed to be easily bent or draped around an exploding bomb or a bomb suspected of imminent detonation. The function of the device described by Cunn is dependent upon a high level of flexibility in conjunction with a plurality of centrally located apertures within the device which cause puckering and surrounding of the exploding bomb through the action of the venturi effect.

[0023] The present invention, by the specified design of multiple layers of multiple tire tread sections abutted and joined to layers of penetration and/or force-resistant materials, results in a device which is more rigid that described by Cunn. The present invention would not be able to be substantially bent or puckered with common hand pressure due to the inherent level of rigidity associated with the design. Although the proposed shield might show flexing characteristics under high stress loads, the level of flexibility would be substantially and notably less than a device which could be puckered simply by tightening an adjustable strap arrangement as described in Cunn.

Additionally, the present invention differs substantially from Cunn in that the art described by Cunn relies upon the "venturi effect" produced as the result of apertures centrally located within his described blanket which will allow the release of gas to create a partial vacuum and cause the puckering action of the blanket about the exploding bomb in order to contain shrapnel. The present invention does not contain apertures, nor does it rely on the venturi effect to contain shrapnel, a critical aspect of the art in Cunn's invention. The action which causes Cunn's invention to work is not possible with the level of rigidity exhibited by the present invention and this fact clearly distinguishes the two as separate. Also, the present invention would be considered much more rigid than the art possibly anticipated by Vaz. The art described in his invention relies upon the fact that footwear, and the sole in particular, need to flex to a certain degree in order to be comfortable to the wearer. Vaz refers to prior art, (U.S. Pat. No. 5,285,583 to Aleven) "this uses a protective layer composed of plastic and including a flexible forepart portion . . . "

[0024] Vaz mentions flexibility as a prerequisite to his art: "The boot soles described in the prior art are insufficient protection against the larger anti-personnel mines containing up to 60 grams of high explosive when it is desired to conserve toe-to-heel flexion." (SUMMARY OF THE INVENTION, paragraph 1)

Vaz directly refers to the necessity for flexibility in his invention; "It also conserves good toe-to-heel flexion in order to enable running, jumping and to clear obstacles such as rope ladders, rope climbing, small steps, while avoiding delamination of the sole 13 in subsequent use." (DESCRIPTION OF THE PREFERRED EMBODIMENTS, paragraph 8). The present invention, by describing a device which is not flexible by ordinary hand pressure, denotes a shield which is rigid to a degree which is clearly distinguishable from that of a typical shoe sole or prior art for bomb blankets. The present invention is further distinguished from other art forms by the virtue of being composed of multiple layers of substantially whole tire tread steel belt sections greater than 72 square inches in area, the multiple layers of which are aligned at varying angles or have their seams offset and which are joined to other layers of projectile and/or force resistant materials. Additionally, the present invention is further distinguished by the description of the above described device which may be formed into a flat panel or may take the form of a curved, angled, or otherwise shaped embodiment or may contain internal or external layers which have shapes, contours, textures, colors, images or other attributes which distinguish them from prior art.

Additional Distinguishing Characteristic

[0025] In Addition to the above characteristics of the present invention which distinguish it from noted prior art, the invention of Danschikov et al. (U.S. Pat. No. 5,492,657) is hereby referenced. In his patent, Danschikov et al. discusses a method of processing used tires (Column 4, lines-45-60) and teaches that recycling of tires for uses in multiple applications is known. The method so described is one whereby the rubber contained in a tire is completely separated from the reinforcement (steel belts) so that the bare steel belt and rubber may be disposed, further processed or used in another application. The present invention requires the use of tire tread sections which contain some residual rubber. The presence of an amount of rubber, in the present invention, is required to aid in keeping the wire fibers in place as the shield is subjected to penetration or forces, as in-house testing has proven that the tensile and penetration resistance of the proposed device is enhanced by the presence of some rubber in conjunction with the steel belts, in much the same manner as a pre-preg agent is known to enhance the tensile strength and penetration resistance properties of ballistic-resistant fabrics. Therefore, the present invention uses a type of processed tire tread which is distinguishable from the material produced by the method described by Danschikov and as such is not anticipated by the Danschikov patent. An invention by Fisher (U.S. Pat. No. 6,500,507) is directed to flexible, impact resistant materials (Title). In his invention, the strike face is made up of a plurality of hard, impact-resistant tiles and subsequent flexible layers. The subsequent layers are "the material having a high resistance to local deformation and by itself being of non-ballistic properties" (Abstract), and "In this regard, it should be noted that the material "being of non-ballistic properties" means that the flexible material layer (which may itself comprise one or more layers), is by itself unable to meet any international ballistics standard. The lowest internationally recognised ballistics standard can, for the purposes of this invention, be regarded as the "CEN 1063 standard for bullet resistance of glazing: handguns and rifles-BRI calibre .22 inch (5.59 mm) long rifle". The flexible material layer of non-ballistic properties according to the invention thus has ballistics resistance properties which are in the range of about 2% to 50% of the aforementioned lowest ballistic standard, preferably between about 5% and 50% of said standard, more preferably between about 10% and 35% of said standard, and most preferably between 15% and 25% of said standard. As such, the flexible material would not have any recognised or useful ballistic resistance by itself." (SUMMARY OF THE INVENTION; paragraph 2). Fisher also lists flexibility as a prerequisite of his invention "There is therefore a need for a material utilising an appropriate strike face, whilst at the same time remaining flexible." (BACKGROUND OF THE INVENTION; final sentence). The present invention is distinguished because the strike face is not a hard layer but is a fabric layer, and subsequent layers may be of a non-flexible material and may have ballistic properties. The present invention is also not flexible in the sense of Fisher's statement and is clearly distinguishable from Fisher in those regards. Fisher also does not discuss the use of low cost tire tread material as layers of the composite structure. Another invention, by Norton (U.S. Pat. No. 4,198,454) describes a lightweight composite panel capable of resisting penetration and forces describes a multi-layered panel with metal plates comprising the front and rear surfaces, honeycomb material filled with subliming material, a projectile-resisting material, and at least one panel of yieldable thermal insulation material (claim 1). The present invention does not include front and rear metal plates, nor does it include a honeycomb structure filled with a subliming material; a critical feature in the functioning of Norton's device. Norton's patent also does not discuss the use of low cost tire tread material as layers of the composite structure.

BRIEF DESCRIPTION OF THE ADDITIONAL DRAWING

[0026] A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description, in which:

[0027] FIG. 8 is an illustration of a composite structure created utilizing the art of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

General

[0028] The novel unit of the invention is advantageous in that it is manufactured partly from inexpensive materials such as used tires.

[0029] The end unit is strong, resistant to projectiles and the elements, and produces the desired resistance at a relatively inexpensive cost.

[0030] The engineered properties of a conventional tire, i.e. strength, durability, and resistance to penetration and the environment, are preserved and reused in the form of a ballistic-resistant fabrication. Also, the use of bonding agents in the comopsiting process improves the desirable characteristics of strength, rigidity, and resistance to the environment and may help reduce the cost of manufacture since tire tread material is commonly considered a low-value material.

FIG. 8 is an illustration of a composite shield utilizing the art described in this application.

[0031] FIG. 8 is a cross-sectional plan view of a partially completed ballistic-resistant shield consistent with an embodiment of the present invention. This shows the construction of the shield with a strike face made of a covering of a fabric layer 99. This is placed next to a layer consisting of a plurality of deformable strips 105, preferably from whole belt sections of recycled tires, shown after being flattened and aligned side-by side abutting each other. The deformable strips 105 would cover an area greater than 72 square inches and constitute a single layer of the shield.

[0032] Additional layers 100 are then added which may include ballistic-resistant sheeting (43, 47 of FIG. 4) such as Kevlar® and/or equivalent materials. Other sheets 115 may also be employed. To create the proper strength, multiple layers of tire tread strips are used but the strips are not aligned with the other layers of tire strips or are oriented at an angle differing from that of the previous layer. This arrangement offsets the locations of where the strips abut, thereby eliminating weak spots. Additional layers of deformable strips (49 of FIG. 4) were shown in phantom in FIG. 3.

[0033] The outer surface may have a covering 120 which provides an appealing finish. This is optional; however some embodiments of the present invention are intended to be used in place of conventional construction materials and must be aesthetically pleasing.

[0034] A layer of sheeting 100 designed to have high tensile strength is employed. This may be formed or woven of a material such as Kevlar® designed to have ballistic-resistant properties.

[0035] Next is a another layer of tire tread strips 110 arranged in a tight side-by-side fashion and oriented in a direction which is angled differently or has offset seams than those of layer 105.

[0036] The next internal layer 115 would be another interstitial layer of sheeting which could include fabric, metal, gel, foam, or any other penetration or force-resistant material.

[0037] The rearmost layer of the composite 125 would be a material which is a ballistic or force-resistant layer, or adds rigidity, or allows attachment of the shield to a substrate, or is compatible with an anchoring substrate.

[0038] An interstitial bonding material may be used to hold the layers together and to fill interstitial spaces, such as an epoxy. Other glues, fillers or materials, such as plastics may be used as interstitial materials.

[0039] In optional embodiments, one or more sheets of metal may be employed between any of the layers described above for additional strength.

[0040] The shield may be constructed of any number of layers in addition to the fabric strike face, two layers of tire treads and an interstitial layer using different locations and combinations of individual layers and are within the scope of the present invention.

[0041] Also, it is envisioned that the shields will be formed in various shapes to fit the specific needs. They may be curved, have irregular shaped edges and be molded and formed to fit and/or retrofit existing structures.

Covering

[0042] The unit of the invention may be further enhanced with additional coverings of solid or liquid materials intended to encapsulate, protect, provide a specific finished surface, physical or chemical characteristic or add aesthetic qualities to the finished product.

Additional Materials

[0043] The unit of the invention may be further enhanced with additional layers of ballistic-resistant materials which are typically used in such products. These layers may include, but not be limited to, metal, ballistic resistant fabrics, ceramics, gels, foams, air entrained substances, force absorbing substances and other ballistic-resistant or force-resistant materials in various shapes, sizes or forms alone or in various combinations along with portions of used tires to produce the desired results.

Bonding Agents

[0044] The ballistic-resistant unit of the invention may be assembled in a loose fashion, be partially bonded, or fully bonded with various bonding agents that are typically used to bond materials together. The bonding agents used may include, but not be limited to, virgin polymers, recycled polymers, paints, epoxies, glues or any bonding agent. The bonding may also be provided through the utilization of physical bonding devices such as nails, pins, staples, stitching, or other mechanical attachment means which may physically bond the subject layers together or attach materials within layers.

[0045] The construction of deformable tire strips in conjunction with high tensile strength sheeting provides surprising ballistic-resistant effects which will be shown and described in connection with the following figures.

Claims

1. A semi-rigid composite shield, as defined in the specification, having a plurality of layers comprising: a. multiple layers of recycled tire treads; and b. a strike face comprised of a fabric layer; and c. at least one interstitial layer of a high tensile strength or penetration or force resistant material.

2. The panel of claim 1 wherein multiple pieces of used tire tread sections of a substantially rectangular shape, containing rubber and steel belts, are abutted in a substantially parallel arrangement to create a layer which is at least 72 square inches in area.

3. The panel of claim 1 wherein the abutted edges of subsequent tire layers are offset or arranged at an angle differing from that of an adjacent tire tread layer.

4. The panel of claim 1 wherein the high tensile strength or force resistant material is a woven or non-woven fabric.

5. The panel of claim 1 wherein the high tensile strength or force resistant material is a metal plate, metal mesh, or metal object.

6. The panel of claim 5 wherein the metal plate, metal mesh, or metal object is substantially flat.

7. The panel of claim 5 wherein the metal plate, metal mesh, or metal object is not substantially flat.

8. The panel of claim 1 wherein the high tensile strength or force resistant material is a ceramic, gel, air entrained material, pad, foam, and/or a crushable material.

9. The panel of claim 1 wherein the high tensile strength or force resistant material is wood or plastic.

10. The panel of claim 1 wherein a bonding agent may be employed to partially or fully bond adjoining surfaces together within or between layers in the composite structure.

11. The panel of claim 1 wherein mechanical attachments are used to partially or fully join surfaces together within or between layers in the composite structure.

12. The panel of claim 1 wherein a covering of functional or aesthetic finish is added over the strike face of the panel. These materials, singly or in combination may be from the group comprising: a. a paint, lacquer, varnish, coloring, pattern, image; b. a texture; c. a chemical treatment; and/or d. construction fascia material.

13. The panel of claim 1 wherein the overall panel is substantially flat.

14. The panel of claim 1 wherein the overall panel is not substantially flat.

15. A semi-rigid composite shield having a plurality of layers comprising: a. multiple layers of recycled tire treads; and b. a strike face comprised of a fabric layer; and c. at least one interstitial layer of a high tensile strength or penetration or force resistant material; and d. at least one layer of a force dampening or absorbing material.

16. The panel of claim 15 wherein the force dampening or absorbing material includes: a. a gel; b. a foam; c. an air entrained substance; d. a pad; and/or e. a crushable material.

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