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.   
     
     
         49 . (canceled) 
     
     
         50 . A method of improving ballistic performance of a ballistic panel comprising:
 forming a ballistic panel by providing a ballistic-resistant component comprising ballistic material, the ballistic-resistant component having a perimeter, and first and second surfaces;   providing first and second waterproof laminate portions comprising, wherein the laminate portions comprise   (i) an outer fabric layer,
 (ii) an inner bonding layer, and 
 (iii) a thermally stable polymer layer between the outer fabric layer and the inner bonding layer that has a melt temperature above the melt temperature of the inner bonding layer; 
   surrounding the ballistic-resistant component with the first and second laminate portions by orienting the inner bonding layer to be positioned adjacent the first and second surfaces of the ballistic-resistant component;   forming a thermal bond comprising the inner bonding layer of first and second waterproof laminate portions and the ballistic-resistant component by bonding the laminate portions directly to the upper and lower surfaces of the ballistic-resistant component; and,   forming a perimeter seal by fusing the inner bonding layer of the first laminate portion and the inner bonding layer of the second laminate portion to form a continuous bond around the perimeter of the ballistic-resistant component,   wherein the ballistic panel has improved ballistic performance when tested after conditioning and submersion in water.   
     
     
         51 . A method of stabilizing a ballistic-resistant component by integrating the ballistic resistant component and a cover, comprising the steps of:
 providing a ballistic-resistant component comprising ballistic material, the ballistic-resistant component having a perimeter, and first and second surfaces;   forming a cover for the ballistic resistant component comprising the steps of a. providing first and second laminate portions, the laminate comprising
 (i) an outer fabric layer, and 
 (ii) an inner bonding layer, 
   b. surrounding the ballistic-resistant component with the first and second laminate portions by orienting the inner bonding layer to be adjacent the first and second surfaces of the ballistic-resistant component; and   c. forming a perimeter seal by bonding the inner bonding layer of the first laminate portion and the inner bonding layer of the second laminate portion together to form a continuous bond around the perimeter of the ballistic-resistant component, forming a cover; and   integrating the cover and the ballistic resistant component by bonding the inner bonding layer of the first and second laminate portions to the upper and lower surfaces of the ballistic-resistant component.   
     
     
         52 . The method of  claim 51 , wherein the inner bonding layer of the first and second laminate portions comprises a thermoplastic polymer and the step of bonding the inner bonding layer to the upper and lower surfaces of ballistic resistant component comprises thermal bonding. 
     
     
         53 . The method of  claim 52 , wherein the step of forming a perimeter seal comprises fusing the inner bonding layer of the 1 st  laminate portion to the inner bonding layer of the 2 nd  laminate portion around the perimeter of the ballistic-resistant component. 
     
     
         54 . The method of  claim 51 , wherein the 1 st  and 2 nd  laminate portions further comprises a thermally stable polymer layer between the outer fabric layer and the inner bonding layer and the thermally stable polymer layer has a melt temperature above the melt temperature of the inner bonding layer. 
     
     
         55 . The method of  claim 54 , wherein the method comprises the steps of applying heat and applying pressure to melt the inner bonding layer and to integrate the first and second laminate portions and the ballistic-resistant component. 
     
     
         56 . The method of  claim 51 , wherein the method improves the ballistic performance of the ballistic panel that is subjected to conditioning and water submersion.