Abstract: An assembly comprises a housing, a bezel and a lens, or a housing heat sink, a housing rim, a bezel and a lens, wherein the housing or the housing heat sink comprises a first surface and the bezel or the housing rim comprises a second surface, a portion of a first surface of the housing or housing heat sink is molded to a portion of the second surface forming an interface surface, the interface surface having an interface angle that does not deviate more than 90 degrees, measured from a central axis perpendicular to the bezel and the housing around which the bezel and the housing are molded, for all interface angles about the central axis.

Abstract: Disclosed are insert-molded electronic modules that include an electrical/electronic component and a heat sink that interlocks with, and optionally also encapsulates, the electrical/electronic component to provide thermal management for the component. The heat sink is formed using a thermally conductive thermoplastic polymer composition and replaces the potting compound and thermal interface material typically used in such assemblies. The electrical/electronic component includes openings that allow the thermally conductive thermoplastic polymer composition to flow therethrough and interlock with the electrical/electronic component. The electronic module may include an insert positioned between the electrical/electronic component and the heat sink, wherein the insert includes holes that allow the conductive thermoplastic polymer composition to flow therethrough and interlock with the insert.

Abstract: Reflective coatings comprise a transparent binder, such as polyurethane, one or more reflective additives, such as metal flakes, coated mica or titanium dioxide particles, and a phosphor. Such coatings may be applied to polymer substrates such as polycarbonate, without any additional reflective coating, film or layer. Processes for the mixing and applying the coatings area described, including introducing a polymer substrate into a mold cavity of a mold, introducing a coating composition into the mold cavity containing the polymer substrate in order to coat the substrate, at processing temperature 50° C.-120° C., at processing pressure 11,000 to 20,700 kPa, and curing the composition in the mold cavity at cure temperature of 62-105° C.

Abstract: Processes for in-mold coating of polymer substrates comprising: introducing a plastic substrate into a mold cavity of a mold; introducing a coating composition into the mold cavity containing the plastic substrate in order to coat the substrate, at processing temperature 50° C.-120° C., and at processing pressure 11,000 to 20,700 kPa; and curing the composition in the mold cavity at cure temperature of 62-105° C.; wherein the coating composition comprises a polymer comprising isocyanate-reactive groups; and a polyisocyanate, and wherein the coating composition has a viscosity of 200 to 500 mPa·s at the processing temperature. Further embodiments include attaching electronic circuits, light emitting diodes and/or graphic images to the plastic substrate before coating.

Abstract: The present invention provides a bi-active method of mounting a monolithic polycarbonate sheet or a laminate in a semi-rigid metallic framing system along two parallel sides of a rectangular shaped sheet or laminate with the two shorter parallel sides being unconstrained. In the case of a square shaped sheet, two parallel sides are supported in the semi-rigid frame, and the other two parallel sides are unconstrained. The semi-rigid frame utilizes cylindrically shaped hardware (i.e., bolts, rivets, studs, etc.) to hold the sheet or laminate. The semi-rigid frame is designed, via section and material properties, to flex and hinge about fixed mounting points along the length of the frame.

Abstract: The present invention provides ultrathin polycarbonate panels for use in security isolation cells to provide a transparent and secure barrier between a prisoner and a guard, where the barrier passes flammability test ASTM E-84 Class A. The panel comprises at least one polycarbonate sheet having a thickness between 0.25 mm and 1 mm. Panels may optionally include a metal support and a frame, and the frame may overbite (edge bite) a portion of the polycarbonate panel, and all points of the polycarbonate panel may be located within four frame widths of the frame.

Abstract: The present invention provides a lightweight blast-mitigating polycarbonate laminate system comprising at least one polycarbonate sheet, a portion of which is laminated to a glass layer having a thickness between 0.25 times and less than 1 times the thickness of the polycarbonate sheet. The laminate system may further include fasteners to attach the system to a building, positioned to prevent the laminate system from breaking or detaching in case of a blast event.

Abstract: The present invention provides a rapid deployment cover system comprising a polycarbonate laminate or a glass-clad polycarbonate laminate in combination with a versatile and cushioned mounting system to yield a highly durable cover which provides protection from forced-entry, blast, ballistics and/or extreme storms in a wide range of climates.

Abstract: The present invention provides a lightweight blast-mitigating polycarbonate laminate system comprising at least one polycarbonate sheet, a portion of which is laminated to a glass layer having a thickness between 0.25 times and less than 1 times the thickness of the polycarbonate sheet. The laminate system may further include fasteners to attach the system to a building, positioned to prevent the laminate system from breaking or detaching in case of a blast event.

Abstract: The present invention provides a rapid deployment cover system comprising a polycarbonate laminate or a glass-clad polycarbonate laminate in combination with a versatile and cushioned mounting system to yield a highly durable cover which provides protection from forced-entry, blast, ballistics and/or extreme storms in a wide range of climates.

Abstract: The present invention provides an energy absorber for a blast barrier system comprising a substantially tubular member extending longitudinally along an axis from a first end portion to a second end portion, each of the first end portion and the second end portion having a substantially similar geometric, profile, wherein the energy absorber collapses under a predetermined load when compressed by a residual blast force. The energy absorber of the present invention may help minimize damage to people and structures by further dissipating force from a blast in a blast barrier system.

Abstract: The present invention provides an energy absorber for a blast barrier system comprising a substantially tubular member extending longitudinally along an axis from a first end portion to a second end portion, each of the first end portion and the second end portion having a substantially similar geometric, profile, wherein the energy absorber collapses under a predetermined load when compressed by a residual blast force. The energy absorber of the present invention may help minimize damage to people and structures by further dissipating force from a blast in a blast barrier system.

Abstract: The present invention provides an energy absorber for a blast barrier system comprising a substantially tubular member extending longitudinally along an axis from a first end portion to a second end portion, each of the first end portion and the second end portion having a substantially similar geometric profile, wherein the energy absorber collapses under a predetermined load when compressed by a residual blast force. The energy absorber of the present invention may help minimize damage to people and structures by further dissipating force from a blast in a blast barrier system.

Abstract: The present invention provides an energy absorber for a blast barrier system comprising a substantially tubular member extending longitudinally along an axis from a first end portion to a second end portion, each of the first end portion and the second end portion having a substantially similar geometric profile, wherein the energy absorber collapses under a predetermined load when compressed by a residual blast force. The energy absorber of the present invention may help minimize damage to people and structures by further dissipating force from a blast in a blast barrier system.

Abstract: The present invention provides a rapidly deployable window cover comprising a laminate panel comprising two or more layers of polycarbonate having layered therebetween one or more layers of a thermoplastic polyurethane, having a plurality of openings arranged around the periphery thereof and the plurality of openings extending through the panel; and a plurality of fasteners; wherein the plurality of openings are sized and shaped to receive the plurality of fasteners therethrough, and wherein the fasteners attach the panel to a structure in which the window is embedded such that the panel shields the window.

Abstract: The present invention provides a laminate for protecting an object against close-proximity blasts, ballistic and severe storm events, the laminate comprising two or more layers of polycarbonate having layered there between one or more layers of a thermoplastic polyurethane. Also provided is a method of protecting an object from a close-proximity blasts, ballistic and severe storm events, the method comprising placing between the object and the close-proximity blast, ballistic or severe storm event, the inventive laminate. The inventive laminate can afford increased protection to an object against 50 lbs. to 100 lbs. of trinitrotoluene-equivalent from distances as close as about 3 feet (0.91 m).

Abstract: A blast-resistant barrier comprising a plurality of units each including a panel having a thickness of greater than 20 to less than 40 millimeter is disclosed. The panel is in the form of a monolithic polycarbonate sheet or laminate that is positioned vertically between the source of a blast and the blast target, the laminate including at least two polycarbonate sheets and an optional image layer interposed therebetween. The panel is fixedly attached to a frame which is firmly embedded in concrete in a manner calculated to provide stiffness sufficient to absorb and withstand external forces resulting from said blast. In a preferred embodiment the panel includes at least two polycarbonate sheets laminated one to the other, optionally including an image layer interposed therebetween. In an additional embodiment, the frame is anchored securely to the target enabling dissipation of the blast force through the target's structure.

Abstract: The present invention provides a bi-active method of mounting a monolithic polycarbonate sheet or a laminate in a semi-rigid metallic framing system along two parallel sides of a rectangular shaped sheet or laminate with the two shorter parallel sides being unconstrained. In the case of a square shaped sheet, two parallel sides are supported in the semi-rigid frame, and the other two parallel sides are unconstrained. The semi-rigid frame utilizes cylindrically shaped hardware (i.e., bolts, rivets, studs, etc.) to hold the sheet or laminate. The semi-rigid frame is designed, via section and material properties, to flex and hinge about fixed mounting points along the length of the frame.