Composite ballistic panels for building and construction

Abstract

A ballistic sheet good is provided that includes a board including two or more fiber reinforced thermoplastic plies; wherein the two or more fiber reinforced thermoplastic plies comprise continuous fibers embedded in a thermoplastic matrix material; and the two or more fiber reinforced thermoplastic plies are adhered to together via the thermoplastic matrix material. A ballistic sheet good may include a length of at least 60 mm, a width of at least 60mm, and a height of at least 2.5 mm.

Description

Composite Ballistic Panels for Building and Construction COMPOSITE BALLISTIC PANELS FOR BUILDING AND CONSTRUCTION CLAIM OF PRIORITY

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 578,546 bearing Attorney Docket Number 1202317 and filed on August 24, 2023, which is hereby incorporated by reference in its entirety. TECHNICAL FIELD

[0002] The present disclosure relates to sheet goods comprising composite ballistic panels. BACKGROUND

[0003] Armor, or ballistic materials, is finding ever increasing application in modern times. With respect to armor has historically taken the form of metal plates, the thickness of which varies depending on the type of projectile the armor is designed to stop. As this metal armor gets thicker, the weight of the armor increases dramatically. Making the metal armor thinner while reducing weight will likewise reduce the ability of the armor to stop the intended projectile.

[0004] Other engineered materials, such as ceramics, have been employed as armor. However, these materials are also heavy and can be prohibitively expensive. Moreover, these materials are often difficult to form and can require costly molds and dies.

[0005] Presently there is a need in the art for lightweight ballistic panels that may be used in permanent or temporary structures such as, for example, walls, doors, roofs, floors, barriers, and fences. SUMMARY

[0006] Disclosed herein are sheet goods comprising composite ballistic panels.

[0007] In one embodiment, a ballistic sheet good is provided that includes a board comprising two or more fiber reinforced thermoplastic plies; wherein the two or more fiber reinforcedComposite Ballistic Panels for Building and Construction thermoplastic plies comprise continuous fibers embedded in a thermoplastic matrix material; and the two or more fiber reinforced thermoplastic plies are adhered together via the thermoplastic matrix material; and wherein the ballistic sheet good has a length of at least 300 mm, a width of at least 300 mm, and a height of at least of 2.5 mm.

[0008] In some embodiments, the thermoplastic plies comprise continuous E-glass fibers.

[0009] In some embodiments, the board comprises 2 to 100 thermoplastic plies.

[0010] In some embodiments, the thermoplastic matrix comprises a semi-crystalline polymer.

[0011] In some embodiments, the thermoplastic matrix comprises an amorphous polymer.

[0012] In some embodiments, the thermoplastic matrix comprises a polyolefin polymer.

[0013] In some embodiments, the core comprises 10% to 90% by weight of the thermoplastic matrix material out of the total weight of the core.

[0014] In some embodiments, the core comprises 10% to 90% by weight of the continuous glass fibers out of the total weight of the core.

[0015] In some embodiments, the core includes a first face and an opposing second face, and wherein the ballistic sheet good further includes a facer adhere to the first face, second face or both the first and second face of the core.

[0016] In some embodiments, the facer is a fiber reinforced composite facer.

[0017] In some embodiments, the facer is a fiber reinforced composite facer comprising two or more fiber reinforced thermoset plies comprise continuous glass fibers embedded in a thermoplastic matrix material.

[0018] In some embodiments, the facer is a ceramic strike face.

[0019] In some embodiments, the facer is paper, foil, a glass reinforced facer, coated glass facer, cellulosic fiber board, glass mat, oriented strand board, or plywood.Composite Ballistic Panels for Building and Construction

[0020] In some embodiments, the ballistic sheet good does not include a ceramic strike face.

[0021] In some embodiments, the ballistic sheet good consists of composite materials.

[0022] In some embodiments, the ballistic sheet good consists essentially of the core and optionally the facer.

[0023] In some embodiments, the ballistic sheet good consists of the core and optionally the facer.

[0024] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 1.

[0025] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 2.

[0026] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 3.

[0027] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 4.

[0028] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 5.

[0029] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 6.

[0030] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 7.

[0031] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 8.

[0032] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 9.

[0033] In some embodiments, the ballistic sheet good meets or exceeds UL 752 level 10.

[0034] In embodiments, a building structure is provided comprising a ballistic sheet good.

[0035] In some embodiments, the ballistic sheet good is attached to a second building material by an adhesive or a mechanical fastener. DRAWINGSComposite Ballistic Panels for Building and Construction

[0036] FIG.1 is a top perspective view of one or more embodiments of a ballistic sheet good;

[0037] FIG. 2 is a side elevation view of one or more embodiments of a ballistic sheet good comprising a facer;

[0038] FIG.3 is a top perspective view of one or more embodiments of a composite ply; and

[0039] FIG. 4 is a top perspective view of one or more embodiments of a layered composite material. DETAILED DESCRIPTION

[0040] The disclosure should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the subject matter to those skilled in the art. Definitions

[0041] Unless otherwise expressly defined, all technical and scientific terms used herein have the same meaning as commonly understood by a person of ordinary skill in the art. The terminology used in the disclosure herein is for describing particular embodiments only and is not intended to be limiting.

[0042] Unless otherwise expressly stated, it is not intended that any method disclosed herein be construed as requiring that its steps be performed in a specific order, nor that any article set forth herein be construed as requiring specific orders or orientations to its individual components.

[0043] Unless otherwise expressly stated, it is intended that any composition or mixture disclosed herein may comprise, consist essentially of, or consist of the disclosed components.

[0044] As used herein, the singular form of a term is intended to include the plural form of the term, unless the context clearly indicates otherwise.

[0045] As used herein, numerical values are not strictly limited to the exact numerical value recited. Instead, unless otherwise expressly stated, each numerical value is intended to mean both the exact numerical value and “about” the numerical value, which encompasses a functionallyComposite Ballistic Panels for Building and Construction equivalent range surrounding that numerical value, such that either possibility is contemplated as an embodiment disclosed herein.

[0046] As used herein, the term “continuous fibers” refers to a fiber that spans all or substantially all of a dimension of a uni-directional tape or ply. As used herein, the term “substantially all of a dimension,” refers a fiber or the average of the fibers in a uni-directional tape or ply that span greater than 75%, greater than 85%, or greater than 95% of a dimension of a uni-directional tape or ply.

[0047] As used herein, the term “average diameter” refers to an average of the diameters of each of the fibers in the plurality of continuous fibers.

[0048] As used herein, the term “uni-directional” refers to the use of fibers that are parallel or substantially parallel (e.g., only a small amount of fibers are running slightly in a different direction or angle). Ballistic Sheet Goods

[0049] Embodiments are based, at least in part, on a ballistic sheet good. The ballistic sheet good may comprise a core comprising two or more fiber reinforced thermoplastic plies; wherein the two or more fiber reinforced thermoplastic plies comprise continuous glass fibers embedded in a thermoplastic matrix material; and the two or more fiber reinforced thermoplastic plies are adhered together via the thermoplastic matrix material. The ballistic sheet good may be made in standard sheet good size and may have, for example, a length of at least 30 cm, a width of at least 30 cm, and a height of at least 2.5 mm. In certain embodiments, a facer may be adhered to or attached to one or more faces of the core of the ballistic sheet good may to help improve resistance to higher powered ballistic strikes. The ballistic sheet good may be used, for example, in permanent or temporary structures such as walls, roofs, floors, barriers, doors, and fences.

[0050] As shown in FIG. 1, the ballistic sheet good 10 comprises a core 20. The core 20 includes a length 30, a width 40, and a height 50. While in certain embodiments, the ballistic sheet good may have one or more additional layers or optional components, the ballistic sheet good 10 as shown may consist or consist essentially of the core 20. A ballistic sheet good 10 that consistsComposite Ballistic Panels for Building and Construction essentially of the core 20 may include the core and one or more components that does not materially affect the ballistic properties (e.g., such as a component for cosmetic purposes such as a coating or adhered layers). Accordingly, as used herein the term “core” does not require additional components and may be the entirety of the ballistic sheet good.

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

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

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

[0054] The ballistic sheet good may be made in a standard sheet good size. In one or more embodiments, ballistic sheet good may be square, rectangle, circular, or oval. The width and length dimensions may be, for example 1ft x 1ft, 1ft x 2ft, 1ft x 4ft, 1ft x 5ft, 1ft x 8ft, 1ft x 10ft, 1ft x 12ft, 2ft x 2ft, 2ft x 4ft, 2ft x 5ft, 2ft x 8ft, 2ft x 10ft, 2ft x 12ft, 4ft x 5ft, 4ft x 8ft, 4ft x 10ft, 4ft x 12ft, 5ft x 5ft, 5ft x 8ft, 5ft x 10ft, 5ft x 12ft, 8ft x 8ft, 8ft x 10ft, 8ft x 12ft, 10ft x 10ft, 10ft x 12ft, or 12ft x 12ft.

[0055] In one or more embodiments, the ballistic sheet good may have a facer. As shown in FIG.2, the ballistic sheet good 110 comprises a core 120. A facer 130 is optionally situated on the core 120. The facer 130 may comprise two or more fiber reinforced plies. The fiber reinforced plies include a fibers in a matrix material. As used herein the matrix material employed in the fiber reinforced plies of the facer 130 may be referred to as the “facer matrix material.” In one or more embodiment, the facer matrix material is different than the thermoplastic matrix material employed in the plies of the core 120.

[0056] The core (and optionally the facer) may be prepared from two or more plies. In one or more embodiments, the ply is a composite ply and comprises fibers disposed in a matrix material. A single composite ply is sometimes referred to as a “uni-directional tape.” As shown in FIG.3, a composite ply 210 includes a plurality of continuous fibers 220 embedded in a matrix material 230.

[0057] The core (and optionally the facer) may include a plurality of plies. Adjacent plies may adhere to each other due to the interaction of the matrix materials therein or they may be bound together by a binder or adhesive. As shown in FIG.4, a plurality of composite plies may form a layered composite material 310. As shown in FIG.4, the layered composite material 310 includesComposite Ballistic Panels for Building and Construction a first ply 320 adhered to a second ply 330. The second ply 330 is adhered to a third ply 340. The third ply 340 is adhered to a forth ply 350. In embodiments, the continuous fibers of each successive ply may be oriented 90 ° to the previous ply (as shown). The angle to which each subsequent sheet can be oriented versus the successive may range between 0° and 90°. In one or more embodiments, each subsequent sheet is oriented versus the successive may be about 90°. Core

[0058] As indicated above the ballistic sheet good may include or consist of a core. The core includes 2 or more plies of continuous fiber reinforced plies in a thermoplastic matrix. Suitable continuous fiber reinforced plies are described in U.S. Pat. No.7,598,158.

[0059] In one or more embodiments, the core may be characterized by the number of plies. In these or other embodiments, the core may have equal to or greater than 2 plies, 3 plies, 4 plies, 5 plies, 6 plies, 7 plies, 8 plies, 9 plies, 10 plies, 11 plies, 12 plies, 13 plies, 14 plies, 15 plies, 16 plies, 17 plies, 18 plies, 19 plies, 20 plies, 21 plies, 22 plies, 23 plies, 24 plies, 25 plies, 26 plies, 27 plies, 28 plies, 29 plies, 30 plies, 31 plies, 32 plies, 33 plies, 34 plies, 35 plies, 36 plies, 37 plies, 38 plies, 39 plies, 40 plies, 41 plies, 42 plies, 43 plies, 44 plies, 45 plies, 46 plies, 47 plies, 48 plies, 49 plies, 50 plies, 51 plies, 52 plies, 53 plies, 54 plies, 55 plies, 56 plies, 57 plies, 58 plies, 59 plies, 60 plies, 61 plies, 62 plies, 63 plies, 64 plies, or 65 plies. In these or other embodiments, the core may have equal to or less than 100 plies, 99 plies, 98 plies, 97 plies, 96 plies, 95 plies, 94 plies, 93 plies, 92 plies, 91 plies, 90 plies, 89 plies, 88 plies, 87 plies, 86 plies, 85 plies, 84 plies, 83 plies, 82 plies, 81 plies, 80 plies, 79 plies, 78 plies, 77 plies, 76 plies, 75 plies, 74 plies, 73 plies, 72 plies, 71 plies, or 70 plies. In one or more embodiments, the core may be characterized by the number of plies. In these or other embodiments, the core may a number of plies in the range of 2 plies to 100 plies, 3 plies to 99 plies, 4 plies to 98 plies, 5 plies to 97 plies, 6 plies to 96 plies, 7 plies to 95 plies, 8 plies to 94 plies, 9 plies to 93 plies, 10 plies to 92 plies, 11 plies to 91 plies, 12 plies to 90 plies, 13 plies to 89 plies, 14 plies to 88 plies, 15 plies to 87 plies, 16 plies to 86 plies, 17 plies to 85 plies, 18 plies to 84 plies, 19 plies to 83 plies, 20 plies to 82 plies, 21 plies to 81 plies, 22 plies to 80 plies, 23 plies to 79 plies, 24 plies to 78 plies, 25 plies to 77 plies, 26 plies to 76 plies, 27 plies to 75 plies, 28 plies to 74 plies, 29 plies to 73 plies, 30 plies to 72 plies, 31 plies to 71 plies, 32 plies to 70 plies, 33 plies to 69 plies, 34 plies to 68 plies, 35 plies to 67 plies, 36 plies to 66Composite Ballistic Panels for Building and Construction plies, 37 plies to 65 plies, 38 plies to 64 plies, 39 plies to 63 plies, 40 plies to 62 plies, 41 plies to 61 plies, 42 plies to 60 plies, or any combination of endpoints listed above.

[0060] Suitable matrix materials for use in the plies of the core include thermoplastic polymer compositions. For example, the thermoplastic polymer compositions may include semi- crystalline, and amorphous thermoplastics. Examples of semi-crystalline polymer matrices include but are not limited to polyolefins, polyethylene terephthalate, polybutylene terephthalate, and polyamides. Examples of amorphous polymer matrices include but are not limited to amorphous polyethylene terephthalate, polymethyl methacrylate, polycarbonate, and acrylonitrile butadiene styrene. Examples of polyolefins include polypropylene (PP), and polyethylene (PE). Suitable matrix materials also include thermoplastic elastomers (TPE).

[0061] In one or more embodiments, the core may be characterized by the weight percent of the fibers out of the total weight of the core. In one or more embodiments, the weight percentage of the fiber may be equal to or greater than 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt%. In these or other embodiments, the weight percentage of the fiber may be equal to or less than 90 wt%, 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%. In one or more embodiments, the weight percentage of the fiber may be in the range of 10 wt% to 90 wt%, 15 wt% to 85 wt%, 20 wt% to 80 wt%, 25 wt% to 75 wt%, 30 wt% to 70 wt%, 35 wt% to 65 wt%, 40 wt% to 60 wt%, 45 wt% to 55 wt%, or any combination of endpoints listed above.

[0062] In one or more embodiments, the core may be characterized by the weight percent of the matrix out of the total weight of the core. In one or more embodiments, the weight percentage of the matrix may be equal to or greater than 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt%. In these or other embodiments, the weight percentage of the matrix may be equal to or less than 90 wt%, 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%. In one or more embodiments, the weight percentage of the matrix may be in the range of 10 wt% to 90 wt%, 15 wt% to 85 wt%, 20 wt% to 80 wt%, 25 wt% to 75 wt%, 30 wt% to 70Composite Ballistic Panels for Building and Construction wt%, 35 wt% to 65 wt%, 40 wt% to 60 wt%, 45 wt% to 55 wt%, or any combination of endpoints listed above.

[0063] In one or more embodiments, the core may be characterized by the height. In one or more embodiments, the core may have a height of that is greater or equal to 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 6 mm, 7mm, 8mm, 9mm, 10mm, 11mm, 12mm, 13mm, 14mm, 15mm, 16mm, 17mm, 18mm, 19mm, 20mm, 21mm, 22mm, or 23 mm. In one or more embodiments, the core may have a height of that is less than or equal to 50 mm, 49 mm, 48 mm, 47 mm, 46 mm, 45 mm, 43 mm, 42 mm, 41 mm, 40 mm, 39 mm, 38 mm, 37 mm, 36 mm, 35 mm, 34 mm, 33 mm, 32 mm, 31 mm, 30 mm, 29 mm, 28 mm, or 27 mm. In one or more embodiments, the core has a height of that is in the range of 2.5 mm to 50 mm, 3 mm to 49 mm, 3.5 mm to 48 mm, 4 mm to 47 mm, 4.5 mm to 46 mm, 5 mm to 45 mm, 6 mm to 43 mm, 7 mm to 42 mm, 8 mm to 40 mm, 9 mm to 39 mm, 10 mm to 38 mm, 11 mm to 37 mm, 12 mm to 36 mm, 13 mm to 35 mm, 14 mm to 34 mm, 15 mm to 33 mm, 16 mm to 32 mm, 17 mm to 31 mm, 18 mm to 30 mm, 19 mm to 29 mm, 20 mm to 28 mm, 21 mm to 27 mm, 22 mm to 26 mm, 23 mm to 25 mm, or any combination of endpoints listed above. Facer

[0064] As indicated above, the ballistic sheet good may have a facer. Suitable facers include those material typical used in sheet goods such as paper, foils, glass reinforced facers, coated glass facers, cellulosic fiber board, glass mats, oriented strand board, or plywood.

[0065] In one or more embodiments the facer may be a fiber reinforced thermoset. In these or other embodiments, the reinforcing fibers may be in a tow, yarn, roving, or woven mat.

[0066] Suitable facer matrix materials may include thermoset polymer compositions. For example, the thermoset polymer compositions may include unsaturated polyester, vinylester, epoxy, and others. In addition to thermoset polymer composition, ceramic or other hardened reactive matrixes may be included. In embodiments, the facer is a ceramic strike face.

[0067] In one or more embodiments, the facer may include plies as described above. The facer be characterized by the number of plies. In these or other embodiments, the facer may have equalComposite Ballistic Panels for Building and Construction to or greater than 2 plies, 3 plies, 4 plies, 5 plies, 6 plies, 7 plies, 8 plies, 9 plies, 10 plies, 11 plies, 12 plies, 13 plies, 14 plies, 15 plies, 16 plies, 17 plies, 18 plies, 19 plies, 20 plies, 21 plies, 22 plies, 23 plies, 24 plies, 25 plies, 26 plies, 27 plies, 28 plies, 29 plies, 30 plies, 31 plies, 32 plies, 33 plies, 34 plies, 35 plies, 36 plies, 37 plies, 38 plies, 39 plies, 40 plies, 41 plies, 42 plies, 43 plies, 44 plies, 45 plies, 46 plies, 47 plies, 48 plies, 49 plies, 50 plies, 51 plies, 52 plies, 53 plies, 54 plies, 55 plies, 56 plies, 57 plies, 58 plies, 59 plies, 60 plies, 61 plies, 62 plies, 63 plies, 64 plies, or 65 plies. In these or other embodiments, the facer may have equal to or less than 100 plies, 99 plies, 98 plies, 97 plies, 96 plies, 95 plies, 94 plies, 93 plies, 92 plies, 91 plies, 90 plies, 89 plies, 88 plies, 87 plies, 86 plies, 85 plies, 84 plies, 83 plies, 82 plies, 81 plies, 80 plies, 79 plies, 78 plies, 77 plies, 76 plies, 75 plies, 74 plies, 73 plies, 72 plies, 71 plies, or 70 plies. In these or other embodiments, the facer may a number of plies in the range of 2 plies to 100 plies, 3 plies to 99 plies, 4 plies to 98 plies, 5 plies to 97 plies, 6 plies to 96 plies, 7 plies to 95 plies, 8 plies to 94 plies, 9 plies to 93 plies, 10 plies to 92 plies, 11 plies to 91 plies, 12 plies to 90 plies, 13 plies to 89 plies, 14 plies to 88 plies, 15 plies to 87 plies, 16 plies to 86 plies, 17 plies to 85 plies, 18 plies to 84 plies, 19 plies to 83 plies, 20 plies to 82 plies, 21 plies to 81 plies, 22 plies to 80 plies, 23 plies to 79 plies, 24 plies to 78 plies, 25 plies to 77 plies, 26 plies to 76 plies, 27 plies to 75 plies, 28 plies to 74 plies, 29 plies to 73 plies, 30 plies to 72 plies, 31 plies to 71 plies, 32 plies to 70 plies, 33 plies to 69 plies, 34 plies to 68 plies, 35 plies to 67 plies, 36 plies to 66 plies, 37 plies to 65 plies, 38 plies to 64 plies, 39 plies to 63 plies, 40 plies to 62 plies, 41 plies to 61 plies, 42 plies to 60 plies, or any combination of endpoints listed above.

[0068] In one or more embodiments, the facer may be characterized by the weight percent of the fibers out of the total weight of the facer. In one or more embodiments, the weight percentage of the fiber may be equal to or greater than 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt% . In these or other embodiments, the weight percentage of the fiber may be equal to or less than 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%. In one or more embodiments, the weight percentage of the fiber may be in the range of 20 wt% to 80 wt%, 25 wt% to 75 wt%, 30 wt% to 70 wt%, 35 wt% to 65 wt%, 40 wt% to 60 wt%, 45 wt% to 55 wt%, or any combination of endpoints listed above.Composite Ballistic Panels for Building and Construction

[0069] In one or more embodiments, the facer may be characterized by the weight percent of the matrix out of the total weight of the facer. In one or more embodiments, the weight percentage of the matrix may be equal to or greater than 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, 60 wt%, 65 wt%, 70 wt%, or 75 wt%. In these or other embodiments, the weight percentage of the matrix may be equal to or less than 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt%. In one or more embodiments, the weight percentage of the matrix may be in the range of 20 wt% to 80 wt%, 25 wt% to 75 wt%, 30 wt% to 70 wt%, 35 wt% to 65 wt%, 40 wt% to 60 wt%, 45 wt% to 55 wt%, or any combination of endpoints listed above.

[0070] In one or more embodiments, the facer may be characterized by the height. In one or more embodiments, the facer has a height of that is greater or equal to 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 6 mm, 7mm, 8mm, 9mm, 10mm, 11mm, 12mm, 13mm, 14mm, or 15mm. In one or more embodiments, the facer has a height of that is less than or equal to 30 mm, 29 mm, 28 mm, 27 mm, 26 mm, 25 mm, 24 mm, 23 mm, 22 mm, 21 mm, or 20 mm. In one or more embodiments, the facer has a height of that is in the range of 2.5 mm to 30 mm, 3 mm to 29 mm, 3.5 mm to 28 mm, 4 mm to 27 mm, 4.5 mm to 26 mm, 5 mm to 25 mm, 6 mm to 24 mm, 7 mm to 23 mm, 8 mm to 22 mm, 9 mm to 21 mm, 10 mm to 20 mm, or any combination of endpoints listed above.

[0071] Exemplary reinforcing fibers for use in the core (and optionally the facer) include one or more of glass fibers, aramid fibers, basalt fibers, carbon fibers, UHMWPE (ultra high molecular weight polyethylene) fibers, and other polymeric fibers. In one or more embodiments, the reinforcing fibers average diameter 5 micrometers to 40 micrometers, 7 micrometers to 38 micrometers, 8 micrometers to 35 micrometers, 10 micrometers to 33 micrometers, 12 micrometers to 30 micrometers, 15 micrometers to 28 micrometers, 5 micrometers to 40 micrometers,

[0072] Additives or other optional minority non-fiber components may be added to the thermoplastic or optional thermoset matrixes. These additives may be used to improve various material properties, such as, but not limited to the following: thermal properties, chemicalComposite Ballistic Panels for Building and Construction properties, and mechanical properties. Examples of such additives include flame retardant additives, UV stabilizers, or processing aids. Ballistic Standards

[0073] Ballistic materials, including panels, are usually tested in accordance with standards that allow for consistent and meaningful evaluation of their performance, i.e., their ability to withstand ballistic impact. Such a standard would be the UL 752: UL Standard for Safety for Bullet-Resisting Equipment. This standard defined the various performances of ballistically resistant structures in regard to variety of threats. Accordingly, the UL standard has classified the protection afforded by different armor grades as follows.

[0074] UL Level 1: Armor classified as UL Level 1 protects against a standard test round in the form of a 9 mm full metal copper jacket with a lead core. This round has a nominal mass of 8 grams, utilizing approximately 124 grains of powder. The resulting round will travel between 358 meters per second and 394 meters per second. The UL Level 1 armor is to survive 3 shots of the described round.

[0075] UL Level 2: Armor classified as UL Level 2 protects against a standard test round in the form of a .357 Magnum jacketed lead soft point. This round has a nominal mass of 10.2 grams, utilizing approximately 158 grains of powder. The resulting round will travel between 381 meters per second and 419 meters per second. The UL Level 2 armor is to survive 3 shots of the described round.

[0076] UL Level 3: Armor classified as UL Level 3 protects against a standard test round in the form of a .44 Magnum lead semi-wadcutter gas checked. This round has a nominal mass of 15.6 grams, utilizing approximately 240 grains of powder. The resulting round will travel between 411 meters per second and 451 meters per second. The UL Level 3 armor is to survive 3 shots of the described round.

[0077] UL Level 4: Armor classified as UL Level 4 protects against a standard test round in the form of a .30 caliber rifle lead core soft point. This round has a nominal mass of 11.7 grams, utilizing approximately 180 grains of powder. The resulting round will travel between 774 metersComposite Ballistic Panels for Building and Construction per second and 851 meters per second. The UL Level 4 armor is to survive 1 shot of the described round.

[0078] UL Level 5: Armor classified as UL Level 5 protects against a standard test round in the form of a 7.62 mm Rifle lead core full metal copper jacket, military ball. This round has a nominal mass of 9.7 grams, utilizing approximately 150 grains of powder. The resulting round will travel between 838 meters per second and 922 meters per second. The UL Level 5 armor is to survive 1 shot of the described round.

[0079] UL Level 6: Armor classified as UL Level 6 protects against a standard test round in the form of a 9 mm full metal copper jacket with lead core. This round has a nominal mass of 8.0 grams, utilizing approximately 124 grains of powder. The resulting round will travel between 427 meters per second and 470 meters per second. The UL Level 6 armor is to survive 5 shots of the described round.

[0080] UL Level 7: Armor classified as UL Level 7 protects against a standard test round in the form of a 5.56 mm Rifle full metal copper jacket with lead core. This round has a nominal mass of 3.56 grams, utilizing approximately 55 grains of powder. The resulting round will travel between 939 meters per second and 1033 meters per second. The UL Level 7 armor is to survive 5 shots of the described round.

[0081] UL Level 8: Armor classified as UL Level 8 protects against a standard test round in the form of a 7.62 mm Rifle lead core full metal copper jacket, military ball. This round has a nominal mass of 9.7 grams, utilizing approximately 150 grains of powder. The resulting round will travel between 838 meters per second and 922 meters per second. The UL Level 8 armor is to survive 5 shots of the described round.

[0082] Those skilled in the art will appreciate that UL 752 recognizes 10 levels. Levels 9 and 10 are predominately employed for military applications. In certain embodiments, the ballistic sheet good may exceed UL Level 8 and meet or exceed UL level 9. In certain embodiments, the ballistic sheet good may exceed UL Level 9 and meet or exceed UL level 10.Composite Ballistic Panels for Building and Construction

[0083] Another standard has been established by the United States Department of Justice's National Institute of Justice and is entitled “NIJ Standard for Ballistic Resistant Protective Materials (hereinafter referred to as the “NIJ Standard”). The ballistic threat posed by a bullet or other projectile depends, inter alia, on its composition, shape, caliber, mass, and impact velocity. Accordingly, the NIJ standard has classified the protection afforded by different armor grades as follows.

[0084] Type II-A (Lower Velocity 357 Magnum and 9 mm): Armor classified as Type II-A protects against a standard test round in the form of a 357 Magnum jacketed soft point, with nominal masses of 10.2 g and measured velocities of 381+ / −15 meters per second. Type II-A ballistic materials also protect against 9 mm full metal jacketed rounds with nominal masses of 8 g and measured velocities of 332+ / −12 meters per second.

[0085] Type II (Higher Velocity 357 Magnum; 9 mm): This armor protects against projectiles akin to 357 Magnum jacketed soft point, with nominal masses of 10.2 g and measured velocities of 425+ / −15 meters per second. Type II ballistic materials also protect against 9 mm full metal jacketed rounds with nominal masses of 8 g and measured velocities of 358+ / −12 meters per second.

[0086] Type III-A (44 Magnum, Submachine Gun 9 mm): This armor provides protection against most handgun threats, as well as projectiles having characteristics similar 44 Magnum, lead semi-wadcutter with gas checks, having nominal masses of 15.55 g and measured velocities of 426+ / −15 meters per second. Type III-A ballistic material also protects against 9 mm submachine gun rounds. These bullets are 9 mm full metal jacketed with nominal masses of 8 g and measured velocities of 426+ / −15 meters per second.

[0087] Type III (High Powered Rifle): This armor protects against 7.62 mm (308 Winchester®) ammunition and most handgun threats.

[0088] Type IV (Armor-Piercing Rifle): This armor protects against 30 caliber armor piercing rounds with nominal masses of 10.8 g and measured velocities of 868+ / −15 meters per second.Composite Ballistic Panels for Building and Construction

[0089] Other threats recognized in the art include Improvised Explosive Devices (IEDs), which may generate shrapnel that may be only a few grains in weight and may have velocities up to 5000 ft / sec.

[0090] As indicated above, the ballistic sheet good may be used in permanent or temporary structures such as, for example, walls, doors, roofs, floors, barriers, and fences. One skilled in the art will appreciate that sheet goods may be cut down or secured to other building material to form a varied of structures. Accordingly, the ballistic sheet goods disclosed herein may replace drywall, oriented strand board, plywood, medium-density fiber board, or other sheet goods used in construction.

[0091] Every document cited herein is incorporated herein by reference in its entirety unless otherwise specified. The citation of any document is not to be construed as an admission that it is prior art with respect to any invention disclosed or claimed herein. To the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

[0092] It will be apparent that modifications and variations are possible without departing from the scope of the disclosure defined in the appended claims. More specifically, although some aspects of the present disclosure are identified herein as preferred or particularly advantageous, it is contemplated that the present disclosure is not necessarily limited to these aspects.

Claims

Composite Ballistic Panels for Building and Construction CLAIMS 1. A ballistic sheet good comprising: a core comprising two or more fiber reinforced thermoplastic plies; wherein the two or more fiber reinforced thermoplastic plies comprise continuous glass fibers embedded in a thermoplastic matrix material; and the two or more fiber reinforced thermoplastic plies are adhered together via the thermoplastic matrix material; and wherein the ballistic sheet good has a length of at least 30 cm, a width of at least 30 cm, and a height of equal to or greater than 2.5 mm.

2. The ballistic sheet good of claim 1, wherein the thermoplastic plies comprise continuous E-glass fibers.

3. The ballistic sheet good of any of the previous claims, wherein the board comprises 2 to 100 thermoplastic plies.

4. The ballistic sheet good of any of the previous claims, wherein the thermoplastic matrix comprises a semi-crystalline polymer.

5. The ballistic sheet good of any of the previous claims, wherein the thermoplastic matrix comprises an amorphous polymer.

6. The ballistic sheet good of any of the previous claims, wherein the thermoplastic matrix comprises a polyolefin polymer.

7. The ballistic sheet good of any of the previous claims, wherein the core comprises 10% to 90% by weight of the thermoplastic matrix material out of the total weight of the core.Composite Ballistic Panels for Building and Construction 8. The ballistic sheet good of any of the previous claims, wherein the core comprises 10% to 90% by weight of the continuous glass fibers out of the total weight of the core.

9. The ballistic sheet good of any of the previous claims, wherein the core includes a first face and an opposing second face, and wherein the ballistic sheet good further includes a facer adhere to the first face, second face or both the first and second face of the core.

10. The ballistic sheet good of any of the previous claims, wherein the facer is a fiber reinforced composite facer.

11. The ballistic sheet good of any of the previous claims, wherein the facer is a fiber reinforced composite facer comprising two or more fiber reinforced thermoset plies comprise continuous glass fibers embedded in a thermoplastic matrix material.

12. The ballistic sheet good of any previous claims, wherein the facer is a ceramic strike face.

13. The ballistic sheet good of any previous claims, wherein the facer is paper, foil, a glass reinforced facer, coated glass facer, cellulosic fiber board, glass mat, oriented strand board, or plywood.

14. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good does not include a ceramic strike face.

15. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good consists of composite materials.

16. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good consists essentially of the core and optionally the facer.Composite Ballistic Panels for Building and Construction 17. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good consists of the core and optionally the facer.

18. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 1.

19. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 2.

20. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 3.

21. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 4.

22. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 5.

23. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 6.

24. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 7.

25. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 8.

26. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 9.

27. The ballistic sheet good of any of the previous claims, wherein the ballistic sheet good meets or exceeds UL 752 level 10.Composite Ballistic Panels for Building and Construction 28. A building structure comprising the ballistic sheet good of any of the previous claims.

29. The building structure of claim 15, the ballistic sheet good is attached to a second building material by an adhesive or a mechanical fastener.

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