Basalt particle-containing compositions and articles for protective coatings and ballistic shield mats/tiles/protective building components

Abstract

It has been found that basalt particles, when combined with a resin binder and a reinforcing material, such as fiberglass, provide unexpected strength, fire-resistance, radiation impermeability, and projectile shielding for ballistic armor/shields, fire-resistant building panels, construction blocks and protective coatings on substrates. The armor panels can be worn, as in a bullet-proof vest, or can be used as a shield to protect a vehicle, aircraft or other structures as projectile penetration-resistant and fire and radiation resistant materials.

1 . (canceled) 
   
   
       2 . The method of  claim 25 , wherein the basalt particles are contained in the ballistic shielding article in an amount of about 20% to about 70% by weight. 
   
   
       3 . The method of  claim 2 , wherein the basalt particles are contained in the ballistic shielding article in an amount of about 30% to about 60% by weight. 
   
   
       4 . The method of  claim 3 , wherein the basalt particles are contained in the ballistic shielding article in an amount of about 40% to about 50% by weight. 
   
   
       5 . The method of  claim 25 , wherein the adhesive resin binder is contained in the ballistic shielding article in an amount of about 10% to about 40% by weight. 
   
   
       6 . The method of  claim 5 , wherein the adhesive resin binder is contained in the ballistic shielding article in an amount of about 20% to about 30% by weight. 
   
   
       7 . The method of  claim 25 , wherein the ballistic shielding article further includes reinforcing fibers in a form selected from the group consisting of chopped, strand, woven fabric, non-woven fabric, unidirectional fabric, twill woven fabric, a plurality of layers of unidirectional fabrics successively placed at 9% angles to each other, and combinations thereof. 
   
   
       8 . The method of  claim 25 , wherein the ballistic shielding article further includes reinforcing fibers in an amount of about 5% to about 40% by weight. 
   
   
       9 . The method of  claim 8 , wherein the reinforcing fibers are contained in the ballistic shielding article in an amount of about 10% to about 30% by weight. 
   
   
       10 . The method of  claim 8 , wherein the reinforcing fibers are selected from the group consisting of glass, basalt, aramid, carbon, boron, basa, boron carbide, and combinations thereof. 
   
   
       11 . The method of  claim 25 , manufactured in the form of a planar panel. 
   
   
       12 . The method of  claim 25 , manufactured in the form of a curved panel. 
   
   
       13 . The method of  claim 25 , manufactured in the form of a form of a 4-sided, 5-sided, or 6-sided rectangular or square construction block. 
   
   
       14 . The method of  claim 13 , wherein each block includes an interlocking structure, formed unitary with the block during manufacture, capable of interlocking with a plurality of adjacent blocks. 
   
   
       15 . The method of  claim 13 , wherein the plurality of adjacent blocks are manufactured to have an identical size and shape. 
   
   
       16 . The method of  claim 25  further including an outer layer of a film or fabric laminated thereto. 
   
   
       17 . (canceled) 
   
   
       18 . (canceled) 
   
   
       19 . The method of  25 , wherein at least 40% of the particles, by number, are smaller than 0.037 mm., and at least 10% of the particles, by number, have a particle size between 0.025 mm. and 0.037 mm. 
   
   
       20 . The method of  claim 19 , wherein at least 20% of the particles, by number, have a particle size between 0.025 mm. and 0.037 mm. 
   
   
       21 .- 24 . (canceled) 
   
   
       25 . A method of protecting a person or structure from damage by a projectile or explosive shock comprising disposing a ballistic shielding article between the person or structure and the projectile or explosion, said ballistic shielding article comprising about 10% to about 80% by weight basalt powder, wherein 100% of the particles have a particle size smaller than 0.044 mm, and about 5 to about 50% by weight of an adhesive resin binder. 
   
   
       26 .- 93 . (canceled) 
   
   
       94 . An article of manufacture comprising about 10% to about 80% by weight basalt powder particles, wherein 100% of the particles have a particle size smaller than 0.044 mm., about 2% to about 50% by weight reinforcing fibers, and about 5% to about 50% by weight of an adhesive resin binder. 
   
   
       95 . (canceled) 
   
   
       96 . The article of  claim 94 , wherein at least 20% of the particles, by number, have a particle size between 0.037 mm. and 0.044 mm., and wherein at least 20% of the particles, by number, have a particle size between 0.025 mm. and 0.037 mm.