Anti-ballistic door

Abstract

An anti-ballistic door that uses glass embedded in the door to provide anti-ballistic protection, including protection against bullets fired from handguns and rifles, but where the glass does not act as a window for the door. The glass can be covered on both sides by an opaque layer, such as by a pair of steel sheets, such that the inserted glass pane is hidden from view, but effectively stops bullet penetration by absorbing the kinetic energy of the bullet through the shattering of the glass within the door, without spalding or any ejection of material on the opposite side of impact of the door.

Description

Anti-Ballistic DoorCROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional patent application serial number 63 / 546,833 filed on November 1 , 2023, incorporated herein by reference.BACKGROUND

[0002] Mass shootings in public facilities have unfortunately been on the increase, in particular with copycat situations due to the extensive publicity that occurs whenever such shootings occur. Furthermore, violence in cities and public areas like shopping malls, night clubs, bars, restaurants, and retail shopping establishments has been a problem as thefts like shoplifting and smash-and- grabs have increased. The police seem more restrained to battle criminal activity that may occur during public demonstrations that occasionally escalate into violence. And school facilities seem to be more tolerant of violent children, leading to an increased risk of violence in schools that may include shooting incidents.

[0003] Protecting innocent children and other civilians during violent episodes is strongly desired, and protection against gun violence is one aspect of such desired protection. But hardening facilities, especially existing facilities, against guns and their projectiles can be expensive and difficult, so additional solutions are desired. In particular, a solution that has the benefits of less weight and bulk are desirable.SUMMARY

[0004] Provided are a plurality of example embodiments, including, but not limited to, a door including one or more glass panels inserted and embeddedwithin the structure of the door to provide protection against ballistic projectiles from weapons such as bullets fired from a gun.

[0005] Also provided is a door configured with anti-ballistic properties, comprising: a door frame having a hollow interior; a panel of glass embedded in said hollow interior, wherein said door is configured such that said panel of glass does not act as a window, and wherein said door is configured to stop at least one high-velocity bullet from penetrating said door through said pane of anti- ballistic glass.

[0006] Further provided is a door configured with anti-ballistic properties, comprising: a door frame having a hollow interior; and an anti-ballistic panel embedded in said hollow interior, said anti-ballistic panel including a layer of glass and a layer of opaque material provided on at least one side of said panel of glass, wherein said anti-ballistic panel is hidden from view when said door is installed in a door frame.

[0007] Stii further provided is a method of providing an anti-ballistic door, comprising the steps of: providing a door frame having a hollow interior; providing an anti-ballistic panel including a layer of glass; and inserting said anti-ballistic panel into said hollow interior in a manner such that said layer of glass does not act as a window, wherein said door is configured to stop at least one high- velocity ballistic object from penetrating said door through said anti-ballistic panel.

[0008] Further provided is a method of providing an anti-ballistic door, comprising the steps of: providing a door having a hollow interior; making an anti- ballistic panel including the steps of: providing a layer of glass, and installing a layer of material on each side of said layer of glass to form said anti-ballistic panel that is not transparent, wherein said anti-ballistic panel is configured to stop a high-speed ballistic object from penetrating said anti-ballistic panel;inserting said anti-ballistic panel into said hollow interior to form said door into an anti-ballistic door.

[0009] Also provided are any of the above methods, wherein said anti- ballistic panel is inserted into said hollow interior in a manner such that said anti- ballistic panel is hidden from view outside of said door when said door is installed in a door frame.

[0010] Further provided are any of the above methods, further comprising the steps of: prior to inserting said anti-ballistic panel into said hollow interior, removing said door from a door frame; and re-installing said door in said door frame.

[0011] Still further provided are any of the above methods, further comprising the step of: forming said hollow interior by removing material from an interior of said door to form said hollow interior.

[0012] Also provided are additional example embodiments, some, but not all of which, are described hereinbelow in more detail.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The features and advantages of the example embodiments described herein will become apparent to those skilled in the art to which this disclosure relates upon reading the following description, with reference to the accompanying drawings, in which:

[0014] Figure 1 is an illustration of an elevation view of a door utilizing an example of the inventive insert for ballistic protection.

[0015] Figure 2 is an illustration of exploded view of the door of Figure 1 .

[0016] Figure 3 is an illustration of an example anti-ballistic panel for insertion into a door.

[0017] Figure 4 is an illustration of another example anti-ballistic panel for insertion into a door.

[0018] Figure 5 is an illustration of an exploded view of an example anti- ballistic panel for insertion into a door for providing UL 752, level 10 protection.

[0019] Figure 6 is cutaway side view of an assembled panel of Figure 5.DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

[0020] The invention relates to using glass embedded in a door to provide anti-ballistic protection including protection against bullets fired from handguns and rifles, but where the glass does not act as a window for the door. Testing has shown that the approach can stop even a 50 caliber rifle round. Essentially, a traditional door is modified to be outfitted with one or more glass sheet insert(s) that are placed inside a cavity in a hollow interior of the door to provide the anti-ballistic protection. The glass can be covered on both sides by an opaque layer, such as by a pair of steel sheets, such that the inserted glass pane is hidden from view, but effectively stops bullet penetration by absorbing the kinetic energy of the bullet through the shattering of the glass within the door, without spalding or any ejection of material on the opposite side of impact of the door.

[0021] Many different types of glass could be utilized, including standard clear float glass; tempered glass; anti-ballistic glass; plexiglass; laminated glass (which may use any layering known in the industry, or that might use anti-ballistic layers, such as polycarbonate sheets or other anti-ballistic materials), etc.

[0022] Note that because the glass will be embedded in the door, and not utilized for the typical transparent features of glass, additives that cloud the glass or make it opaque can be utilized to improve the performance of the glass where desired. Also, non-transparent layers can be added to the glass as well to form laminates that improve the performance of the glass in protection fromballistic projectiles like shrapnel and bullets. Such glass may be useful in protecting doors from explosions and other weaponized attacks. The glass should be provided of sufficient thickness to stop bullets of the desired mass and / or velocity.

[0023] Figure 1 shows an example door incorporating the anti-ballistic features as internal structures shown in the diagram. The door 10 includes at least one primary glass insert 11 that is comprised of glass as described in more detail hereinbelow. To ensure that the entire door is fully protected, additional edge inserts 12, 13, and 14 can be provided to protected edges of the door at the seams.

[0024] Cutouts are provided in the inserts for a glass window cutout 17, and door hardware cutout 15 to support, for example, a door knob 16. The region of the cutout may be provided with a protective material to extend the anti- ballistic protection into that cutout. For example, steel plates, glass panels, ceramic plates, anti-ballistic gels or fibers or cloth, or other materials could be used for this purpose. Additional cutouts can be provided as needed and similarly treated.

[0025] If the door has one or more windows 18, bullet proof glass could be utilized for that window, to ensure that the window is protected against ballistic projectiles as well.

[0026] Figure 2 shows an exploded view, such as of the example door of Fig. 1. The panels with “A” designation reflect first anti-ballistic panel inserts, whereas the panels with “B” designation reflect optional second anti-ballistic panel inserts that may be of the same, or different, composition, as shown the “A” inserts.

[0027] Hence, panel A1 is an example primary glass insert that has the desired cutouts to support the door hardware, with panel B1 being an optional additional primary glass insert. Panels A1 and B1 , if both used, can be “stacked”to provide a system having double the panel protection as using only a single panel A1.

[0028] Similarly, panel A2 is one side edge insert, and panel A4 is a second side insert. Depending on the door design, panels A2 and A4 might be identical. Optional second side inserts B2 and B4 can be provided to add a second layer of protection for the door edges. Furthermore, top edge insert panel A3 and optional second optional edge insert panel B3 can be provided as well. By the use of panels A1, A2, A3, and A4 (and, if utilized, optional second panels B1, B2, B3, and / or B4)), almost all of the door is provided with anti- ballistic protection as described herein.

[0029] Note that these panels can be provided as separate pieces that are individually inserted into the door to make installation easier but that in combination provide protection to the entire door except for the small cutout regions (which can be protected in a different manner as described herein).

[0030] Figure 3 shows an example insert panel structure 5 that can be utilized for the panel A or B structure. A Protective core material 1 is utilized that can be comprised of a non-crystalline transparent amorphous soda-lime solid glass panel, for example (or another desirable form of glass, such as tempered glass or a laminate or plexiglass or an anti-ballistic glass). This glass panel can be an Annealed or Float Glass (standard float or annealed type glass) of reasonable cost. On each side of the core material 1 is provided a structural layer 2, which can be comprised of steel, aluminum, wood or composite types of material, or any desired metal alloy.

[0031] The protective core material 1 is the layer that substantially provides the ballistic protection function of the panel. The protective core material 1 assembled along with the structural layers have been tested to UL 752, level 10 and will stop the penetration of a .50 Caliber rifle (lead core full metal copper jacket military ball; US Military M2 bullet). The protective corematerial 1 inserted into the door will protect against at least one shot from a military sniper riffle, such as the Barrett M82 A1 (XM 107), with a muzzle energy of 12,439 - 12,706 foot-pounds (16,863 - 20,404 J).

[0032] The protective core material 1 can be used with or without one or both of the structural layers 2 to form the panel 5, which can be used to create any of the A or B panels described hereinabove. This structural layer 2 can be comprised of steel, aluminum, wood or composite types of material that can be provided on either one side or on both sides to increase the ballistic protection and absorb the additional energy caused by the force applied. Since the glass core material 1 will tend to shatter when engaged and stopping a projectile like a bullet, the structural layers 2 help hold the shattered glass in place.

[0033] Acceptable thicknesses of the glass layer 1 can range from 1 / 2” (13mm) and up to 1” (25mm), or more if desired. Two pieces of the protective core material (1 ) separated by steel, aluminum, wood, or a composite type of material (2) has been used to achieve the protection rating of UL 752, level 10 (see discussion for Figure 4, hereinbelow).

[0034] Note that this glass core material 1 is typically embedded within the door in the form of the panel, and need not provide any of the normal function of glass like windowing (e.g., transparency). Rather, the glass core material 1 is typically fully embedded in the door, hidden from view, and it is not at all apparent from outside the door that there is glass embedded therein.

[0035] This protective core material 1 has never before been utilized with this make-up and thickness range for certification to UL 752, level 10. This protective core material 1 is thinner and more cost effective than typical ballistic material produced that passes UL 752, level 10 currently available. This protective core material 1 has never been used in any door core material types for ballistic doors. This protective core material 1 is the thinnest cost effective material on the market that can pass UL 752, level 10. This protective corematerial 1 can be used in a standard 1 -3 / 4” steel, aluminum, wood or composite type door.

[0036] Figure 4 shows a cross section of a door 25 utilizing another embodiment of a single ballistic insert panel 20 that can be used to harden the door against ballistic projectiles. In this case, there are 2 layers of the glass protective core material 21 provided, that can be separated by an inner structural layer 22 that can be comprised of steel, aluminum, wood or composite or some other structural material. Hence, this design can provide similar protection as using the A and B panels, but with a single insert having two glass layers. Then, outer structural layers 23 are provided that can also be comprised of steel, aluminum, wood or composite type door. Note that the inner structural layer 22 could be comprised of a different material than the other structural layers 23, if desired.

[0037] These layers 21 , 22, and 23 can be provided as described hereinabove for Fig. 3, or they might be configured in an alternative manner. For example, by using two layers of core material 21 , each individual layer might be made thinner than the use of a single layer as in Fig. 3. Alternatively, the layers 21 might be configured to each separately stop a projectiles, such that if one layer is compromised, the other layer can provide additional ballistic protection. Hence, each of these layers 21 might be provided of thickness in range from 1 / 2” (13mm) and up to 1” (25mm), or more if desired. If desired, each layer 21 might be comprised of different thicknesses as well. And a panel having more than two layers 21 might also be provided.

[0038] Since the panel 20 is not likely to be as thick as the thickness of the door in which it is utilized for most applications, packing material 25 may be provided on one or both sides of the ballistic panel 20 within the outer door skin 24. Such packing material can be comprised of drywall, gypsum, a composite material, mineral core, Styrofoam or other insulation material, or any other material that can fill the voids left after insertion of the core 20. If desired, thepacking material might be selected to add additional anti-ballistic properties to the door, such as by using Kevlar (cloth or fibers or matts), or other anti-ballistic materials, so that the addition of filler material could provide additional anti- ballistic properties as desired.

[0039] Figure 5 shows the components of a panel of an exemplary embodiment of a panel that can be used to provide UL 752, level 10 protection to a door in a thinner and lighter design than current designs that meet level 10 protection.

[0040] The panel 30 is provided with a pair of protective core material glass sheets 31, comprised of, for example, a non-crystalline transparent amorphous soda-lime solid glass, such as annealed or float glass (standard float or annealed type glass). These glass sheets are separated by a steel sheet 33, that can be comprised of 10 Gauge (—0.1345”) steel, for example. Outer sheets 32 used as structural layers can also be comprised of 10 Gauge (-0.1345”) steel, for example, or some other material that can then fit within the desired door.

[0041] The outer sheet structural layers can be secured to the inner glass layers using a adhesive (e.g., glue), rivets, fasteners, or by welding edges together. The inner sheet can be similarly attached. For example, during manufacture of the inserts, a spray adhesive may be used to attached the sheets to the respective glass layers. Note that if the entire door is being assembled, the sheets might just be placed on the glass layers without securing the layers together, all eventually being held together in the assembled door.

[0042] Figure 6 shows an example cutaway of the panel 30 as assembled, supporting potential thickness of a door being as thin as 1 7 / 8 inches while providing UL 752, level 10 protection. The outer sheets 32 can be used as the door outer surface for the thinnest doors, or can be covered by the desired outer material of the door, such as outer panels of wood or other material.

[0043] In this manner, a UL 752, level 10 protection qualified door can be provided that is as thin as 1 7 / 8 inches. The protective core material of the panel 31 can be used for ballistic protection, and since it has been tested to UL 752, level 10, it will stop the penetration of a .50 Caliber rifle (lead core full metal copper jacket military ball; US Military M2 bullet). The protective panel 31 will protect against at least one shot from a military sniper riffle, such as the Barrett M82 A1 (XM 107), with a muzzle energy of 12,439 - 12,706 foot-pounds (16,863 - 20,404 J). The protective panel can be used with steel to increase the protection and absorb the additional energy caused by the force applied. Two pieces of the protective core material glass panels 31 separated by steel sheet 33 has been used to achieve the protection rating of UL 752, level 10. This steel and glass make-up combination panel is the thinnest cost effective material on the market that can pass UL 752, level 10. This steel and glass make-up combination can be used in a standard 2” steel, aluminum, wood or composite type door by inserting the panel 31 into the door.

[0044] In application, these ballistic protection panels would be inserted into the inner voids (hollow regions) of a door (e.g., see Fig. 1) either during manufacture of the door, or as a retrofit operation on doors that might already be installed. Note that filler material already present in a door would be removed / replaced by the anti-ballistic panel with any new filler material added to secure the panel in place within the door. Because the anti-ballistic panel is typically to be inserted into an opaque door or portions of the door that are opaque, and the panel may have one or more structural layers covering the glass core material, the transparent property of the glass itself is not typically utilized by this application. In typical applications, the fact that glass is used in the interior of the door is not apparent in viewing the installed door, and in fact the glass core material would tend to be entirely embedded and sealed within the door itself.

[0045] As discussed above, types of glass panels other than annealed or float glass might be utilized for any of the above described panels, includingtempered glass; anti-ballistic glass; plexiglass; ceramic glass; laminated glass (which may use any layering known in the industry, or that might use anti-ballistic layers, such as polycarbonate sheets or other anti-ballistic materials), etc. Additives that cloud the glass or make it opaque can be utilized to improve the performance of the glass where desired. Also, non-transparent layers can be added to the glass as well to form laminates that improve the performance of the glass in protection from ballistic projectiles like shrapnel and bullets.

[0046] Many other example embodiments can be provided through various combinations of the above described features. Although the embodiments described hereinabove use specific examples and alternatives, it will be understood by those skilled in the art that various additional alternatives may be used and equivalents may be substituted for elements and / or steps described herein, without necessarily deviating from the intended scope of the application. Modifications may be necessary to adapt the embodiments to a particular situation or to particular needs without departing from the intended scope of the application. It is intended that the application not be limited to the particular example implementations and example embodiments described herein, but that the claims be given their broadest reasonable interpretation to cover all novel and non-obvious embodiments, literal or equivalent, disclosed or not, covered thereby.

Claims

CLAIMSWhat is claimed is:1 . A door configured with anti-ballistic properties, comprising: a door frame having a hollow interior; a panel of glass embedded in said hollow interior, wherein said door is configured such that said panel of glass does not act as a window, and wherein said door is configured to stop at least one high-velocity bullet from penetrating said door through said pane of anti-ballistic glass.

2. The door of claim 1 , wherein said door is configured to be certified to a protection rating of UL 752, level 10.

3. The door of claim 1 , wherein packing material is provided in said hollow interior adjacent to said glass panel.

4. The door of claim 1 , wherein said glass panel is comprised of a clear float glass.

5. The door of claim 1 , wherein said glass panel is comprised of an annealed glass.

6. The door of claim 1 , wherein said glass panel is comprised of a tempered glass.

7. The door of claim 1 , wherein said glass panel is comprised of a laminated glass.

8. The door of claim 1 , wherein said glass panel is comprised of aplexiglass.

9. The door of claim 1 , wherein said glass panel is not fully transparent.

10. The door of claim 1 , wherein said glass panel is opaque.11 . The door of claim 1 , wherein said glass panel is a laminate including an opaque layer.

12. The door of claim 1 , wherein packing material having anti-ballistic properties is provided in said hollow interior adjacent to said glass panel.

13. The door of claim 1 , wherein said glass panel is comprised of a bullet resistant or bullet proof glass.

14. The door of claim 1 , wherein said glass panel is comprised of a laminate including a layer of glass or plexiglass and a pair of outer layers of opaque material.

15. The door of claim 1 , wherein said pair of outer layers of opaque material are comprised of a sheet of metal or metal alloy.

16. The door of claim 14, wherein said pair of outer layers of opaque material are comprised of a composite or plastic material.

17. A door configured with anti-ballistic properties, comprising: a door frame having a hollow interior; and an anti-ballistic panel embedded in said hollow interior, said anti-ballistic panel including a layer of glass and a layer of opaque material provided on at least one side of said panel of glass, whereinsaid anti-ballistic panel is hidden from view when said door is installed in a door frame.

18. The door of claim 17, wherein said layer of glass is comprised of a clear float glass.

19. The door of claim 17, wherein said layer of glass comprised of an annealed glass.

20. The door of claim 17, wherein said layer of glass is comprised of a tempered glass.21 . The door of claim 17, wherein said layer of glass is comprised of a laminated glass.

22. The door of claim 17, wherein said layer of glass is comprised of a plexiglass.

23. The door of claim 17, wherein said layer of glass is comprised of a bullet resistant or bullet proof glass.

24. The door of any of the above claims, wherein said anti-ballistic panel is comprised of a pair of said layers of opaque material, with one of said pair of layers provided on each side of said layer of layer of glass.

25. The door of claim 24, wherein at least one of said layers of opaque material are comprised of a sheet of metal or metal alloy.

26. The door of claim 24, wherein at least one of said layers of opaque material are comprised of a composite or plastic material.

27. The door of claim 24, wherein at least one of said layers of opaque material are comprised of an anti-ballistic material.

28. The door of any of the above claims, wherein said layer of glass is not fully transparent.

29. The door of any of the above claims, wherein packing material is provided in said hollow interior adjacent to said anti-ballistic panel.

30. The door of any of the above claims, wherein said door is configured to be certified to a protection rating of UL 752, level 10.31 . A method of providing an anti-ballistic door, comprising the steps of: providing a door frame having a hollow interior; providing an anti-ballistic panel including a layer of glass; and inserting said anti-ballistic panel into said hollow interior in a manner such that said layer of glass does not act as a window, wherein said door is configured to stop at least one high-velocity ballistic object from penetrating said door through said anti-ballistic panel.

32. The method of claim 31 , wherein said anti-ballistic panel is inserted into said interior in a manner such that said anti-ballistic panel is hidden from view outside of said door when said door is installed in a door frame.

33. The method of claim 31 , further comprising the step of inserting packing material in said hollow interior adjacent to said anti-ballistic panel to fully fill said hollow interior.

34. The method of claim 31 , wherein said layer of glass is comprised ofa clear float glass.

35. The method of claim 31 , wherein said layer of glass comprised of an annealed glass.

36. The method of claim 31 , wherein said layer of glass is comprised of a tempered glass.

37. The method of claim 31 , wherein said layer of glass is comprised of a laminated glass.

38. The method of claim 31 , wherein said layer of glass is comprised of a plexiglass.

39. The method of claim 31 , wherein said layer of glass is comprised of a bullet resistant or bullet proof glass.

40. The method of any of the above claims, wherein said anti-ballistic panel is comprised of a pair of said layers of opaque material, with one of said pair of layers provided on each side of said layer of layer of glass.41 . The method of claim 40, wherein at least one of said layers of opaque material are comprised of a sheet of metal or metal alloy.

42. The method of claim 40, wherein at least one of said layers of opaque material are comprised of a composite or plastic material.

43. The method of any of the above claims, wherein said layer of glass is not fully transparent.

44. The method of any of the above claims, wherein packing material isprovided in said hollow interior adjacent to said anti-ballistic panel.

45. The method of any of the above claims, wherein said door is configured to be certified to a protection rating of UL 752, level 10.

46. A method of providing an anti-ballistic door, comprising the steps of: providing a door having a hollow interior; making an anti-ballistic panel including the steps of: providing a layer of glass, and installing a layer of material on each side of said layer of glass to form said anti-ballistic panel that is not transparent, wherein said anti-ballistic panel is configured to stop a high-speed ballistic object from penetrating said anti-ballistic panel; inserting said anti-ballistic panel into said hollow interior to form said door into an anti-ballistic door.

47. The method of claim 46, wherein said anti-ballistic panel is inserted into said hollow interior in a manner such that said anti-ballistic panel is hidden from view outside of said door when said door is installed in a door frame.

48. The door of claim 46, further comprising the steps of: prior to inserting said anti-ballistic panel into said hollow interior, removing said door from a door frame; forming said hollow interior by removing material from an interior of said door to form said hollow interior; and re-installing said door in said door frame.

49. The door of claim 46, further comprising the steps of: prior to inserting said anti-ballistic panel into said hollow interior,removing material from an interior of said door to form said hollow interior.

50. The door of claim 46, further comprising the steps of: prior to inserting said anti-ballistic panel into said hollow interior, removing said door from a door frame; and after inserting said anti-ballistic panel into said hollow interior, re-installing said door in said door frame.

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