Transport Armor / Cockpit Door

Cockpit Door Armor

The patent pending cockpit armor system was originally designed and offered to the aviation industry in February of 1994. The composite armor in this configuration provides for exceptional forced entry resistance, ballistic resistant capabilities, and explosive blast and fragmentation resistance.

The composite is manufactured from aerospace grade composites and resins thereby exceeding the requirements of the OSU65/65 and the FAR25.853 fire ratings. The unit can be configured in flat rigid or pre-formed shapes to accomodate practically any mounting and/or covering requirement. The completed panel system is only 1.09" inches in nominal thickness with exceptionally high shear strength.

There is a honeycomb core system, allowing for a 3/4" space between the panels. This space allows for the thin line multipoint locking mechanism to be mounted. The multipoint locking system is offered in two configurations, each offering other options for monitoring. The first is a three point locking mechanism where all three hard points are on the strike side of the door in addition to the lockset strike. This allows for the top, bottom and center of the door strike side to be integrally locked into the bulkhead. The second provides for a upper point hard strike on the top of the door, strike side, the bottom of the door, strike side and one along with the lockset strike in the center of the door strike side. Again, this provides for a fully integrally locked door assembly, unlike the bar systems that allow for the top or botom corners of the door to be either kicked in or pulled out.

The multipoint locking mechanism is offered in a manual or electrical operated system. The doors have an optional "pick proof" keyed option for emergency access from the cabin side. There is an optional LED visual monitoring system to constantly show the door condidtion of locked or unlocked with either the green or red indicator lights.

Electronically Operated Door

• Cockpit side of electronically operated door. The perimeter of the door, the locking mechanism and handle are manufactured from stainless steel for secured continuous strength.

• Side view of electronically operated door with locking bolts retracted. Fail safe sensor shown at top. Sensor precludes inadvertently extending locking bolts prior to the door being aligned with jamb in closed position.

• Cabin side of electronically operated door. Keyed lockset is designed to resist forced "pull out" from attack. Full length continuous hinge is attack resistant and carries a 90 minute fire rating.

• Close up of key. Key uses all four sides of shank for programmable options. This ensures a "pick proof" capability.

• Electronically operated door with side strike and locking bolt extended. This configuration shows upper and lower locking bolts. Also shown is the fail safe sensor held in place to allow locking bolts to be extended.

Mechanically Operated Door

• Cockpit side of mechanically operated door with locking bolts extended. The perimeter of the door, the locking mechanism and handle are manufactured from stainless steel for secured continuous strength.

• Close up of hardened locking bolts. This proprietary design precludes not being able to retract bolts during emergency egress should the door be jammed from attack or other means.

• Cabin side of mechanically operated door without optional keyed lockset. Full length continuous hinge is attack resistant and carries a 90 minute fire rating.

Testing Results

1. 9 - 32 caliber, 00 buckshot pellets from 12-gauge 3" magnum shotgun round.
   43 - hatchet strikes subsequent to shotgun buckshot impact.
2. Demonstrated multiple repeat hit capability. Close up of 9mm 3 shot grouping.
   All three shots are within a one inch area.
3. 3" magnum 00 buckshot from 16 feet. 12 gauge shotgun load of 9 - 32 caliber pellets.

Following are the specifications of the cockpit armor composite

• Weight: 2.6 pounds per square foot.
• Thickness: 1.09" in total nominal thickness.
• Ballistic Capability: A full NIJ 3-A+ capability.
• Forced Entry Capability: In excess of 3,000 foot pounds of high energy resistance for sustained attack.
• Explosive Blast Capability: Capable of handling 1 to 2 PSI of overpressure at 15 msec, and fragmentation, such as from a grenade type explosive device.
• Fire Rating: Exceeds the OSU 65/65 and the FAR 25.853 fire rating requirements.
• Warranty: Ten year warranty.

This unit can be provided as the door assembly, or the bulkhead and door assembly for total integral strength in a kit for easy installation. Custom configurations are also available.