Barrier structure for security panel or door and method for making same

Abstract

A method (100) of fabricating a barrier structure (200) for constructing or assembling a panel or door for a security enclosure, the method (100) including: providing conveyor belt material; processing the conveyor belt material to form a belt body (202); and strengthening the belt body (202) to at least aid in impeding penetration thereof.

Description

BARRIER STRUCTURE FOR SECURITY PANEL OR DOOR AND METHOD FOR MAKING SAMEField

[0001] The present invention relates generally to barrier materials. More particularly, the present invention relates to a method of fabricating a barrier structure for a security panel or door used in the construction of vaults. However, the invention is not limited to this particular use and is also suitable for use in the construction or assembly of safes, strongrooms or other security enclosures and ballistic suppression products, as well as for use in applications such as road barriers and lining of rooms (such as rooms designed for currency counting, for example, a bank counting room) which require a level of security and fire protection.Background

[0002] Security barrier structures are utilised in the construction of panels or doors for security enclosures (such as bank vaults) to at least impede penetration or breach of the secured enclosure during criminal or nefarious activities.

[0003] Disadvantageously, the materials utilised in these barrier structures are expensive, heavy, difficult to obtain, associated with high manufacturing cost and / or environmentally harmful.Summary of Invention

[0004] It is an object of the present invention to substantially overcome, or at least ameliorate, at least one drawback of present arrangements, for example, at least one of the above drawbacks, or to provide a useful alternative.

[0005] In one aspect, the invention provides a method of fabricating a barrier structure for constructing or assembling a panel or door for a security enclosure, the method including: providing conveyor belt material; processing the conveyor belt material to form a belt body; and strengthening the belt body to at least aid in impeding penetration thereof.

[0006] In one embodiment, providing conveyor belt material includes reclaiming an existing or decommissioned conveyor belt.

[0007] In one embodiment, the conveyor belt material includes a metal reinforcement.

[0008] In one embodiment, the metal reinforcement is in the form of a plurality of elongated metal lengths arranged so that their respective longitudinal axes are parallel to each other and extend along a length of the conveyor belt material.

[0009] In one embodiment, each of the metal lengths is in the form of a steel cord.

[0010] In one embodiment, in a transverse cross-section of the conveyor belt material, each of the metal lengths or steel cords is uniformly arranged and positioned to minimise interstitial space between each of the metal lengths or steel cords.

[0011] In one embodiment, processing the conveyor belt material includes forming a plurality of layers of the conveyor belt material into a belt body, and strengthening the belt body includes arranging the plurality of layers of the conveyor belt material with respect to each other so that each of the metal lengths or steel cords in one of the layers has a first direction of extension, and each of the metal lengths or steel cords in an adjacent one of the layers has a second direction of extension different to the first direction of extension.

[0012] In one embodiment, the second direction of extension is perpendicular to the first direction of extension.

[0013] In one embodiment, strengthening the belt body includes joining the conveyor belt material with one or more supplementary materials selected from the group consisting of a polymeric material, a metallic material, a natural material, a synthetic material and a composite material.

[0014] In one embodiment, strengthening the belt body includes embedding the belt body in resin to form a hardened and flexible belt body.

[0015] In one embodiment, the resin includes one or more additives to strengthen the belt body, reduce weight for a given volume of the belt body, and / or provide fire retardancy to the belt body up to a Group 1 Fire Rating.

[0016] In one embodiment, the resin includes sheets of fiberglass, metal or synthetic mesh to strengthen the resin and / or to minimise cracking of the resin.

[0017] In one embodiment, strengthening the belt body includes encasing the belt body in metal.

[0018] In one embodiment, strengthening the belt body includes encasing the belt body in metal prior to embedding the belt body in resin.

[0019] In another aspect, the invention provides a barrier structure fabricated in accordance with the method as described above.

[0020] In a further aspect, the invention provides a security panel or door for impeding entry into a security enclosure, the security panel or door including a barrier structure formed of conveyor belt material.

[0021] In one embodiment, the conveyor belt material includes an elastomeric matrix within which is embedded metal reinforcement.

[0022] In one embodiment, the barrier structure includes a belt body having a plurality of layers each of which are formed of the conveyor belt material.

[0023] In one embodiment, the belt body is encased with steel and / or sealed with resin.Brief Description of Drawings

[0024] Exemplary embodiments of the present disclosure will now be described, by way of examples only, with reference to the accompanying description and drawing in which:

[0025] FIG. 1 illustrates a method of fabricating a barrier structure according to the present disclosure;

[0026] FIG. 2 is a top end view of the barrier structure fabricated in accordance with the method of FIG. 1;

[0027] FIG. 3 is a front view of the barrier structure of FIG. 2;

[0028] FIG. 4 is an enlarged, vertically cross-sectioned view of the barrier structure taken along line A-A of FIG. 3;

[0029] FIG. 5 is a horizontally cross-sectioned view of the barrier structure taken along line B-B of FIG. 3; and

[0030] FIG. 6 is an enlarged, detail view of portion C of FIG. 5.Description of Embodiments

[0031] Referring to FIG. 1, a method 100 of fabricating a barrier structure 200 (see FIGs. 2 and 3) according to the present disclosure is shown. The fabricated barrier structure 200 can be utilised in the making or assembly of security panels or doors for construction of safes, vaults, strongrooms or other security enclosures to impede entry therein. In other applications, the barrier structure may be used to provide ballistic suppression.

[0032] In an initial step 102, conveyor belt material is provided. The conveyor belt material is preferably obtained by reclaiming or recycling an existing or decommissioned conveyor belt, that is, reclaiming or recycling conveyor belting previously used in a belt conveyor system. In other embodiments, the conveyor belt material may be sourced from new stock or custom-made.

[0033] Various types or grades (and combinations thereof) of the conveyor belt material may be provided in the method 100 depending on the required performance characteristics of the barrier structure. For example, the selection of the conveyor belt material may be influenced by factors such as mechanical strength, weight, and resistance to wear, abrasion, penetration, heat or chemicals. Preferably, the conveyor belt material provided in the method 100 has a composition and / or form which configures the conveyor belt material to be desirable or particularly suitable for use in mining, quarrying and other industrial applications. For example, the composition of the conveyor belt material may be multilayered or laminated and include a protective top and bottom cover comprised of a polymer or an elastomer (such as natural rubber, butadiene orstyrenebutadiene), a carcass between the top and bottom cover, and reinforcement embedded or integrated within the carcass.

[0034] In one embodiment, the reinforcement may be in the form of a plurality of elongated metal lengths which are arranged so that their respective longitudinal axes are parallel to each other and extend along a length of the conveyor belt material. In this embodiment, in a transverse cross-section of the conveyor belt material, each of the metal lengths may be uniformly arranged and positioned to minimise interstitial space between each of the metal lengths. Preferably, each of the metal lengths are spaced about 5 to 20 mm apart from each other. The elongated metal lengths are preferably in the form of stainless steel cords, but may be cables, rods, bars or fibers each of which may be formed of stainless steel or other metal alloys.

[0035] In other embodiments, the reinforcement may include (in addition to or instead of metal reinforcement) one or more layers of textiles or woven fabric plies. In some embodiments, the woven fabric plies may include warp and weft fibers comprised of polyester, nylon, aramid, carbon or glass.

[0036] After providing the conveyor belt material in step 102, the method includes a next step 104 of processing the conveyor belt material to form a belt body. In this step 104, the conveyor belt material may be cut, spliced, sized or otherwise processed to form a desired shape and / or configuration of the belt body with desired dimensions (such as thickness, width and length) depending on the application. For example, the conveyor belt material may be processed to form a belt body having one or more layers, strips, lengths or sections of the conveyor belt material arranged in a planar configuration, such as a rectangular plate-like configuration.

[0037] Subsequently, the method 100 includes a further step 106 of strengthening the belt body to at least aid in impeding penetration of the belt body. For example, the belt body may be strengthened to enhance the ability of the belt body to withstand or retard damage or destruction caused by criminal or nefarious attacks for a predetermined time, such as during attempted breach or penetration of the barrier structure when used in the construction of a panel or door for a security enclosure.

[0038] In one or more embodiments, the belt body may be strengthened by arranging the multiple layers of the conveyor belt material with respect to each other so that each of the steel cords in one of the layers has a first direction of extension, and each of the steel cords in anotherone of the layers has a second direction of extension different to the first direction of extension. In one form, the second direction of extension is perpendicular to the first direction of extension.

[0039] In one or more embodiments, the belt body may be strengthened via joining or bonding (via, for example, adhesives and / or fasteners) one or more auxiliary or supplementary materials with the conveyor belt material. The supplementary materials may include a polymeric material (such as poly(methyl methacrylate)), a metallic material (such as steel), a natural material (such as wood), or a composite material (such as concrete), each of which may be in various dimensions, forms or configurations. Optionally, both the conveyor belt material and the supplementary material may be in the form of layers and arranged to form a composite alternating layered arrangement. Each of the fasteners may be driven or otherwise inserted obliquely (such as at 45 degrees) through each of the layers to enhance penetration resistance of the layered arrangement.

[0040] In one or more embodiments, the belt body may be strengthened by encasing the belt body in metal, such as steel, to form a metallic enclosure surrounding the belt body. The belt body may be additionally strengthened by pouring a resin composition into the metallic enclosure and subsequently curing the resin composition to form a hardened, yet flexible, sealed belt body cast. In some embodiments, the resin composition may contain a curable resin (such as epoxy, polyester, vinyl ester or polyurethane) and a mixture of inorganic or organic additives or fillers to selectively alter the mechanical or structural properties or characteristics of the belt body cast depending on the desired application. For example, the additives or fillers may include: 1) carbon fiber or fiberglass to enhance strength whilst reducing weight for a given volume of the belt body cast; 2) calcium carbonate to enhance impact resistance and stiffness of the belt body cast; and / or 3) aluminium hydroxide to enhance fire performance (that is, fire retardancy / resistance) of the belt body cast. The resin composition may also include other reinforcement such as sheets of metal, fibreglass or synthetic mesh to strengthen the cured resin and to minimise cracking thereof.

[0041] In an alternative embodiment, strengthening the belt body may forgo the step of encasing the belt body in metal and instead includes a step of resin casting utilising a temporary mould to form the belt body cast. In another embodiment, strengthening the belt body may forgo the step of resin casting and instead includes a step of encasing the belt body in metal.

[0042] FIGs. 2 to 6 show a barrier structure 200 fabricated according to the method 100. The barrier structure 200 includes a belt body 202 which employs a combination of strengthening processes as described above to enhance the performance characteristics of the barrier structure 200. With particular reference to FIG. 6, the belt body 202 includes conveyor belt material which has been processed to form a plurality of planar sheets 204 each having a desired thickness for the intended application. In some embodiments, the conveyor belt material which is to be processed into the sheets 204 may satisfy the requirements specified in AS 1333, ISO 22721 or equivalent international standards. In the illustrated embodiment, the belt body 202 includes a supplementary panel 206 formed of wood (such as medium-density fibreboard) which is arranged between a respective pair of the sheets 204 to form a multilayered structure. The sheets 204 and panel 206 of wood are secured together via fasteners 208 (such as screws or nails) which are inserted through the respective faces of each of the sheets 204 and the panel 206 of wood. The fasteners 208 may be inserted at varying spacings and in varying directions with respect to the respective faces (such as at oblique or perpendicular insertion angles). In the illustrated embodiment, the belt body 202 is further strengthened by addition of a metal mesh 210 which is secured in a planar arrangement with the composite multilayered structure of the sheets 204 and the panel 206 of wood.

[0043] To further strengthen the belt body 202, the composite multilayered structure of the sheets 204 and the panel 206 of wood with the metal mesh 210 is encased by a steel enclosure, casing or shell 212 and embedded therein within a resin composition 214 to form a hardened and flexible belt body cast 216. The resin composition 214 also aids in sealing and removing any voids within the composite multilayered structure of the belt body 202. In the illustrated embodiment, the barrier structure 200 fabricated according to the method 100 has a thickness in the range of about 40 mm to 300 mm or greater depending on requirements for the intended application. The barrier structure 200 also has an overall length and width which may be varied depending on the intended application.

[0044] One or more of the barrier structures 200 fabricated by the method 100 may be used to construct or assemble a security panel or door for impeding or retarding entry into a security enclosure. In this application, the barrier structure 200 can achieve a Group 1 Fire Rating as determined in accordance with AS 5637.1 :2015 and as tested in accordance with AS / NZS 3837: 1998. The barrier structure 200 is also capable of being assessed to at least the level of Grade XI in compliance with AS / NZ3809: 1998.

[0045] The method 100 may therefore provide a cost-effective and environmentally-friendly process for fabricating a barrier structure 200 with greater specific strength, as compared to existing heavier barrier materials, for use in security enclosures thereby mitigating drawbacks associated with floor loading requirements, delivery and installation costs and efficiency whilst supporting the circular economy. In other applications, the barrier structure 200 may also be employed in the provision of a ballistic suppression product or in applications such as road safety (as a road barrier, for example) or building construction (such as lining of bank counting rooms) where a level of security or protection and fire rating is required, whilst achieving similar benefits as described above.

Claims

CLAIMS1. A method of fabricating a barrier structure for constructing or assembling a panel or door for a security enclosure, the method including: providing conveyor belt material; processing the conveyor belt material to form a belt body; and strengthening the belt body to at least aid in impeding penetration thereof.

2. The method of claim 1, wherein providing conveyor belt material includes reclaiming an existing or decommissioned conveyor belt.

3. The method of claim 1 or 2, wherein the conveyor belt material includes a metal reinforcement.

4. The method of claim 3, wherein the metal reinforcement is in the form of a plurality of elongated metal lengths arranged so that their respective longitudinal axes are parallel to each other and extend along a length of the conveyor belt material.

5. The method of claim 4, wherein each of the metal lengths is in the form of a steel cord.

6. The method of claim 4 or 5, wherein, in a transverse cross-section of the conveyor belt material, each of the metal lengths or steel cords is uniformly arranged and positioned to minimise interstitial space between each of the metal lengths or steel cords.

7. The method of any one of claims 4 to 6, wherein processing the conveyor belt material includes forming a plurality of layers of the conveyor belt material into a belt body, and wherein strengthening the belt body includes arranging the plurality of layers of the conveyor belt material with respect to each other so that each of the metal lengths or steel cords in one of the layers has a first direction of extension, and each of the metal lengths or steel cords in an adjacent one of the layers has a second direction of extension different to the first direction of extension.

8. The method of claim 7, wherein the second direction of extension is perpendicular to the first direction of extension.

9. The method of any one of the preceding claims, wherein strengthening the belt body includes joining the conveyor belt material with one or more supplementary materials selected from the group consisting of a polymeric material, a metallic material, a natural material, a synthetic material and a composite material.

10. The method of any one of the preceding claims, wherein strengthening the belt body includes embedding the belt body in resin to form a hardened and flexible belt body.

11. The method of claim 10, wherein the resin includes one or more additives to strengthen the belt body, reduce weight for a given volume of the belt body, and / or provide fire retardancy to the belt body up to a Group 1 Fire Rating.

12. The method of claim 10 or 11, wherein the resin includes sheets of fiberglass, metal or synthetic mesh to strengthen the resin and / or to minimise cracking of the resin.

13. The method of any one of the preceding claims, wherein strengthening the belt body includes encasing the belt body in metal.

14. The method of any one of claims 10 to 12, wherein strengthening the belt body includes encasing the belt body in metal prior to embedding the belt body in resin.

15. A barrier structure fabricated in accordance with the method of any one of claims 1 to 14.

16. A security panel or door for impeding entry into a security enclosure, the security panel or door including a barrier structure formed of conveyor belt material.

17. The security panel or door of claim 16, wherein the conveyor belt material includes an elastomeric matrix within which is embedded metal reinforcement.

18. The security panel or door of claim 16 or 17, wherein the barrier structure includes a belt body having a plurality of layers each of which are formed of the conveyor belt material.

19. The security panel or door of claim 18, wherein the belt body is encased with steel and / or sealed with resin.

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