Ballistic Panels and Method of Making the Same

Abstract

A ballistic panel is described that comprises a ballistic-resistant component and a cover that comprises a laminate comprising (i) a substrate layer and (ii) an inner bonding layer. The cover is bonded to at least one surface of the ballistic-resistant component by the inner bonding layer of the laminate, and is bonded around the perimeter of the ballistic resistant component to form a perimeter seal. A method for making the ballistic panel is also described.

1 - 20 . (canceled) 
     
     
         21 . A method of making a ballistic panel comprising:
 a. providing a ballistic-resistant component having a perimeter, first and second surfaces, and an edge that extends between the first and second surfaces for the perimeter of the ballistic-resistant component,   b. providing first and second portions of a waterproof laminate having a surface area greater than the 1 st  and 2 nd  surfaces of the ballistic-resistant component, the waterproof laminate comprising
 (i) a woven fabric layer, 
 (ii) an inner bonding layer comprising a layer of thermoplastic polyurethane having a thickness greater than or equal to 25 μm, and 
 (iii) a thermally stable polymer layer comprising porous polytetrafluoroethylene (PTFE) laminated between the woven fabric layer and the inner bonding layer; 
   c. forming a stack comprising the 1 st  and 2 nd  waterproof laminate portions and the ballistic-resistant component by placing the ballistic-resistant component there between;   d. orienting the stack so that the layer of thermoplastic polyurethane of the 1 st  laminate portion is adjacent the 1 st  surface of the ballistic-resistant component, the layer of thermoplastic polyurethane of the 2 nd  laminate portion is adjacent the 2 nd  surface of the ballistic-resistant component, and the 1 st  and 2 nd  laminate portions extend beyond the edge of the ballistic-resistant component for the entire perimeter;   e. applying heat and pressure to the stack;   f. melting and adhering the melted thermoplastic polyurethane of the 1 st  and 2 nd  laminate portions to the 1 st  and 2 nd  surfaces of the ballistic resistant component to form a thermal bond between the laminate and the ballistic-resistant component; and   g. melting and adhering together the thermoplastic polyurethane of the 1 st  and 2 nd  laminate portions that extend beyond the edge of the ballistic-resistant component around the entire perimeter of the ballistic-resistant component to form a seal.   
     
     
         22 . The method of  claim 21 , wherein at least 1 psi pressure is applied to the stack containing the laminate portions and ballistic-resistant component. 
     
     
         23 . The method of  claim 21 , wherein the heat applied to the laminate and ballistic-resistant component is greater than about 150° C. 
     
     
         24 . The method of  claim 21 , wherein the step of applying heat and pressure is applied with a heat press. 
     
     
         25 . The method of  claim 21 , wherein step of applying heat and pressure is applied with a soldering iron. 
     
     
         26 . The method of  claim 21 , wherein the ballistic-resistant component comprises multiple layers and further comprises a thermoplastic resin, and wherein the step of applying heat and pressure further comprises fusing at least a portion of the multiple layers of the ballistic-resistant component together. 
     
     
         27 . The method of  claim 21 , wherein the polyurethane of the 1 st  and 2 nd  laminate portions is adhered to at least 15% of the surface area of the 1 st  and 2 nd  surfaces of the ballistic resistant component. 
     
     
         28 . The method of  claim 21 , wherein the polyurethane of the 1 st  and 2 nd  laminate portions is adhered to at least 50% of the surface area of the 1 st  and 2 nd  surfaces of the ballistic resistant component 
     
     
         29 - 47 . (canceled) 
     
     
         48 . A method for making a ballistic panel comprising:
 providing a ballistic-resistant component having a perimeter, and 1 st  and 2 nd  surfaces;   providing a waterproof laminate;   bonding the waterproof laminate to one of the 1 st  and 2 nd  surfaces of the ballistic-resistant component, the waterproof laminate comprising   (i) a substrate layer, and   (ii) an inner bonding layer laminated to the substrate layer, and bonded to one of the 1 st  and 2 nd  surfaces of the ballistic-resistant component;   providing a second waterproof material layer and positioning the second waterproof material layer adjacent a surface of the ballistic-resistant component opposite the surface to which the waterproof laminate is bonded; and   bonding the waterproof laminate to the second waterproof material beyond the edge and around the perimeter of the ballistic-resistant component to form a perimeter seal.