Ballistic wall assemblies with springs and interior air gaps

Abstract

A ballistic wall assembly can protects personnel from ballistic projectiles. The assembly may include an outer ballistic panel and an inner ballistic panel spaced apart to define an air gap therebetween. Springs positioned between the panels can allow the outer panel to move toward the inner panel upon projectile impact, absorbing kinetic energy. The air gap can trap bullets that pass through the outer panel and are stopped by the inner panel, preventing dangerous ricochets. A frame with a slip joint can allow outer panel movement while a crimped edge provides retention and security for the outer panel. The assembly may include a suspension system with rollers and overhead rail for mobility between stored and deployed positions. An optional MOLLE panel on the inner surface can supports everyday items, concealing the ballistic nature while maintaining emergency protection capability.

Description

RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 63 / 733,452, filed Dec. 13, 2024, entitled BALLISTIC PANELS WITH SPRINGS AND INTERIOR AIR GAPS, the entire disclosure of which is herein incorporated by reference.FIELD OF THE INVENTION

[0002] This application relates to ballistic protection, and more particularly, mobile ballistic protection for quick deployment in schools and other facilities.BACKGROUND OF THE INVENTION

[0003] Ballistic protection systems have long been employed in various settings where individuals or assets face potential threats from firearms and explosive devices. Traditional ballistic barriers, such as those used in military installations, law enforcement facilities, and secure commercial environments, have relied primarily on static, rigid materials to stop projectiles. Conventional approaches typically employ thick steel plates, concrete walls, or layered composite materials that attempt to absorb or deflect incoming rounds through sheer mass and hardness.

[0004] The need for effective ballistic protection has become particularly acute in civilian settings, especially schools, where active shooter incidents have created an urgent demand for protective measures that can save lives. In recent years, there has been an alarming increase in the number of active shooter attacks, with a very high percentage occurring in schools, businesses, and other public places. During such incidents, students, teachers, and staff often find themselves trapped in classrooms or other rooms with limited means of protection. The Department of Homeland Security recommends sheltering in place when evacuation is not possible, but conventional building construction using studs and drywall provides virtually no protection against gunfire. Even locked classroom doors can be penetrated by bullets, leaving occupants vulnerable.

[0005] However, existing ballistic protection systems suffer from several critical drawbacks that have prevented their widespread adoption in schools and similar civilian environments. Conventional ballistic walls constructed from solid steel or concrete are extremely heavy, making them difficult to transport, install, and reconfigure as needed. The weight of such systems often requires specialized equipment for installation and limits their use in temporary or mobile applications. Traditional rigid barriers are prone to creating dangerous ricochets when bullets strike their hard surfaces at certain angles, potentially redirecting projectiles back toward protected personnel or bystanders. This ricochet effect represents a serious safety hazard that undermines the protective purpose of the barrier.

[0006] Conventional ballistic panels typically lack any mechanism for dissipating the kinetic energy of incoming projectiles beyond the material properties of the barrier itself. When a bullet strikes a rigid steel plate, for example, the entire force of impact is concentrated at the point of contact, often resulting in deformation, spalling, or eventual penetration after repeated strikes in the same location. The lack of energy-absorbing mechanisms means that conventional barriers must be made thicker and heavier to achieve adequate protection levels, further exacerbating weight and mobility issues.

[0007] Traditional ballistic protection systems are generally fixed installations that cannot be easily repositioned or deployed on demand. In dynamic threat situations, such as active shooter scenarios in schools, offices, or public buildings, the inability to quickly deploy protective barriers where needed most represents a critical limitation. Fixed barriers also cannot adapt to changing room configurations or be moved to block specific entry points as circumstances require. The inability to rapidly transform an ordinary classroom or office into a protected shelter represents a fundamental shortcoming of existing technology.

[0008] Conventional ballistic walls present an intimidating, fortress-like appearance that can create anxiety in everyday environments such as schools, offices, and public spaces. The harsh industrial aesthetic of traditional steel or concrete barriers makes them psychologically unsuitable for environments where people gather for normal daily activities. This appearance problem has limited the adoption of ballistic protection in many settings where such protection would otherwise be beneficial, particularly in schools where creating a welcoming learning environment is essential.

[0009] Prior art systems have failed to provide effective mechanisms for preventing bullets from passing completely through a protective barrier after the barrier material has been weakened by previous impacts. Once a conventional steel plate or composite panel has been struck multiple times in proximity, its structural integrity is compromised, and subsequent rounds may penetrate through to the protected area. The lack of redundant protective layers or bullet-trapping mechanisms in traditional designs represents a significant vulnerability.

[0010] Existing ballistic protection systems have not adequately addressed the need for multi-functional barriers that can serve everyday purposes while providing emergency protection. The single-purpose nature of conventional ballistic walls means that dedicated space and resources must be allocated solely for protective barriers, which remain unused during normal operations. This inefficiency has discouraged the widespread adoption of ballistic protection in schools, offices, and other civilian environments where such protection could save lives during active shooter events.

[0011] Therefore, a need exists for an improved ballistic protection system that overcomes these limitations by providing effective bullet-stopping capability while remaining lightweight and mobile, preventing dangerous ricochets through bullet-trapping mechanisms, incorporating energy-absorbing elements to dissipate projectile kinetic energy, enabling rapid deployment and repositioning as needed, presenting a non-threatening appearance suitable for everyday environments, providing redundant protective layers to maintain effectiveness after multiple impacts, and serving dual purposes by supporting everyday activities while remaining ready for emergency deployment.SUMMARY OF THE INVENTION

[0012] This invention overcomes disadvantages of the prior art by providing a ballistic wall assembly that effectively protects personnel from ballistic projectiles while addressing the critical limitations of conventional rigid barriers. The ballistic wall assembly includes an outer ballistic panel and an inner ballistic panel spaced apart to define an air gap therebetween, with springs positioned between the panels to allow the outer panel to move toward the inner panel upon projectile impact, thereby absorbing kinetic energy and reducing the force transmitted to the inner panel. The air gap traps bullets that pass through the outer panel and are stopped by the inner panel, preventing dangerous ricochets that plague conventional hard-surface barriers. The assembly may include a frame with a slip joint that permits controlled movement of the outer panel while a crimped edge provides secure retention and prevents external tampering. The system may be configured as a mobile ballistic wall with a suspension system featuring rollers and an overhead rail, enabling rapid deployment from a stored position to block doorways or other entry points. An optional inner cover on the interior surface supports everyday items such as educational materials or office supplies, allowing the ballistic wall to blend into normal classroom or workplace environments while maintaining full protective capability.

[0013] According to an aspect of the invention, a ballistic wall assembly for protecting personnel from ballistic projectiles may include an outer ballistic panel, an inner ballistic panel spaced from the outer ballistic panel to define an air gap therebetween, and a plurality of springs positioned between the outer ballistic panel and the inner ballistic panel, wherein the springs may be configured to allow the outer ballistic panel to move toward the inner ballistic panel upon impact from a ballistic projectile, and wherein the air gap may be configured to trap bullets that pass through the outer ballistic panel and are stopped by the inner ballistic panel, thereby preventing ricochets. This configuration can provide a multi-layered defense system that absorbs projectile energy through spring-mounted panel movement while eliminating the ricochet hazard inherent in rigid barrier systems.

[0014] According to an embodiment, the ballistic wall assembly may include a frame surrounding the outer ballistic panel and the inner ballistic panel, wherein the frame may include a slip joint that allows the outer ballistic panel to move within the frame. According to an embodiment, the frame may include a crimped edge that holds the outer ballistic panel in place within the frame while allowing the outer ballistic panel to move in response to ballistic impact. According to an embodiment, the crimped edge may provide a counterforce to the springs when the springs are preloaded to bias the outer ballistic panel outward. According to an embodiment, the crimped edge may cover the slip joint to prevent the slip joint from being pried apart from outside the ballistic wall assembly. According to an embodiment, the ballistic wall assembly may include bearings positioned to facilitate movement of the outer ballistic panel within the frame. According to an embodiment, the ballistic wall assembly may include an outer cover positioned on an exterior surface of the outer ballistic panel, the outer cover concealing the ballistic nature of the ballistic wall assembly. According to an embodiment, the ballistic wall assembly may include a MOLLE panel positioned on an interior surface of the inner ballistic panel, wherein the MOLLE panel is configured to support decorative items to conceal the ballistic nature of the ballistic wall assembly. According to an embodiment, the ballistic wall assembly may have a wall thickness in a range between approximately 2 inches and approximately 4 inches. According to an embodiment, the ballistic wall assembly may include a suspension system configured to support the ballistic wall assembly for movement, wherein the suspension system includes rollers and an overhead rail.

[0015] According to an aspect of the invention, a mobile ballistic wall for protecting personnel from ballistic projectiles may include an outer ballistic panel, an inner ballistic panel spaced from the outer ballistic panel to define an air gap therebetween, a plurality of springs positioned between the outer ballistic panel and the inner ballistic panel, wherein the springs are configured to allow the outer ballistic panel to move toward the inner ballistic panel upon impact from a ballistic projectile, a frame surrounding the outer ballistic panel and the inner ballistic panel, wherein the frame includes a slip joint that allows the outer ballistic panel to move within the frame, and a suspension system configured to support the mobile ballistic wall for movement between a stored position and a deployed position. This mobile configuration can enable the ballistic wall to be concealed during normal operations and rapidly deployed to create protected areas during emergency situations, addressing the need for adaptable protection in dynamic threat scenarios.

[0016] According to an embodiment, the suspension system may include rollers configured to engage an overhead rail. According to an embodiment, the mobile ballistic wall may include a MOLLE panel positioned on an interior surface of the inner ballistic panel, wherein the MOLLE panel can be configured to support items for everyday use in a classroom or office environment. According to an embodiment, the frame may include a crimped edge that holds the outer ballistic panel in place within the frame and covers the slip joint to prevent tampering. According to an embodiment, the air gap may be configured to trap bullets that pass through the outer ballistic panel and are stopped by the inner ballistic panel, thereby preventing ricochets. According to an embodiment, the mobile ballistic wall may include bearings positioned to facilitate movement of the outer ballistic panel within the frame.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The invention description below refers to the accompanying drawings, of which:

[0018] FIG. 1A is a schematic front view of a ballistic wall with an interior air gap, according to an illustrative embodiment;

[0019] FIG. 1B is a cross section of the ballistic wall of FIG. 1A, taken along cross section line 1B-1B, according to an illustrative embodiment;

[0020] FIG. 2A is a schematic front view of a mobile ballistic wall suspended on an overhead rail, according to an illustrative embodiment;

[0021] FIG. 2B is a cross section of the mobile ballistic wall of FIG. 2A, taken along cross section line 2B-2B, according to an illustrative embodiment;

[0022] FIG. 3 shows a slip joint that allows an outer panel to move back and forth within a frame while springs connect the outer panel to an inner panel, according to an illustrative embodiment;

[0023] FIG. 4A is a schematic view of a ballistic wall assembly with a frame having a crimped edge, according to an illustrative embodiment;

[0024] FIG. 4B is a top view of a ballistic wall assembly showing the upper crimped edge, according to an illustrative embodiment;

[0025] FIG. 4C is a cross section view of the ballistic wall assembly of FIG. 4A, taken along cross section line 4C-4C, according to an illustrative embodiment;

[0026] FIG. 5A is a front view of a mobile ballistic wall assembly, according to an illustrative embodiment;

[0027] FIG. 5B is a cross section view of the mobile ballistic wall assembly of FIG. 5A, taken along cross section 5B-5B of FIG. 5A, according to an illustrative embodiment; and

[0028] FIG. 5C is an inside view of the mobile ballistic wall assembly, showing a MOLLE panel as seen from inside the protected area formed by the mobile ballistic wall assembly, according to an illustrative embodiment.DETAILED DESCRIPTION

[0029] The description herein includes a mobile ballistic wall assembly system. There are a great many possible implementations of the invention, too many to describe herein. Some possible implementations that are presently preferred are described below. It cannot be emphasized too strongly, however, that these are descriptions of implementations of the invention, and not descriptions of the invention, which is not limited to the detailed implementations described in this section but is described in broader terms in the claims. Although this invention is disclosed in the context of certain preferred embodiments and examples, it should be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments and / or uses of the invention and obvious modifications and equivalents thereof. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the invention.

[0030] Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention and do not limit the scope of the invention. Additionally, any particular embodiment need not have all the aspects or advantages described herein. Thus, in various embodiments, any of the features described herein from different embodiments may be combined.

[0031] FIG. 1A is a schematic front view of a ballistic wall assembly with an interior air gap, according to an illustrative embodiment, and FIG. 1B is a cross section of the ballistic wall of FIG. 1A, taken along cross section line 1B-1B, according to an illustrative embodiment. As shown in FIGS. 1A and 1B, a ballistic wall 100 may have an interior air gap 104 that can trap bullets and prevent ricochets. This bullet-trapping feature can provide a significant safety advantage over conventional rigid ballistic barriers that can create dangerous ricochets when bullets strike their hard surfaces.

[0032] The ballistic wall assembly 100 may have an outer ballistic panel 102 and an inner ballistic panel 110. The outer ballistic panel 102 may face towards potential shooters or ballistic events. The inner ballistic panel 110 may face towards a shelter or other safe area. The outer ballistic panel 102 may be bullet resistant, may trap bullets, or may absorb some of the energy from the bullets as the bullets pass through the outer ballistic panel 102. The inner ballistic panel 110 may be a hardened ballistic defense that will prevent bullets from passing through to the interior sheltered area. This dual-panel configuration may provide redundant protective layers that maintain effectiveness even after the outer panel has been compromised by multiple impacts.

[0033] The ballistic wall assembly 100 may have an air gap 104 between the outer ballistic panel 102 and the inner ballistic panel 110. Air gap 104 may have an air gap width AG, and in various embodiments, air gap width AG may be in a range between approximately 1 inch and approximately 1.5 inches. In various embodiments, air gap width AG can be approximately 1.25 inches. In various embodiments, various air gap widths may be possible. The air gap 104 may serve multiple protective functions, including providing space for bullets to be trapped after passing through the outer panel and allowing the outer panel to move in response to impact without immediately contacting the inner panel.

[0034] A series of springs 106 or other resilient materials may separate the inner ballistic panel 110 and outer ballistic panel 102. The resilient materials such as springs 106 can help to absorb energy from the bullet impacting the outer ballistic panel 102, so that the springs 106 may help to reduce the energy of the bullet as the bullet impacts and / or passes through the outer ballistic panel 102. By absorbing kinetic energy through controlled movement of the outer panel, the spring-mounted system may significantly reduce the force transmitted to the inner panel, enhancing the overall protective capability of the ballistic wall assembly.

[0035] The inner ballistic panel 110 and outer ballistic panel 102 may include armored steel, ceramic ballistic materials, composite materials, and / or other ballistic materials known in the art for stopping or slowing bullets. A bullet can initially impact the outer ballistic panel 102, and the outer ballistic panel 102 may be deflected or moved as the springs 106 or other resilient materials absorb some of the energy. The bullet may be blocked by the outer ballistic panel 102 or captured by the outer ballistic panel 102, or the bullet can continue to pass through the outer ballistic panel 102 into the air gap.

[0036] If the bullet passes through the outer ballistic panel 102, the bullet will have lost a significant portion of its initial energy by the time it enters the air gap 104 area between panels. The bullet can then impact the inner ballistic panel 110 with significantly reduced energy. The inner ballistic panel 110 can stop the bullet and prevent the bullet from passing through into the sheltered safe area behind the ballistic wall. The bullet can then be trapped in the air gap 104 area between the outer ballistic panel 102 and inner ballistic panel 110. The bullet can bounce around within the air gap 104 area and fall harmlessly to the bottom of the air gap instead of bouncing off of the ballistic wall 100 and becoming a dangerous ricochet. This bullet-trapping mechanism can eliminate the ricochet hazard that represents a serious safety concern with conventional rigid ballistic barriers.

[0037] The interaction between the bullet and the outer ballistic panel 102 as the bullet passes through can cause significant deformation and destabilization of the projectile that further enhances the protective capability of the system. When a bullet strikes and penetrates the outer ballistic panel 102, the ballistic material can deform the bullet's shape, blunting the pointed nose that normally enables penetration of subsequent barriers. The outer ballistic panel 102 can also cause the bullet to tumble or yaw as it emerges into the air gap 104, rather than maintaining the stable spin-stabilized flight that gives bullets their penetrating power. A tumbling bullet presents a much larger cross-sectional area to the inner ballistic panel 110 than a nose-forward bullet, distributing the impact force over a larger area and making penetration of the inner panel significantly more difficult. Additionally, the passage through the outer ballistic panel 102 can fragment the bullet, breaking it into multiple smaller pieces that individually possess far less penetrating capability than the intact projectile. These deformed, tumbling, or fragmented projectiles emerging into the air gap 104 are substantially less capable of penetrating the inner ballistic panel 110 than the original intact bullet would have been.

[0038] The combined effects of energy loss, deformation, tumbling, and potential fragmentation mean that by the time a bullet reaches the inner ballistic panel 110, it may be in a severely degraded state compared to its initial condition. The bullet may have lost a significant amount of its initial kinetic energy to the outer ballistic panel 102 and the spring-mounted energy absorption system. The bullet's aerodynamic shape may be destroyed, eliminating the penetrating geometry that allows bullets to pierce barriers effectively. The bullet may be tumbling chaotically rather than flying straight, causing it to strike the inner ballistic panel 110 at an oblique angle that further reduces penetrating capability. In many cases, the bullet may have fragmented into multiple pieces, each with only a fraction of the original projectile's mass and energy. This severely degraded state of the projectile as it crosses the air gap 104 represents a critical advantage of the dual-panel spring-mounted system over conventional single-layer barriers that must stop the full force of an intact, undamaged bullet.

[0039] The inner ballistic panel 110 therefore faces a much easier task than it would in a conventional barrier system, as it must stop a weakened, deformed, tumbling, or fragmented projectile rather than an intact high-velocity bullet. This allows the inner ballistic panel 110 to be thinner and lighter than would otherwise be required, contributing to the overall weight savings of the system while still providing reliable protection. The degraded state of projectiles emerging from the outer panel also means that the inner panel is unlikely to be penetrated even after the outer panel has been compromised by previous impacts, ensuring continued protection throughout an extended attack. This represents a significant advantage over conventional barriers where a single layer must stop intact bullets, and where damage from previous impacts can compromise the barrier's ability to stop subsequent rounds.

[0040] A ballistic wall assembly 100 can have a wall thickness WT. In various embodiments, wall thickness WT can be in a range between approximately 2 inches and approximately 4 inches. In various embodiments, wall thickness WT can be approximately 3 inches. This compact profile can allow the ballistic wall assembly 100 to fit within standard wall pockets or concealed storage areas while providing effective protection against common ballistic threats. In various embodiments, a ballistic wall assembly 100 can be designed to fit within a wall pocket inside of a neighboring wall. Mobile ballistic wall assemblies can be hidden or stored out of the way in a classroom or other area, and can be deployed quickly when necessary, as taught in U.S. Patent Publication Number 2023 / 0408226 to Giordano, titled BALLISTIC PROTECTION SYSTEM AND METHOD OF USE, and in U.S. Patent Publication Number 2025 / 0003718 to Giordano, titled BALLISTIC PROTECTION SYSTEM AND METHOD OF USE, the entire disclosures of which are incorporated herein by reference. The ballistic wall assembly 100 can slide out from a wall pocket to seal a doorway, and wall thickness WT can be designed to be slim enough to fit within a pocket inside a neighboring wall, or other concealed area so that it can be deployed out from the wall or other concealed area when needed.

[0041] Outer panel 102 may have an outer panel thickness OP, and in various embodiments, outer panel thickness OP may be in a range between approximately ⅛ inch and approximately ⅝ inch. In various embodiments, outer panel thickness OP may be approximately ⅜ inch. Similarly, inner panel 110 may have an inner panel thickness IP, an in various embodiments, inner panel thickness IP may be in a range between approximately ⅛ inch and approximately ⅝ inch. In various embodiments, inner panel thickness IP may be approximately ⅜ inch.

[0042] An optional outer cover 108 can be a white board, tack board, chalk board, or other functional outer covering that can be used in a school setting while also obscuring the cold ballistic nature of the ballistic wall assembly. This outer cover 108 can address psychological concerns by allowing the protective barrier to blend into everyday environments such as classrooms or offices without creating anxiety or drawing unwanted attention. Outer cover 108 may have an outer cover thickness OC, and in various embodiments, outer cover thickness OC can be in a range between approximately 0 inch and approximately 1 inch or more. In various embodiments, outer cover thickness OC can be approximately ¾ inch. With or without the optional outer cover 108, the ballistic wall assembly 100 can have a total wall thickness WT, including the inner panel, the air gap, the outer panel, the optional outer cover, and an optional inner cover, that can be in a range between approximately 2 and approximately 4 inches.

[0043] A ballistic wall assembly 100 may have a panel height PH, and in various embodiments, panel height PH may be in a range between approximately 7 feet and approximately 10 feet or more. In various embodiments, panel height PH may be approximately 8 feet. However, it should be clear that panel height PH may be highly variable, and may be adapted to fit the needs of any particular space. In various embodiments, the panel height PH may be adapted to cover from floor to ceiling. In various embodiments, the panel height PH may be adapted to seal a doorway to create a safe area behind the ballistic wall.

[0044] A ballistic wall assembly may have a panel width PW, and in various embodiments, panel width PW may be in a range between approximately 3 feet and approximately 8 feet or more. In various embodiments, panel width PW may be approximately 4 feet. However, it should be clear that panel width PW may be highly variable, and may be adapted to fit the needs of any particular space. In various embodiments, the panel width PW may be adapted to seal a doorway to create a safe area behind the ballistic wall.

[0045] FIG. 2A is a schematic front view of a mobile ballistic wall assembly suspended on an overhead rail, according to an illustrative embodiment, and FIG. 2B is a cross section of the mobile ballistic wall of FIG. 2A, taken along cross section line 2B-2B, according to an illustrative embodiment. As shown in FIGS. 2A and 2B, a ballistic wall may also be a mobile ballistic wall. By way of non-limiting example, the ballistic wall can swivel on hinges, or can be suspended on rollers 232 from an overhead rail 230 like a sliding barn door, or can be carried on a track in the floor, or other means for making a ballistic wall a mobile ballistic wall. Mobile ballistic wall assemblies can be hidden or stored out of the way in a classroom or other area, and can be moved quickly into deployment when necessary, as taught in U.S. Patent Publication Number 2023 / 0408226 to Giordano, titled BALLISTIC PROTECTION SYSTEM AND METHOD OF USE, and in U.S. Patent Publication Number 2025 / 0003718 to Giordano, titled BALLISTIC PROTECTION SYSTEM AND METHOD OF USE, the entire disclosures of which are incorporated herein by reference. Various means for moving a mobile ballistic wall are possible and are specifically contemplated herein.

[0046] In various embodiments, the mobile ballistic wall may ride on an overhead rail so that the mobile ballistic wall can slide in front of, and block a door or entrance way. In this way, the mobile ballistic wall can turn a room into a safe shelter by blocking the door. This mobility feature can enable rapid deployment of the protective barrier to block doorways or other entry points during emergency situations, addressing the need for rapid protection in dynamic threat scenarios. The ballistic wall 200 may include an outer ballistic panel 202 and an inner ballistic panel 210. The inner ballistic panel 210 may be mounted within the frame 212 of the ballistic wall 200. In various embodiments, a chalkboard, whiteboard, tack board, or other useful materials can be on the interior side of the inner ballistic panel, facing towards the sheltered area. In various embodiments, a Modular Lightweight Load-carrying Equipment (MOLLE) panel, straps, hooks, or other means to suspend objects can be on the interior side of the inner ballistic panel 210, facing towards the sheltered area. Various chalkboards, white boards, tack boards, or other materials can hang on the MOLLE panel on the inside of the ballistic wall. This can hide the harsh, ballistic nature of the ballistic wall while also allowing the space on the inside of the wall to be utilized during normal day-to-day activities.

[0047] FIG. 3 shows a slip joint that allows an outer panel to move back and forth within a frame while springs connect the outer panel to an inner panel, according to an illustrative embodiment. As shown in FIG. 3, the ballistic wall assembly 300 may include an outer ballistic panel 302, an inner ballistic panel 310, and a frame 340. A slip joint 342 allows the outer ballistic panel 302 to move back and forth within the frame 340. This structural arrangement can enable controlled movement of the outer panel in response to ballistic impact while maintaining the overall integrity and alignment of the protective barrier. Springs 306 may connect the outer ballistic panel 302 to the inner ballistic panel 310, and may allow the outer ballistic panel 302 to flex towards the inner ballistic panel 310 upon ballistic impact. The ballistic wall 300 may also include spring retention clips 344 that may secure the springs 306 in position. An outer ballistic panel retention clip 346 may hold the outer ballistic panel 302 in place within the frame 340 while still allowing the outer ballistic panel 302 to move in response to ballistic impact. The slip joint 342 may allow the outer ballistic panel 302 to move back and forth within the frame 340 while maintaining the structural integrity of the ballistic wall 300. The springs 306 may be positioned between the outer ballistic panel 302 and the inner ballistic panel 310 to absorb energy from incoming projectiles and reduce the force transmitted to the inner ballistic panel 310.

[0048] FIG. 4A is a schematic view of a ballistic wall assembly with a frame having a crimped edge, according to an illustrative embodiment, FIG. 4B is a top view of a ballistic wall assembly showing the upper lip of the frame before crimping, according to an illustrative embodiment, and FIG. 4C is a cross section view of the ballistic wall assembly of FIG. 4A, taken along cross section line 4C-4C, according to an illustrative embodiment. The frame 440 may include a crimped edge 454 at the outer portion of the wall, and the crimped edge 454 can wrap around the outer ballistic panel 402. The crimped edge 454 can hold the outer ballistic panel 402 in place and provide a counterforce to outward-pushing springs 406. This crimped edge configuration may provide secure retention of the outer panel without preventing its energy-absorbing movement, ensuring reliable operation under ballistic attack. The corners of the frame 440 may be notched before final assembly. The notched corners 456 may allow the crimped edges to fold inward and meet and form the corner seam 458. Prior to folding or crimping, the frame 440 may have lips 452 that may be crimped or folded in, and the lips 452 may form the crimped edges 454 that can hold the outer ballistic panel 402 in place. The crimped edge 454 may have a crimped edge width CE, and in various embodiments The crimped edge width CE may be in a range between approximately ¼ inch and approximately 1 inch. In various embodiments, crimped edge width CE can be in a range between approximately ¼ inch and approximately ⅝ inch.

[0049] The springs 406 and outer ballistic panel 402 may be assembled within the frame 440, and the springs 406 may optionally be pre-tensioned so that they are biased outwards, pushing the outer panel 402 outwards. Then the notched lips 452 around the frame 440 may be crimped inward at bend line 460 to form the crimped edge 454 that holds the outer ballistic panel 402 in place. The crimped edge 454 can provide a counterforce that can optionally keep the springs 406 in a preloaded conformation behind the outer ballistic panel 402, with the springs pushing the outer panel against the crimped edge. This preloading arrangement can ensure that the outer panel returns to its ready position quickly after impact, maintaining the system's readiness for subsequent projectile strikes.

[0050] The crimped edge 454 can also protect the slip joint 442 from being pried apart from the outside. This protection is important because the slip joint 442 represents a potential vulnerability in the ballistic wall structure. Without the crimped edge 454 covering and securing the slip joint 442, an attacker could potentially insert tools or implements into the slip joint 442 to pry the frame 440 apart, compromising the integrity of the ballistic wall 400. The crimped edge 454 can create a physical barrier that prevents access to the slip joint 442 from the exterior, making it extremely difficult to tamper with or breach the wall structure through mechanical means. By covering the slip joint 442, the crimped edge 454 ensures that the only way to defeat the ballistic wall 400 is through ballistic impact, for which the wall is specifically designed to provide protection.

[0051] Upon impact from a bullet, the spring loaded outer ballistic panel 402 can move in the direction of arrow 420, towards the inner ballistic panel 410. As the springs 406 and the outer ballistic panel 402 both absorb the impact, bullets that pass through the outer ballistic panel 402 can bounce off of the inner ballistic panel 410 and be trapped within the air gap 404, dropping harmlessly within the wall 400. Bearings 416 may be positioned between the outer ballistic panel 402 and the frame 440 to facilitate smooth movement of the outer ballistic panel 402 within the frame 440. The bearings 416 can reduce friction between the outer ballistic panel 402 and the frame 440, allowing the outer ballistic panel 402 to move more freely in response to ballistic impact. By reducing resistance to movement, the bearings 416 can enable the outer ballistic panel 402 to respond more effectively to incoming projectiles, enhancing the energy absorption capability of the spring-mounted system. This enhanced responsiveness and efficiency can improve the overall protective performance of the ballistic wall assembly by ensuring that the energy-absorbing movement occurs with minimal resistance. The bearings 416 may be positioned at multiple locations along the edges of the outer ballistic panel 402 to ensure smooth, uniform movement across the entire panel surface. In various embodiments, the bearings 416 may be roller bearings, ball bearings, or other low-friction bearing mechanisms suitable for supporting the weight of the outer ballistic panel 402 while allowing it to move freely within the slip joint 442 of the frame 440.

[0052] In various embodiments, an outer cover 408 can hide the outer ballistic panel and crimped edge 454 to create a softer, more pleasant appearance within a school. However, the outer ballistic panel can still move inward to absorb the impact when a bullet hits the front side of the mobile ballistic wall, even when an outer cover is hiding the ballistic nature of the wall.

[0053] FIG. 5A is a front view of a mobile ballistic wall assembly, according to an illustrative embodiment. FIG. 5B is a cross section view of the mobile ballistic wall assembly of FIG. 5A, taken along cross section 5B-5B of FIG. 5A, according to an illustrative embodiment. FIG. 5C is an inside view of the mobile ballistic wall assembly, showing an inner cover as seen from inside the protected area formed by the mobile ballistic wall assembly 500, according to an illustrative embodiment. The mobile ballistic assembly 500 may provide ballistic protection while serving dual purposes in everyday environments such as classrooms, offices, or other spaces where both functionality and security are desired. The ballistic wall 500 may have various configurations of inner covers or mounting systems on the sheltered side of the mobile ballistic wall to support everyday activities while maintaining readiness for emergency deployment.

[0054] The outer ballistic panel 502 may be a ballistic panel constructed of armored steel, ceramic ballistic materials, composite materials, or other materials known in the art for stopping or slowing bullets. The outer ballistic panel 502 may be held by springs 506 that can allow the outer ballistic panel 502 to flex or move towards the inner ballistic panel 510 when impacted by a projectile. This spring-mounted configuration can enable the outer ballistic panel 502 to absorb kinetic energy from incoming bullets, reducing the force transmitted to the inner ballistic panel 510. The springs 506 may be positioned at multiple locations between the outer ballistic panel 502 and the inner ballistic panel 510 to distribute the energy absorption across the panel surface.

[0055] The ballistic wall 500 may have an air gap 504 between the outer ballistic panel 502 and the inner ballistic panel 510. The air gap 504 may serve multiple protective functions. When a bullet passes through the outer ballistic panel 502, having already lost significant energy to the outer panel and the spring-mounted system, the bullet can enter the air gap 504 where it can be further slowed and destabilized. If the bullet then strikes the inner ballistic panel 510 and is stopped, the bullet becomes trapped within the air gap 504. The trapped bullet can bounce harmlessly within the air gap 504 and fall to the bottom of the ballistic wall 500, rather than ricocheting back toward the shooter or other personnel. This bullet-trapping feature represents a significant safety advantage over conventional rigid ballistic barriers that can create dangerous ricochets.

[0056] The inner ballistic panel 510 may serve as the final line of defense, preventing bullets from passing through into the sheltered area behind the ballistic wall 500. The inner ballistic panel 510 may be constructed of hardened ballistic materials capable of stopping projectiles that have already been significantly slowed by the outer ballistic panel 502 and the spring-mounted energy absorption system. In various embodiments, the inner ballistic panel 510 may have a chalkboard, white board, tack board, MOLLE panel 570, or other useful inner coverings mounted on its interior surface, facing toward the protected area.

[0057] A MOLLE panel 570 may provide a versatile mounting system that allows various items to be attached to the interior surface of the ballistic wall 500. A MOLLE panel may include a series of webbing straps or attachment points arranged in a standardized pattern. The MOLLE panel 570 may support chalkboards, whiteboards, tack boards, screens, decorations, educational materials, or other objects that serve everyday functions in classroom or office environments. By incorporating the MOLLE panel 570 on the interior surface, the ballistic wall 500 can blend into normal educational or workplace settings, hiding its protective ballistic nature while remaining ready for emergency deployment. This dual-purpose functionality addresses the psychological concerns associated with visible ballistic protection in everyday environments, particularly in schools where creating a welcoming atmosphere is important. The MOLLE panel 570 can enable dual-purpose functionality by supporting everyday items while maintaining full ballistic protection capability, making the system suitable for civilian environments.

[0058] In various embodiments, items can be hung on the MOLLE panel 570 using standard MOLLE-compatible attachments, straps, hooks, or clips. The modular nature of the MOLLE system can allow users to easily reconfigure what is displayed on the interior surface of the ballistic wall 500 according to changing needs or preferences. For example, in a classroom setting, teachers can attach educational posters, student work displays, classroom rules, or teaching aids to the MOLLE panel 570. In an office environment, the MOLLE panel 570 can support organizational charts, notices, calendars, or decorative elements. The ability to customize the interior appearance of the ballistic wall 500 enhances its suitability for civilian environments while maintaining full ballistic protection capability.

[0059] The combination of the outer ballistic panel, springs, air gap, inner ballistic panel, outer cover, and inner cover, creates a comprehensive ballistic protection system that addresses multiple shortcomings of prior art systems. The spring-mounted outer panel provides energy absorption, the air gap traps bullets and prevents ricochets, the inner panel provides final protection, and the outer cover and inner cover can enable the system to serve everyday functions while remaining ready for emergency use. This multi-layered approach to ballistic protection, combined with the dual-purpose functionality, represents a significant advancement over conventional single-purpose ballistic barriers.

[0060] Overall, the use of an air gap instead of solid heavy ballistic materials can provide a significant weight advantage over conventional ballistic protection systems. Traditional ballistic barriers typically rely on thick layers of dense materials such as solid steel plates, concrete, ceramic composites, or multiple layers of heavy materials to achieve adequate protection levels. These conventional approaches result in extremely heavy barriers that are difficult to transport, install, and reposition. For example, a conventional solid steel ballistic wall of comparable protective capability might weigh several hundred pounds per panel, requiring specialized lifting equipment and multiple personnel for installation and movement.

[0061] In contrast, the ballistic wall assembly described herein can achieve effective ballistic protection while maintaining a lightweight profile by utilizing the air gap as a key protective element rather than relying solely on material mass. The air gap can occupy space that would otherwise be filled with heavy ballistic materials in conventional designs, yet provides critical protective functions including bullet trapping and ricochet prevention. By replacing dense solid materials with the air gap, the overall weight of the ballistic wall assembly can be substantially reduced compared to conventional barriers of equivalent protective capability. This weight reduction can make the ballistic wall assembly significantly more practical for applications requiring mobility, rapid deployment, or installation in weight-sensitive environments.

[0062] The lightweight nature of the ballistic wall assembly can enable a single person to handle and deploy the barrier without specialized equipment. This represents a substantial advantage over conventional heavy ballistic barriers that require forklifts, cranes, or multiple personnel for movement and installation. In emergency situations, such as active shooter scenarios in schools or offices, the ability to quickly deploy protective barriers can be critical to saving lives. The lightweight design of the ballistic wall assembly can make such rapid deployment feasible, whereas heavy conventional barriers would remain impractical for quick emergency deployment.

[0063] The combination of lightweight construction and the suspension system described herein enables the ballistic wall assembly to function as a mobile protective barrier that can be easily deployed as needed. The reduced weight can allow the ballistic wall assembly to be suspended on hinges or suspended from overhead rails using rollers, without requiring heavy-duty structural supports. This mobility feature would be impractical or impossible with conventional heavy ballistic barriers. The lightweight design can also reduce the load on building structures, making it possible to install ballistic protection in existing buildings without requiring structural reinforcement to support the weight of the protective barriers.

[0064] The spring-mounted configuration of the ballistic wall assembly can reduce damage to the outer panel, while also providing a self-healing capability that represents a significant advantage over conventional rigid ballistic barriers. After a bullet impacts the outer ballistic panel and the springs compress to absorb the kinetic energy, thereby reducing damage to the outer panel, the springs can return the outer ballistic panel to its original position once the impact force has dissipated. This self-healing action restores the ballistic wall assembly to its ready state, prepared to absorb subsequent projectile strikes with the same effectiveness as before the initial impact. In contrast, conventional rigid steel plates or concrete barriers remain permanently deformed after impact, with dents, dimples, or craters that can compromise the barrier's ability to effectively stop subsequent rounds. These permanent deformations in conventional barriers can create weak points where future projectiles may more easily penetrate, and the deformed surfaces can increase the likelihood of dangerous ricochets. The damage-reducing and self-healing capability of the spring-mounted system can ensure that the ballistic wall assembly maintains consistent protective performance even after absorbing multiple impacts.

[0065] The ballistic wall assembly can withstand multiple projectile impacts in close proximity without catastrophic failure, addressing a critical limitation of conventional ballistic barriers. Traditional armor plates and rigid ballistic panels typically weaken significantly after repeated strikes in the same location, as each impact creates stress concentrations, material fatigue, and structural damage that accumulates with each subsequent hit. After several impacts in proximity, conventional barriers can fail completely, allowing projectiles to penetrate through to the protected area. This vulnerability is particularly dangerous in active shooter scenarios where an unchallenged and unimpeded attacker may fire multiple rounds at the same general area of a protective barrier. The ballistic wall assembly described herein overcomes this limitation through the combination of the spring-mounted outer panel, the air gap, and the inner panel working together to distribute and absorb impact forces. When multiple bullets strike the same area of the outer ballistic panel, the springs can compress and extend repeatedly, absorbing energy from each impact without permanent structural failure. The air gap provides space for the outer panel to move and deform in response to each impact, preventing the stress concentrations that occur in rigid barriers. The inner ballistic panel serves as a backup protective layer that can stop projectiles even if the outer panel has been compromised by previous impacts. This multi-hit capability ensures that the ballistic wall assembly continues to provide effective protection throughout an extended attack, rather than failing after the first few impacts as conventional barriers often do.

[0066] The ballistic wall assembly can provide cost-effectiveness advantages over conventional solid ballistic barriers by utilizing the air gap as a protective element rather than filling the entire thickness with expensive ballistic materials. Traditional ballistic protection systems typically require thick layers of specialized materials such as hardened steel, ceramic composites, aramid fibers, or other costly ballistic-resistant materials throughout their entire thickness to achieve adequate protection levels. The material costs for such conventional systems can be substantial, particularly when protecting large areas such as entire classrooms or office spaces. The ballistic wall assembly described herein may achieve comparable or superior protective performance while using thinner panels of ballistic material separated by the air gap. The air gap itself requires no material cost, yet contributes significantly to the protective capability of the system by trapping bullets and preventing ricochets. The overall material cost savings can make ballistic protection more accessible and affordable for schools, offices, and other civilian facilities that might otherwise be unable to afford conventional heavy ballistic barriers. The cost-effectiveness of the system can enable wider deployment of ballistic protection, potentially saving more lives by making such protection available in more locations.

[0067] The lightweight design of the ballistic wall assembly can eliminate the need for structural reinforcement of existing buildings, providing significant installation advantages over conventional heavy ballistic barriers. Traditional ballistic protection systems constructed from thick steel plates, concrete, or multiple layers of dense materials can impose substantial loads on building structures, often requiring expensive structural modifications to support the weight. Floor joists, wall studs, ceiling supports, and foundation elements in existing buildings may not be designed to carry the additional loads imposed by heavy conventional ballistic barriers. Installing such barriers often requires engineering analysis, structural reinforcement with additional beams or columns, and construction work that can be costly and disruptive. The ballistic wall assembly described herein, by virtue of its lightweight construction utilizing the air gap rather than solid heavy materials, can be installed in existing buildings without requiring structural modifications. The reduced weight means that standard building structures can support the ballistic wall assembly without reinforcement, significantly reducing installation costs and complexity. This advantage makes it practical to retrofit existing schools, offices, and other facilities with ballistic protection, whereas the cost and disruption of structural reinforcement required for conventional heavy barriers often makes such retrofitting prohibitively expensive or impractical.

[0068] The ballistic wall assembly can provide modular advantages that enable flexible deployment configurations tailored to specific protection needs and spatial constraints. Individual ballistic wall assemblies can be deployed alone to protect specific vulnerable areas, or multiple assemblies can be positioned together to create extended protective barriers or enclosed safe areas. The lightweight nature of each assembly makes it practical to transport, store, and deploy multiple units as needed, whereas the weight of conventional heavy ballistic barriers typically limits the number of units that can be practically managed. In a school setting, for example, multiple ballistic wall assemblies could be stored in different locations throughout the classroom and deployed as needed to create protected areas. The modular nature of the system allows protection to be placed at all key locations, providing flexibility that fixed heavy barriers cannot match. Furthermore, the scalability enables institutions to start with a smaller number of ballistic wall assemblies and expand their protective capabilities over time as budgets allow, rather than requiring a large upfront investment in a fixed barrier system. The ability to reconfigure the protective barriers by repositioning individual assemblies also allows the protection to adapt to changing room layouts, occupancy patterns, or threat scenarios, providing long-term value and versatility.

[0069] Although this invention has been disclosed in the context of certain preferred embodiments and examples, it should be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments and / or uses of the invention and obvious modifications and equivalents thereof. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims that follow.

[0070] The foregoing has been a detailed description of illustrative embodiments of the invention. Various modifications and additions can be made without departing from the spirit and scope of this invention. Features of each of the various embodiments described above may be combined with features of other described embodiments as appropriate in order to provide a multiplicity of feature combinations in associated new embodiments. Furthermore, while the foregoing describes a number of separate embodiments of the apparatus and method of the present invention, what has been described herein is merely illustrative of the application of the principles of the present invention. Also, as used herein, various directional and orientational terms (and grammatical variations thereof) such as “vertical”, “horizontal”, “up”, “down”, “bottom”, “top”, “side”, “front”, “rear”, “left”, “right”, “forward”, “rearward”, and the like, are used only as relative conventions and not as absolute orientations with respect to a fixed coordinate system, such as the acting direction of gravity. Additionally, where the term “substantially” or “approximately” is employed with respect to a given measurement, value or characteristic, it refers to a quantity that is within a normal operating range to achieve desired results, but that includes some variability due to inherent inaccuracy and error within the allowed tolerances (e.g. 5%) of the system. Accordingly, this description is meant to be taken only by way of example, and not to otherwise limit the scope of this invention.

Claims

1. A ballistic wall assembly for protecting personnel from ballistic projectiles, the ballistic wall assembly comprising:an outer ballistic panel;an inner ballistic panel spaced from the outer ballistic panel to define an air gap therebetween;a plurality of springs positioned between the outer ballistic panel and the inner ballistic panel, wherein the springs are configured to provide resistance while allowing the outer ballistic panel to move toward the inner ballistic panel upon impact from a ballistic projectile; andwherein the air gap is configured to trap bullets that pass through the outer ballistic panel and are stopped by the inner ballistic panel, thereby preventing ricochets.

2. The ballistic wall assembly of claim 1, further comprising a frame surrounding the outer ballistic panel and the inner ballistic panel, wherein the frame includes a slip joint that allows the outer ballistic panel to move within the frame.

3. The ballistic wall assembly of claim 2, wherein the frame further comprises a crimped edge that holds the outer ballistic panel in place within the frame while allowing the outer ballistic panel to move in response to ballistic impact.

4. The ballistic wall assembly of claim 3, wherein the crimped edge provides a counterforce to the springs when the springs are preloaded to bias the outer ballistic panel outward.

5. The ballistic wall assembly of claim 3, wherein the crimped edge covers the slip joint to prevent the slip joint from being pried apart from outside the ballistic wall assembly.

6. The ballistic wall assembly of claim 2, further comprising bearings between the outer ballistic panel and the frame to facilitate movement of the outer ballistic panel within the frame.

7. The ballistic wall assembly of claim 1, further comprising an outer cover positioned on an exterior surface of the outer ballistic panel, the outer cover concealing the ballistic nature of the ballistic wall assembly.

8. The ballistic wall assembly of claim 1, further comprising a MOLLE panel positioned on an interior surface of the inner ballistic panel, wherein the MOLLE panel is configured to support decorative items to conceal the ballistic nature of the ballistic wall assembly.

9. The ballistic wall assembly of claim 1, wherein the ballistic wall assembly has a wall thickness in a range between approximately 2 inches and approximately 4 inches.

10. The ballistic wall assembly of claim 1, further comprising a suspension system configured to support the ballistic wall assembly for movement, wherein the suspension system includes rollers and an overhead rail.

11. A mobile ballistic wall for protecting personnel from ballistic projectiles, the mobile ballistic wall comprising:an outer ballistic panel;an inner ballistic panel spaced from the outer ballistic panel to define an air gap therebetween;a plurality of springs positioned between the outer ballistic panel and the inner ballistic panel, wherein the springs are configured to allow the outer ballistic panel to move toward the inner ballistic panel upon impact from a ballistic projectile;a frame surrounding the outer ballistic panel and the inner ballistic panel, wherein the frame includes a slip joint that allows the outer ballistic panel to move within the frame; anda suspension system configured to support the mobile ballistic wall for movement between a stored position and a deployed position.

12. The mobile ballistic wall of claim 11, wherein the suspension system includes rollers configured to engage an overhead rail.

13. The mobile ballistic wall of claim 11, further comprising a MOLLE panel positioned on an interior surface of the inner ballistic panel, wherein the MOLLE panel is configured to support items for everyday use in a classroom or office environment.

14. The mobile ballistic wall of claim 11, wherein the frame further comprises a crimped edge that holds the outer ballistic panel in place within the frame and covers the slip joint to prevent tampering.

15. The mobile ballistic wall of claim 11, wherein the air gap is configured to trap bullets that pass through the outer ballistic panel and are stopped by the inner ballistic panel, thereby preventing ricochets.

16. The mobile ballistic wall of claim 11, further comprising bearings positioned to facilitate movement of the outer ballistic panel within the frame.

Images