Composite bulletproof plate for building and construction

Abstract

A ballistic resistant sheet product is provided, the product comprising a panel comprising two or more fiber reinforced thermoplastic layers; wherein the two or more fiber reinforced thermoplastic layers comprise continuous fibers embedded in a thermoplastic matrix material; and the two or more fiber reinforced thermoplastic layers are adhered together through a thermoplastic matrix material. The ballistic resistant sheet product may include a length of at least 60 cm, a width of at least 60 cm, and a height of at least 2.5 mm.

Description

[0001] Claiming priority

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 578,546, filed August 24, 2023, Agent's File No. 1202317, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure relates to sheet products including composite bulletproof plates. Background Technology

[0004] Armor, or ballistic protection materials, are increasingly widely used in modern applications. Historically, armor typically existed in the form of metal plates, with its thickness varying depending on the type of munition it was designed to intercept. As metal armor becomes thicker, its weight also increases significantly. Conversely, thinning metal armor to reduce weight would reduce its ability to intercept target munitions.

[0005] Other engineering materials, such as ceramics, have been used in armor. However, these materials are also heavy and can be excessively expensive. Furthermore, these materials are often difficult to mold and may require expensive molds and die heads.

[0006] Currently, there is a need in the field for lightweight bulletproof plates that can be used in permanent or temporary structures such as walls, doors, roofs, floors, barriers, and fences. Summary of the Invention

[0007] This article discloses sheet products containing composite bulletproof plates.

[0008] In one embodiment, a bulletproof sheet product is provided, the bulletproof sheet product comprising a sheet body containing two or more fiber-reinforced thermoplastic layers; wherein the two or more fiber-reinforced thermoplastic layers comprise continuous fibers embedded in a thermoplastic matrix material; and the two or more fiber-reinforced thermoplastic layers are adhered together by the thermoplastic matrix material; and wherein the bulletproof sheet product has a length of at least 300 mm, a width of at least 300 mm, and a height of at least 2.5 mm.

[0009] In some embodiments, the thermoplastic layer comprises continuous E-glass fibers.

[0010] In some implementations, the plate comprises 2 to 100 thermoplastic layers.

[0011] In some embodiments, the thermoplastic matrix comprises a semi-crystalline polymer.

[0012] In some embodiments, the thermoplastic matrix includes an amorphous polymer.

[0013] In some embodiments, the thermoplastic matrix includes a polyolefin polymer.

[0014] In some embodiments, the core comprises 10% to 90% by weight of a thermoplastic matrix material.

[0015] In some embodiments, the core comprises 10% to 90% by weight of continuous glass fiber.

[0016] In some embodiments, the core includes a first side and an opposing second side, and the ballistic sheet product also includes a ballistic facet adhered to the first side, the second side, or the first and second sides of the core.

[0017] In some implementations, the impact-resistant panel is a fiber-reinforced composite impact-resistant panel.

[0018] In some embodiments, the impact-resistant panel is a fiber-reinforced composite impact-resistant panel comprising two or more fiber-reinforced thermosetting layers containing continuous glass fibers embedded in a thermoplastic matrix material.

[0019] In some implementations, the impact plate is a ceramic strike face.

[0020] In some embodiments, the impact-resistant panel is paper, foil, glass-reinforced impact-resistant panel, coated glass impact-resistant panel, cellulose fiberboard, glass mat, oriented strand board, or plywood.

[0021] In some implementations, the ballistic sheet product does not contain a ceramic impact surface.

[0022] In some implementations, the bulletproof sheet product is composed of composite materials.

[0023] In some implementations, the ballistic sheet product consists primarily of a core and optionally a ballistic faceplate.

[0024] In some implementations, the ballistic sheet product consists of a core and optionally a ballistic faceplate.

[0025] In some implementations, the ballistic sheet product meets or exceeds UL 752 Level 1.

[0026] In some implementations, the ballistic sheet product meets or exceeds UL 752 Level 2.

[0027] In some implementations, the ballistic sheet product meets or exceeds UL 752 Level 3.

[0028] In some implementations, the ballistic sheet product meets or exceeds UL 752 Level 4.

[0029] In some implementations, the ballistic sheet product meets or exceeds UL 752 5 level.

[0030] In some implementations, the ballistic sheet product meets or exceeds UL 752 Level 6.

[0031] In some implementations, the ballistic sheet product meets or exceeds UL 752 7 level.

[0032] In some implementations, the ballistic sheet product meets or exceeds UL 752 8 standards.

[0033] In some implementations, the ballistic sheet product meets or exceeds UL 752 9 standards.

[0034] In some implementations, the ballistic sheet product meets or exceeds UL 752 10 level.

[0035] In some embodiments, a building structure is provided that includes bulletproof sheet products.

[0036] In some embodiments, the ballistic sheet good is attached to a second building material by adhesives or mechanical fasteners. Attached Figure Description

[0037] Figure 1 This is a top perspective view of one or more embodiments of the bulletproof sheet product; Figure 2 It is a side view of one or more embodiments of a bulletproof sheet product including a ballistic shield panel; Figure 3 This is a top perspective view of one or more embodiments of the composite layer; and Figure 4 This is a top perspective view of one or more embodiments of a layered composite material. Detailed Implementation

[0038] This disclosure should not be construed as limiting itself to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the subject matter to those skilled in the art.

[0039] definition

[0040] Unless otherwise expressly defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. The terminology used in this disclosure is for describing particular embodiments only and is not intended to be limiting.

[0041] Unless otherwise expressly defined, no method disclosed herein should be construed as requiring its steps to be performed in a particular order, nor should any article described herein be construed as requiring a particular order or orientation of its individual components.

[0042] Unless otherwise expressly stated, any composition or mixture disclosed herein may contain, consist substantially of, or consist of the disclosed components.

[0043] Unless the context clearly indicates otherwise, the singular form of a term as used herein is intended to include the plural form of the term.

[0044] As used herein, numerical values ​​are not strictly limited to the exact values ​​stated herein. Rather, unless otherwise expressly stated, each numerical value implies both an exact value and an “approximate” value, which includes a range of functional equivalences around that value, and therefore any possibility can be considered as an implementation disclosed herein.

[0045] As used herein, the term "continuous fiber" refers to a fiber that spans all or substantially all of the dimensions of a unidirectional band or layer. As used herein, the term "substantially all dimensions" refers to a fiber or average fiber size in a unidirectional band or layer that spans more than 75%, more than 85%, or more than 95% of the dimensions of the unidirectional band or layer.

[0046] As used in this article, the term "average diameter" refers to the average diameter of the individual fibers in a series of continuous fibers.

[0047] As used in this article, the term "unidirectional" refers to the use of parallel or substantially parallel fibers (e.g., only a small number of fibers extend slightly in different directions or at different angles).

[0048] Bulletproof sheet products

[0049] The implementation is at least partially based on ballistic sheet products. Ballistic sheet products may include a core comprising two or more fiber-reinforced thermoplastic layers; wherein the two or more fiber-reinforced thermoplastic layers comprise continuous glass fibers embedded in a thermoplastic matrix material; and the two or more fiber-reinforced thermoplastic layers are adhered together by the thermoplastic matrix material. Ballistic sheet products may be prepared in standard sheet product sizes, and for example, have a length of at least 30 cm, a width of at least 30 cm, and a height of at least 2.5 mm. In some embodiments, a ballistic shield may be adhered to or attached to one or more sides of the core of the ballistic sheet product, which may help improve resistance to higher-power ballistic impacts. Ballistic sheet products may be used in, for example, permanent or temporary structures, such as walls, roofs, floors, barriers, doors, and fences.

[0050] like Figure 1 As shown, the ballistic sheet product 10 includes a core 20. The core 20 includes a length 30, a width 40, and a height 50. In some embodiments, the ballistic sheet product may have one or more additional layers or optional components; the ballistic sheet product shown may consist of or be substantially composed of the core 20. A ballistic sheet product 10 substantially composed of the core 20 may include the core and one or more components that do not substantially affect ballistic performance (e.g., components for decorative purposes, such as coatings or adhesive layers). Therefore, as used herein, the term "core" does not require additional components and can be the entire ballistic sheet product.

[0051] In one or more embodiments, the bulletproof sheet product may be characterized by its length. In one or more embodiments, the length of the bulletproof sheet product may be at least 30 cm, 60 cm, 75 cm, 90 cm, 105 cm, 120 cm, 135 cm, 150 cm, 165 cm, or 180 cm. In one or more embodiments, the length of the bulletproof sheet product may be at most 420 cm, 405 cm, 390 cm, 375 cm, 360 cm, 345 cm, 330 cm, 315 cm, 300 cm, 285 cm, 270 cm, 55 cm, 240 cm, 225 cm, 210 cm, or 195 cm. In one or more embodiments, the length of the bulletproof sheet product is 30 cm to 420 cm, 60 cm to 410 cm, 75 cm to 405 cm, 90 cm to 390 cm, 105 cm to 375 cm, 120 cm to 360 cm, 135 cm to 345 cm, 150 cm to 330 cm, 165 cm to 315 cm, 180 cm to 300 cm, or any combination of the above endpoints.

[0052] In one or more embodiments, the bulletproof sheet product may be characterized by its width. In one or more embodiments, the width of the bulletproof sheet product may be at least 30 cm, 60 cm, 75 cm, 90 cm, 105 cm, 120 cm, 135 cm, 150 cm, 165 cm, or 180 cm. In one or more embodiments, the length of the bulletproof sheet product may be at most 420 cm, 405 cm, 390 cm, 375 cm, 360 cm, 345 cm, 330 cm, 315 cm, 300 cm, 285 cm, 270 cm, 55 cm, 240 cm, 225 cm, 210 cm, or 195 cm. In one or more embodiments, the width of the bulletproof sheet product is 30 cm to 420 cm, 60 cm to 410 cm, 75 cm to 405 cm, 90 cm to 390 cm, 105 cm to 375 cm, 120 cm to 360 cm, 135 cm to 345 cm, 150 cm to 330 cm, 165 cm to 315 cm, 180 cm to 300 cm, or any combination of the above endpoints.

[0053] In one or more embodiments, the bulletproof sheet product may be characterized by its height. In one or more embodiments, the height of the bulletproof sheet product is greater than or equal to 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, or 23 mm. In one or more embodiments, the height of the bulletproof sheet product is less than or equal to 50 mm, 49 mm, 48 mm, 47 mm, 46 mm, 45 mm, 43 mm, 42 mm, 41 mm, 40 mm, 39 mm, 38 mm, 37 mm, 36 mm, 35 mm, 34 mm, 33 mm, 32 mm, 31 mm, 30 mm, 29 mm, 28 mm, 27 mm, or any combination of the above endpoints. In one or more embodiments, the height of the bulletproof sheet product is 2.5 mm to 50 mm, 3 mm to 49 mm, 3.5 mm to 48 mm, 4 mm to 47 mm, 4.5 mm to 46 mm, 5 mm to 45 mm, 6 mm to 43 mm, 7 mm to 42 mm, 8 mm to 40 mm, 9 mm to 39 mm, 10 mm to 38 mm, 11 mm to 37 mm, 12 mm to 36 mm, 13 mm to 35 mm, 14 mm to 34 mm, 15 mm to 33 mm, 16 mm to 32 mm, 17 mm to 31 mm, 18 mm to 30 mm, 19 mm to 29 mm, 20 mm to 28 mm, 21 mm to 27 mm, 22 mm to 26 mm, 23 mm to 25 mm, or any combination of the above endpoints.

[0054] The ballistic sheet product can be manufactured in standard sheet product dimensions. In one or more embodiments, the ballistic sheet product can be square, rectangular, circular, or elliptical. Width and length dimensions can be, for example, 1ft x 1ft, 1ft x 2ft, 1ft x 4ft, 1ft x 5ft, 1ft x 8ft, 1ft x 10ft, 1ft x 12ft, 2ft x 2ft, 2ft x 4ft, 2ft x 5ft, 2ft x 8ft, 2ft x 10ft, 2ft x 12ft, 4ft x 5ft, 4ft x 8ft, 4ft x 10ft, 4ft x 12ft, 5ft x 5ft, 5ft x 8ft, 5ft x 10ft, 5ft x 12ft, 8ft x 8ft, 8ft x 10ft, 8ft x 12ft, 10ft x 10ft, 10ft x 12ft, or 12ft x 12ft.

[0055] In one or more embodiments, the bulletproof sheet product may have a projectile-receiving panel. For example... Figure 2 As shown, the ballistic sheet product 110 includes a core 120. A ballistic shield 130 is optionally located on the core 120. The ballistic shield 130 may include two or more fiber reinforcement layers. The fiber reinforcement layers include fibers in a matrix material. As used herein, the matrix material used in the fiber reinforcement layers of the ballistic shield 130 may be referred to as the "ballistic shield matrix material." In one or more embodiments, the ballistic shield matrix material differs from the thermoplastic matrix material used in the layers of the core 120.

[0056] The core (and optionally the bombardment panel) can be fabricated from two or more layers. In one or more embodiments, the layers are composite layers and include fibers disposed within a matrix material. A single composite layer is sometimes referred to as a "unidirectional strip." Figure 3 As shown, the composite layer 210 includes multiple continuous fibers 220 embedded in the matrix material 230.

[0057] The core (and optionally the bombardment panel) may comprise multiple layers. Adjacent layers may adhere to each other due to the interaction of the matrix materials therein, or they may be bonded together using adhesives or bonding agents. Figure 4 As shown, multiple composite layers can form a layered composite material 310. (As illustrated...) Figure 4As shown, the layered composite material 310 includes a first layer 320 adhered to a second layer 330. The second layer 330 is adhered to a third layer 340. The third layer 340 is adhered to a fourth layer 350. In some embodiments, the continuous fibers of each subsequent layer may be oriented at 90° relative to the preceding layer (as shown). The orientation angle of each subsequent sheet relative to the successive sheet may be from 0° to 90°. In one or more embodiments, the orientation of each subsequent sheet relative to the successive sheet may be approximately 90°.

[0058] Core

[0059] As described above, ballistic sheet products may include or consist of a core. The core comprises two or more continuous fiber reinforcement layers within a thermoplastic matrix. Suitable continuous fiber reinforcement layers are described in U.S. Patent No. 7,598,158.

[0060] In one or more embodiments, the core may be characterized by the number of layers. In these or other embodiments, the core may have 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, or more layers. Floors 2, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, or 65. In these or other embodiments, the core may have 100, 99, 98, 97, 96, 95, 94, 93, 92, 91, 90, 89, 88, 87, 86, 85, 84, 83, 82, 81, 80, 79, 78, 77, 76, 75, 74, 73, 72, 71, or 70 layers. In one or more embodiments, the core may be characterized by the number of layers. In these or other embodiments, the core may have the following number of layers: 2 to 100 layers, 3 to 99 layers, 4 to 98 layers, 5 to 97 layers, 6 to 96 layers, 7 to 95 layers, 8 to 94 layers, 9 to 93 layers, 10 to 92 layers, 11 to 91 layers, 12 to 90 layers, 13 to 89 layers, 14 to 88 layers, 15 to 87 layers, 16 to 86 layers, 17 to 85 layers, 18 to 84 layers, 19 to 83 layers, 20 to 82 layers, 21 to 81 layers, Floors 22 to 80, 23 to 79, 24 to 78, 25 to 77, 26 to 76, 27 to 75, 28 to 74, 29 to 73, 30 to 72, 31 to 71, 32 to 70, 33 to 69, 34 to 68, 35 to 67, 36 to 66, 37 to 65, 38 to 64, 39 to 63, 40 to 62, 41 to 61, 42 to 60, or any combination of the above endpoints.

[0061] Suitable matrix materials for the core layer include thermoplastic polymer compositions. For example, the thermoplastic polymer composition may include semi-crystalline and amorphous thermoplastics. Examples of semi-crystalline polymer matrices include, but are not limited to, polyolefins, polyethylene terephthalate, polybutylene terephthalate, and polyamides. Examples of amorphous polymer matrices include, but are not limited to, amorphous polyethylene terephthalate, polymethyl methacrylate, polycarbonate, and acrylonitrile-butadiene-styrene. Examples of polyolefins include polypropylene (PP) and polyethylene (PE). Suitable matrix materials also include thermoplastic elastomers (TPE).

[0062] In one or more embodiments, the core is characterized by the weight percentage of fibers in the total core volume. In one or more embodiments, the weight percentage of fibers can be equal to or greater than 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt%. In these or other embodiments, the weight percentage of fibers can be equal to or less than 90 wt%, 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%. In one or more embodiments, the weight percentage of fibers can be from 10 wt% to 90 wt%, 15 wt% to 85 wt%, 20 wt% to 80 wt%, 25 wt% to 75 wt%, 30 wt% to 70 wt%, 35 wt% to 65 wt%, 40 wt% to 60 wt%, 45 wt% to 55 wt%, or any combination of the foregoing endpoints.

[0063] In one or more embodiments, the core is characterized by a substrate weight percentage of the total core volume. In one or more embodiments, the substrate weight percentage may be equal to or greater than 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt%. In these or other embodiments, the substrate weight percentage may be equal to or less than 90 wt%, 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%. In one or more embodiments, the substrate weight percentage may be from 10 wt% to 90 wt%, 15 wt% to 85 wt%, 20 wt% to 80 wt%, 25 wt% to 75 wt%, 30 wt% to 70 wt%, 35 wt% to 65 wt%, 40 wt% to 60 wt%, 45 wt% to 55 wt%, or any combination of the above endpoints.

[0064] In one or more embodiments, the core may be characterized by its height. In one or more embodiments, the height of the core may be greater than or equal to 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, or 23 mm. In one or more embodiments, the height of the core may be less than or equal to 50 mm, 49 mm, 48 mm, 47 mm, 46 mm, 45 mm, 43 mm, 42 mm, 41 mm, 40 mm, 39 mm, 38 mm, 37 mm, 36 mm, 35 mm, 34 mm, 33 mm, 32 mm, 31 mm, 30 mm, 29 mm, 28 mm, or 27 mm. In one or more embodiments, the height of the core is 2.5 mm to 50 mm, 3 mm to 49 mm, 3.5 mm to 48 mm, 4 mm to 47 mm, 4.5 mm to 46 mm, 5 mm to 45 mm, 6 mm to 43 mm, 7 mm to 42 mm, 8 mm to 40 mm, 9 mm to 39 mm, 10 mm to 38 mm, 11 mm to 37 mm, 12 mm to 36 mm, 13 mm to 35 mm, 14 mm to 34 mm, 15 mm to 33 mm, 16 mm to 32 mm, 17 mm to 31 mm, 18 mm to 30 mm, 19 mm to 29 mm, 20 mm to 28 mm, 21 mm to 27 mm, 22 mm to 26 mm, 23 mm to 25 mm, or any combination of the above endpoints.

[0065] Missile response panel

[0066] As mentioned above, bulletproof sheet products can have ballistic panels. Suitable ballistic panels include those materials commonly used in sheet products, such as paper, foil, glass-reinforced ballistic panels, coated glass ballistic panels, cellulose fiberboard, glass mat, oriented strand board, or plywood.

[0067] In one or more embodiments, the impact-resistant panel may be fiber-reinforced thermosetting. In these or other embodiments, the reinforcing fibers may be tows, yarns, rovings, or woven mats.

[0068] Suitable impact-receiving panel matrix materials may include thermosetting polymer compositions. For example, thermosetting polymer compositions may include unsaturated polyesters, vinyl esters, epoxy resins, and others. In addition to thermosetting polymer compositions, ceramic or other hardened reactive matrices may be included. In some embodiments, the impact-receiving panel is a ceramic impact surface.

[0069] In one or more embodiments, the bomb reception panel includes the layers described above. A characteristic of the bomb reception panel can be the number of layers. In these or other embodiments, the bomb reception panel may have 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, or 31 layers. Floors 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, or 65. In these or other embodiments, the bomb-receiving panel may have 100, 99, 98, 97, 96, 95, 94, 93, 92, 91, 90, 89, 88, 87, 86, 85, 84, 83, 82, 81, 80, 79, 78, 77, 76, 75, 74, 73, 72, 71, or 70 layers. In these or other embodiments, the bomb-receiving panel may have the following number of layers: 2 to 100 layers, 3 to 99 layers, 4 to 98 layers, 5 to 97 layers, 6 to 96 layers, 7 to 95 layers, 8 to 94 layers, 9 to 93 layers, 10 to 92 layers, 11 to 91 layers, 12 to 90 layers, 13 to 89 layers, 14 to 88 layers, 15 to 87 layers, 16 to 86 layers, 17 to 85 layers, 18 to 84 layers, 19 to 83 layers, 20 to 82 layers, 21 to 81 layers. Floors 22 to 80, 23 to 79, 24 to 78, 25 to 77, 26 to 76, 27 to 75, 28 to 74, 29 to 73, 30 to 72, 31 to 71, 32 to 70, 33 to 69, 34 to 68, 35 to 67, 36 to 66, 37 to 65, 38 to 64, 39 to 63, 40 to 62, 41 to 61, 42 to 60, or any combination of the above endpoints.

[0070] In one or more embodiments, the bomb-receiving panel is characterized by the weight percentage of fibers relative to the total core volume. In one or more embodiments, the weight percentage of fibers can be equal to or greater than 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt%. In these or other embodiments, the weight percentage of fibers can be equal to or less than 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%. In one or more embodiments, the weight percentage of fibers can be from 20 wt% to 80 wt%, 25 wt% to 75 wt%, 30 wt% to 70 wt%, 35 wt% to 65 wt%, 40 wt% to 60 wt%, 45 wt% to 55 wt%, or any combination of the above endpoints.

[0071] In one or more embodiments, the impact-receiving panel is characterized by a substrate weight percentage relative to the total weight of the core. In one or more embodiments, the substrate weight percentage may be equal to or greater than 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt%. In these or other embodiments, the substrate weight percentage may be equal to or less than 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%. In one or more embodiments, the substrate weight percentage may be from 20 wt% to 80 wt%, 25 wt% to 75 wt%, 30 wt% to 70 wt%, 35 wt% to 65 wt%, 40 wt% to 60 wt%, 45 wt% to 55 wt%, or any combination of the above endpoints.

[0072] In one or more embodiments, the impact-receiving panel may be characterized by its height. In one or more embodiments, the height of the impact-receiving panel may be greater than or equal to 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm. In one or more embodiments, the height of the impact-receiving panel is less than or equal to 30 mm, 29 mm, 28 mm, 27 mm, 26 mm, 25 mm, 24 mm, 23 mm, 22 mm, 21 mm, or 20 mm. In one or more embodiments, the height of the impact-receiving panel is 2.5 mm to 30 mm, 3 mm to 29 mm, 3.5 mm to 28 mm, 4 mm to 27 mm, 4.5 mm to 26 mm, 5 mm to 25 mm, 6 mm to 24 mm, 7 mm to 23 mm, 8 mm to 22 mm, 9 mm to 21 mm, 10 mm to 20 mm, or any combination of the above endpoints.

[0073] Exemplary reinforcing fibers used for the core (and optionally the bombardment panel) include one or more of the following materials: glass fiber, aramid fiber, basalt fiber, carbon fiber, UHMWPE (ultra-high molecular weight polyethylene) fiber, and other polymer fibers. In one or more embodiments, the average diameter of the reinforcing fibers is 5 micrometers to 40 micrometers, 7 micrometers to 38 micrometers, 8 micrometers to 35 micrometers, 10 micrometers to 33 micrometers, 12 micrometers to 30 micrometers, 15 micrometers to 28 micrometers, 5 micrometers to 40 micrometers, etc. Additives or other optional small amounts of non-fibrous components may be added to the thermoplastic matrix or optionally the thermosetting matrix. These additives can be used to improve a variety of material properties, such as, but not limited to, thermal, chemical, and mechanical properties. Examples of these additives include flame retardant additives, UV stabilizers, or processing aids.

[0074] Bulletproof standards

[0075] Ballistic materials (including panels) are typically tested according to standards that allow for a consistent and meaningful assessment of the material's performance—i.e., its ability to withstand ballistic impacts. This standard is UL 752: UL Standard for Safety for Bullet-Resisting Equipment. This standard defines the various performance characteristics of ballistic structures against a range of threats. Therefore, the UL standard categorizes the protection provided by different armor levels as follows.

[0076] UL Level 1: Armor classified as UL Level 1 withstands standard test rounds in the form of 9mm lead-core, full-copper jacketed cartridges. The cartridge has a nominal weight of 8 grams and uses approximately 124 grains of powder. The resulting cartridge will travel at a speed of 358 to 394 meters per second. UL Level 1 armor can withstand three shots from this cartridge.

[0077] UL Level 2: Armor classified as UL Level 2 for protection against standard test rounds in the form of .357 Magnum jacketed lead soft-point bullets. This bullet has a nominal weight of 10.2 grams and uses approximately 158 grains of powder. The resulting bullet will travel at a speed of 381 to 419 meters per second. UL Level 2 armor can withstand three shots from this bullet.

[0078] UL Level 3: Armor classified as UL Level 3 for protection against a standard test round in the form of a .44 Magnum lead semi-wadcutter gas-checked round. This round has a nominal weight of 15.6 grams and uses approximately 240 grains of powder. The resulting round will travel at a speed of 411 to 451 meters per second. UL Level 3 armor can withstand three shots from this round.

[0079] UL Level 4: Classified as UL Level 4 armor protection against standard test rounds in the form of .30 caliber rifle lead-core soft-point bullets. The bullet has a nominal weight of 11.7 grams and uses approximately 180 grains of powder. The resulting bullet will travel at a speed of 774 to 851 meters per second. UL Level 4 armor can withstand one shot from this bullet.

[0080] UL Level 5: Armor classified as UL Level 5 withstands standard test ammunition in the form of a 7.62mm rifle lead-core full metal copper jacket (MMT) ball. This ball has a nominal weight of 9.7 grams and uses approximately 150 grains of powder. The resulting bullet will travel at a speed of 838 to 922 meters per second. UL Level 5 armor can withstand one shot from this ammunition.

[0081] UL Level 6: Armor classified as UL Level 6 withstands standard test rounds of 9mm lead-core copper jacketed cartridges. The cartridge has a nominal weight of 8.0 grams and uses approximately 124 grains of powder. The resulting round will travel at 427 to 470 meters per second. UL Level 6 armor can withstand five shots from this cartridge.

[0082] UL Level 7: Armor classified as UL Level 7 withstands standard test rounds of 5.56mm rifle lead-core copper jacket cartridges. The cartridge has a nominal weight of 3.56 grams and uses approximately 55 grains of powder. The resulting round will travel at a speed of 939 to 1033 meters per second. UL Level 7 armor can withstand five shots from this cartridge.

[0083] UL Level 8: Armor classified as UL Level 8 withstands standard test ammunition in the form of a 7.62mm rifle lead-core full metal copper jacket (MMT) ball. This ball has a nominal weight of 9.7 grams and uses approximately 150 grains of powder. The resulting bullet will travel at a speed of 838 to 922 meters per second. UL Level 8 armor can withstand five shots from this ammunition.

[0084] Those skilled in the art will understand that UL 752 recognizes 10 levels. Levels 9 and 10 are primarily used for military applications. In some embodiments, ballistic sheet products may exceed UL level 8 and meet or exceed UL level 9. In some embodiments, ballistic sheet products may exceed UL level 9 and meet or exceed UL level 10.

[0085] The National Institute of Justice of the U.S. Department of Justice has developed another standard entitled "NIJ Standard for Ballistic Resistant Protective Materials" (hereinafter referred to as the "NIJ Standard"). The ballistic threat posed by bullets or other projectiles depends particularly on their composition, shape, caliber, mass, and impact velocity. Therefore, the NIJ Standard classifies the protection provided by different armor grades as follows.

[0086] Category II-A (Low-velocity .357 Magnum and 9 mm): Armor classified as Category II-A is effective against standard test rounds in the form of .357 Magnum jacketed soft-point projectiles, with a nominal mass of 10.2 grams and a measured velocity of 381 ± 15 m / s. Category II-A ballistic protection materials also provide protection against 9 mm full metal jacketed rounds, with a nominal mass of 8 grams and a measured velocity of 332 ± 12 m / s.

[0087] Category II (Higher-speed .357 Magnum; 9 mm): This armor protects against projectiles equivalent to .357 Magnum jacketed soft-point rounds, with a nominal mass of 10.2 grams and a measured velocity of 425 ± 15 m / s. Category II ballistic protection also protects against 9 mm full metal jacket rounds, with a nominal mass of 8 grams and a measured velocity of 358 ± 12 m / s.

[0088] Category III-A (.44 Magnum, 9mm submachine gun rounds): This armor provides protection against most handgun threats and a projectile with characteristics similar to .44 Magnum lead semi-wadcutter with gas checks; its nominal weight is 15.55 grams, and its measured velocity is 426 ± 15 m / s. Category III-A ballistic protection also protects against 9mm submachine gun rounds. These are 9mm full metal jacketed rounds with a nominal weight of 8 grams and a measured velocity of 426 ± 15 m / s.

[0089] Category III (High-powered rifles): This armor protects against 7.62 mm (.308 Winchester®) ammunition and most handgun threats.

[0090] Category IV (Armor-Piercing Rifle): This armor can withstand .30 caliber armor-piercing rounds with a nominal weight of 10.8 grams and a measured velocity of 868±15 m / s.

[0091] Other recognized threats in the field include improvised explosive devices (IEDs), which can produce shrapnel that may weigh only a few grains and travel at speeds of up to 5,000 feet per second.

[0092] As described above, bulletproof sheet products can be used in, for example, permanent or temporary structures, such as walls, doors, roofs, floors, barriers, and fences. Those skilled in the art will understand that the sheets can be cut or attached to other building materials to form various structures. Therefore, the bulletproof sheet products disclosed herein can replace drywall, oriented strand board, plywood, medium-density fiberboard, or other sheets used in construction.

[0093] Unless otherwise stated, every document cited herein is incorporated herein by reference in its entirety. No citation of any reference constitutes an admission that it is prior art to any invention claimed or disclosed herein. In the event of any conflict between the meaning or definition of any term in this text and the meaning or definition of any term in the referenced documents, the meaning or definition specified herein shall prevail.

[0094] Obviously, modifications and variations can be made without departing from the scope of the disclosure as defined in the appended claims. More specifically, while some aspects of this disclosure are considered preferred or particularly advantageous herein, it is conceivable that this disclosure is not necessarily limited to these aspects.

Claims

1. A bulletproof sheet product, comprising: The core comprises two or more fiber-reinforced thermoplastic layers; The two or more fiber-reinforced thermoplastic layers comprise continuous glass fibers embedded in a thermoplastic matrix material; and the two or more fiber-reinforced thermoplastic layers are adhered together by the thermoplastic matrix material; and The bulletproof sheet material must be at least 30 cm long, at least 30 cm wide, and at least 2.5 mm high.

2. The bulletproof sheet product as described in claim 1, wherein, The thermoplastic layer contains continuous E-glass fibers.

3. The bulletproof sheet product as described in any of the preceding claims, wherein, The sheet contains 2 to 100 thermoplastic layers.

4. The bulletproof sheet product as described in any of the preceding claims, wherein, The thermoplastic matrix contains a semi-crystalline polymer.

5. The bulletproof sheet product as described in any one of the preceding claims, wherein, Thermoplastic matrix contains amorphous polymers.

6. The bulletproof sheet product as described in any of the preceding claims, wherein, The thermoplastic matrix contains polyolefin polymers.

7. The bulletproof sheet product as described in any of the preceding claims, wherein, The core comprises 10% to 90% by weight of thermoplastic matrix material, which is the total weight of the core.

8. The bulletproof sheet product as described in any of the preceding claims, wherein, The core contains 10% to 90% by weight of continuous glass fiber.

9. The bulletproof sheet product as described in any of the preceding claims, wherein, The core includes a first side and an opposite second side, and the ballistic sheet product also includes a ballistic faceplate adhered to the first side, the second side, or the first and second sides of the core.

10. The bulletproof sheet product as claimed in any of the preceding claims, wherein, The impact-resistant panel is a fiber-reinforced composite impact-resistant panel.

11. The bulletproof sheet product as claimed in any of the preceding claims, wherein, The ballistic panel is a fiber-reinforced composite ballistic panel, which comprises two or more fiber-reinforced thermosetting layers, wherein the fiber-reinforced thermosetting layers include continuous glass fibers embedded in a thermoplastic matrix material.

12. The bulletproof sheet product as described in any of the preceding claims, wherein, The impact plate is made of ceramic.

13. The bulletproof sheet product as described in any of the preceding claims, wherein, The spring-loaded panels are made of paper, foil, glass-reinforced spring-loaded panels, coated glass spring-loaded panels, cellulose fiberboard, glass mat, oriented strand board, or plywood.

14. The bulletproof sheet product as described in any of the preceding claims, wherein, Bulletproof sheet products do not include ceramic impact surfaces.

15. The bulletproof sheet product as claimed in any of the preceding claims, wherein, The thermoplastic matrix contains a semi-crystalline polymer.

16. The bulletproof sheet product as claimed in any of the preceding claims, wherein, Bulletproof sheet products are basically composed of a core and an optional anti-ballistic panel.

17. The bulletproof sheet product as claimed in any of the preceding claims, wherein, The bulletproof sheet product consists of a core and an optional ballistic faceplate.

18. The bulletproof sheet product as claimed in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 1.

19. The bulletproof sheet product as claimed in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 2.

20. The bulletproof sheet product as claimed in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 3.

21. The bulletproof sheet product as described in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 4.

22. The bulletproof sheet product as described in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 5.

23. The bulletproof sheet product as claimed in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 6.

24. The bulletproof sheet product as claimed in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 7.

25. The bulletproof sheet product as claimed in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 8.

26. The bulletproof sheet product as described in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 9.

27. The bulletproof sheet product as claimed in any of the preceding claims, wherein, Bulletproof sheet products meet or exceed UL752 Level 10.

28. A building structure comprising the bulletproof sheet product as described in any of the preceding claims.

29. The building structure of claim 15, wherein the bulletproof sheet product is attached to the second building material by an adhesive or mechanical fastener.

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