Abstract:
Provided is an anti-ballistic protective assembly including a plurality of layers of anti-ballistic material including at least two types of anti-ballistic materials, and an enclosure which is at least partially injection molded over the plurality of layers of anti-ballistic material and retains the plurality of layers of anti-ballistic material in a mutually compressed operative orientation.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to anti-ballistic protection generally and more particularly to anti-ballistic protective assemblies and methods of manufacture thereof. 
       BACKGROUND OF THE INVENTION 
       [0002]    The following patent publications are believed to represent the current state of the art: 
         [0003]    U.S. Pat. Nos. 5,970,843; 6,537,654; 6,709,736 and 7,598,185; and 
         [0004]    US Published Patent Application Nos: 2007/0089597; 2007/0105706 and 2008/0095958. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention seeks to provide improved anti-ballistic protective assemblies and methods of manufacture thereof. 
         [0006]    There is thus provided in accordance with a preferred embodiment of the present invention an anti-ballistic protective assembly including a plurality of layers of anti-ballistic material including at least two types of anti-ballistic materials, and an enclosure which is at least partially injection molded over the plurality of layers of anti-ballistic material and retains the plurality of layers of anti-ballistic material in a mutually compressed operative orientation. 
         [0007]    In accordance with a preferred embodiment of the present invention, the enclosure includes a first enclosure element and a second enclosure element integrally molded with the first enclosure element. Preferably, the first enclosure element is formed with a curved back portion. Preferably, the first enclosure element is formed with a raised peripheral edge. Additionally, the plurality of layers of anti-ballistic material is positioned within the first enclosure element. 
         [0008]    Preferably, the plurality of layers of anti-ballistic material includes layers of unidirectional polyethylene. Preferably, the plurality of layers of anti-ballistic material includes at least one ceramic plate. Preferably, at least one side of the at least one ceramic plate is coated with a layer of Kevlar®. Additionally or alternatively, at least one side of the at least one ceramic plate is coated with a layer of fiberglass. 
         [0009]    Additionally or alternatively, the plurality of layers of anti-ballistic material includes at least one steel plate. Preferably, at least one side of the at least one steel plate is coated with a layer of Kevlar®. Additionally or alternatively, at least one side of the at least one steel plate is coated with a layer of fiberglass. 
         [0010]    Preferably, the assembly also includes a protective vest, wherein the enclosure is inserted into a pocket of the protective vest. Additionally or alternatively, the enclosure is mounted in close proximity to an exterior of a motor vehicle. Additionally or alternatively, the enclosure is mounted in close proximity to an exterior of a stationary structure. 
         [0011]    There is also provided in accordance with another preferred embodiment of the present invention an anti-ballistic protective assembly including a plurality of layers of anti-ballistic material including at least two types of anti-ballistic materials, and an enclosure which is at least partially vacuum formed over the plurality of layers of anti-ballistic material and retains the plurality of layers of anti-ballistic material in a mutually compressed operative orientation. 
         [0012]    In accordance with a preferred embodiment of the present invention, the enclosure includes a first enclosure element and a second enclosure element which is heat welded to the first enclosure element. Preferably, the first enclosure element is formed with a curved back portion. Preferably, the first enclosure element is formed with a raised peripheral edge. Additionally, the plurality of layers of anti-ballistic material is positioned within the first enclosure element. 
         [0013]    Preferably, the plurality of layers of anti-ballistic material includes layers of unidirectional polyethylene. Preferably, the plurality of layers of anti-ballistic material includes at least one ceramic plate. Preferably, at least one side of the at least one ceramic plate is coated with a layer of Kevlar®. Additionally or alternatively, at least one side of the at least one ceramic plate is coated with a layer of fiberglass. 
         [0014]    Additionally or alternatively, the plurality of layers of anti-ballistic material includes at least one steel plate. Preferably, at least one side of the at least one steel plate is coated with a layer of Kevlar®. Additionally or alternatively, at least one side of the at least one steel plate is coated with a layer of fiberglass. 
         [0015]    Preferably, the assembly also includes a protective vest, wherein the enclosure is inserted into a pocket of the protective vest. Additionally or alternatively, the enclosure is mounted in close proximity to an exterior of a motor vehicle. Additionally or alternatively, the enclosure is mounted in close proximity to an exterior of a stationary structure. 
         [0016]    There is further provided in accordance with yet another preferred embodiment of the present invention a method of manufacturing an anti-ballistic protective assembly including providing a first enclosure element, positioning various layers of anti-ballistic protective materials in association with the first enclosure element into a cavity of a injection molding machine, and operating the injection molding machine to injection mold a second enclosure element integrally with first enclosure element and to compress the various layers of anti-ballistic protective material and to define an enclosure therefor, which retains the various layers of protective material in a compressed state in very tight mutual engagement. 
         [0017]    In accordance with a preferred embodiment of the present invention, the method also includes preheating the first enclosure element prior to the positioning various layers of anti-ballistic protective materials in association therewith. Preferably, the method also includes mutually compressing the various layers of anti-ballistic protective materials prior to the positioning various layers of anti-ballistic protective materials in association with the first enclosure element. 
         [0018]    Preferably, the first enclosure element includes a curved back portion. Preferably, the first enclosure element is formed with a raised peripheral edge. 
         [0019]    Preferably, the various layers of anti-ballistic material include layers of unidirectional polyethylene. Preferably, the various layers of anti-ballistic material include at least one ceramic plate. Preferably, at least one side of the at least one ceramic plate is coated with a layer of Kevlar®. Additionally or alternatively, at least one side of the at least one ceramic plate is coated with a layer of fiberglass. 
         [0020]    Additionally or alternatively, the various layers of anti-ballistic material includes at least one steel plate. Preferably, at least one side of the at least one steel plate is coated with a layer of Kevlar®. Additionally or alternatively, at least one side of the at least one steel plate is coated with a layer of fiberglass. 
         [0021]    Preferably, the assembly also includes a protective vest, wherein the enclosure is inserted into a pocket of the protective vest. Additionally or alternatively, the enclosure is mounted in close proximity to an exterior of a motor vehicle. Additionally or alternatively, the enclosure is mounted in close proximity to an exterior of a stationary structure. 
         [0022]    There is yet further provided in accordance with still another preferred embodiment of the present invention a method of manufacturing an anti-ballistic protective assembly including providing a first enclosure element, positioning various layers of anti-ballistic protective materials in association with the first enclosure element into a cavity of a vacuum forming molding machine, positioning a layer of vacuum formable material over the various layers of anti-ballistic protective materials in association with the first enclosure element in the cavity of a vacuum forming molding machine, and operating the vacuum forming molding machine to vacuum form a second enclosure element integrally with first enclosure element and to compress the various layers of anti-ballistic protective material and to define an enclosure therefor, which retains the various layers of protective material in a compressed state in very tight mutual engagement. 
         [0023]    In accordance with a preferred embodiment of the present invention, the method also includes preheating the first enclosure element prior to the positioning various layers of anti-ballistic protective materials in association therewith. Preferably, the method also includes mutually compressing the various layers of anti-ballistic protective materials prior to the positioning various layers of anti-ballistic protective materials in association with the first enclosure element into a cavity of a vacuum forming molding machine. 
         [0024]    Preferably, the first enclosure element includes a curved back portion. Preferably, the first enclosure element is formed with a raised peripheral edge. 
         [0025]    Preferably, the various layers of anti-ballistic material include layers of unidirectional polyethylene. Preferably, the various layers of anti-ballistic material include at least one ceramic plate. Preferably, at least one side of the at least one ceramic plate is coated with a layer of Kevlar®. Additionally or alternatively, at least one side of the at least one ceramic plate is coated with a layer of fiberglass. 
         [0026]    Additionally or alternatively, the various layers of anti-ballistic material include at least one steel plate. Preferably, at least one side of the at least one steel plate is coated with a layer of Kevlar®. Additionally or alternatively, at least one side of the at least one steel plate is coated with a layer of fiberglass. 
         [0027]    Preferably, the assembly also includes a protective vest, wherein the enclosure is inserted into a pocket of the protective vest. Additionally or alternatively, the enclosure is mounted in close proximity to an exterior of a motor vehicle. Additionally or alternatively, the enclosure is mounted in close proximity to an exterior of a stationary structure. 
         [0028]    Additionally, operating the vacuum forming molding machine includes tightly engaging the layer of vacuum formable material with a sealing ring formed on the periphery of the cavity. Additionally, tightly engaging the layer of vacuum formable material is achieved by lowering a peripheral cover element onto the layer of vacuum formable material over the sealing ring. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0029]    The present invention will be understood and appreciated more fully from the following detailed description, taken in conjunction with the drawings in which: 
           [0030]      FIGS. 1A-1C  are together a simplified illustration of a method of manufacturing an anti-ballistic protective assembly in accordance with a preferred embodiment of the present invention; and 
           [0031]      FIGS. 2A-2F  are together a simplified illustration of a method of manufacturing an anti-ballistic protective assembly in accordance with another preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0032]    Reference is now made to  FIGS. 1A-1C , which are together a simplified illustration of a method of manufacturing an anti-ballistic protective assembly in accordance with a preferred embodiment of the present invention, employing a conventional injection molding machine. 
         [0033]    As seen in  FIG. 1A , a pre-manufactured first enclosure element  100 , having a preferably somewhat curved back portion  102  and a preferably raised peripheral edge  104  is provided, and various layers of anti-ballistic protective materials are positioned therein generally as shown. Back portion  102  is preferably formed with polypropylene, ABS or other thermoplastic material, and is preferably comolded with Kevlar® aramid fiber, commercially available from DuPont, of Wilmington, Del. 
         [0034]    Alternatively, back portion  102  may be flat. 
         [0035]    The layers of anti-ballistic protective materials preferably include multiple layers  106  of anti-ballistic fabrics, preferably layers of unidirectional polyethylene such as Dyneema® HB50 or Dyneema® HB80, commercially available from DSM of Urmond, Holland. Preferably 40-50 layers  106  are provided. A flat or shaped plate  108  preferably formed of ceramic material such as Alumina FG-98, SC-DS direct-sintered silicon carbide or Boron carbide reaction-bonded boron carbide, each of which is commercially available from Coorstek Inc. of Golden, Colo., is preferably also provided as shown. Alternatively, plate  108  may be formed of annealed steel such as annealed carbon steel strips of 1070 or 1075 SAE/ASI commercially available from Inac s.p.a, of Valmadrera, Italy, which annealed steel is hardened to a hardness of HRC 58-60 by a process comprising quenching and tempering. Preferably, both sides of plate  108  are coated with a layer of Kevlar® or fiberglass  110 . 
         [0036]    The first enclosure element  100  and the above-described layers of protective materials, positioned therein are placed, as shown in enlargement A of  FIG. 1B , in a cavity  120  formed in a bottom portion  122  of a mold, which is installed in a conventional vertical injection molding machine  124 , such as an ALLROUNDER 420 S vertical injection molding machine, commercially available from ARBURG GmbH of Lossburg, Germany. A top portion  126  of the mold, having an injection passageway  128  formed therein is also installed in the injection molding machine  124  and is arranged for operative engagement with bottom portion  122  during injection molding, shown in enlargement B of  FIG. 1B . 
         [0037]    Portions  122  and  126  of the mold are configured to injection mold a second enclosure element  130  integrally with first enclosure element  100 , thereby to compress the layers of anti-ballistic protective material described hereinabove and to define a complete or nearly complete enclosure  132  therefor, which retains the various layers of protective material in a compressed state in very tight mutual engagement. 
         [0038]    Alternatively, a horizontal injection molding machine may be employed to injection mold second enclosure element  130  integrally with first enclosure element  100 , thereby to compress the layers of anti-ballistic protective material described hereinabove and to define a complete or nearly complete enclosure  132  therefor, which retains the various layers of protective material in a compressed state in very tight mutual engagement. 
         [0039]    As seen in  FIG. 1C , separation of portions  122  and  126  of the mold releases an antiballistic protective assembly  140  comprising enclosure  132  which tightly encloses the mutually compressed various layers of protective material in very tight mutual engagement. The edges of the antiballistic protective assembly  140  are preferably trimmed as needed by any suitable technique and the assembly may be inserted into a pocket  142  of a protective vest  144  as shown. Alternatively, antiballistic protective assembly  140  may be of various sizes and may be utilized, for example, for antiballistic protection of motor vehicles and stationary structures. 
         [0040]    Reference is now made to  FIGS. 2A-2F , which are together a simplified illustration of a method of manufacturing an anti-ballistic protective assembly in accordance with another preferred embodiment of the present invention, employing a conventional vacuum forming molding machine. 
         [0041]    As seen in  FIG. 2A , a plurality of pre-manufactured first enclosure elements  200 , each having a preferably somewhat curved back portion  202  and a preferably raised peripheral edge  204  are provided, and various layers of anti-ballistic protective materials are positioned in each of the first enclosure elements  200  generally as shown. Back portion  202  is preferably formed with polypropylene, ABS or other thermoplastic material, and is preferably comolded with Kevlar® aramid fiber, commercially available from DuPont, of Wilmington, Del. 
         [0042]    Alternatively, back portion  202  may be flat. 
         [0043]    The layers of anti-ballistic protective materials preferably include multiple layers  206  of anti-ballistic fabrics, preferably layers of unidirectional polyethylene such as Dyneema® HB50 or Dyneema® HB80, commercially available from DSM of Urmond, Holland. Preferably 40-50 layers  206  are provided. A flat or shaped plate  208  preferably formed of ceramic material such as Alumina FG-98, SC-DS direct-sintered silicon carbide or Boron carbide reaction-bonded boron carbide, each of which is commercially available from Coorstek Inc. of Golden, Colo. is preferably also provided as shown. Alternatively, plate  208  may be formed of annealed steel such as annealed carbon steel strips of 1070 or 1075 SAE/ASI, commercially available from Inac s.p.a, of Valmadrera, Italy, which annealed steel is hardened to a hardness of HRC 58-60 by a process comprising quenching and tempering. Preferably, both sides of plate  208  are coated with a layer of Kevlar or fiberglass  210 . Preferably, layers  206  and plate  208  are mutually compressed. 
         [0044]    The plurality of first enclosure elements  200  each containing the above-described layers of protective materials, positioned therein, are placed, as shown  FIG. 2A , in a plurality of vacuum forming cavities  220  formed in a conventional vacuum forming molding machine  224 , which are surrounded by a vacuum sealing ring  226 . The vacuum forming molding machine  224  may be, for example, a Model BV-E-Class Manual Sheet Fed Vacuum Former, commercially available from Bel-O-Vac of Banning, Calif. 
         [0045]    Preferably, an adhesive epoxy is applied to edge  204  of each of enclosure elements  200 . As seen in  FIG. 2B , sheet  228  of vacuum formable material, such as an ABS sheet, is placed over cavities  220 , containing the first enclosure elements  200  and the above-described layers of protective materials and sealing ring  226  and a peripheral cover element  229  is lowered onto sheet  228  over sealing ring  226 , bringing the sheet  228  into vacuum sealing engagement with sealing ring  226 , as seen in  FIG. 2C . 
         [0046]    As seen in  FIG. 2D , vacuum is then applied to the cavities  220 , containing the first enclosure elements  200  and the above-described layers of protective materials, drawing sheet  228  into tight vacuum engagement therewith, compressing the layers of protective materials against the respective first enclosure elements  200 . Suitable heating of sheet  228  and of the first enclosure elements  200  welds the sheet  228  to the peripheries of the first enclosure elements  200  in cavities  220  by adhesively engaging with edges  204  of each of enclosure elements  200 , thereby defining second enclosure elements  230  integrally formed with first enclosure elements  200  and defining complete or nearly complete enclosures  232  for the layers of anti-ballistic protective material described hereinabove, which retains the various layers of protective material in a compressed state in very tight mutual engagement. 
         [0047]    As seen in  FIG. 2E , raising of the peripheral cover element  229  enables removal of a plurality of joined together antiballistic protective assemblies  240 , shown in  FIG. 2F , each comprising an enclosure  232  which tightly encloses the various layers of protective material in a compressed state in very tight mutual engagement. Separation and trimming of the protective assemblies  240  may be carried out by any suitable technique and the assembly may be inserted into a pocket  242  of a protective vest  244  as shown in  FIG. 2F . Alternatively, antiballistic protective assembly  140  may be of various sizes and may be utilized, for example, for antiballistic protection of motor vehicles and stationary structures. 
         [0048]    It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described hereinabove. Rather the scope of the present invention includes both combinations and subcombinations of various features described hereinabove as well as modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not in the prior art.