Ballistic edges

Abstract

A ballistic barrier can include a first surface, a second surface positioned opposite the first surface, and a fold positioned adjacent an edge of the first ballistic panel. The fold may include a first portion, a second portion extending from the first portion, and a third portion extending between the second portion and the edge of the first ballistic panel. The fold may be configured such that a portion of the second surface of the first ballistic panel at the third portion is positioned adjacent to a portion of the second surface of the first ballistic panel at the first portion.

Description

Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application BALLISTIC EDGES FIELD OF THE INVENTION

[0001] The field of the invention relates to ballistic-resistant features for the interior of passenger vehicles such as aircrafts. BACKGROUND

[0002] Passenger, crew, and pilot safety can be an important consideration in carrier industries such as aviation. Most interiors of aircraft or other passenger vehicles include features such as bullet proof or ballistic structures that line at least a portion of the aircraft, for example, the cockpit. Generally, such structures provide for a ballistic proof or ballistic resistant barrier. However, currently used methods require the use of heavy materials, such as steel or composites, to ensure a robust barrier capable of receiving multiple projectiles. In such instances, the type and quantity of materials used add a significant amount of weight to the vehicle. Therefore, there is an interest in providing a bullet proof and / or ballistic barrier that is sufficient to pass the rigorous testing required by the Federal Aviation Administration while reducing the overall weight of the barrier.

[0003] A significant amount of the weight may be found in the metals that may be used to protect the edges of the ballistic materials. For example, present methods may include wrapping metal, such as steel, around the edges of the barrier or other discontinuities, such as vents, eye holes, or other openings. The additional wrapped metal reinforces the discontinuities against ballistic intrusions. In some existing cases, heavy plated ¼” steel may be used, greatly increasing the weight of existing ballistic barriers. Therefore, there is interest in a solution for providing a ballistic barrier while reducing the overall weight of such a barrier.US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application SUMMARY

[0004] The terms “invention,” “the invention,” “this invention” and “the present invention used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below. Embodiments of the invention covered by this patent are defined by the claims below, not this summary. This summary provides a high-level overview of various aspects of the invention and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, ay or all drawings and each claim.

[0005] Some embodiments of the present technology relate to a ballistic barrier, including: a first ballistic panel including a first surface, a second surface positioned opposite the first surface, and a fold positioned adjacent an edge of the first ballistic panel, wherein the fold includes: a first portion; a second portion extending from the first portion; and a third portion extending between the second portion and the edge of the first ballistic panel, wherein a portion of the second surface of first ballistic panel at the third portion is positioned adjacent to a portion of the second surface of the first ballistic panel at the first portion.

[0006] Some embodiments of the present technology relate to a method for manufacturing a ballistic barrier, the method including: providing a structural core including a first surface, and a second surface positioned opposite the first surface, the structural core including: a first portion; a second portion extending from the first portion; and a third portion extending between the second portion and an edge of the structural core; providingUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application and positioning a wire at the second surface of the structural core; wrapping the second portion of the core about the wire, such that the second portion of the structural core substantially surrounds at least a portion of the wire and the second surface positioned at the first portion contacts with the second surface positioned at the third portion; providing a binding compound to the structural core; and applying heat and pressure to the structural core and the binding compound.

[0007] Some embodiments of the present technology relate to a ballistic barrier, including: a ballistic panel including a first surface, a second surface positioned opposite the first surface, and a through hole extending from the first surface to the second surface; a first edge support positioned adjacent to the second surface of the ballistic panel, wherein at least a portion of the first support is positioned within the through hole; and a second edge support positioned adjacent to the first support, wherein at least a portion of the second support is positioned within the through hole, wherein at least a portion of the through hole remains unblocked by either the first edge support or the second edge support. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a perspective cross-section view of an embodiment of a ballistic barrier, according to various embodiments of the present invention.

[0009] FIG.2 is a perspective cross-section view of another embodiment of a ballistic barrier, according to various embodiments of the present invention.

[0010] FIG.3 is a rear view of the ballistic barrier as depicted in FIG.1.

[0011] FIG.4 is a side cross-section view of the ballistic barrier as depicted in FIG.1.

[0012] FIG. 5 is a flow chart of a method of manufacturing a ballistic barrier, according to various embodiments of the present invention.

[0013] FIG. 6 is a perspective cross-section view of yet another embodiment of a ballistic barrier, according to various embodiments of the present invention.US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application

[0014] FIG.7 is a rear view of the ballistic barrier as depicted in FIG.6.

[0015] FIG.8 is a side cross-section view of the ballistic barrier as depicted in FIG.6. DETAILED DESCRIPTION

[0016] The subject matter of embodiments of the present invention is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described.

[0017] Embodiments herein may provide for a ballistic resistance or ballistic proof structure for use within the construction of a vehicle, such as an interior of an aircraft. While the structures described herein are discussed for use in relation to the interior of an aircraft, they are by no means so limited. Rather, embodiments of the ballistic resistant barrier may be used in interiors of other vehicles or structures of any type or otherwise as descried. For example, embodiments may be used in trains, buses, personal vehicles, commercial or residential buildings, or any other instance when a ballistic proof barrier may be useful. The ballistic barrier may be typically designed to either supplement existing structure or to form the entirety of the structure. For example, it may be desired to separate the cockpit of an airplane form the passenger cabin in order to protect the pilots.

[0018] In various embodiments, the ballistic barrier may correspond to a structure that may be used to line or create a barrier within the cabin of an aircraft. For the sake of brevity, the term “ballistic barrier” will be used within this application to describe ballistic resistant, ballistic proof, bullet-proof, or bullet-resistant structures, or ballistic resistant, ballistic proof, bullet-proof, or bullet-resistant barriers. The ballistic barrier may provide for a wall or otherUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application structure having a first surface facing towards an anticipated direction from which a projectile may begin and a second surface opposite the first surface and facing towards a space that is intended to be protected from a potential projectile. The ballistic barrier is generally configured to limit or completely stop any projectiles which may contact the first surface from puncturing, piercing, or penetrating through the second surface of the ballistic barrier. In some embodiments, openings, corners, or edges present in the ballistic barrier may provide weak points where additional protection may be required. For example, the heat and force created by a projectile colliding with the ballistic structure may cause elements of the ballistic structure to partially liquify and extend past the openings, corners, or edges of the ballistic structure potentially compromising the anti-ballistic properties of the ballistic structure. Therefore, as mentioned previously, additional structure may be positioned at the openings, corners, or edges to stop this phenomenon.

[0019] Referring now to the figures, a ballistic barrier 100, according to certain embodiments is shown in a perspective cross-section view in FIG. 1. As depicted, the ballistic barrier 100 is shown including a first ballistic panel 102 and a second ballistic panel 104 positioned adjacent to one another. In further detail, the first ballistic panel 102 includes a first surface 106, a second surface 108, and an exposed edge 110. Similarly, the second ballistic panel 104 includes a first surface 112, a second surface 114 opposite the first surface 112, and an exposed edge 116. As depicted, the exposed edge 110 of the first ballistic panel 102 and the exposed edge 116 of the second ballistic panel 104 may abut creating a discontinuity 118, which is discussed in further detail below. Furthermore, the first surface 106, 112 may be configured to face the direction which a projectile may originate. In other words, the first ballistic panel 102 and the second ballistic panel 104 are configured to accept an impact from a projectile at the first surfaces 106, 112.US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application

[0020] The first ballistic panel 102 and the second ballistic panel 104 may be composite materials manufactured using a structural core and may be manufactured using a structural core and a binding material. The fiber core may be made of a variety of materials including, but not limited to, paper, Kevlar, resin, Dyneema, woven materials, non-woven materials, monofilament fibers, or other materials which may include a high strength-to- weight ratio. The binding material may be provided in a liquid, gel, or other injectable, extrudable, or brush-able form, or may be supplied by inclusion in a pre-impregnated state in the in the structural core. During manufacturing, the binding compound may be configured to surround and / or extend through the structural core when in use. When dried and / or cured the binding compound may partially or wholly encapsulate portions or an entirety of the structural core to create a composite material. The combination of the structural core and the binding compound may add strength and / or flexibility to the ballistic barrier 100. The binding compound may be made of any individual or combination of a variety of materials typically associated with composites including, but not limited to vinylester resin, polyester resin, or epoxy resin. The resulting composite may be ballistic resistant and / or ballistic proof. Additionally, the resulting composite may be resistant to chemicals, fire, extreme temperatures, and electrical conditions.

[0021] FIG. 1 depicts a discontinuity 118 where the exposed edge 110 of the first ballistic panel 102 and the exposed edge 116 of the second ballistic panel 104 may meet. As noted briefly above, discontinuities 118 within the ballistic barrier 100 lead to locations which may be more prone to deformation or damage due to the high forces that are often accompanied by the impact of a ballistic object. Such deformation or damage may reduce the effectiveness of the ballistic barrier 100 allowing for entire ballistic object, fragments of ballistic objects, or even damage from the ballistic barrier 100 to penetrate through the barrier 100. Such discontinues 118 take the form of openings, edges, or corners. In one particularUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application embodiment, a ballistic barrier 100 may separate a cockpit of an airplane from a passenger cabin, extending across the entire fuselage of the airplane. Such a ballistic barrier 100 may include a multitude of discontinuities, including but not limited to: a door, a vent, a plurality of ballistic panels, a window, meeting points between the fuselage and the airplane, etc. Therefore, there may be a significant amount of material that may be necessary to ensure that each of these discontinuities are adequately protected, without compromising the integrity of the barrier 100.

[0022] Referring now to FIG. 2 and FIG. 4, which depict an embodiment of the ballistic barrier 100 according to certain embodiments of the present disclosure. Similarly to FIG. 1, the barrier 100 includes the first ballistic panel 102 and the second ballistic panel 104, however, the panels 102, 104 are positioned such that a fold 120 is created at the discontinuity 118. The fold 120 may be configured to provide additional support to the discontinuity 118 such that the integrity of ballistic barrier 100 as a whole may remain intact.

[0023] Generally, the fold 120 may be created from a portion of the first ballistic panel 102 extending downward from the exposed edge 110. In further detail, the first ballistic panel 102 may include three portions. The first portion 121 forms the majority of the first ballistic panel 102. The second portion 122 extends from the first portion 121 and may be configured to form the curved portion of the fold 120. Lastly, the third portion 124 extends between the second portion 122 and the exposed edge 110. During manufacturing, the second portion 122 may be wrapped around a wire 128 which may be configured to provide for a circular geometry. As depicted in FIG. 2, the second portion 122 may wrapped or folded about the wire 128 such that the second surface 108 wraps back around onto itself. In other words, the second surface 108 of the third portion 124 may be positioned flat against or adjacent to the second surface 108 of the first portion 121. In some embodiments, the third portion 124 may be coupled to or attached to the first portion 121 which may secure the foldUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application 120. The portions described herein are merely exemplary are provided to help describe the structure of the fold 120, however, are not intended to be limiting, any number or description of portions may be included within the scope of this disclosure.

[0024] As noted above, a wire 128 may be used to assist in during the manufacture of the first ballistic panel 102 to include the fold 120. As mentioned previously, the first ballistic panel 102 may be made of a composite material. During the manufacturing process, the wire 128 may be positioned at the second portion 122 of the structure or fiber core. Once positioned, the second portion 122 may be wrapped about the wire 128 to substantially cover or contact the wire 128. The third portion 124 may then be positioned adjacent to or flat against the first portion 121. Once properly positioned, a binding compound, as described above, may be introduced to the structural core. High heat and pressure may be applied to the combination of the structural core and the binding compound such that the binding compound flows through the structural core. The high heat and pressure may be applied using a heated press or other method known in the art. As the heat and pressure are applied to the fold 120, the first portion 121, the second portion 122, and the third portion 124, may be compressed together. In such instances, the first portion 121 may be pressed into the third portion 124 such that the binding compound flows between the two portions 120,124. The resulting heated structural core and binding compound may then be passively or actively cooled, causing the binding compound to harden, creating a composite ballistic panel 102. Furthermore, once cooled, the first portion 121 and the third portion 124 may be secured or attached to one another via the binding compound. However, it is not necessary for the first portion 121 and the third portion 124 to be secured or attached to one another.

[0025] In some embodiments, the dimensions and material of the wire 128 may be configured to adjust the fold 120 for various applications. For example, in some embodiments it may be desired to increase or decrease the size of the fold 120 by using adjusting theUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application diameter of the wire 128. For example, a larger fold 120 may increase the strength of the ballistic panel 302, while a smaller fold 120 may provide for a smaller profile. Furthermore, diameter of the wire 128 may be consistent as to create a uniform sized fold 120 or, in the alternative, the diameter of the wire 128 may be tapered or non-uniform such that the dimensions of the fold 120 may be tailored for specific use cases. Similarly, it is envisioned that, in some embodiments, the wire 128 is positioned in parallel to the exposed edge 110 of the first ballistic panel 102 as to create a fold 120 which is uniformly positioned along the first panel or, in the alternative, the wire 128 may be positioned in a non-parallel manner such that the position of the wire 128 may vary along a length of the first ballistic panel 102.

[0026] In some embodiments, the second ballistic panel 104 may additionally positioned as to overlap with the fold 120 of the first ballistic panel 102 as to provide additional strength and integrity to the ballistic barrier 100. As depicted in FIG. 2, the second ballistic panel 104 may include an overlapping portion 130 which extends over the fold 120 of the first ballistic panel 102. The overlapping portion 130 may extend at least partially or completely over the first surface 106 of the first portion 121 and the second portion 122 of the first ballistic panel 102. In other words, the second surface 108 of the overlapping portion 130 may be positioned along the first surface 106 of at least a portion of the first portion 121 and the second portion 122 of the first ballistic panel 102. In some embodiments, the overlapping portion 130 may be configured such that a projectile may contact the overlapping portion 130 prior to contacting the fold 120 of the first ballistic panel, decreasing the total force applied to the fold 120 and increasing the overall strength and integrity of the ballistic barrier 100.

[0027] Furthermore, as shown in FIG.3 which depicts a back view of an embodiment of a first ballistic panel 102 in accordance with the embodiments of the disclosure, some ballistic panels may include multiple discontinuities 118. In such a case, a multitude of foldsUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application 120 may be included to ensure that the strength and integrity of the ballistic barrier 100 is intact. For example, a plurality of wires 128 as described above may be positioned along each discontinuity 118 or, as is depicted in FIG. 3, a singular wire 128 may be positioned along a plurality of discontinuity 118 where a fold 120 may be desired.

[0028] Additionally, in some embodiments, the second ballistic panel 104 may be manufactured separately from the first ballistic panel 102. For example, the shape of the second ballistic panel 102, in particular the overlapping portion 130, may be shaped during the manufacturing of the second ballistic panel 104. For example, a structural core may be positioned within a mold or form which includes the shape of the overlapping portion 130. Similarly, to the manufacture of first ballistic panel 102, once the structural core is positioned, a binding compound may be introduced to the structural core. High heat and pressure may be applied to the combination of the structural core and binding compound such that the binding compound flows through the structural core. The heat and pressure may be applied using a press or other methods known in the art. The resulting heated structural core and binding compound may then be passively or actively cooled, causing the binding compound to harden, creating a composite ballistic panel 104.

[0029] Alternatively, the second ballistic panel 104 may be manufactured in concert with the first ballistic panel 102. For example, prior to applying heat and pressure to the first ballistic panel 102, the structural core of the second ballistic panel 104, may be positioned such that the overlapping portion 130 is positioned adjacent to or in contact with the first portion 121 and the second portion 122 of the first ballistic panel 102. Similarly to above, a binding compound may then be provided to the structural core and then heat and pressure may be applied to the combination of the first ballistic panel 102 and the second ballistic panel 104 using a heated press or other methods known in the art. The first ballistic panel 102US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application and the second ballistic panel 104 may then be passively or actively cooled, causing the binding compound to harden, creating a composite ballistic barrier 100.

[0030] In some embodiments, it may be advantageous for the overlapping portion 130 of the second ballistic panel 104 to be coupled to or secured to the first ballistic panel 102. For example, in discontinuities 118 wherein the two exposed edges 110, 116 do not move relative to one another, such as a meeting point of two plates 102, 104 or a non-dynamic feature such as a vent, it may be beneficial to secure the panels 102, 104 together. In the alternative, there may be applications wherein it may be advantageous for the first ballistic panel 102 and the second ballistic panel 104 to be independent and not connected. For example, a dynamic discontinuity 118 such as a door may include edges 110, 116 wherein the first ballistic panel 102 and the second ballistic panel 104 slide by or separate from one another.

[0031] During impact the geometry of the fold 120 may be configured such that any force and heat that is applied to the discontinuity 118 may be absorbed without allowing for the projectile, fragments of the projectile, portions of either the first or second panels 102, 104 or any other materials to extend pass the second surface 108, 114 of either the first ballistic panel 102 or the second ballistic panel 104.

[0032] Referring back to FIG. 2, in some exemplary embodiments, a projectile may contact the discontinuity 118 at the overlapping portion 130 of the second ballistic panel 104. The force applied may be partially absorbed and the remaining force may be transferred to the fold 120 at either the first portion 121 or the second portion 122. In such an instance, the force may be appreciably dissipated such that no substantial damage is applied to the ballistic barrier 100. However, in some instances, the transferred force may cause the fold 120 to deform which, in turn, absorbs the additional force. For example, the force is applied to the fold 120 may cause the third portion 124 to deform as to unwrap or unfold the fold 120. DueUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application to the geometry of the fold 120, a significant amount of force may be required for the fold 120 to completely unfold and damage and possibly compromise the integrity of the ballistic barrier 100. In other words, the unfolding action provides high encapsulating deformation, providing for increased integrity of the ballistic barrier 100.

[0033] Additionally, and as described earlier, the third portion 124 may additional be secured to the first portion 121 during the manufacturing process, which provides for additional strength of the fold 120. In such instances, the additional force may have to delaminate the fold 120 prior to the fold 120 beginning to deform. Similarly, additional strength may be provided in embodiments wherein the overlapping portion 130 of the second ballistic panel 104 is secured to the first portion 121 and the second portion 122 of the first ballistic panel 102. Furthermore, projectiles which may contact the discontinuity 118 may cause the first ballistic panel 102 and the second ballistic panel 104 to collapse or fold further upon itself. In other words, due to the overlapping nature of the panels 102, 104, a high force which may cause a high degree of deformation to the ballistic barrier 100 may still provide adequate protection against additional projectiles despite the deformation.

[0034] As mentioned previously, some embodiments of the ballistic barrier 100 are manufactured from composite materials. A method 200 for manufacturing a ballistic barrier is described herein and depicted in FIG.5.

[0035] The method 200 at 202 may include providing a structural core including a first surface 106 and a second surface 108 opposing the first surface 106. As mentioned previously, the first surface 106 is configured to be positioned in the direction that a projectile may originate from. The structural core may be manufactured using a structural core and a binding material. The fiber core may be made of a variety of materials including, but not limited to, paper, Kevlar, resin, Dyneema, woven materials, non-woven materials, monofilament fibers, or other materials which may include a high strength-to-weight ratio.US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application

[0036] The method 200 at 204 includes providing a wire 128 at the second surface of the structural core. The wire 128 may be positioned in parallel to an exposed edge 110 of the structural core or, in the alternative, the wire 128 may be positioned in a non-parallel manner such that the position of the wire 128 may vary along a length of the first ballistic panel 102. Furthermore, the dimensions and material of the wire 128 may be configured to be adjusted for various applications.

[0037] The method 200 at 206 includes wrapping or folding a portion of the second surface 108 of the structural core about the wire 128 as to create a fold 120. In some embodiments, the structural core is wrapped to sufficiently cover or contact a surface of the wire 128. To explain further, the structural core may be broken into three portions; the first portion 121 forms the majority of the structural core, the second portion 122 extends from the first portion 121, and lastly, the third portion 124 extends between the second portion 122 and the exposed edge 110. During the manufacturing process the second portion 122 may be positioned at and wrapped about the wire 128 forming a generally circular or curved geometry. Additionally, in some embodiments, the third portion 124 may be positioned adjacent to or flat against the second surface 108 of the structural core and, more specifically, at the first portion 121.

[0038] The method 200 at 208 may include providing a binding compound to the first structural core. Said binding compound may be configured to surround and / or extend through the structural core when in use. When dried and / or cured the binding compound may partially or wholly encapsulate portions or an entirety of the structural core to create a composite material. The combination of the structural core and the binding compound may add strength and / or flexibility to the ballistic barrier 100. The binding compound may be made of any individual or combination of a variety of materials typically associated with composites including, but not limited to vinylester resin, polyester resin, or epoxy resin. In someUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application embodiments, the binding material may be provided in a liquid, gel, or other injectable, extrudable, or brush-able form, or may be supplied by inclusion in a pre-impregnated state in the in the structural core.

[0039] The method 200 at 210 includes applying heat and pressure to the structural core and binding compound. In some embodiments, heat and pressure may be applied to the combination of the structural core and the binding compound such that the binding compound flows through the structural core. The heat and pressure may be applied using a heated press or other method known in the art. As the heat and pressure are applied to the fold 120, the first portion 121, the second portion 122, and the third portion 124, may be compressed together. In such instances, the first portion 121 may be pressed into the third portion 124 such that the binding compound flows between the two portions 120,124.

[0040] The method 200 at 212 includes cooling the combination of the structural core and binding compound. In some embodiments, the structural core and binding compound may then be passively or actively cooled, causing the binding compound to harden, creating a composite ballistic panel 102. Furthermore, once cooled, the first portion 121 and the third portion 124 may be secured or attached to one another via the binding compound.

[0041] Referring now to the figures, a ballistic barrier 300 is shown in a perspective cross-section view in FIG. 6. As depicted the ballistic barrier is shown including a ballistic panel 302 having a first surface 304 and a second surface opposite the 306, with a circular discontinuity 308 extending through from the first surface 304 to the second surface 306. Similarly to the ballistic barrier 100 discussed above, the first surface 304 of the ballistic panel 302 may be configured to face the direction which a projectile may originate from, or, in other words, the ballistic panel 302 may be configured to accept an impact from a projectile at the first surface 304.US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application

[0042] The ballistic panel 302 may be configured to be a composite material manufactured using a structural core a binding material. The structural core may be made of a variety of materials including, but not limited to, paper, Kevlar, resin, Dyneema, woven materials, non-woven materials, monofilament fibers, or other materials which may include a high strength-to-weight ratio. The binding material may be provided in a liquid, gel, or other injectable, extrudable, or brush-able form, or may be supplied by inclusion in a pre- impregnated state in the in the structural core. During manufacturing, the binding compound may be configured to surround and / or extend through the structural core when in use. When dried and / or cured the binding compound may partially or wholly encapsulate portions or an entirety of the structural core to create a composite material. The combination of the structural core and the binding compound may add strength and / or flexibility to the ballistic barrier 300. The binding compound may be made of any individual or combination of a variety of materials typically associated with composites including, but not limited to vinylester resin, polyester resin, or epoxy resin. The resulting composite may be ballistic resistant and / or ballistic proof. Additionally, the resulting composite may be resistant to chemicals, fire, extreme temperatures, and electrical conditions.

[0043] As noted above, FIG. 6 depicts a circular discontinuity 308 which extends through the ballistic panel 302 from the first surface 304 to the second surface 306. As discussed in detail above, discontinuities 308 within the ballistic barrier 300 or the ballistic barrier 302 lead to locations which may be more prone to deformation or damage due to the high forces that are often accompanied by the impact of a ballistic object. Such deformation or damage may reduce the effectiveness of the ballistic barrier 300 allowing for entire ballistic object, fragments of ballistic objects, or even damage from the ballistic barrier 300 to penetrate through the barrier 300. As depicted in FIG. 6, the discontinuity 308 may take the form of an eye-hole, circular or curved hole, or a curved plate. Typically used methods, asUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application discussed above, may use a large amount of heavy materials (e.g., stainless or hardened steel) to support circular or curved discontinuities, resulting in increase weight to ensure the integrity of the ballistic barrier 300 is not compromised. Therefore, there is an interest in providing different geometries and materials to maintain the integrity of the ballistic barrier 300 while reducing weight. The ballistic barrier described herein may use a combination of light weight material, traditional materials, and geometry, to reduce the overall weight of ballistic barrier 300.

[0044] Still in reference to FIG.6, the ballistic barrier 300 additionally includes a first edge support 310 and a second edge support 312 which are configured to provide strength to the ballistic panel 302 at the point of the discontinuity 308.

[0045] The first edge support 310 is configured to be positioned adjacent to the ballistic barrier 300 and may be configured to support the exposed edge created by the discontinuity 308. As depicted in FIG. 6 and FIG. 8, the first edge support 310 may include a first portion 314 positioned against or flush with the second surface 304 of the ballistic panel 302, and a second portion 316 positioned at least partially within the discontinuity 308.

[0046] In some embodiments, the first edge support 310 may be manufactured using a composite material similar to the ballistic panel 302. Furthermore, it is envisioned that the first edge support 310 may be manufactured in concert with the ballistic panel 302 such that the first edge support 310 is secured to the ballistic panel 302, providing additional strength to the ballistic barrier 300. In further detail, the structural core of the first edge support 310 may be positioned against the structural core of the ballistic panel 302 prior to adding a binding compound. As heat and pressure are applied to the combination, the binding compound may flow through first edge support 310 and the ballistic panel 302 such that when the binding compound cools and hardens, the resulting first edge support 310 and ballistic panel 302 are secured together. However, in some embodiments, it is not necessaryUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application for the ballistic panel 302 and the first edge support 310 to be secured together and, in such instances, may be manufactured separately.

[0047] Still referring to FIG.6 and FIG.8, the second edge support 312 may include a first portion 318, a second portion 320 extending from the first portion 318, and a through hole 322 extending through the first portion 318 and the second portion 320. The first portion 318 may be positioned adjacent to or flush against the first portion 314 of the first edge support 310. As noted above, the second portion 320 extends outwards from the first portion 318 and, in some embodiments, may be positioned within the discontinuity 308 of the ballistic panel 302.

[0048] Referring now to FIG. 8, the first edge support 310 may configured to surround the entirety of the second edge support 312 providing additional support to the ballistic barrier 300. The first edge support 310 may be manufactured using metals such as, stainless steel, aluminum, or other metals known in the art and typically associated with ballistic-proof applications. Furthermore, it is envisioned within the scope of the disclosure, that the second edge support 312 may be secured to the first edge support 310 using adhesives, fasteners, or other methods known in the art, though this is not required. In some embodiments, bullet-proof glass may be positioned within said through hole 322. The discontinuity 308 is described in relation to an eye-hole, however, the structure and method described herein may be applied to any curved surface and the description herein is intended to be exemplary and not intended to be limiting to the scope of the disclosure.

[0049] During impact, the geometry of the first edge support 310 and the second support edge 312 may be configured such that any force and heat that is applied to the discontinuity 118 may be absorbed without allowing for the projectile, fragments of the projectile, portions of the ballistic panel 302 or any other material to extend pass the second surface 306 of the ballistic panel 302. A projectile may contact the discontinuity 308 at eitherUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application the ballistic panel 302, the first edge support 310, or the second edge support 31. The force applied may be partially absorbed by any of said components and the remaining force that may potentially damage the ballistic barrier 302 may be dissipated to the remaining components. For example, if a projectile was to contact the edge of the ballistic panel 302 the resulting deformation or force may be transferred into the first edge support 310 and subsequently into the second edge support 312 without critically damaging the integrity of the ballistic barrier 300 as a whole. In some cases, the force applied to the ballistic panel 302 may be so great as to cause the ballistic panel 302 and / or the first edge support 310 to deform or delaminate. In such a case, the second edge support 312 may act as a stop to ensure that the damage to the ballistic panel 302 and / or the first edge support 310 is contained against the second edge support 312. In other words, more flexible and lighter materials may be used to support the discontinuity 308 and receive the initial impact of the projectile while more traditional heavier materials may be used to support said materials and ensure that the integrity of the ballistic barrier 300 remain intact. In such embodiments, the total amount of the heavier materials may be reduced and at least partially replaced with the lighter materials while maintain the integrity of the ballistic barrier 300.

[0050] The embodiments described herein are described in relation to aircraft and aircraft components, however, this is merely exemplary purposes. The embodiments and disclosure herein may be used in any application wherein the use of ballistic resistant or ballistic proof barriers may be beneficial. For example, the embodiments herein may used with, but not limited, to the following applications: passenger vehicles, military vehicles, autonomous vehicles, residential buildings, commercial building, and / or outdoor structure. Examples

[0051] A collection of exemplary embodiments, including at least some explicitly enumerated as “Examples” providing additional description of a variety of example types inUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application accordance with the concepts described herein are provided below. These examples are not meant to be mutually exclusive, exhaustive, or restrictive; and the invention is not limited to these examples but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0052] Example 1. A ballistic barrier including: a first ballistic panel including a first surface, a second surface positioned opposite the first surface, and a fold positioned adjacent an edge of the first ballistic panel, wherein the fold includes: a first portion; a second portion extending from the first portion; and a third portion extending between the second portion and the edge of the first ballistic panel, wherein a portion of the second surface of first ballistic panel at the third portion is positioned adjacent to a portion of the second surface of the first ballistic panel at the first portion.

[0053] Example 2. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, further including a wire, wherein the second portion of the fold of the first ballistic panel is configured to be wrapped at least partially about the wire.

[0054] Example 3. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein the wire is positioned in parallel to the edge of the first ballistic panel.

[0055] Example 4. The ballistic barrier of any of the preceding or subsequent examples or combinations of examples, wherein the wire is positioned in non-parallel to the edge of the first ballistic panel.

[0056] Example 5. The ballistic barrier of any of the preceding or subsequent examples or combinations of examples, wherein the second surface of the first ballistic panel at the third portion is secured to the second surface of the first ballistic panel at the first portion.US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application

[0057] Example 6. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, further including a second ballistic panel, wherein the second ballistic panel including a first surface and a second surface opposite the first surface, wherein the second ballistic panel includes an overlapping portion positioned adjacent the fold of the first ballistic panel.

[0058] Example 7. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein the overlapping portion is positioned adjacent to the first portion of the fold and the second portion of the fold.

[0059] Example 8. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein the overlapping portion is secured to the first portion of the fold and / or the second portion of the fold.

[0060] Example 9. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, further including a second fold positioned at a second edge of the first ballistic panel, wherein the second fold includes: a first portion; a second portion extending from the first portion; and a third portion extending between the second portion and the second edge of the first ballistic panel, wherein a portion of the second surface of the second surface of first ballistic panel at the third portion is positioned adjacent to a portion of the second surface of the first ballistic panel at the first portion.

[0061] Example 10. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, further including a wire, wherein the second portion of the first fold and the second portion of the second fold are wrapped at least partially about the wire.

[0062] Example 11. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein at least a first portion of the wire is configured to be positioned in parallel with the edge associated with the first fold and at leastUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application a second portion of the wire is configured to be positioned in parallel with the second edge associated with the second fold.

[0063] Example 12. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein the first ballistic panel includes a composite material.

[0064] Example 13. A method for manufacturing a ballistic barrier, the method including providing a structural core including a first surface, and a second surface positioned opposite the first surface, the structural core including: a first portion; a second portion extending from the first portion; and a third portion extending between the second portion and an edge of the structural core; providing and positioning a wire at the second surface of the structural core; wrapping the second portion of the core about the wire, such that the second portion of the structural core substantially surrounds at least a portion of the wire and the second surface positioned at the first portion contacts with the second surface positioned at the third portion; providing a binding compound to the structural core; and applying heat and pressure to the structural core and the binding compound.

[0065] Example 14. The method for manufacturing a ballistic barrier of any of the preceding or subsequent examples or combination of examples, further including cooling the structural core and the binding compound such that the second surface positioned at the first portion is secured to the second surface positioned at the third portion.

[0066] Example 15. A ballistic barrier including: a ballistic panel including a first surface, a second surface positioned opposite the first surface, and a through hole extending from the first surface to the second surface; a first edge support positioned adjacent to the second surface of the ballistic panel, wherein at least a portion of the first support is positioned within the through hole; and a second edge support positioned adjacent to the first support, wherein at least a portion of the second support is positioned within the throughUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application hole, wherein at least a portion of the through hole remains unblocked by either the first edge support or the second edge support.

[0067] Example 16. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein the ballistic panel and the first edge support comprise composite materials.

[0068] Example 17. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein the second surface of the ballistic panel is secured to the first edge support.

[0069] Example 18. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein the second edge support is secured to the first edge support.

[0070] Example 19. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, wherein the second edge support comprises steel.

[0071] Example 20. The ballistic barrier of any of the preceding or subsequent examples or combination of examples, further including bullet-proof glass positioned within the through hole.

[0072] Different arrangements of the components depicted in the drawings or described above, as well as components and steps not shown or described are possible. Similarly, some features and sub-combinations are useful and may be employed without reference to other features and sub-combinations. Embodiments of the invention have been described for illustrative and not restrictive purposes, and alternative embodiments will become apparent to readers of this patent. Accordingly, the present invention is not limited to the embodiments described above or depicted in the drawings, and various embodiments and modifications may be made without departing from the scope of the claims below.US2008231648231

Claims

Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application CLAIMS That which is claimed is:

1. A ballistic barrier, comprising: a first ballistic panel including a first surface, a second surface positioned opposite the first surface, and a fold positioned adjacent an edge of the first ballistic panel, wherein the fold comprises: a first portion; a second portion extending from the first portion; and a third portion extending between the second portion and the edge of the first ballistic panel, wherein a portion of the second surface of first ballistic panel at the third portion is positioned adjacent to a portion of the second surface of the first ballistic panel at the first portion.

2. The ballistic barrier of claim 1 further comprising a wire, wherein the second portion of the fold of the first ballistic panel is configured to be wrapped at least partially about the wire.

3. The ballistic barrier of claim 2, wherein the wire is positioned in parallel to the edge of the first ballistic panel.

4. The ballistic barrier of claim 2, wherein the wire is positioned in non-parallel to the edge of the first ballistic panel.

5. The ballistic barrier of claim 1, wherein the second surface of the first ballistic panel at the third portion is secured to the second surface of the first ballistic panel at the first portion.

6. The ballistic barrier of claim 1 further comprising a second ballistic panel, wherein the second ballistic panel including a first surface and a second surface opposite the first surface, wherein the second ballistic panel includes an overlapping portion positioned adjacent the fold of the first ballistic panel.US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application 7. The ballistic barrier of claim 6, wherein the overlapping portion is positioned adjacent to the first portion of the fold and the second portion of the fold.

8. The ballistic barrier of claim 7, wherein the overlapping portion is secured the first portion of the fold and / or the second portion of the fold.

9. The ballistic barrier of claim 1 further comprising a second fold positioned adjacent a second edge of the first ballistic panel, wherein the second fold comprises: a first portion; a second portion extending from the first portion; and a third portion extending between the second portion and the second edge of the first ballistic panel, wherein a portion of the second surface of the second surface of first ballistic panel at the third portion is positioned adjacent to a portion of the second surface of the first ballistic panel at the first portion.

10. The ballistic barrier of claim 9 further comprising a wire, wherein the second portion of the first fold and the second portion of the second fold are wrapped at least partially about the wire.

11. The ballistic barrier of claim 10, wherein at least a first portion of the wire is configured to be positioned in parallel with the edge associated with the first fold and at least a second portion of the wire is configured to be positioned in parallel with the second edge associated with the second fold.

12. The ballistic barrier of claim 1, wherein the first ballistic panel comprises a composite material.

13. A method for manufacturing a ballistic barrier, the method comprising: providing a structural core including a first surface, and a second surface positioned opposite the first surface, the structural core including: a first portion; a second portion extending from the first portion; andUS2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application a third portion extending between the second portion and an edge of the structural core; providing and positioning a wire adjacent to the second surface of the structural core; wrapping the second portion of the core about the wire, such that the second portion of the structural core substantially surrounds at least a portion of the wire and the second surface positioned at the first portion contacts with the second surface positioned at the third portion; providing a binding compound to the structural core; and applying heat and pressure to the structural core and the binding compound.

14. The method for manufacturing a ballistic barrier of claim 13, further comprising cooling the structural core and the binding compound such that the second surface positioned at the first portion is secured to the second surface positioned at the third portion.

15. A ballistic barrier, comprising: a ballistic panel including a first surface, a second surface positioned opposite the first surface, and a through hole extending from the first surface to the second surface; a first edge support positioned adjacent to the second surface of the ballistic panel, wherein at least a portion of the first support is positioned within the through hole; and a second edge support positioned adjacent to the first support, wherein at least a portion of the second support is positioned within the through hole, wherein at least a portion of the through hole remains unblocked by either the first edge support or the second edge support.

16. The ballistic barrier of claim 15, wherein the ballistic panel and the first edge support comprise composite materials.

17. The ballistic barrier of claim 16, wherein the second surface of the ballistic panel is secured to the first edge support.

18. The ballistic barrier of claim 17, wherein the second edge support is secured to the first edge support.

19. The ballistic barrier of claim 15, wherein the second edge support comprises steel.US2008231648231Attorney Docket 110708-1418788 Client Ref. B-029374PCT01 Patent Application 20. The ballistic barrier of claim 15 further comprising bullet-proof glass positioned within the through hole.US2008231648231

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