Ordnance – Shields – Transportable
Reexamination Certificate
1996-07-20
2001-12-11
Johnson, Stephen M. (Department: 3641)
Ordnance
Shields
Transportable
C089S036020, C296S096210
Reexamination Certificate
active
06327954
ABSTRACT:
BACKGROUND OF THE INVENTION
An improved lightweight armored vehicle and cost effective method of retrofitting standard automobiles to make them lightweight armored vehicles is disclosed. Metal caps fit about laminated windows to protect the laminated edges from stress, moisture and atmosphere and fit within the standard automobile's original window frame. Alternative laminated break-in resistant windows fit within a standard automobile's original window frames. Prefabricated rigidly formed lightweight opaque armor is molded to closely fit within the standard automobile. The armor is designed for cost effective on-site manufacture of components and cost effective installation procedures to produce an affordable lightweight armored vehicle.
BRIEF DESCRIPTION OF THE PRIOR ART
The most prevalent method of armoring a standard automobile is by adding steel plate where opaque armor is appropriate, replacing standard window frames with larger window frames and adding laminated transparent armor within the new larger window frames. Such retrofitted armored vehicles are heavy, expensive to manufacture and maintain, have limited maneuverability, and have other deficiencies.
Prior to the present invention, modifying a standard automobile to give it lightweight armored protection generally involved retrofitting the vehicle by stripping its inner furnishings, then measuring the vehicle as needed to determine the needed armor, then preparing, sizing and shaping armor and mountings and modifying the vehicle to accept the armor and mountings, then installing the armor and mountings, trimming the same for final fit during installation, then doing body work as needed to hide the armor and reassembling the interior furnishings of the vehicle. This process was best described in U.S. Pat. Nos. 4,352,316; 4,316,404; 4,336,644; and 4,333,282 the disclosures of which are fully incorporated herein by reference. As discussed there in more detail, the window mechanisms are removed, and a support system installed in each door for supporting a composite lexguard and laminate safety plate glass window in a permanently closed position. Frames are rebuilt to receive and permanently seal with the new sidelights. The automobile's frame is stuffed with flexible bullet resistant material such as woven ballistic cloth which is cut on the spot to fit and glued within the frame. Flat opaque portions of the automobile, including the doors, sidewalls, fire wall and rear seat area are measured and retrofitted with a flat rigidly woven polyester-glass protective layer cut as needed to fit the vehicle together with overlapping flexible layers of woven ballistic polyester glass fibers. The vehicle's top and bottom were equipped with multiple layers of flexible ballistic nylon secured by silicone. The fuel tank was wrapped in flexible ballistic nylon attached with glue to make it become rigid.
The prior method of producing lightweight armored vehicles was time consuming, expensive, and required extensive modification of the vehicle, particularly to accept armored windows. The permanent window mountings made it difficult to replace damaged windows. Body work was required to hide the substantial modification of the vehicle's window frames to accept the thick outer edges of laminated armored windows. The edges of the laminated windows were not adequately sealed from atmosphere and moisture, thus permitting some of the laminated armored windows to delaminate or discolor over time. The ad hoc reframing subjected the edges of the armored windows to stress during manufacture and use. This caused some of the unreinforced armored window edges to crack, particularly in the event of temperature changes. Substantial deconstruction and reconstruction was required to replace delaminated, yellowed or cracked windows because the armored window was permanently installed. The opaque armor, flexible woven ballistic cloth linings, flat rigidly formed plate, etc. was chosen for ease of manufacture and ease of ad hoc adaption of individual armor components to varied vehicles rather than ballistic qualities.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved lightweight armored vehicle, improved components for lightweight armored vehicles and other armored structures and improved methods of manufacturing lightweight armored vehicles and such components.
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Kevlar, Aramid, Lightweight protective armor of Kevlar® aramid, Du Pont (Brochure, pp. 1-8).
Jackson Walker L.L.P.
Johnson Stephen M.
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