HK1112036A - Shrapnel and projectile containment systems and methods for producing same - Google Patents

Description

Fragment and projectile receiving system and method for preparing same

Technical Field

The present invention relates generally to a system, and apparatus and methods for making such systems, which is mounted on or adjacent to a wall, floor or ceiling of a structure or on a side, bottom or top of a vehicle to receive debris from an explosion and/or a projectile emitted by a projectile launcher.

Brief Description of Drawings

The invention will be better understood from a reading of the following description taken in conjunction with the drawings in which like elements are given like reference numerals and in which:

fig. 1 schematically shows a plate preparation apparatus according to an embodiment of the present invention.

Fig. 2 is a principal schematic view of a debris receiving panel according to an embodiment of the present invention installed inside a structural wall of a building.

Fig. 3 shows a debris receiving plate according to an embodiment of the invention.

Figure 4 is a cross-sectional view of a panel having a channel member secured to its periphery according to one embodiment of the present invention.

Fig. 5 is a cross-sectional view of two abutting panels joined at their edges by panel fastening means according to one embodiment of the invention.

Fig. 6 is a substantially schematic top view of a test layout (test layout) conducted according to the study of the present invention.

FIG. 7 is a side perspective view of a panel having a flange that surrounds an edge of the panel and is substantially perpendicular to the panel, according to one embodiment of the invention.

FIG. 8 is a cross-sectional view of the plate of FIG. 7 taken along line 8-8 according to one embodiment of the present invention.

FIG. 9 is a partial top view of a continuous fastening strip having fasteners to secure a portion of a flange of a panel to a concrete surface according to one embodiment of the present invention.

FIG. 10 is a partial top view of a discontinuous fastening strip having fasteners to secure a portion of a flange of a panel to a concrete surface according to one embodiment of the invention.

FIG. 11 is a partial top view of several fastening systems securing a portion of a flange of a panel to a concrete surface according to one embodiment of the present invention.

Fig. 12 is a cross-sectional top view of a wall system made with a reinforcement panel fastened to an existing frame member by fasteners, according to one embodiment of the present invention.

Fig. 13 is a partial cross-sectional top view of another wall system made with a reinforcement plate secured to an existing frame member according to one embodiment of the present invention.

Fig. 14 is a partial cross-sectional top view of a grooved section of a frame in a wall system made with reinforcing sheets according to one embodiment of the present invention, which can be used to secure the sheets to existing frame elements.

FIG. 15 is a partial cross-sectional side view of a concrete floor fabricated with a reinforcing plate inside the concrete floor according to an embodiment of the present invention.

Fig. 16 is a partial cross-sectional top view of a concrete wall constructed with rebar and a reinforcing plate inside the concrete wall according to one embodiment of the invention.

Fig. 17 is a partial cross-sectional top view of a concrete wall constructed with rebar and a reinforcing plate on an exterior surface of the concrete wall according to one embodiment of the invention.

Fig. 18 is a cross-sectional top view of a one-piece (one-piece) plate system for protecting concrete columns according to one embodiment of the present invention.

Figure 19 is a cross-sectional top view of an L-shaped bracket for securing a one-piece or multi-piece panel system around a concrete column according to one embodiment of the present invention.

Figure 20 is a cross-sectional top view of an L-channel bracket for securing one or more panel systems around a concrete column according to one embodiment of the present invention.

Fig. 21 is a partial cross-sectional top view of the L-shaped bracket of fig. 18 securing a plate system for protecting a concrete column to a corner of the concrete column according to one embodiment of the present invention.

Figure 22 is a cross-sectional top view of a two-piece panel system for protecting concrete columns according to one embodiment of the present invention.

FIG. 23 is a partial cross-sectional side view of a panel system for protecting concrete columns showing a diamond-like arrangement of reinforcing layers according to one embodiment of the present invention.

FIG. 24 is a partial cross-sectional top view of a hollow core door having a debris and projectile resistant panel disposed within the door in accordance with an embodiment of the present invention.

Figure 25 is a partial cross-sectional front view of a dual tube tunnel system having debris and projectile resistant panels disposed on the exterior of the inner tube of the two tubes in accordance with one embodiment of the present invention.

FIG. 26 is a side view of a removable debris and projectile resistant door panel disposed on an interior surface of a door in accordance with an embodiment of the present invention.

Fig. 27 is a side view of a fragment and projectile resistant multi-layer panel according to one embodiment of the present invention.

Fig. 28 is a side view of a fragment and projectile resistant multi-layer panel according to another embodiment of the present invention.

FIG. 29 is a side view of a debris and projectile resistant panel applied directly to a release agent on a surface of a structure and secured to the surface of the structure with mechanical fasteners according to one embodiment of the invention.

FIG. 30 is a side view of a debris and projectile resistant panel applied directly to a release agent on a surface of a structure and secured to the surface of the structure with a mechanical fastener according to another embodiment of the invention.

FIG. 31 is a side view of a fragment and projectile resistant panel having a textile/fiber reinforcement layer between two layers of elastomer, the panel being applied directly to a release agent on the surface of a structure and secured to the surface of the structure with a mechanical fastener according to another embodiment of the invention.

FIG. 32 is a side view of a fragment and projectile resistant panel having a textile/fiber reinforcement layer between two layers of elastomer, the panel being applied directly to a release agent on a surface of a structure and secured to multiple surfaces of the structure with mechanical fasteners, according to another embodiment of the invention.

FIG. 33 is a side view of an automated system for producing debris and projectile resistant panels according to one embodiment of the present invention.

FIG. 34 is an automated system for producing a debris and projectile resistant panel according to another embodiment of the present invention.

FIG. 35 is a top view of the automated fragment and projectile resistant panel production system of FIG. 34 according to one embodiment of the present invention.

FIG. 36 is a cross-sectional view of the automated fragment and projectile resistant panel production system according to another embodiment of the present invention taken along line 36-36 of FIG. 35.

FIG. 37 is a top view of a cross-section of a vehicle having pre-positioned anchor posts for anchoring a fragment and projectile resistant panel to the vehicle, according to one embodiment of the present invention.

Fig. 38 is a side view in cross-section of the vehicle chassis, walls, doors and/or roof in fig. 37, according to an embodiment of the invention.

FIG. 39 is an open side view of a prefabricated wall system having debris and projectile resistant panels embedded therein according to one embodiment of the present invention.

Fig. 40 is a partial cross-sectional view of the prefabricated wall system of fig. 40 having debris and projectile resistant panels embedded therein, taken along line 40-40, according to one embodiment of the present invention.

Fig. 41 is a side view of the prefabricated wall system in fig. 40 with debris and projectile resistant panels embedded therein, according to another embodiment of the present invention.

Fig. 42 is a close-up side view of the top of the prefabricated wall system of fig. 41 with debris and projectile resistant panels embedded therein, according to one embodiment of the present invention.

Detailed description of the preferred embodiments

The present invention relates to the preparation of pre-formed panels that can be formed in various shapes, cut to the appropriate size as needed, and installed on or adjacent to the surface of a wall and/or door of a building. Generally, to increase the effectiveness of the protection provided by the present invention, the wall may be a structural wall. In preparing materials with improved elongation and tensile strength properties, the panels may be prepared by spraying polyurea or other elastomeric material specifically selected to facilitate the production process and the performance of the finished panel. The method of making the panel may also include forming a finished panel by brushing, rolling, and/or troweling the polyurea material or other elastomeric material to a desired thickness. Alternatively, the polyurea material or other elastomeric material may be coated (i.e., sprayed, brushed, rolled and/or troweled) and bonded directly to the interior surface of the structural wall or building. In another alternative, the polyurea material or other elastomeric material may be applied (i.e., sprayed, brushed, rolled, and/or troweled) onto a release agent (e.g., polytetrafluoroethylene, silicon, wax, and/or any other release agent) that has been previously applied to the interior surface of the structural wall or building, and then a mechanical fastener may be inserted through the elastomeric material and release agent, into and anchored to the interior surface. The interior surfaces to which the elastomeric material may be applied and secured may include walls, ceilings, floors, pillars, doors, windows, and the like.

Elastomers such as silicones, polyurethanes and polyurea/polyurethane blends can be used as a replacement for polyurea in the construction of panels or in the direct bonding of one or more layers of material to a wall.

The invention may also be directed to a method of making blast-, shock-and projectile-resistant panels comprising applying two or more layers of a two-part high solids polyurea elastomer material to a releasable substrate to a desired thickness. The two or more layers of elastomeric material may be applied with or without one or more fiber or fabric reinforcement layers disposed between the two or more layers of elastomeric material, the material cured, and the cured plate removed from the releasable substrate. The panels may be prepared at a location remote from the building site and transported to the building site, or prepared at the building site. Panels may be mounted on structural walls, doors and other portions of buildings, structures or vehicles to provide protection from debris and projectiles. In addition, panels may be installed inside the elevator shaft and/or stair towers to provide additional structural integrity in the event of seismic activity, as well as inside the residential walls to increase strength and wind resistance. Likewise, panels may be used to cover windows and doors and secured in place to protect them from high winds and inclement weather such as tornadoes and hurricanes.

According to another embodiment of the invention, the elastomeric material may be injection molded to form a sealed tube that may be used on the exterior of the hull of a ship to protect the hull from damage from other ships, docks, and the like.

In fig. 1, the plate substrate 10 may serve as a mold surface onto which a polyurea elastomeric material may be applied, e.g., sprayed, brushed, rolled and/or troweled, to produce an explosion and/or projectile resistant or debris arresting plate 100 according to a preferred embodiment of the present invention. Although the board substrate 10 is shown as a flat two-dimensional surface, it is contemplated that in other embodiments, the board substrate 10 may have concave and/or convex contours and/or sides that may conform to the configuration of the particular wall, door, etc. to which the board 100 is applied. If desired, the substrate 10 may be treated with a release agent/compound to facilitate removal of the cured plate from the substrate.

The two-part high solids elastomer composition is sprayed as a liquid (uncured) onto the substrate 10 using known standard spray coating equipment. The spray coating device for illustrative purposes may include a nozzle 20 connected to a coating pump 24 via a flexible tube 22. The container or reservoir 26 may be used to supply the components that make up the elastomeric composition through supply lines 28, 30, where the components are mixed at a valve 32 at the supply lines 28, 30. The nozzle 20 may be manually manipulated to apply the polyurea material to the entire substrate in the production panel. Alternatively, the nozzle (more than one nozzle may be used) may be mounted on a support (not shown) of known construction having drive means for moving the nozzle 20 laterally or horizontally and vertically to ensure that the composition is applied in a uniform thickness across the substrate. Other spray coating arrangements are possible, and the one shown in FIG. 1 is just one example.

It is envisaged that for mass production, using computer controlled and robotic elements to control the spray equipment, the spray process may be substantially fully automated, including movement of the spray and transport of the material to be sprayed, and handling of the panels. However, the same basic process is almost identical, and figures 33-36 provide diagrams of two embodiments of possible automated systems for mass production of finished boards. For example, the automated system may produce at least one finished board at least every 5 minutes.

In a particularly preferred embodiment, the panel is further reinforced by including a reinforcing layer 102, which reinforcing layer 102 may be disposed at the outer or inner surface of the panel 100, or may be disposed internally within the panel. The method of producing such panels (with the reinforcing layer located inside the panel) may preferably include placing a reinforcing fabric material against the substrate 10 and spraying polyurea or other sprayable elastomer onto the fabric to a thickness of about half the thickness of the finished panel. The fabric 102 with the sprayed-on polyurea is then rotated or flipped over so that the polyurea faces the substrate and the fabric 102 faces the spraying device. The polyurea is then coated or sprayed a second time onto the opposite side of the fabric 102 to produce a panel having the desired final or finished thickness.

This preferred process sequence can be modified. Where it is desired to have a reinforcing layer on the outer surface of the panel 100, the reinforcing layer may be placed in intimate contact with the substrate 10 and the elastomer may be sprayed onto the layer until the desired panel thickness is achieved. Where the layer 102 is to be disposed within the board 100, the layer may be spaced from the substrate 10 by polyurea that is sprayed through the layer to seal the layer 102. Alternatively, a portion of the plate may be sprayed onto the substrate, followed by introduction of the layer 102, and then spraying the remaining thickness of the plate to complete the plate.

Once the spray coating process is complete and the polyurea material is partially or fully cured, the layers can be separated from the substrate 10, forming the panel 100.

Thus, the panel 100 can be manufactured in an economical manner, substantially on a large scale. If for some reason it is found to be more economical or desirable, this can be done in a real factory environment, or in a portable or temporary production facility built at the construction site. The panel 100 is then transported to the building where the panels are to be assembled.

The interior structural wall 104 of the building to which the panels are to be secured is either left exposed during initial construction or, in the renovation of the building, the decorative interior wall surfaces are removed to expose the interior surfaces of the structural wall. The panel 100 is cut to size as needed and is preferably secured to the inner surface of the wall 104 using any suitable adhesive or by mechanical attachment. Since structural wall 104 is typically made of block or poured concrete, suitable forms of mechanical attachment may include threaded concrete wall anchors, or screws and anchors, or nailing with appropriate cement.

Fig. 2 is a principal schematic illustration of the installation of a debris receiving panel according to an embodiment of the invention inside a structural wall of a building.

Fig. 3 shows a preferred embodiment of the panel 100 ready for installation. In this embodiment, the periphery of the panel 100 is bounded by a channel member 120, which channel member 120 holds the edges of the panel 100 between two cross bars 122, 124 located on opposite sides (e.g., front and back) of the panel (see fig. 4). The channel member, preferably made of stainless steel, helps to structurally strengthen the edges of the panel, increasing its stiffness. Additionally, the use of slots at the panel edges during the process of securing the panels to the building wall improves the reliability of mechanical fasteners 121, such as, but not limited to, concrete wall anchors, screws, nails, and the like.

Fig. 5 shows another panel securing member 126 adapted for use when two panels are joined to span a distance wider than the width of a single panel. The adjacent edges of the two panels are secured to the two cross bars 128, 130 of this panel fastening means using suitable mechanical fasteners 131. The cross bars 128, 130 are offset by connecting plates (webs) 132 so that the fastening members hold the two plates in substantially edge abutting relationship. In addition to or in lieu of the channel member 120, a fastening member 126 may be used at the edges where bonding is to occur. The fastening member may also be secured to the building wall by a suitable mechanical fastener, such as, but not limited to, a concrete wall anchor or the like.

Blast shock waves or other types of impact forces outside of a building can cause structural walls to break and produce wall fragments of various sizes, also commonly referred to as fragments. A plate 100 with improved elongation and tensile strength characteristics will serve to effectively absorb a large portion of the kinetic energy imparted to the chips. This kinetic energy absorption will prevent debris from flying through the building interior. In the event that the blast shock wave also causes the panel 100 to break, the kinetic energy absorbed or dissipated by the panel will significantly reduce the amount and/or velocity of debris that may enter the interior of the building. Thus, people inside the building are better protected from injury due to an attack on the building.

In addition, it is believed that the panels contribute to the structural integrity of the wall itself, particularly when fastened to the wall by mechanical fasteners at the perimeter of the panels.

To effectively absorb or dissipate potentially high energy kinetic energy that may result from an explosion or other shock event, it is preferred that the sheet thickness be in the range of about 100 to about 250 mils. Even more preferably, the sheet thickness will be about 180 mils. However, thicker plates than 250 mils may also be used, and it is expected that the possible incremental increase in debris acceptance or burst force provided by thicker plates may outweigh the increase in cost (material cost) in a cost/benefit analysis.

The elastomeric material used in the chip receiving plate preferably has a particular combination of physical or other material properties in its cured state. Of particular importance are elongation at break and tensile strength. The elastomer will preferably have an elongation at break in the range of about 100-800%, more preferably at the higher end of this range, such as at 400-800%. The tensile strength of the elastomer is preferably a minimum of 2000 psi.

Furthermore, the adhesion of the elastomer is considered important whether the panel is constructed separately or formed in place on the wall of the building or other structure to be protected. Preferably, the elastomer exhibits a minimum (or at concrete failure) adhesion to concrete of 300psi and a minimum adhesion to steel of 1200 psi.

As previously mentioned, polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane blends can produce desirable physical and material properties. Currently, in one embodiment, the elastomer is a 100% solids spray-applied aromatic polyurea material available as a two-part (isocyanate-based quasi-polymer; amine mixture with pigments) sprayable material designed primarily as a flexible impact-resistant waterproof coating and lining system.

The liner system has been tested in the panels produced with the textile reinforcement. The fabric reinforcement layer provides a frame to which the uncured elastomer will adhere in forming the shape of the panel. The fabric reinforcement also preferably contributes to the structural integrity of the panel in resisting shock waves and in receiving debris, and in particular to limit the amount of elongation experienced by the elastomer in absorbing the energy of a shock wave or other impact.

Heretofore, fabrics that have been used in the production of test panels have been made from aramid or polyester yarns or fibers in which the size of the open grid (openings between warp and fill yarns) is about 0.25in, or 0.5in 0.25in, however, smaller or larger grid opening sizes have been considered suitable for use. The tensile strength of the fabric used in the current test panels is about 1200psi x 1200 psi. Fabrics made from aramid yarns under the brand name Technora & Twaron or Fibers produced by Teijin Fibers are particularly suitable for use in this application.

The debris receiving system and method of the present invention may also be in the form of a layer of elastomeric material that is coated and adhered directly to the wall or other structure to be reinforced. In this case, the walls are preferably cleaned of loose material and impurities, while the elastomer is applied by spraying in a manner similar to that in which the panels are sprayed onto the panel substrate. As noted above, the elastomer is preferably selected to have a minimum bond strength or adhesion to concrete of 300psi, and the concrete will typically have a sufficiently large number of small surface irregularities that the elastomer will find a mechanically attached area of enhanced adhesion.

When the system is to have fabric or fiber reinforcement elements, it is also preferred to partially coat the elastomer, then position the reinforcement elements, and then spray the remaining portion of the elastomer layer. Alternatively, the reinforcing element may be placed first against the wall, followed by applying the entire thickness of the elastomer layer thereto.

Tests have been conducted on an explosion proof/debris receiving panel according to the present invention. A physical test layout (not to scale) is shown in the schematic top view of fig. 6. In fig. 6, explosive charge 200 is centered on four (4) identically constructed concrete block masonry target walls 202 distributed on a circumference of 30' radius from the explosive. The masonry target wall 202 has two reinforcing legs 204 which together with the target wall form a square "U" shape so that the target wall 202 facing the explosive charge has some degree of structural reinforcement as it is typically in a building.

Panels A, B, and C (thicknesses not drawn to scale relative to wall thickness) are installed on the interior of three walls, while the fourth wall has no mounting plate or lining. The panel includes a stainless steel channel 120 around its perimeter and is secured to the interior of the wall 202 using concrete anchor fasteners.

All three of panels A, B, and C were prepared at a nominal thickness of 180 mils of polyurea material having a textile reinforcement layer disposed therein. Further structural details of the plate are as follows:

TABLE 1

Board	Elastic body	Fabric reinforcement
			A	AR425, 180 mil	Technora T200 fabric, 0.5X 0.25' grid openings
B	AR425, 180 mil	Technora T200 fabric, 0.5X 0.25' grid openings
			C	AR425, 180 mil	Twaron T1000 fabric, 0.25X 0.25 "grid openings

Explosive charge 200 includes 42 blocks (52.5 Ibs.) of C-4 explosive material configured to create a uniform explosive overpressure on the face of each target wall 202. The amount of this C-4 explosive was equal to 67.2 pounds of TNT. The charge was lifted four feet above the ground so that it was aligned with the center point of each wall (wall 202 was 8 feet high). The explosive charge was statically detonated, producing a peak instantaneous overpressure of 17.67psi and a reflected pressure of 51.22 psi.

Initial post-blast observations indicate that the unprotected wall (without the panels affixed to the interior) has suffered catastrophic structural damage, and that virtually none of the concrete of the target wall 202 or reinforcing legs 204 has left its place above the wall base. It was found that fragments or fragments of the wall due to the explosion reached 54 feet furthest behind the wall (i.e., into the interior of the wall).

In contrast, the three target walls with the panels installed at the inner surfaces are still upright, while the concrete blocks are damaged to varying degrees. These connection areas appear to experience the most damage due to the stresses induced by the explosion at the connection point of the target wall 202 and the reinforcement leg 204. The target wall itself contains varying degrees of cracking and fracture.

Inspection of the panels shows that small areas of the logo paint coating on the interior surface of the panel have chipped or knocked off, possibly due to concrete fragments striking the opposite side of the panel during the explosion. Little or no plastic deformation of the sheet was observed, and no chipping or perforation was observed. No concrete fragments were found behind the panel (to the inside).

After removal of the panels, fragments of the target wall were found behind each test panel. Tables 2-5 list the data found after the test to be associated with wall fragments (chips). It should be noted that for walls to which panels are fastened, no data relating to "distance from wall" is provided, as no debris passes through the panels.

Table 1: debris found behind baseline target wall

Fragment numbering	Quality (ounce)	Distance from wall (foot)
			i.1	b. 1.0	c. 49
i.2	ii. .4	d. 45.2
			i.3	ii. .3	e. 54
i.4	ii. .1	f. 41.5
			i.5	ii. .3	g. 41
i.6	h. 1.7	i.33
			i.7	13.0	j. 30
i.8	k. 1.5	1. 24.4
			i.9	m. 1.1	n. 19
i.10	o. 3.4	p. 19
			i.11	ii. .5	q. 18.5
i.12	r. 6.7	s. 19
			i.13	ii. .1	t. 19

Table 2: debris received by test plate T1402

Fragment numbering	Quality (ounce)
		u.1	v..9
w.2	1.1
		x.3	1.1
y.4	z..2
		aa.5	bb..1

Table 3: test plate T1403 of the debris received

Fragment numbering	Quality (ounce)
		cc.1	dd. .5
ee.2	ff. .2
		gg.3	1.2
hh.4	ii. .3
		jj.5	kk..1
11.6	mm..1
		nn.7	2.1
oo.8	pp..6

Table 4: debris received by the test plate T1404

Fragment numbering	Quality (ounce)
		qq.1	rr..8
ss.2	1.3
		tt.3	5.2

FIG. 7 is a side perspective view of a panel having a flange at the periphery of the panel and substantially perpendicular to the panel, according to one embodiment of the invention. In fig. 7, panel 700 may be made to any desired size and may include a body portion 710 having an inner surface 711 and an outer surface 712. body portion 710 may be, for example, but not limited to, 2 'x 2', 2 'x 3', 2 'x 4', 4 'x 8' and larger and/or smaller sizes to cover a wall or portion thereof. The plate 700 may also include 2, 3, or 4 flanges, such as a top flange 713, a bottom flange 714, a left side flange 715, and a right side flange 716, each of which generally depends from the body portion 710 on a single side of the body portion 710, such as on the side having the inner surface 711. However, it is contemplated that in some embodiments, for example, the top flange 713 and the bottom flange 714 may overhang opposite sides of the body portion 710, e.g., the top flange 713 may overhang a side of the body portion 710 having the outer surface 712, and the bottom flange 714 may overhang a side of the body portion 710 having the inner surface 711.

Typically, the flanges 713, 714, 715, 716 in FIG. 7 depend from the body portion 710 at substantially 90, although other angles, both greater and less than 90, are contemplated. In embodiments having only 2 flanges, these flanges are typically located on opposite edges of the panel 700, such as the top and bottom or left and right. As shown in fig. 7, with 4 flanges, the panel 700 resembles an open box or container having shorter sides represented by flanges 713, 714, 715, 716. Each flange may extend 1 inch or more from the body portion 710 and may generally extend the length of the side of the panel 700 on which the flange is located.

The plate 700 and flanges 713, 714, 715, 716 of fig. 7 may be formed as a single piece (single piece) having a substantially uniform thickness using various methods. For example, in one method, the plate 700 and flanges 713, 714, 715, 716 may be formed by injecting an elastomeric material into a mold (not shown) having a shape substantially similar to the shape of the plate 700, curing the elastomeric material, and removing the plate 700 from the mold, in accordance with one embodiment of the present invention. Using this method, panels with 2, 3 and 4 flanges can be prepared. Although preparing the panels in the shape shown in fig. 7 may help to speed up the installation process, as they are ready to be installed, there may be some logistical problems involved in the transportation and storage of panels constructed in this way. In particular, when panel 700 is prepared with flanges 713, 714, 715, 716, it may become more difficult to stack and/or combine a plurality of such panels 700 for shipping, and thus it is more expensive than a flat panel.

In fig. 7, the panel 700 may be placed against a wall of a structure and typically the top flange 713 and the bottom flange 714 may be fastened to the ceiling and floor, respectively, adjacent to the wall of the structure. If the panel 700 includes one or more side flanges 714, 715 that abut one or more walls and/or one or more column portions of the structure, the side flanges may also be fastened to the one or more walls and/or one or more column portions. For example, mechanical fasteners such as concrete anchors, screws, and/or nails may be used to secure the panel 700 to the structure. In one embodiment of the invention, the fasteners may be concrete fasteners such as, but not limited to, 1/4 "diameter x 13/4" length Kwik-Con II + fasteners manufactured by hitti USA, with or without washers, and spaced about 12 "apart centrally along the length of the fastened flange. Alternatively, if the panel 700 has only 2 or 3 flanges, then Z-channel fastening members as described in FIGS. 3, 4 and 5 can be used, as well as fastening together the non-flanged edges that are bordered by the adjacent non-flanged panels and similarly configured edges, by the use of wall frames as will be described below, such as wooden and/or metal base (i.e., bottom) and cover (i.e., top) panels and/or struts along the side flanges.

FIG. 8 is a cross-sectional view of the plate of FIG. 7 taken along line 8-8 according to one embodiment of the present invention. In fig. 8, the substantially uniform thickness of the plate 700 may be such that there is a visual agreement between the body portion 710 and the top and bottom flanges 713, 714. Although the plate 700 may be shown as having a relatively sharp outer edge where the top flange 713 and the bottom flange 714 depend from the body portion 710, slightly rounded and/or curved edges may also be provided by using a mold having rounded and/or curved edges.

FIG. 9 is a partial top view of a continuous fastening strip having fasteners to secure a portion of a flange of a panel to a concrete surface according to one embodiment of the present invention. In fig. 9, flange 910 may have a continuous fastening strip 920 disposed thereon, and a plurality of fasteners 930 may be passed through continuous fastening strip 920 and flange 910 into concrete 940, which concrete 940 may be, for example, a floor, ceiling, wall, and/or column of a structure. The continuous fastening strip 920 may be made of metal (e.g., cold rolled steel and/or steel sheet having a thickness of 1/8 ", 1/4", etc. and a width of 1 ", 2", 3 ", etc.), wood (e.g., 2" x 4 ", 2" x 6 ", etc. wood panels used as panels and/or posts for constructing walls), and/or any other material having strength and durability similar to metal and/or wood. Fasteners 930 may be screws such as Kwik-Con + II screws, concrete nails, bolts, and/or other concrete fastening systems. The fastener 930 may be used in combination with an epoxy and/or other adhesive or fixing agent to help secure the fastener 930 in the concrete 940.

FIG. 10 is a partial top view of a discontinuous fastening strip having fasteners to secure a portion of a flange of a panel to a concrete surface according to one embodiment of the invention. In fig. 10, flange 1010 may have at least one discontinuous fastening strip/feature 1020 disposed thereon, and a plurality of fasteners 1030 may be passed through each discontinuous fastening strip/feature 1020 and flange 1010 into concrete 1040, which concrete 1040 may be a floor, ceiling, wall, and/or column of a structure. The non-continuous fastening strip 1020 may be made of metal (e.g., cold rolled steel and/or steel sheet having a thickness of 1/8 ", 1/4", and a width of 1 ", 2", 3 ", etc.), wood (e.g., 2" x 4 ", 2" x 6 ", etc. wood panels used as panels and/or posts for constructing walls), and/or any other material having strength and durability similar to metal and/or wood. The fastener 1030 may be used in combination with an epoxy and/or other adhesive or fixing agent to help secure the fastener 1030 in the concrete 1040.

FIG. 11 is a partial top view of several individual fastening systems for securing a portion of a flange of a panel to a concrete surface according to one embodiment of the present invention. In fig. 11, each of a plurality of fasteners 1130 passes through washer 1135 and flange 1110 into concrete 1140, which concrete 1140 may be a floor, ceiling, wall and/or column of a structure. The washer 1135 may be made of metal (e.g., steel, zinc, etc.) and/or other materials having strength and durability similar to metal. The fasteners 1130 may be used in combination with epoxy and/or other adhesives or fixatives to aid in securing the fasteners 1130 in the concrete 1140.

Fig. 12 is a cross-sectional top view of a wall system having a reinforcing plate fastened to an existing frame member with fasteners made in accordance with an embodiment of the present invention. In fig. 12, one side of the wall system portion 1200, such as one side of the wall system portion 1200 of a metal building and/or vehicle, is shown connected to the exterior side 1202 of the interior wall 1203, while the opposite side of the wall system 1200 is connected to the interior side 1204 of the exterior wall panel 1205. The wall system portion 1200 may include a pair of opposing U-shaped channel assemblies, namely a first U-shaped channel assembly 1210 and a second U-shaped channel assembly 1215, each of which may extend along the entire vertical length of the opposing sides of the wall system portion 1200. Each opposing U-channel assembly may include a pair of left and right flanges 1211, 1212 and 1216, 1217, respectively, wherein each flange depends at a generally 90 ° angle from the body portions 1213 and 1218 and extends generally the vertical height of the wall system portion 1200.

Although not shown, additional portions of the U-shaped channel may be disposed along the top and bottom edges of the wall system portion 1200 to form a frame. These additional portions of the U-shaped channel can be adapted to fit snugly within the first and second U-shaped channel assemblies 1210, 1215. Between the U-channel assemblies 1210, 1215, one or more stiffening plate 1220, 1225 members may be provided, which may be fastened along the vertical height of the right flange 1212. In general, each stiffener 1220, 1225 may be manufactured in various sizes, such as, but not limited to, 2 'x 2', 2 'x 3', 4 'x 8', etc., and may have a thickness ranging from about 100 mils to 250 mils or greater. If desired, the wall system portion 1200 may also include one or more I-channel assemblies 1230 disposed between and substantially parallel to the first U-channel assembly 1210 and the second U-channel assembly 1215. Each I-channel assembly 1230 resembles an I-beam and may have two pairs of opposing flanges, namely a first flange 1231 paired with a second flange 1232 and a third flange 1233 paired with a fourth flange 1234, each of which depends generally perpendicularly from the main body portion 1235 of the I-channel assembly 1230.

In fig. 12, the reinforcement plate 1220 may be secured along the length of the right flange 1212 of the first U-channel 1210 and along the length of the third flange 1233 of the I-channel assembly 1230 using, for example, a plurality of nuts 1240 and bolts 1242. Alternatively, the fastening may be accomplished using a plurality of rivets 1244 and washers 1245. The wall system portion 1200 may also include one or more foam portions 1250, 1255 between the reinforcement panel and the flanges 1211, 1231, 1232, 1216.

Generally, the U-shaped and I-shaped channel assemblies 1210, 1215, 1230, respectively, of fig. 12 can be made of a material, such as metal, composite, etc., that has sufficient strength and rigidity to support the wall system portion 1200 and impart structural strength to support the interior and exterior wall panels connected thereto and the wall and floor portions that are placed on top of the wall system portion 1200.

Fig. 13 is a partial cross-sectional top view of another wall system having a reinforcement plate secured to an existing frame member according to an embodiment of the present invention. In fig. 13, a wall system portion 1300 similar to the wall system portion 1200 of fig. 12 is shown, wherein no mechanical fasteners are used to connect the reinforcement plate 1220 to either of the first U-shaped channel 1210 and the I-shaped channel 1230. Instead, the reinforcement plate 1220 may be adhesively attached to the flanges on the first U-shaped channel 1210 and the I-shaped channel 1230. Alternatively, the flanges on the U-shaped groove 1210 and the I-shaped groove 1230 may be configured to have a slotted portion into which the vertical edge of the reinforcing plate 1220 may be inserted. This design is shown and described herein with reference to fig. 14. The slotted portion may be located alongside one or all of the flanges on each of the U-shaped channel 1210 and I-shaped channel 1230.

Fig. 14 is a partial cross-sectional top view of a slotted portion of a frame that may be used to secure a panel to an existing frame element in a wall system having a reinforcement panel made in accordance with an embodiment of the present invention. In fig. 14, the right side of the U-channel assembly 1410 is shown with a slotted portion 1411, the slotted portion 1411 being defined by a first flange 1412 that depends substantially perpendicularly from a body portion 1415 of the U-channel assembly 1410 and a first flange lip 1413 that depends at a substantially perpendicular angle from a lower end of the flange 1412 and is substantially parallel to the body portion 1415. Similarly, second lip 1414 is shown depending substantially perpendicularly from the same side of body portion 1415 of U-shaped channel assembly 1410 as first lip 1412. The second flange 1414 may also have a second flange lip 1414, the second flange lip 1414 depending at a substantially perpendicular angle from a lower end of the flange 1412 and being substantially parallel with the body portion 1415. Typically, first flange lip 1413 and second flange lip 1416 are coplanar and have substantially equal lengths.

As can be seen in fig. 14, the reinforcement plate 1420 may include a wedge portion 1430 that fits into the slotted portion 1411 along an edge thereof, and the wedge portion 1430 may be positioned indefinitely along the edge of the reinforcement plate 1420 such that the outer surface 1421 of the reinforcement plate 1420 is aligned with an outer edge of the first flange 1412 or the outer surface 1422 is aligned with an inner edge of the first flange 1412. The wedge 1430 can be installed into the slotted portion 1411 by, for example, sliding the wedge 1430 into the slotted portion 1411 or by snapping (snap) the wedge 1430 into the slotted portion 1411. In contemplated embodiments of the wall system portion 1200, the reinforcing sheet may be prepared with or without the use of a fabric/fiber reinforcement layer in the reinforcing sheet 1220 used to make the wall system portion 1200.

FIG. 15 is a partial cross-sectional side view of a concrete floor having a reinforcing plate therein made in accordance with one embodiment of the present invention. In fig. 15, a concrete slab 1500 may comprise an upper concrete portion 1510 and a lower concrete portion 1520, and may sandwich a reinforcing plate 1530 therebetween. The stiffener 1530 may comprise a plurality of plates having one or more elastomeric layers, either with or without one or more fabric/fiber reinforcement layers in the elastomeric layers. In one embodiment of the present invention, the concrete panel 1500 may be prepared by the following method: concrete is poured to form the lower concrete portion 1520, one or more reinforcing plates 1530 are placed over the lower concrete portion 1520 before and/or after the concrete is cured, and concrete is poured onto the reinforcing plates 1530 to form the upper concrete portion 1510. Typically, the one or more reinforcing sheets 1530 are pre-prepared cured sheets, and as described herein, with and without one or more fabric/fiber layers. However, whether with one or more fabric/fiber layers and/or without one or more fabric/fiber layers, the reinforcement plate 1530 may be sprayed onto the lower concrete portion 1520, and then the lower concrete portion 1510 may be poured onto the reinforcement plate 1530.

In fig. 15, although not shown, the concrete slab 1500 may also contain I-beams, rebar, steel wires, and/or other reinforcements and/or structural support elements. For example, one or both of upper concrete portion 1510 and lower concrete portion 1520 may contain mesh and/or cages of rebar that have been bundled together to increase the strength and rigidity of concrete slab 1500. Examples of possible stiffeners and/or structural support elements are depicted in fig. 16 and 17.

Fig. 16 is a partial cross-sectional top view of a concrete wall having rebar and reinforcing plates therein constructed according to an embodiment of the present invention. In fig. 16, a concrete wall 1600 may include a first concrete side 1610, a second concrete side 1620, and a reinforcement slab 1630 sandwiched between the first concrete side 1610 and the second concrete side 1620. Reinforcing layer 1630 may comprise a plurality of plates having one or more elastomeric layers, either with or without one or more fabric/fiber reinforcing layers. Although concrete wall 1600 is similar in appearance to concrete slab 1500 in fig. 15, the construction method may be different. For example, unlike concrete slabs in which the concrete is typically 4 inches to 12 inches thick (high) and oriented in a horizontal plane, in concrete walls the concrete is typically 4 inches to 12 inches thick (wide) and oriented in a vertical plane that is 4 feet to 10 feet high and extends along the entire side/portion of the structure. As a result, concrete walls must be poured into tall forms (forms) that are typically made of reinforced metal and are combined with portions of rebar and/or other metal reinforcing elements. Typically, concrete walls in homes and/or buildings may be about 4 feet to 12 feet tall. Of course, these walls may be shorter and/or taller as desired for a particular building application. In addition, reinforcing steel and/or steel mesh and/or cages may be placed within the forms so that the concrete may wrap around the reinforcing steel and/or wires as it is poured into the forms.

For example, according to one embodiment of the present invention, a method of constructing a concrete wall 1600 may include assembling one or more steel reinforcement bars and/or steel mesh layers and placing the one or more steel reinforcement bars and/or steel mesh layers within a form. One or more reinforcing plates 1630 may be placed approximately in the middle of the form and between one or more of the rebar 1640 and/or steel mesh layers. In at least one embodiment, at least one or more stiffening plates 1630 may be attached using a Z-channel and/or I-channel connector 1650 and fasteners, bolts, screws, staples, straps, or the like. Additionally, one or more layers of rebar and/or steel mesh may be tied together by passing rebar and/or steel wire through holes in one or more of the reinforcing plates 1630. In the method, concrete is poured into the form and around the slab and the steel reinforcement and/or steel mesh and allowed to cure. Once the concrete has cured, the form may be removed to reveal the concrete wall 1600 with the embedded reinforcing layers 1630.

Fig. 17 is a partial cross-sectional top view of a concrete wall constructed according to an embodiment of the present invention having rebar and a reinforcing plate on an exterior surface of the concrete wall. In fig. 17, a concrete wall 1700 may include a concrete portion 1710 and at least one reinforcing plate portion on one or both sides of the concrete wall 1700. Concrete wall 1700 may be constructed by placing one or more reinforcing plates 1720 against one or both sides of a form and placing rebar and/or wire mesh and/or cages substantially in the middle of the form. Concrete may be poured into the form and once it has cured, the form may be removed to reveal a concrete wall 1700 having a reinforcing plate 1720 on one side. As in fig. 16, adjacent reinforcing plates for the concrete wall 1700 in fig. 17 may be fastened together as described above for fig. 16.

Figure 18 is a cross-sectional top view of a monolithic slab system for protecting concrete columns according to one embodiment of the present invention. In fig. 18, the column plate housing 1800 may be formed to be substantially rectangular, such as square, or any other profile (e.g., oval, ring, etc.) to match the outer dimensions of the column. Regardless of the shape of the column, the column plate housing 1800 may be pre-formed around a form-fitting mold to match the shape of the column. As shown in fig. 18, this may be substantially a square shape: the outer edges 1802, 1804 of the columnsheet housing 1800 are not joined to provide an opening 1810 extending along the length of the outer edges 1802, 1804.

In fig. 18, the openings 1810 may allow the edges 1802, 1804 to spread apart and the post plate housing 1800 may be placed around the post. Alternatively, the column plate housing 1800 may be formed by heating a flat reinforcing plate, and then bending it around the outside of the column. Generally, when the post plate housing 1800 is placed around a post, the outer edges 1802, 1804 will be as close to each other as possible to completely close or make as small an opening 1810 as possible. Alternatively, the outer edges 1802, 1804 may actually overlap. Regardless of whether the edges 1802, 1804 overlap, the column plate housing 1800 may be fastened to the columns along the seams formed by the edges 1802, 1804, at least around the corners of the columns, with or without the use of epoxy, using mechanical fasteners as described herein. If desired, a column plate cover 1800 may also be secured around each edge of the column, as well as on each face/surface of the column. An adhesive may also be used with the mechanical fasteners to attach the column plate cover 1800 to the column.

In another embodiment of the invention, the column plate housing 1800 of fig. 18 may comprise two or more separation plates, which plates may be manufactured and/or cut to fit each side of the column such that the separation plates abut and/or overlap on each corner of the column. For example, column plate housing 1800 may include two L-shaped halves (half); a U-shaped member covering three sides and a planar member covering a fourth side; and/or four separate planar members covering each side of the post.

Figure 19 is a cross-sectional top view of an L-shaped bracket for securing one or more pieces of a panel system around a concrete column according to one embodiment of the present invention. In fig. 19, an L-shaped bracket 1900, such as one having a width in the range of 1/2 inches to 2 inches, 3 inches, 4 inches, etc. above 4 inches, may be used with mechanical fasteners to fasten the column plate cover 1800 around the corner of the column. Generally, a plurality of L-brackets 1900, each having two or more fasteners, may be arranged evenly spaced along the opening 1810 and over the edges 1802, 1804 of the column plate housing 1800 from bottom to top and anchored into the column. In an alternative embodiment, the L-shaped bracket 1900 may be a single piece and the single piece may have a width substantially equal to the height of the floor covering 1800, effectively completely covering the opening 1810 and/or each outer edge of the floor covering 1800.

Figure 20 is a cross-sectional top view of an L-channel bracket for securing one or more panel systems around a concrete column according to one embodiment of the present invention. In fig. 20, similar to the L-shaped bracket 1900, an L-shaped slotted bracket 2000, such as an L-shaped slotted bracket having a width ranging from 1/2 inches to 2 inches over 4 inches, 3 inches, 4 inches, etc., can be used with mechanical fasteners to fasten the column plate cover 1800 to the column. Generally, from the bottom to the top of the column plate housing 1800, a plurality of L-shaped channel brackets 2000, each having two or more fasteners, may be evenly spaced along the opening 1810, and the edges 1802, 1804 may be inserted into the slots 2005, 2010 of the L-shaped channel brackets and anchored around or within the corners of the column with fasteners that may pass through the L-shaped channel brackets 2000 and the column plate housing 1800. Generally, from the bottom to the top of the post plate housing 1800, a plurality of L-shaped channel brackets 2000, each having two or more fasteners, may be evenly spaced along the opening 1810 and on the edges 1802, 1804 and anchored into the post. In an alternative embodiment, the L-shaped slotted bracket 2000 may be a single piece, and the single piece may have a width substantially equal to the height of the floor covering 1800, thereby effectively completely covering the opening 1810 and/or each outer edge of the floor covering 1800.

Fig. 21 is a partial cross-sectional top view of the L-shaped bracket of fig. 18 securing a plate system for protecting a concrete column to a corner of the concrete column according to one embodiment of the present invention. In fig. 21, the column plate cover 1800 is installed completely around the concrete column 2000 using an L-shaped bracket 1900 and two fasteners 2110 passing through the L-shaped bracket 1900, the column plate cover 1800 and into the concrete column 2000. Although not shown, epoxy may also be used to adhere the column plate cover 1800 to the concrete column 2000 and to attach the fasteners 2110 within the concrete column 2000.

Figure 22 is a cross-sectional top view of a two-piece panel system for protecting concrete columns according to one embodiment of the present invention. The two-piece column shroud 2200 shown in fig. 22 includes a first half 2210 and a second half 2220. Two column plate covers 2200 are installed to cover the two openings that exist in the two column plate covers 2200 using similar methods and fastening materials as described above for the column plate cover 1800.

FIG. 23 is a partially exploded side view of a panel system for protecting concrete columns showing reinforcement layers arranged like a diamond in accordance with one embodiment of the present invention. As can be seen in fig. 23, the pillar panel cover 2300 includes a fabric/fiber layer 2310 arranged in a diamond-like pattern. Alternatively, the fabric/fiber layers 2310 may also be arranged in a criss-cross and/or overlapping pattern.

FIG. 24 is a partial cross-sectional top view of a hollow core door having a debris and projectile resistant panel positioned within the door in accordance with an embodiment of the present invention. In fig. 24, the hollow door/wall portion 2400 can include a first side 2410, an opposing second side 2420, a first end 2430, and an opposing second end 2440. The one or more pieces of the structural brace 2450 can extend from the bottom to the top of the hollow door/wall portion 2400 substantially along the inner surface of the first end 2430 and the inner surface of the second end 2440. For example, the structural brace 2450 can be made of wood, metal, insulated fiberboard, and/or composite materials. Although not shown, one or more similar structural braces may extend across the top and bottom of the hollow door/wall section 2400 to provide a complete structural internal framework. As shown in fig. 24, a reinforcement panel 2460 can be disposed between the interior of the hollow door/wall portion 2400 and the structural brace 2450 according to one or more embodiments described herein. Generally, the reinforcement panel 2460 can extend substantially the entire width and height of the hollow door/wall portion 2400 and be fastened using any of the various fastening methods described herein. Any spaces 2470, 2475 between the reinforcement panel 2460 and the first and second sides 2410, 2420 can be empty and/or can be filled with foam, insulation, and/or other materials that provide additional acoustic/thermal insulation, density, and/or reinforcement.

The basic structure of the hollow door/wall section 2400 of fig. 24 can be used to fabricate aircraft doors and bulkheads using materials suitable for aircraft construction, such as aluminum, carbon fiber composite, and the like. The reinforcing sheet may also comprise one or more fabric/fiber layers and have different thicknesses. Fig. 27 and 28 below describe examples of possible alternative embodiments of the reinforcing plate.

The hollow core door/wall portion 2400 of fig. 24 can also be manufactured as a prefabricated wall portion 2400 using standard building materials, such as two inch by four inch (2 x 4) or larger (2 x 6, 2 x 8, etc.) panels. In this embodiment of the invention, the wall portion 2400, the first end 2430, and the second end 2440 can be, for example, 2 x 4 panels, and the width of the reinforcement panel 2460 can be just wide enough to fit between the first edge 2430 and the second edge 2440, and the pair of structural brackets 2450 can be attached to the first edge 2430, one edge of the reinforcement panel 2460, the second edge 2440, and the other edge of the reinforcement panel 2460. Prefabricated wall section 2400 can also have one or more intermediate braces 2480, which braces 2480 are placed at approximately equal distances between first edge 2430 and second edge 2440. For example, in the wall 2400, where the first and second ends 2430, 2440 are 2 x 4, each of the intermediate brackets 2480 can be a 2 x 2, 2 x 3, and/or 2 x 4 panel. In the case of a 2 x 4 intermediate bracket 2480, the intermediate bracket 2480 can have a slot cut down and through substantially the middle of the 4-inch sides and along substantially the entire length of the 2 x 4 so that the reinforcement plate 2460 can pass through the slot. If a pair of 2 x 2, 2 x 3, and/or 2 x 4 sheets are used, the reinforcement panel 2460 can be sandwiched between and attached to the pair of sheets. In this embodiment, the first side 2410 and the second side 2420 can be any standard building material including, but not limited to, for example, drywall, plywood, particle board, foam core insulation, and the like.

Figure 25 is a partial cross-sectional front view of a dual tube tunnel system having debris and projectile resistant panels disposed on the exterior of the inner tube of the two tubes in accordance with one embodiment of the present invention. In fig. 25, the dual tunnel system 2500 may include an outer tunnel 2510 having an inner surface 2512 and an outer surface 2514, the inner surface 2512 defining an outer tunnel open space 2520; and a smaller inner tunnel 2530 having an inner surface 2532 and an outer surface 2534, the inner surface 2532 defining an inner tunnel open space 2536, the outer surface 2534 being disposed within the open space 2520 such that the inner tunnel 2530 does not completely fill the open space 2520. For example, as seen in the embodiment of fig. 25, the inner tunnel 2530 and the outer tunnel 2510 may each have a substantially flat and coplanar bottom and substantially rounded walls, with a portion of the open space 2520 still not being filled by the inner tunnel 2530. Other embodiments contemplate that the tunnel may have various shapes including, but not limited to, for example, a better rectangular shape with vertical sidewalls and arched roofs, a triangular shape, and the like. Moreover, in still other embodiments, the inner surface 2512 of the outer tunnel 2510 may have an embodiment on which a plate is disposed.

In fig. 25, multiple protective sheets 2540 of elastomer with one or more or no fabric/fiber layers can be pre-formed using any of the designs disclosed herein. Each protective plate 2540 can be preformed to have an outer shape that is about the same shape as the outer surface 2534 of the inner tunnel 2530 and can be attached to the outer surface 2534 of the tunnel 2530 using mechanical fasteners and/or epoxy to seal the outer surface 2534 of the tunnel 2530. Alternatively, the elastomer and/or fiber/fiber layers may be applied directly to the outer surface 2534 of the inner tunnel 2530. However, generally, for direct coating to be successful, the outer surface 2534 of the inner tunnel 2530 should be cleaned and dried.

FIG. 26 is a side view of a removable debris and projectile resistant door panel positioned on an interior surface of a door of a vehicle according to one embodiment of the invention. The debris and projectile resistant door panel 2600 is shown in fig. 26 on a door 2610 within a channel-type retaining unit 2614, while the channel-type retaining unit 2614 is on an interior surface 2616 of the door 2610. In the embodiment shown in fig. 26, the debris and projectile resistant door panel 2600 is removable, however, it is contemplated that the debris and projectile resistant door panel 2600 may be permanently secured to the interior surface 2616 of the door 2610 and throughout the interior surface of the vehicle in some embodiments.

In general, the slotted fixing unit 2614 may include a left vertical slot 2621, a right vertical slot 2622, and a bottom slot 2623, the bottom slot 2623 connecting the bottom end of each of the left and right vertical slots 2621, 2622, all of which may be permanently secured to the inner surface 2616 of the door 2610. The slot-type fixing unit 2614 may further include a top slot 2624, and the top slot 2624 may connect the top of each of the left and right vertical slots 2621 and 2622 at either end. Typically, the channel-type retaining unit 2614 is fabricated from a U-shaped channel forming material as described previously, for example, in fig. 4, 13 and 14. Alternatively, top groove 2624 may be permanently attached to door panel 2600 to resist debris and projectiles and may be configured to removably connect each of left and right vertical grooves 2621, 2622. For example, the top groove 2623, left vertical groove 2621, and right vertical groove 2622 may have mating latches and/or latching mechanisms to allow for the removable mounting of the debris and projectile resistant door panel 2600 in the channel retaining unit 2614. In addition, manually tightened fasteners may be permanently secured to and through each of the slots 2621, 2622, 2623, 2624 and through the debris and projectile resistant door panel 2600 to engage and secure the door 2610.

In fig. 26, left and right vertical slots 2621 and 2622 may be configured similar to the slotted slots described above with respect to fig. 14, in accordance with an alternative embodiment of the present invention. Thus, as shown and described in fig. 14, the left and right edges of door panel 2600 of the debris and projectile resistant door may also be tapered to fit within the slotted channels of left and right vertical slots 2621 and 2622. Because the embodiment of the debris and projectile resistant door panel 2600 includes a removable panel, the debris and projectile resistant door panel 2600 may be removed from the vehicle and similarly mounted on an interior wall of a building through which a person traveling with the vehicle may pass.

Furthermore, according to another embodiment of the invention, the debris and projectile resistant door panel 2600 may be provided as a floor panel that is most often permanently installed on the floor of the vehicle. For example, the floor panel may have an outer shape that matches the shape of the floor and is pre-perforated to receive a bolt extending upwardly from the floor to which a washer and nut may be secured to attach the floor panel to the floor of the vehicle. The floor panel may be made into the shape of the floor by manufacturing the floor panel in a mold having the shape of the vehicle floor or heating and processing a substantially flat plate to conform to the shape of the floor. Generally, the floor panels can have a thickness ranging from about 1/4 inches to 3/4 inches or more.

Fig. 27 is a side view of a fragment and projectile resistant multi-layer panel according to one embodiment of the present invention. In fig. 27, a reinforcing plate 2700 having two layers of fabric/fiber embedded therein includes an elastomeric top layer 2710, where the elastomeric top layer 2710 overlies the fabric/fiber top layer 2720, the fabric/fiber top layer 2720 overlies an elastomeric middle layer 2730, the elastomeric middle layer 2730 overlies a fabric/fiber bottom layer 2740, and the fabric/fiber bottom layer 2740 overlies an elastomeric bottom layer 2750.

In general, the fabric/fiber layer of fig. 28 may comprise an open weave fabric, such as the fabric described previously made from Technora and Twaron-brand aramid yarn or fibers from Teijin. In addition, the layers may be offset and/or placed in an alternating pattern to minimize the size of any openings in the open-cell fabric of each fabric/fiber layer. Embodiments of the reinforcing panel 2700 may provide resistance to ballistic projectiles.

Fig. 28 is a side view of a fragment and projectile resistant multi-layer panel according to another embodiment of the present invention. In fig. 28, a stiffener 2800 with embedded three layers of fabric/fiber includes a first layer of elastomer 2810, where the first layer of elastomer 2810 is on a first layer of apertured woven fabric/fiber 2820, the first layer of apertured woven fabric/fiber 2820 is on a second layer of elastomer 2830, the second layer of elastomer 2830 is on a second layer of tightly woven fabric/fiber 2840, and the second layer of tightly woven fabric/fiber 2840 is on a third layer of elastomer 2850, the third layer of elastomer 2850 is on a third layer of open woven fabric/fiber 2860, and the third layer of open woven fabric/fiber 2860 is on a fourth layer of elastomer 2870. As shown in the embodiment of fig. 28, while the tightly woven fabric/fiber 2840 is between two layers of open-weave fabric/fiber 2820, 2860, other embodiments contemplate the order of the fabric/fiber layers being reversed from fig. 28, as well as any other various possible combinations. Although the reinforcement plate 2800 of fig. 28 has only three layers of fabric/fiber, in other embodiments it is contemplated that more layers of fabric/fiber may be used, and the fabric/fiber direction in each layer may be offset from the other layers of fabric. Such offsetting may be accomplished, for example, by rotating the orientation of the fabric/fibers of each subsequent layer about the circumference by, for example, but not limited to, a fixed number of degrees, such as 1, 2, 3 degrees, etc. Further, it is contemplated in some embodiments that the fabric/fiber layers may be layered on top of each other and bonded together with an epoxy, and then coated with an elastomer.

Typically, the fabric/fiber layer comprises a fabric, for example, a fabric made from Technora and Twaron-brand aramid yarn or fiber from Teijin, as described previously. Further, the layers may be offset and/or placed in an alternating pattern to minimize the size of any openings between the apertured webs of each layer of web/fiber. Embodiments of the reinforcement plate 2800 may provide resistance to ballistic projectiles.

FIG. 29 is a cross-sectional side view of a debris and projectile resistant panel applied directly to a release agent on a surface of a structure and secured to the surface of the structure with a mechanical fastener in accordance with an embodiment of the invention. In fig. 29, an apparatus 2900 may include a structural wall 2902 of a building and/or structure, the surface 2903 of the structural wall 2902 being coated with a release agent 2910, according to one embodiment of the invention. Release agent 2910 may be applied to surface 2903 by spraying, brushing, rolling, troweling, etc., and release agent 2910 may include, for example, but is not limited to, Polytetrafluoroethylene (PTFE), oils, waxes, silicon, and other release agents. The structural wall 2902 may also be a floor and/or ceiling. Similar to the release agent 2910, an elastomer layer 2920 may be applied directly on the surface 2903 and above the release agent 2910 and secured to the structure wall 2902 with a mechanical fastening system 2930. The mechanical fastening system 2930 can include a continuous metal fastening strip/flange 2932, a plurality of metal fastening elements 2934, and an anchoring mechanism 2936 (e.g., epoxy, concrete anchors, etc.) to help protect the metal fastening elements 2934 within the structural wall 2902. Other embodiments of the mechanical fastening system 2930 can include any of the fastening systems described above in fig. 9, 10, and/or 11.

FIG. 30 is a cross-sectional side view of a debris and projectile resistant panel applied directly to a release agent on a surface of a structure and secured to the surface of the structure with a mechanical fastener according to another embodiment of the invention. In fig. 30, an apparatus 3000 according to one embodiment of the invention can include a structural wall 3002, the structural wall 3002 connected at a top end to a structural ceiling 3004 of a building and/or structure and at a bottom end to a structural floor 3006 of the building and/or structure; a release agent 3010 is applied to a surface 3003 of the structural wall 3002, a surface 3005 of the ceiling 3004 and a surface 3007 of the floor 3006. The release agent 3010 may be applied to the surfaces 3003, 3005, 3007 by spraying, brushing, rolling, troweling, etc., and the release agent 3010 may include, for example, but not limited to, Polytetrafluoroethylene (PTFE), oils, waxes, silicon, and other release agents.

An elastomer layer 3020 may similarly be applied directly on release agent 3010 on surfaces 3003, 3005, 3007 and above release agent 3010 and fastened to structural top panel 3004 and structural bottom panel 3006 using mechanical fastening system 3030. The elastomer 3020 may also be fastened to the structural wall 3002 shown in fig. 29 using a mechanical fastening system 3030. The mechanical fastening system 3030 may include a continuous metallic fastening band/flange 3032, a metallic fastening element 3034, and an anchoring mechanism 3036 (e.g., epoxy, concrete anchors, etc.) to help protect the metallic fastening 3034 within the structural wall 3002. Other embodiments of the mechanical fastening system 3030 may include any of the fastening systems described above in fig. 9, 10, and/or 11.

FIG. 31 is a cross-sectional side view of a fragment and projectile resistant panel having a fabric/fiber reinforcement layer between two layers of elastomer applied directly to a release agent on the surface of a structure and secured to the surface of the structure with a mechanical fastener in accordance with another embodiment of the invention. In fig. 31, an apparatus 3100 may include a structural wall 3102 of a building and/or structure, a surface 3103 of the structural wall 3102 coated with a release agent 3110, according to one embodiment of the invention. The release agent 3102 may be applied to the surface 3103 by spraying, brushing, rolling, troweling, or the like. The structural wall 3102 may also be a floor and/or ceiling. Similar to the release agent 3110, the first layer of elastomer 3120 may be applied directly on the surface 3103 and above the release agent 3110.

The fabric/fiber layer 3130 may be adhered to the first layer of elastomer 3120 and the second layer of elastomer 3140 may be applied over the fabric/fiber layer 3130 using one of the methods described above, and all of the layers may be fastened to the structural wall 3102 using the mechanical fastening system 3150. The mechanical fastening system 3150 may include a continuous metal fastening strip/flange 3152, metal fastening elements 3154, and an anchoring mechanism 3156 (e.g., epoxy, concrete anchor, etc.) to help protect the metal fasteners 3154 within the structural wall 3102. Other embodiments of mechanical fastening system 3150 may include any of the fastening systems described in fig. 9, 10, and/or 11 above.

FIG. 32 is a cross-sectional side view of a fragment and projectile resistant panel having a textile/fiber reinforcement layer between two layers of elastomer applied directly to a release agent on the surface of a structure and secured to the surface of the structure with a mechanical fastener in accordance with another embodiment of the invention. In fig. 32, a system 3200 according to one embodiment of the invention may include a structural wall 3202, the structural wall 3202 connecting a structural top plate 3204 of a building and/or structure at a top end and a structural bottom plate 3206 of the building and/or structure at a bottom end, a release agent 3210 coated on a surface 3203 of the structural wall 3202, a surface 3205 of the top plate 3204, and a surface 3207 of the bottom plate 3206. The release agent 3210 may be applied to the surfaces 3203, 3205, 3207 by spraying, brushing, rolling, troweling, or the like.

The elastomer layer 3220 may similarly be coated directly on the release agent 3210 on the surfaces 3203, 3205, 3207. The fabric/fiber layer 3230 may be adhered to the first layer of elastomer 3220, and the second layer of elastomer 3240 may be applied to the fabric/fiber layer 3230 using one of the methods described above, and all layers fastened to the structural top plate 3204 and the structural bottom plate 3206 using the mechanical fastening system 3250. The elastomer 3220 may also be fastened to the structural wall 3202 shown in fig. 29, 30, and/or 31 using a mechanical fastening system 3250. Mechanical fastening system 3250 may include continuous metal fastening strip/flange 3252 and metal fastening element 3254, as well as anchoring mechanism 3256 (e.g., epoxy, concrete anchor, etc.) to help protect metal fastening element 3254 within structural wall 3202. Other embodiments of mechanical fastening system 3250 can include any of the fastening systems described in fig. 9, 10, and/or 11 above.

FIG. 33 is a side view of an automated system for producing debris and projectile resistant panels according to one embodiment of the present invention. In fig. 33, the automated fragment and projectile resistant panel production system 3300 may include a first spray booth 3310, and the first spray booth 3310 may include a first pair of drive rollers 3311 to assist in pulling the fabric/fiber layer 3302 out of the fabric/fiber roller system 3305 and into the first spray booth 3310. The first spray coating 3310 may also include one or more automated first nozzles 3312 to spray elastomer onto a first side of the fabric/fiber layer 3302 on a conveying system 3313 (e.g., without limitation, a conveyor belt system) to form a middle plate layer 3315, the conveying system 3313 moving the combined fabric/fiber layer 3302 and first layer elastomer 3314 through the first spray coating 3310. The first spraycoating part 3310 may further include a second pair of drive rollers 3316 at the output end of the first spraycoating part 3310. The second pair of drive rollers 3316 may pull the middle plate layer 3315 out of the first spray stage 3310 and supply it to a turn 3320, which turn 3320 may operatively connect to the output of the first spray stage 3310 to receive the middle plate layer 3315.

In fig. 33, the turnaround portion 3320 may include at least one large roller/cylinder 3321, or equivalently functioning structure, and may also include one or more smaller cylinders 3324 around which the middle plate layer 3315 may pass and effectively turn over so that the fabric/fiber layer 3302 in the middle plate layer 3315 faces upward when the third drive roller 3341 pulls the middle plate layer 3315 into the second spray land portion 3340. While the turn 3320 may appear to turn the middle plate layer 3315 through a U-turn, which results in the automated plate production system 3300 may appear to be a two-stage configuration, other configurations and turned shapes are contemplated.

For example, one or more rollers are angled with respect to the effusion table portion 3310 and positioned behind the effusion table portion 3310 and in a plane higher than the effusion table portion 3310 to completely invert the intermediate plate layer 3315. For example, a single roller is placed at the end of the jet stage 3310 and at an angle of 45 degrees to the conveying path of the middle plate layer 3315 such that the second side of the fabric layer is exposed when the middle plate layer 3315 passes over the roller, and the middle plate layer 3315 may be conveyed at exactly a substantially 90 degree angle to its conveying path when the middle plate layer 3315 is on the jet stage 3310. At this time, the middle plate layer 3315 may be at a certain level above the surface of the stage 3310, and thus the second stage 3310 may need to be higher or the middle plate layer 3315 may need to return to its height before the 45 degree roller. This can be achieved, for example, by: the intermediate layer 3315 is passed under a roller disposed at a 90 degree angle in front of the second stage part 3310 and having a height substantially equal to the 45 degree roller height.

Alternatively, in another embodiment of the turnaround 3320 in fig. 33, a three-roll system may be implemented by, for example, a first roll at a 45 degree angle as in the previous embodiments. The three-roller system may further include a second roller having a 90 degree angle with the end of the spouting table portion 3310 and being higher than the first roller to allow the middle plate layer 3315 to pass under the second roller and wrap around the second roller such that the middle plate layer 3315 moves 180 degrees in the opposite direction, wherein the spouting table portion 3310 is parallel to the transfer route of the middle plate layer 3315 on the spouting table portion 3310.

The three-roller system may finally comprise a third roller at an opposite 45-degree angle to the first roller, and the third roller may be disposed in a plane higher than the first and second rollers, and may be disposed directly substantially directly above the first roller, so that the first roller and the third roller may appear to form an "X" shape from above. The intermediate plate layer 3315 may be conveyed under the third roller and wrapped around the third roller so that the intermediate plate layer 3315 is again conveyed in the same direction and course as it was on the jet table portion 3310, but on a slightly elevated plane.

The intermediate plate layer 3315 may be returned to its same height on the ejection table portion 3310, if desired, by passing the intermediate plate layer 3315 under an additional roller following the third roller, which may be located just before the second ejection table portion 3340 and substantially equal in height to the first roller, crossing the path of the intermediate plate layer 3315 by 90 degrees, and onto the second ejection table portion 3340. Of course, the above alternatives can also be achieved using rollers below and/or above the surface of each of the ejection stage portion 3310 and the second ejection stage portion 3340, as appropriate.

It should be clear that the above described alternative roller embodiments for the turnaround 3320 are illustrative only and should in no way be construed as being exclusive and should not be construed as limiting the possible contemplated embodiments.

The second spray table section 3340 may further include one or more automated second nozzles 3342 to spray elastomer onto the second side of the fabric/fiber layer 3302 and another conveyor system 3343 (e.g., without limitation, a conveyor belt system, a plurality of free-moving rollers, etc.) to form a final ply layer 3345 and move the final ply layer 3345 through and out of the second spray table section 3340. The second ejection stage section 3340 may further comprise a fourth pair of drive rollers 3346 at the output end of the second ejection stage section 3340. The fourth pair of drive rollers 3346 may be operated to pull the final sheet layer 3345 out of the second spray land section 3340 and supply it to a finishing section 3350, which finishing section 3350 may be operatively connected to the output end of the second spray land section 3340 to receive the final sheet layer 3315 through the fifth pair of drive rollers 3351.

The fifth pair of drive rollers 3351 may be operated to pull the final slab layer 3345 into and through the trim portion 3350, across the trim bed 3354 and into the sixth pair of drive rollers 3356. A sixth pair of drive rollers 3356 may be operated to pull the final slab layer 3345 across the conditioning bed 3354 and out of the conditioning section 3350. A cutting device 3360 may be provided between the second sprayed part 3340 and the finished part 3350, and the final slab layer 3345 may be cut into a plate 3355 having a predetermined length, if necessary. The cutting device 3360 may include a large blade, an anvil, a waterjet cutter, and/or any other cutting mechanism capable of quickly cutting the entire width of the final ply 3345 and not interfering with the movement of the final ply 3345 through the second jet deck section 3340. Alternatively, in another embodiment, the cutting device 3360 may be positioned at the output end of the finisher 3350 closest to the sixth drive roller 3356. Alternatively, the cutting device 3360 may be inserted into the hole of the final ply in any orientation.

In fig. 33, the automated board production system 3300 may further include a winding system 3370, which winding system 3370 may include a winding roller system 3371 to receive the final board layer 3345 exiting the finishing section 3350 through a sixth pair of drive rollers 3356. The take-up roller system 3371 may include a roller 3372 driven by a motor 3373, the leading width of the final ply 3345 may be attached to the roller 3372, and the final ply 3345 may be wound around the roller 3372. The roller 3372 may receive a wound roll of empty pressboard or the like. The leading end of the final ply 3345 may be attached to a wound roll and a thin plastic sheet 3375 (e.g., similar to a plastic wrapping material) may be supplied from a roll of plastic sheet 3380, the plastic sheet 3375 being applied to one side of the final ply 3345 when the final ply 3345 is rolled on a roll 3372 to help prevent the final ply 3345 from sticking to itself when wound.

FIG. 34 is a side view and FIG. 35 is a top view of an automated production system for debris and projectile resistant panels according to another embodiment of the present invention. In fig. 34 and 35, an automated fragment and projectile resistant panel production system 3400 may include a web feed system 3402 that supplies web to a panel production system 3404.

The web supply system 3402 may include a web supply system 3410 that operates (operational) to supply the web 3411 from the roll 3412 to the web feeder/cutter 3420. Fabric feeder/cutter 3420 may include tension rollers 3421 that receive fabric 3411 from roll 3412 and feed rollers/drives 3423 that may, in operation, pull fabric 3411 across tension rollers 3421 and feed fabric 3411 to fabric table portion 3430 of board production system 3404. The feed rollers/drives 3423 may include an electric drive unit that drives one or more rollers to supply the fabric 3411 to the fabric table portion 3430, and a cutting device that follows the one or more rollers to cut the fabric 3411 into sheets having a length required to produce a board. The board production system 3404 may further include a jet stage part 3460 and a board stripper part 3480, the jet stage part 3460 connecting the web stage part 3430 at opposite ends of the web feeder/cutter 3420, and the board stripper part 3480 connecting opposite ends of the jet stage part 3460.

The fabric table portion 3430 in fig. 34 and 35 may include a fabric table 3431, the fabric table 3431 having a table top 3432, and the height of the table top 3432 being substantially the same as the height at which the feed rollers/drives 3423 may output the fabric 3411. The table 3432 may be provided as a solid surface, a series of substantially parallel rollers across the width of the table 3432, a set of substantially equally spaced tracks along the length of the table 3432, etc. The web table portion 3430 may further include a guide rail 3433, and the guide rail 3433 may be fixed to the web table 3431 and extend (run) above the web table 3431 to move the web holder 3434 back and forth along the guide rail 3433. The guide rail 3433 may extend along the entire length of the sheet production system 3404 and be fixed to other parts of the sheet production system 3404, including the ejection stage part 3460 and the sheet peeler part 3470. The fabric holder 3434 may include a fabric gripping device 3435, which fabric gripping device 3435 may, in operation, grasp the cut piece of fabric 3411 longitudinally along opposite sides of the cut piece, lift it off the table 3432, and pull the cut piece of fabric 3411 taut across its width. The fabric carrier 3434 may further include a fabric loading device 3436, which fabric loading device 3436 may be movably attached to the top of the fabric carrier 3434 and located between the top of the fabric carrier 3434 and the table top 3432. The fabric loading device 3436 may be of a size nearly equal to the sheet of fabric 3411 and may include a single section or multiple independent control sections that may be moved up and down relative to the table 3432. Typically, the fabric loading device 3436 is made of and/or coated with a material that does not adhere to the polymer used to make the panels. For example, such materials may include, but are not limited to, Polytetrafluoroethylene (PTFE), oils, waxes, silicon, and other non-stick materials.

The fabric support 3434 may further include a first drive device 3437 located adjacent a front end 3450 of the fabric support 3434, the first drive device 3737 being operable to move the fabric support 3434 along guide rails 3433 to and from the spray station 3460 or, alternatively, the board stripper assembly 3482 may be moved along guide rails 3433 from the board stripper portion 3480 to and from the spray station 3460. The fabric support 3434 may further include a spray gun 3440 secured to a front end 3450 of the fabric support 3434. Generally, the gun 3440 may be rigidly secured to the fabric support 3434 to ensure that a uniform and consistent polymer distribution may be obtained from the gun 3440.

According to one embodiment of the present invention, the spray table portion 3460 may include a spray table 3461 having a substantially planar spray table surface 3462, the spray table surface 3462 having a length and width suitable for producing a variety of different board sizes and generally rectangular board sizes. For example, in one embodiment, the sparging table surface 3462 can be rectangular in shape and at least 48 inches wide by about 15 feet long. Alternatively, injection table surface 3462 may be larger and/or smaller, but typically, injection table surface 3462 is not designed to be quickly and easily removable/replaceable. To facilitate the production of smaller boards, the jet table surface 3461 may have a number of smaller tables attached thereto, the system may be programmed to cut the fabric into different sizes, jet the elastomer in a particular pattern (including, but not limited to, for example, smaller rectangles, squares, ovals, ellipses, circles, parallelograms, etc.) only onto the smaller tables, place the cut fabric accurately onto the elastomer jetted onto the smaller tables, and selectively pick and remove the finished board from the smaller tables. While this may not be as efficient as manufacturing a larger panel and then cutting it into smaller sections of standard rectangular dimensions (e.g., 2 feet by 4 feet, etc.), these assemblies and this procedure may prove beneficial in producing panels having special configurations with non-rectangular shapes.

Further, the system may be configured to selectively spray elastomer onto the spray table surface 3462 to provide a preformed panel having openings (e.g., window and door openings) of a predetermined size and located at predetermined locations on the panel. Typically, the sheet of fabric 3411 cut from the roll of fabric 3412 does not have a precut opening for a window or door, but rather remains intact to provide handling and shipping stability and to enable it to be properly cut and wrapped around the structural wall elements during installation. For example, in a panel with a prefabricated rectangular window, the fabric from sheet of fabric 3411 may be cut two diagonal lines to form four substantially triangular pieces of fabric 3411 that may be wrapped around the window frame and secured to the frame. Similar processes can be used for different shaped windows as well as doors and other openings (e.g., heating and cooling vents, receptacles, etc.).

Plate stripper portion 3480 may include a plate stripper frame 3481, a plate stripper assembly 3482, said plate stripper assembly 3482 being removably engaged with plate stripper frame 3481 and movable to and from the ejector stage to pick up and carry the finished plate back. The plate stripper assembly 3482 may include selectively engageable plate pickup elements 3483, which plate pickup elements 3483 may be symmetrically disposed in a pattern over an area equal in size to the ejection table surface 3462. The plate stripper assembly 3482 may further include a second drive 3487 located near a rear end 3488 of the plate stripper assembly 3482, and the second drive 3487 may be operative to move the fabric support 3434 along guide rails 3433 to and from the spray station 3460, or alternatively, the plate stripper assembly 3482 may be moved along guide rails 3433 from the plate stripper portion 3480 to and from the spray station 3460, respectively.

In fig. 35, the automatic production system for debris and projectile resistant panels 3400 may further comprise a control panel 3505 and a multi-element metering machine 3510, the control panel 3505 may be individually associated with and control each element of the automatic production system for debris and projectile resistant panels 3400, the multi-element metering machine 3510 may be in fluid communication with the spray gun assembly 3440. The metering machine 3510 may include a pair of fluid storage tanks 3511, 3513 for separately storing the polymer matrix and isocyanate, and a pair of heat exchangers 3512, 3514 for cooling the returned polymer matrix and isocyanate as they are returned to their respective storage tanks 3511, 3513. The meter 3510 may also include hydraulic pump systems 3516, 3518, 3525, each connected to only one of the pair of fluid storage tanks 3511, 3513. The hydraulic pump systems 3516, 3518, 3525 may also be in fluid communication with the spray gun 3440 via a plurality of supply conduits that may be supported by a swing arm unit 3520, which swing arm unit 3520 may include a two-part rotatable vertical portion 3522, the two-part rotatable vertical portion 3522 having a fixed lower portion and a rotatable upper portion that may be fixedly attached to the spray bar portion 3524 such that the rotatable upper portion and the spray bar portion 3524 may move in unison with the spray gun 3440. The metering machine 3510 may also include a power source that powers the gun 3440 and the hydraulic pump systems 3516, 3518, 3525, all under control of the control panel 3505.

FIG. 36 is a cross-sectional view of the automated fragment and projectile resistant panel production system taken along line 36-36 of FIG. 34, in accordance with one embodiment of the present invention. In fig. 36, a substantially triangular spray pattern shown from spray head 3441 of spray gun 3440 indicates that spray gun 3440 is operating.

FIG. 37 is a top view of a cross-section of a vehicle having pre-positioned anchor posts for anchoring a debris and projectile resistant panel to the vehicle in accordance with one embodiment of the present invention. In fig. 37, a portion of the vehicle surface 3700 may include, for example and without limitation, a floor (floor pan)3710 having a plurality of substantially evenly spaced, pre-positioned posts 3720. Alternatively, portions of the vehicle surface 3700 may also include walls, doors, and/or ceilings (roof pan). In other embodiments, it is contemplated that: the pre-positioned posts 3720 may not be evenly spaced, but may be spaced around the bottom plate 3710 to conform to the shape of the bottom plate 3710 to minimize loose and/or poor fit portions between the bottom plate 3710 and the debris and projectile resistant plates mounted thereon. The pre-positioned post may be solid, smooth and/or threaded, and partially hollow with internal and/or external threads.

Alternatively, the vehicle surface 3700 in fig. 37 may not actually be within a vehicle, but may be a separate mold having similar properties to the other molds described herein. Thus, the vehicle surface 3700 may be designed and reused to make new pre-formed debris and projectile resistant panels that may be installed in vehicles of similar construction. Generally, if the vehicle surface 3700 is a cast mold, the pre-positioned posts 3720 will be solid and unthreaded so that the molded plate can be easily removed.

Fig. 38 is a side view in cross-section of the vehicle chassis, walls, doors and/or roof in fig. 37, according to an embodiment of the invention. In fig. 38, the release agent layer 3810 may be applied directly to the chassis 3710 and the plurality of substantially evenly spaced pre-positioned posts 3720, and the elastomer layer 3820 may be applied directly to the release agent layer 3810 and the plurality of substantially evenly spaced pre-positioned posts 3720. Both the release agent layer 3810 and the elastomer layer 3820 may be applied by spraying, rolling, brushing, troweling, pouring, etc., and any release agent layer 3810 and elastomer layer 3820 that may cover the plurality of substantially evenly spaced pre-positioned posts 3720 may be removed using a sharp cutting tool, such as a utility knife, a disk cutter, etc., to expose each of the plurality of substantially evenly spaced pre-positioned posts 3720. Washers and/or other fastening mechanisms 3830, such as, but not limited to, at least those described above in fig. 9, 10, 11, and 12, may be formed to substantially conform to the shape of the chassis 3710. A locking mechanism 3840, such as, but not limited to, a nut, a locking nut, or the like, may be secured to each of the plurality of substantially evenly spaced pre-positioned posts 3720, and each locking mechanism may be tightened down onto a respective fastening mechanism 3830 to securely retain the elastomeric layer 3820 to the chassis 3710.

In other embodiments of the invention, the elastomeric layer 3820 in fig. 38 may also include one or more fabric layers embedded in the elastomeric layer 3820, and both the elastomeric layer 3820 with and without a fabric layer may be applied directly to the chassis plate 3710.

FIG. 39 is an open side view of a prefabricated wall system having debris and projectile resistant panels embedded therein according to one embodiment of the present invention. In fig. 39, prefabricated wall system 3900 can be made in a variety of heights (e.g., without limitation, 6 ', 8 ', 9 ', etc.), widths (e.g., without limitation, 18 ", 2 ', 4 ', 6 ', 8 ', etc.), and thicknesses (e.g., without limitation, 4", 6 ", 8", etc.), and prefabricated wall system 3900 can include two outer vertical support members 3910 attached to opposite ends of top plate 3920 and opposite ends of bottom plate. Although fig. 39 shows only a single roof and floor and solid wall, it is contemplated that two or more roofs and/or floors may be used in alternative embodiments, and that openings for windows and doors may be constructed that may include a plurality of adjoining outer and/or inner vertical support members and header supports. Prefabricated wall system 3900 may also include a plurality of internal vertical support members 3940, typically, plurality of internal vertical support members 3940 are substantially equally spaced between external vertical supports 3910, and each internal vertical support 3940 is attached at opposite ends to a top plate 3920 and a bottom plate 3930.

In fig. 39, prefabricated wall system 3900 may further include explosion proof plates 3950, and explosion proof plates 3950 may be attached to the front, back, and/or middle of prefabricated wall system 3900. Prefabricated wall system 3900 may also include a plurality of vertical frame members 3960, and the plurality of vertical frame members 3960 may be attached to interior sides 3911 of each of the plurality of vertical frame members 3960. Prefabricated wall system 3900 may also include a plurality of horizontal bottom frame members 3970, which may be attached to interior sides 3911 of bottom plate 3930 between outer vertical support members 3910 and the plurality of inner vertical support members 3940, and may also include a plurality of horizontal top frame members 3980, which may be attached to interior sides 3921 of top plate 3920 between opposite ends of each of outer vertical support members 3910 and the plurality of inner vertical support members 3940. A burst panel 3950 may be attached to each vertical support member 3910, 3940 and each horizontal vertical member 3970, 3980, and may further be attached to each individual frame member 3960, 3970, 3980.

Fig. 40 is a partial cross-sectional view of the prefabricated wall system of fig. 40 having debris and projectile resistant panels embedded therein, taken along line 40-40, according to one embodiment of the present invention. In fig. 40, prefabricated wall system 3900 may include vertical fastening device 4010, said vertical fastening device 4010 being inserted vertically into each of plurality of horizontal top framing members 3980 and into top plate 3920, thereby attaching plurality of horizontal top framing members 3980 thereto. Similarly, horizontal fastening device 4020 may be inserted horizontally into each of the plurality of horizontal top frame members 3980 on one side of prefabricated wall system 3900 and through debris and projectile resistant plate 3950 and into the other plurality of horizontal top frame members 3981 on the other side of debris and projectile resistant plate 3950. Horizontal fastening devices 4020 may be inserted into the plurality of horizontal top frame members 3980 from both sides of prefabricated wall system 3900. Likewise, vertical fastening device 4010 may also be inserted through horizontal framing members 3980 into top plate 3920, or through top plate 3920 into horizontal framing members 3980. Both fastening means 4010, 4020 may include, but are not limited to, screws, nails, lag bolts, nuts/bolts/washers, etc., and may also be used with and/or without adhesive between the frame and the plate/vertical support members. Although not shown for ease of illustration, horizontal and vertical fastening devices 4020, 4010 may be used at floor 3930.

As shown in fig. 40, typically, an explosion and projectile resistant panel 3950 may be disposed in the center of the prefabricated wall system 3900. Thus, the plurality of internal vertical support members 3940 may be longitudinally split into two substantially equal halves between which the explosion proof and projectile panel 3950 may be sandwiched. Although not shown, in some embodiments, the horizontal fastening devices 4020 may be used to fasten the two halves and the explosion proof and projectile plate 3950 together with or without an adhesive between the explosion proof and projectile plate 3950 and the horizontal fastening devices 3950.

Fig. 41 is a side view of the prefabricated wall system in fig. 40 with debris and projectile resistant panels embedded therein, according to another embodiment of the present invention. In fig. 41, an explosion and projectile resistant panel 3950 is shown inserted into an opening extending through and along a longitudinal axis of one of the plurality of inner vertical support members 3940. Explosion and projectile resistant panel 3950 may be extruded around its perimeter and attached to frames 3960, 3970, 3980 using the fastening and adhesive means described herein.

FIG. 42 is a close-up side view of the top of the prefabricated wall system of FIG. 41 with debris and projectile resistant panels embedded therein, according to one embodiment of the present invention. In fig. 42, it can be seen that one of the inner vertical support members 3940 has a slot/opening 4210 along its longitudinal axis through which slot/opening 4210 an explosion and projectile resistant plate 3950 is placed. Explosion and projectile resistant plate 3950 may be a single piece to extend the length of prefabricated wall system 3900 and is slotted at its top and bottom at a predetermined distance to enable it to pass through slots/openings 4210 in each of the internal vertical support members 3940 of prefabricated wall system 3900. Horizontal fastening device 4020 may be inserted into horizontal frame 3980 on one side of prefabricated wall system 3900, through explosion proof and ballistic panel 3950 and into horizontal frame 3980 on the other side of explosion proof and ballistic panel 3950.

Although not shown, horizontal fastening device 4020 may also be inserted on and through one side of each inner vertical support member 3940 that is vertical and along slot/opening 4210, through explosion and projectile resistant plate 3950 and into the other side of inner vertical support member 3940. Adhesive may also be used between the frame and the blast proof and projectile plate 3950 and in the slot/opening 4210 located between the inner vertical support member 3904 and the blast proof and projectile plate 3950 inserted therein.

In fig. 42, the explosion proof and projectile plate 3950 may also be provided as a plurality of separate portions and secured together, for example, but not limited to, within the slot/opening 4210. This can be achieved by: the edges of adjacent portions of the explosion proof and projectile panels 3950 of adjacent panels are overlapped and a plurality of horizontal fastening devices 4020 are inserted from one side of inner vertical support member 3940, through the explosion proof and projectile panels 3950 in groove/opening 4210 and into the other side of inner vertical support member 3940. This may or may not use adhesive within slot/opening 4210.

It can thus be seen that the present invention provides an economical means of greatly improving the safety of workers and/or equipment or other objects within a building or other structure which is subjected to blast shock waves or other forms of large impacts which would otherwise cause wall fragments to pass through the interior of the structure. The system of the present invention may be readily incorporated into existing buildings and structures, particularly when using pre-sprayed panels, or may be incorporated into any new building or structure being constructed. The finished interior wall may have substantially the same appearance as an interior wall not equipped with the system of the present invention, so as not to affect the aesthetics of the workplace.

Although the system and method of the present invention is disclosed primarily for shielding the interior of a wall and receiving debris produced by the wall under an explosion or other impact, it is believed that the system and method of the present invention, particularly in the form of a panel, provides a high level of penetration resistance in the event of a more concentrated or localized impact. As such, it is desirable that the panels or systems be suitable for use as armor "panels" in applications requiring energy absorption and resistance to penetration by, for example, the generally smaller projectiles fired by rifles and other firearms and guns, including use in defeating or resisting projectiles designed to "pierce armor" in nature. Such features described herein may be summarized by the term "blast-proof" and, as the term is used herein, such features are used for "debris acceptance".

The foregoing description is provided for the purpose of illustration. Variations and modifications to the embodiments described herein will be apparent to those skilled in the art upon reading the present disclosure, provided they do not depart from the spirit and scope of the invention.

Claims (170)

1. An explosion proof panel, comprising:

a layer of pre-cured elastomeric material having a predetermined thickness, a body portion, and a plurality of flanges, each of the plurality of flanges having a substantially equal width and depending from the same side of the body portion at an angle approximately equal to a right angle, an

A plurality of fastening elements for securing the layer of pre-cured elastomeric material to the surface of the structure through the plurality of flanges of the layer of pre-cured elastomeric material.

2. The panel of claim 1, wherein the elastomeric material is selected from the group consisting of polyurea, polysiloxane, polyurethane, and polyurea/polyurethane blends.

3. The panel of claim 2 wherein the elastomeric material is a polyurea material.

4. The panel of claim 2 wherein said elastomeric material has an elongation at break in the range of about 100 and 800% and has a tensile strength of greater than about 2000 psi.

5. The panel of claim 4 wherein said elastomeric material has an elongation at break in the range of about 400 and 800%.

6. The panel of claim 1 wherein the pre-cured layer of elastomeric material of a predetermined thickness is formed by spraying an uncured layer of elastomeric material to a predetermined thickness.

7. The panel of claim 6 wherein the elastomeric material is selected from the group consisting of polyurea, polysiloxane, polyurethane, and polyurea/polyurethane blends.

8. The panel of claim 7 wherein the elastomeric material is a polyurea material.

9. The panel of claim 7 wherein said elastomeric material has an elongation at break in the range of about 100 and 800% and has a tensile strength of greater than about 2000 psi.

10. The panel as in claim 9, wherein said elastomeric material has an elongation at break in the range of about 400-800%.

11. The panel of claim 6, said spraying of said layer of elastomeric material further comprising spraying the elastomeric material onto a fabric reinforcement layer.

12. The panel according to claim 1, said pre-cured layer of elastomeric material of predetermined thickness comprising at least two opposing flanges.

13. The panel of claim 12 further comprising a fabric reinforcement layer in an elastomeric material comprising a body portion and at least two opposing flanges.

14. The panel of claim 1, wherein the plurality of fastening elements comprise at least one of U-shaped channels of various lengths, Z-shaped channels of various lengths, continuous fastening strips of various lengths, discontinuous fastening strips of various lengths, and washers.

15. The panel of claim 14, wherein the plurality of fastening elements further comprises at least one of a plurality of nails, a plurality of screws, a plurality of concrete nails, and a plurality of concrete screws.

16. The panel of claim 14, wherein the plurality of fastening elements further comprise glue or epoxy.

17. A method for making an explosion proof panel, the method comprising:

spraying a layer of elastomeric material having a predetermined thickness to form a blast-resistant panel comprising a body portion and a plurality of flanges, each of the plurality of flanges having substantially equal widths and depending from the same side of the body portion at an angle approximately equal to a right angle;

curing the sprayed explosion-proof plate; and

a plurality of fastening elements are provided for securing the cured blast resistant panel to a surface of the structure through the plurality of flanges of the cured layer of elastomeric material.

18. The method of claim 17, wherein the elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

19. The method of claim 18, wherein the elastomeric material is a polyurea material.

20. The method of claim 18 wherein the elastomeric material has an elongation at break in the range of about 100 and 800% and has a tensile strength of greater than about 2000 psi.

21. The method of claim 20 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

22. The method of claim 17, wherein the cured layer of elastomeric material of a predetermined thickness is formed by spraying a layer of uncured elastomeric material to a predetermined thickness.

23. The method of claim 22, wherein the elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

24. The method of claim 23, wherein the elastomeric material is a polyurea material.

25. The method of claim 23 wherein the elastomeric material has an elongation at break in the range of about 100 and 800% and has a tensile strength of greater than about 2000 psi.

26. The method of claim 25 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

27. The method of claim 22, the spraying of the layer of elastomeric material further comprising spraying the elastomeric material onto a fabric reinforcing layer.

28. The method according to claim 17, wherein said pre-cured layer of predetermined thickness of elastomeric material comprises at least two opposing flanges.

29. The method of claim 28, further comprising a fabric reinforcement layer in the elastomeric material, the elastomeric material comprising a body portion and at least two opposing flanges.

30. The method of claim 29, wherein the plurality of fastening elements comprises at least one of U-shaped channels of various lengths, Z-shaped channels of various lengths, continuous fastening strips of various lengths, discontinuous fastening strips of various lengths, and washers.

31. The method of claim 30, wherein the plurality of fasteners further comprises at least one of a plurality of nails, a plurality of screws, a plurality of concrete nails, and a plurality of concrete screws.

32. The method of claim 31, wherein the plurality of fastening elements further comprises glue or epoxy.

33. A system for preparing a blast-resistant panel, the system comprising:

means for spraying a layer of elastomeric material having a predetermined thickness to form a blast-resistant panel comprising a body portion and a plurality of flanges, each of said plurality of flanges having a substantially equal width and depending from the same side of said body portion at an angle approximately equal to a right angle;

means for curing the sprayed blast-resistant panel; and

means for providing a plurality of fastening elements that secure the cured blast resistant panel to a surface of a structure through the plurality of flanges of the cured layer of elastomeric material.

34. The system of claim 33, wherein the elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

35. The system of claim 34, wherein the elastomeric material is a polyurea material.

36. The system of claim 34 wherein the elastomeric material has an elongation at break in the range of about 100 and 800% and has a tensile strength of greater than about 2000 psi.

37. The system of claim 36 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

38. The system of claim 33, wherein the cured layer of elastomeric material of a predetermined thickness is formed by a device for spraying an uncured layer of elastomeric material to a predetermined thickness.

39. The system of claim 38, wherein the elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

40. The system of claim 39, wherein the elastomeric material is a polyurea material.

41. The system of claim 39 wherein the elastomeric material has an elongation at break in the range of about 100 and 800% and has a tensile strength of greater than about 2000 psi.

42. The system of claim 41 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

43. The system of claim 38, wherein the means for spraying the layer of elastomeric material further comprises means for spraying uncured elastomeric material onto the fabric reinforcing layer.

44. The system of claim 33, wherein the pre-cured layer of predetermined thickness of elastomeric material comprises at least two opposing flanges.

45. The system of claim 44, further comprising a fabric reinforcement layer in an elastomeric material comprising a body portion and at least two opposing flanges.

46. The system of claim 45, wherein the plurality of fastening elements comprises at least one of a plurality of lengths of U-shaped channels, a plurality of lengths of Z-shaped channels, a plurality of lengths of continuous fastening strips, a plurality of lengths of non-continuous fastening strips, and a plurality of washers.

47. The system of claim 46, wherein the plurality of fastening elements further comprises at least one of a plurality of nails, a plurality of screws, a plurality of concrete nails, and a plurality of concrete screws.

48. The system of claim 47, wherein the plurality of fastening elements further comprise glue or epoxy.

49. A method, comprising:

applying a layer of release agent directly onto a surface of at least one wall of the object;

applying a layer of elastomeric material to the layer of release agent to a predetermined thickness; and

securing the layer of elastomeric material to the wall with a mechanical fastener, wherein the mechanical fastener passes through the elastomeric material and the layer of release agent and into the wall and anchors the mechanical fastener within the wall.

50. The method of claim 49, wherein said elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

51. The method of claim 50, wherein the elastomeric material is a polyurea material.

52. The method of claim 50 wherein the elastomeric material has an elongation at break in the range of about 100-800% and has a tensile strength of greater than about 2000 psi.

53. The method of claim 52 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

54. The method of claim 49, wherein said applying a layer of elastomeric material to a predetermined thickness comprises:

the layer of elastomeric material is sprayed to a predetermined thickness.

55. The method of claim 54, wherein said elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

56. The method of claim 55, wherein said elastomeric material is a polyurea material.

57. The method of claim 55 wherein the elastomeric material has an elongation at break in the range of about 100 and 800% and has a tensile strength of greater than about 2000 psi.

58. The method of claim 57 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

59. The method of claim 54, wherein said spraying a layer of elastomeric material further comprises spraying the elastomeric material onto a fabric reinforcing layer.

60. The method of claim 49, wherein applying the layer of mold release agent directly to the surface of the at least one wall of the object comprises spraying the layer of mold release agent directly onto the surface of the at least one wall of the object.

61. The method of claim 60, wherein said spraying a layer of elastomeric material further comprises applying a fabric reinforcing layer to said layer of release agent and spraying an elastomeric material onto said fabric reinforcing layer.

62. A system, comprising:

means for applying a layer of release agent directly to a surface of at least one wall of the object;

means for applying a layer of elastomeric material to the layer of release agent to a predetermined thickness; and

means for securing said layer of elastomeric material to said wall by means for securing through said layer of elastomeric material and said release agent and into and anchoring within said wall.

63. The system of claim 62, wherein the elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

64. The system of claim 63, wherein the elastomeric material is a polyurea material.

65. The system of claim 63 wherein the elastomeric material has an elongation at break in the range of about 100 and 800% and has a tensile strength of greater than about 2000 psi.

66. The system of claim 65 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

67. The system of claim 62, wherein the means for applying the layer of elastomeric material to the layer of release agent to a predetermined thickness comprises:

and a sprayer for spraying the elastomer material layer to a predetermined thickness on the release agent layer.

68. The system of claim 67, wherein the elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

69. The system of claim 68, wherein the elastomeric material is a polyurea material.

70. The system of claim 68 wherein the elastomeric material has an elongation at break in the range of about 100-800% and has a tensile strength of greater than about 2000 psi.

71. The system of claim 70, wherein the elastomeric material has an elongation at break in the range of about 400-800%.

72. The system of claim 62, wherein the means for applying the layer of release agent directly to the wall surface of the target layer of polymeric material comprises a release agent sprayer that sprays the layer of release agent directly onto the wall surface of the target.

73. A reinforced wall section, comprising:

a first side portion substantially U-shaped and having an open end along a first end length;

a second side portion that is substantially U-shaped and has an open end along a length of the second end, and the open end of each of the first and second side portions face each other;

a bottom plate portion including a first end and a second end, the first end of the bottom plate being attached to a bottom end of the first side portion, and the second side of the bottom plate being attached to a bottom end of the second side portion;

a top panel portion including a first end and a second end, the first end of the top panel being attached to the top end of the first side portion and the second end of the top panel being attached to the top end of the second side portion;

elastomeric plates attached to the opposing vertical ends along respective lengths of the first and second ends and defining a substantially square channel along the lengths of the first and second ends, the explosion-proof elastomeric plates also being attached to the bottom panel portion along a length of the bottom panel portion and to the top panel portion along a length of the top panel portion; and

a foam insulator disposed within and substantially filling the substantially square channel.

74. The reinforced wall section of claim 73, further comprising:

a middle portion, substantially I-shaped, having a first side with a first side open end along a length of the middle portion and an opposing second side with a second side open end along the length of the middle portion, wherein the middle portion is disposed between and attaches the first and second end portions to the top and bottom panels; and

an elastomeric plate attached to the opposing vertical portions along the length of the middle portion.

75. The reinforced wall section of claim 74, wherein the elastomeric sheet is attached to the first side section and the second side section using mechanical fasteners.

76. The reinforced wall section of claim 75, wherein the elastomeric sheet is further attached to the top and bottom panel sections using mechanical fasteners.

77. The reinforced wall section of claim 73, wherein the elastomeric sheet is attached to the first side section and the second side section using mechanical fasteners.

78. A reinforced wall section as claimed in claim 77, wherein the elastomeric sheet is further attached to the top and bottom panel sections using mechanical fasteners.

79. The reinforced wall section of claim 74, wherein the elastomeric sheet includes a wedge portion on each edge adapted to fit into and adhere to a complementary grooved portion along the first side section.

80. A reinforced wall section as claimed in claim 79, wherein the elastomeric sheet is further attached to the top and bottom panel sections.

81. The reinforced wall section of claim 73, further comprising:

a middle portion that is substantially I-shaped and has a first side and an opposing second side, wherein the first side has a first side open end along a length of the middle portion and the second side has a second side open end along the length of the middle portion, wherein the middle portion is disposed between and attaches the first and second end portions to the top and bottom panels; and

an elastomeric plate attached to the opposing vertical portions along the length of the middle portion.

82. An explosion proof concrete wall section comprising:

an explosion-proof elastomeric plate;

a metal cage surrounding and maintaining the explosion-proof elastomeric plate in a substantially constant central position; and

and a concrete portion substantially completely enclosing the metal cage and the explosion-proof elastomer plate.

83. The blast-resistant concrete wall section of claim 82, wherein said blast-resistant elastomer panel comprises:

a plurality of blast-resistant elastomeric panels coupled together using at least one channel connector and a plurality of fasteners.

84. The blast-resistant concrete wall section of claim 82, wherein said metal cage comprises:

a plurality of metal support members oriented at an angle substantially normal to a face of the explosion-proof elastomer plate and passing through the explosion-proof elastomer plate and then joined together with the first and second sides of the metal cage.

85. The blast-resistant concrete wall section of claim 82, wherein said blast-resistant elastomer panel and metal cage are substantially completely encased within the concrete portion of the blast-resistant concrete wall.

86. A method of making a blast-resistant concrete wall section, the method comprising:

positioning a plate of an explosion proof elastomer within the metal cage to surround and maintain the plate of the explosion proof elastomer in a substantially constant centered position within the metal cage;

positioning the combination of the metal cage and the blast-resistant elastomeric panel substantially in the middle of the concrete wall form; and

pouring concrete into the concrete wall form to substantially encase and seal the combination of the metal cage and the explosion proof elastomer plate;

allowing the concrete to cure; and

the concrete wall form is removed.

87. The method of claim 86, further comprising:

a plurality of blast-resistant elastomer panels are connected together using at least one channel connector and a plurality of fasteners.

88. The method of claim 87, wherein the metal cage comprises:

a plurality of metal support members positioned at substantially orthogonal angles to the face of the panel of explosion proof elastomer, and said metal support members pass through said panel of explosion proof elastomer and then join together the first and second sides of the metal cage.

89. The method of claim 82, further comprising:

the explosion proof elastomer plate and the metal cage are substantially completely enclosed in the concrete portion.

90. An explosion proof concrete wall section comprising:

an explosion-proof elastomeric plate;

a metal cage surrounding and holding the explosion-proof elastomer plate in a substantially constant central position; and

a concrete portion substantially completely surrounding the metal cage and the explosion proof elastomer plate.

91. The blast-resistant concrete wall section of claim 90, wherein the blast-resistant elastomer panel comprises:

a plurality of blast-resistant elastomeric panels coupled together using at least one channel connector and a plurality of fasteners.

92. The blast-resistant concrete wall section of claim 90, wherein the metal cage comprises:

a plurality of metal support members positioned at substantially orthogonal angles to the face of the panel of explosion proof elastomer, and which pass through the panel of explosion proof elastomer and then join the first and second sides of the metal cage together.

93. The blast-resistant concrete wall section of claim 90, wherein the blast-resistant elastomer panel and the metal cage are substantially completely enclosed within the concrete portion of the blast-resistant concrete wall.

94. An explosion proof concrete wall section comprising:

a metal cage;

a concrete portion substantially completely surrounding said metal cage; and

an explosion proof elastomer panel disposed on and substantially completely covering a vertical surface of the concrete portion.

95. The blast-resistant concrete wall section of claim 94, wherein said blast-resistant elastomer panel comprises:

a plurality of blast-resistant elastomeric panels coupled together using at least one channel connector and a plurality of fasteners.

96. A method of making a blast-resistant concrete wall section, the method comprising:

positioning a blast-resistant elastomer panel within and against a side of a concrete wall form;

positioning a metal cage substantially in the middle of a concrete wall form;

pouring concrete into the concrete wall form to substantially surround and seal the metal cage and to force and hold the blast-resistant elastomer panel against one side of the concrete wall form;

allowing the concrete to cure; and

and removing the concrete wall formwork.

97. The method of claim 96, further comprising:

the panel is formed by joining a plurality of panels together using at least one channel connector and a plurality of fasteners.

98. An explosion proof concrete wall section comprising:

means for positioning a blast-resistant elastomer panel in and against a side of a concrete wall form;

means for positioning a metal cage substantially in the middle of said concrete wall form;

means for pouring concrete into the concrete wall form such that the concrete substantially surrounds and seals the metal cage and forces and holds the explosion proof elastomer plate against one side of the concrete wall form;

means for curing the concrete; and

means for removing said concrete wall form from around the panel and concrete.

99. The blast-resistant concrete wall section of claim 98, further comprising:

apparatus for forming a panel of explosion proof elastomer by joining a plurality of panels of explosion proof elastomer together using at least one channel connector and a plurality of fasteners.

100. A method, comprising:

applying a layer of release agent directly to a plurality of surfaces adjacent to a wall of a structure;

applying a layer of elastomeric material to a predetermined thickness over the layer of release agent on the plurality of surfaces adjacent the wall of the structure; and

securing the layer of elastomeric material to a structure adjacent the wall with a mechanical fastener that passes through the layer of elastomeric material and release agent and into the structure and anchors the mechanical fastener within the structure.

101. The method of claim 100, wherein the elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

102. The method of claim 101, wherein the elastomeric material is a polyurea material.

103. The method of claim 101 wherein the elastomeric material has an elongation at break in the range of about 100-800% and has a tensile strength of greater than about 2000 psi.

104. The method of claim 103 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

105. The method of claim 100, wherein said applying a layer of elastomeric material to a predetermined thickness comprises:

a layer of elastomeric material is sprayed to a predetermined thickness on a plurality of surfaces adjacent to the wall of the structure.

106. The method of claim 100, wherein said securing a layer of elastomeric material to a structure adjacent to said wall with a mechanical fastener comprises:

securing the layer of elastomeric material to the floor and ceiling adjacent the wall with mechanical fasteners that pass through the layer of elastomeric material and release agent and into the floor and ceiling and anchor the mechanical fasteners within the floor and ceiling.

107. The method of claim 105, wherein said spraying a layer of elastomeric material onto a plurality of surfaces adjacent to a wall of a structure further comprises: the elastomeric material is sprayed onto the fabric reinforcement layers located on the various surfaces adjacent the walls of the structure.

108. A system, comprising:

means for applying a layer of release agent directly to a plurality of surfaces adjacent to a wall of a structure;

means for applying a layer of elastomeric material to a predetermined thickness on the release agent layer on the plurality of surfaces adjacent the wall of the structure; and

means for securing a layer of elastomeric material to a structure adjacent the wall using a mechanical fastener that passes through the elastomeric material and the layer of release agent and into the structure and anchors the mechanical fastener within the structure.

109. The system of claim 108, wherein said applying a layer of elastomeric material to a predetermined thickness comprises:

spraying a layer of elastomeric material to a predetermined thickness on a plurality of surfaces adjacent to the wall of the structure.

110. The system of claim 108, wherein said securing said layer of elastomeric material to a structure adjacent said wall with a mechanical fastener comprises:

securing the layer of elastomeric material to the floor and ceiling adjacent the wall with mechanical fasteners that pass through the layer of elastomeric material and release agent and into the floor and ceiling and anchor the mechanical fasteners within the floor and ceiling.

111. The system of claim 109, wherein said spraying a layer of elastomeric material onto a plurality of surfaces adjacent to a wall of a structure further comprises: the elastomeric material is sprayed onto the fabric reinforcement layers located on the various surfaces adjacent the walls of the structure.

112. A method, comprising:

applying a cured and preformed elastomeric sheet to a column within a structure, the preformed elastomeric sheet substantially conforming in shape to the column; and

a cured and preformed elastomeric sheet is secured to the columns using a plurality of brackets and a plurality of mechanical fasteners.

113. The method of claim 112, wherein said elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

114. The method of claim 113, wherein the elastomeric material is a polyurea material.

115. The method of claim 113 wherein the elastomeric material has an elongation at break in the range of about 100-800% and has a tensile strength of greater than about 2000 psi.

116. The method of claim 115 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

117. The method of claim 112, wherein said fastening a cured and preformed elastomeric sheet to the column using a plurality of brackets and a plurality of mechanical fasteners comprises:

securing the elastomeric sheet around a seam of an elastomeric sheet with a bracket and a mechanical fastener, and passing the mechanical fastener through the bracket and the elastomeric sheet into the column and anchoring the mechanical fastener within the column.

118. A system, comprising:

means for applying a cured and preformed elastomeric sheet to a column within a structure, the preformed elastomeric sheet substantially conforming in shape to the column; and

means for securing the cured and preformed elastomeric plates to the columns.

119. The system of claim 118, wherein the means for securing the cured and preformed elastomeric plate to the column comprises:

a plurality of brackets adapted to conform to a shape of a portion of a column and a plurality of fasteners passing through the plurality of brackets and the preformed elastomeric plate and into the column.

120. The system of claim 118, wherein the plurality of brackets comprises at least one of a plurality of L-shaped brackets and a plurality of L-shaped slotted brackets.

121. The system of claim 118, wherein the plurality of fasteners comprises:

at least one of a plurality of concrete nails, a plurality of concrete screws, a plurality of nails, and a plurality of screws.

122. The system of claim 121, wherein the plurality of fasteners further comprises:

glue and/or adhesive.

123. The system of claim 122, wherein the plurality of fasteners comprises at least one of: a plurality of concrete nails, a plurality of concrete screws, a plurality of nails, and a plurality of screws.

124. The system of claim 118, wherein the preformed elastomeric plate comprises at least two portions.

125. The system of claim 118, wherein the preformed elastomeric plate further comprises a fabric layer embedded within the elastomeric plate.

126. A method, comprising:

applying a plurality of cured and preformed elastomeric sheets to an exterior surface of a tunnel, wherein the preformed sheets substantially conform in shape to the exterior surface of the tunnel; and

the cured and preformed elastomeric sheet is fastened to the exterior of the tunnel using a plurality of brackets and a plurality of mechanical fasteners.

127. The method of claim 126, wherein said elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

128. The method of claim 127, wherein the elastomeric material is a polyurea material.

129. The method of claim 127 wherein the elastomeric material has an elongation at break in the range of about 100-800% and has a tensile strength of greater than about 2000 psi.

130. The method of claim 126, wherein the elastomeric material has an elongation at break in the range of about 400-800%.

131. The method of claim 126, wherein said fastening the cured and preformed elastomeric sheet to the exterior of the tunnel with a plurality of brackets and a plurality of mechanical fasteners comprises:

securing the preformed elastomeric sheets around the outer surface of the tunnel such that each sheet is in intimate contact with each adjacent sheet; and

sealing a plurality of seams between the secured preformed elastomeric sheets.

132. A system, comprising:

means for applying a plurality of cured and preformed elastomeric sheets to the outer surface of the tunnel, wherein the preformed elastomeric sheets substantially conform in shape to the outer surface of the tunnel; and

means for fastening a cured and preformed elastomeric sheet to the exterior of the tunnel using a plurality of brackets and a plurality of mechanical fasteners.

133. The system of claim 132, wherein the means for securing the cured and preformed elastomeric sheet to the exterior of the tunnel comprises:

a plurality of brackets adapted to conform to a shape of a portion of the exterior of the tunnel, and a plurality of fasteners passing through the plurality of brackets and the preformed elastomeric plate and into the exterior of the tunnel.

134. The system of claim 132, wherein the plurality of carriages comprises at least one of:

a plurality of curved brackets, a plurality of short straight brackets, and a plurality of washers.

135. The system of claim 132, wherein the plurality of fasteners comprises at least one of:

a plurality of concrete nails, a plurality of concrete screws, a plurality of nails, and a plurality of screws.

136. The system of claim 135, wherein the plurality of fasteners further comprises:

adhesives and/or glues.

137. The system of claim 136, wherein the plurality of fasteners comprise at least one of:

a plurality of concrete nails and a plurality of concrete screws.

138. An explosion proof panel, comprising:

a cured and preformed elastomeric sheet having a predetermined shape and thickness and adapted to fit an interior surface of a structure, wherein the preformed elastomeric sheet substantially conforms in shape to the interior surface of the structure; and

a fastening system for fastening the cured and preformed elastomeric sheet within the interior of the structure.

139. The blast-resistant panel of claim 138, wherein a fastening system for fastening the cured and preformed elastomeric panel to the interior of the structure comprises:

a plurality of bolts;

at least one of a continuous fastening strip, a plurality of discontinuous fastening strips, a plurality of washers; and a plurality of nuts.

140. A method, comprising:

applying a plurality of cured and preformed elastomeric sheets to an exterior surface of a tunnel, wherein the preformed elastomeric sheets substantially conform in shape to the exterior surface of the tunnel; and

a cured and preformed elastomeric sheet is secured to the exterior of the tunnel using a plurality of brackets and a plurality of mechanical fasteners.

141. The method of claim 140, wherein the elastomeric material is selected from the group consisting of polyureas, polysiloxanes, polyurethanes, and polyurea/polyurethane mixtures.

142. The method of claim 141, wherein the elastomeric material is a polyurea material.

143. The method of claim 141 wherein the elastomeric material has an elongation at break in the range of about 100-800% and has a tensile strength of greater than about 2000 psi.

144. The method of claim 140 wherein the elastomeric material has an elongation at break in the range of about 400-800%.

145. The method of claim 140, wherein said securing the plurality of cured and preformed elastomeric plates outside of the tunnel with a plurality of brackets and a plurality of mechanical fasteners comprises:

securing the preformed elastomeric plates around the outer surface of the tunnel so that each plate is in intimate contact with an adjacent plate; and

sealing a plurality of seams between the secured preformed elastomeric plates.

146. A system, comprising:

for applying a plurality of cured and preformed elastomeric sheets to an exterior surface of a tunnel, wherein the preformed elastomeric sheets substantially conform in shape to the exterior surface of the tunnel; and

means for securing a cured and preformed elastomeric sheet to the exterior of the tunnel using a plurality of brackets and a plurality of mechanical fasteners,

147. The system of claim 146, wherein said means for securing said cured and preformed elastomeric sheet outside of said tunnel comprises:

a plurality of brackets adapted to conform to a shape of a portion of an exterior of the tunnel and a plurality of fasteners passing through the plurality of brackets and the preformed elastomeric plate and into the exterior of the tunnel.

148. The system of claim 146, wherein the plurality of carriages comprises at least one of:

a plurality of curved brackets, a plurality of short straight brackets, and a plurality of washers.

149. The system of claim 146, wherein the plurality of fasteners comprise at least one of:

a plurality of concrete nails, a plurality of concrete screws, a plurality of nails, and a plurality of screws.

150. The system of claim 149, wherein the plurality of fasteners further comprises:

adhesives and/or glues.

151. The system of claim 149, wherein the plurality of fasteners comprise at least one of:

a plurality of concrete nails and a plurality of concrete screws.

152. The invention substantially as described herein.

153. A machine, comprising:

feeding a first portion of material;

a second portion connecting the first portion, the second portion receiving the material and applying a first layer of elastomer to a first side of a fabric to make an intermediate sheet;

a third portion connecting the second portions, the third portion receiving the intermediate sheet and inverting the intermediate sheet to expose a second side of the material;

a fourth portion connecting the third portions, the fourth portion applying a second layer of elastomer to a second side of the material to produce a finished panel;

a fifth section connecting the fourth sections, the fifth section receiving the finished panel and allowing it to continue to cure; and

a sixth section connecting the fifth section, the sixth section receiving the finished panel, bonding the finished panel to the non-adhesive sheet, and rolling the finished panel and non-adhesive sheet together into a roll.

154. The machine of claim 153, wherein the first portion of feed material comprises at least one of:

a roll of woven material; and

a roll of elongated fibers.

155. The machine of claim 153, wherein said second portion comprises:

means for receiving the fabric from the first portion.

156. The machine of claim 153, wherein said second, fourth and fifth sections comprise:

means for controlling the movement of the sheet.

157. The machine of claim 153, further comprising:

means for cutting the finished panel.

158. A machine, comprising:

means for supplying a material;

means for receiving a material and applying a first layer of elastomer to a first side of the material to produce an intermediate sheet;

means for receiving the intermediate sheet and inverting it to expose a second side of the material;

means for applying a second layer of elastomer to a second side of the material to produce a finished slab;

means for receiving said finished slab for curing thereof; and

means for receiving the finished panel, bonding the finished panel to a non-adhesive sheet, and rolling the finished panel and non-adhesive sheet together into a roll.

159. A method of making a rupture disc, the method comprising:

supplying a material;

receiving the material and applying a first layer of elastomer to a first side of the material to produce an intermediate sheet;

receiving the intermediate sheet and inverting it to expose a second side of the material;

applying the second layer of elastomer to a second side of the material to produce a finished slab;

receiving the finished plate for curing; and

the method includes receiving the finished panel, bonding the finished panel to a non-adhesive sheet, and rolling the finished panel and non-adhesive sheet together into a roll.

160. The machine of claim 159, further comprising:

and cutting the finished plate.

161. A machine, comprising:

means for supplying a material;

means for receiving and securing the material;

means for applying a first layer of elastomer to the plate forming surface;

means for positioning the material on the first layer of elastomer;

means for applying a second layer of elastomer to the material and the first layer of elastomer to produce a finished board; and

means for removing said finished board.

162. The machine of claim 161, further comprising:

means for loading the material into the first layer of elastomer.

163. The machine of claim 161, further comprising:

apparatus for stacking product boards.

164. A method of making a blast-resistant panel, the method comprising:

supplying a material;

receiving and securing the material;

applying a first layer of elastomer to the sheet forming surface;

positioning the material on the first layer of elastomer;

applying a second layer of elastomer to the material and the first layer of elastomer to produce a finished panel; and

and removing the finished board.

165. The method of claim 164, further comprising:

loading the material into the first layer of elastomer.

166. The method of claim 164, further comprising:

and stacking the finished plates.

167. A machine, comprising:

a device capable of supplying a material;

means capable of receiving and securing the material;

means for applying a first layer of elastomer to the plate forming surface;

means capable of positioning said material on said first layer of elastomer;

means for applying a second layer of elastomer to the first layer of elastomer to produce a finished panel; and

means for removing said finished board.

168. The machine of claim 167, further comprising:

means for laminating the finished board.

169. The machine of claim 167, wherein said sheet forming surface is a non-stick material, means for laminating the finished sheet.

170. An apparatus for preparing the product of any of claims 1-16, 73-85, 90-95, 98, 99, 138, and 139.