Patent Application
20090126057
This disclosure relates to garments, and, particularly, to garments worn by an individual underneath body armor.
Body armor is well known for use by persons in combat and battlefield or analogous situations for preventing ballistic projectiles from penetrating covered regions of the body of the wearer. More recently, body armor covering increased surface area of the body has been developed. For example, U.S. Pat. No. 5,060,314 to Lewis describes a ballistic resistant jacket that extends up to 3 inches below the wearer's waist, with a back panel, a combined front and left side panel, a combined front and right side panel, a collar and over-the-shoulder portions. U.S. Pat. No. 6,363,527 to Biermann et al. describes a body armor vest formed of thermally conductive fibers, for improved heat transfer, and moisture-wicking materials, to keep moisture away from the body and the body armor. U.S. Pat. No. 6,892,392 to Crye et al. describes a body armor vest having foam pads affixed to an interior of the vest defining multiple vertically extending air channels between the wearer and the vest, wherein the air channels promote ventilation and cooling of the wearer.
The present disclosure is directed, in part, to garments, such as battlefield and analogous garments, worn under body armor to provide a durable, low stretch or no stretch outer layer covering regions of a user's body left exposed by the body armor with a ventilated, stretchable inner layer covering regions of the wearer's body covered by the body armor.
According to one aspect, an under body armor hybrid fabric garment comprises a first fabric portion and a second fabric portion. The first fabric portion comprises low stretch or no stretch fabric configured to cover an upper torso region of a user's body, wherein the first fabric portion covers a first body region left exposed by the body armor and extends into a second body transition region covered by the body armor. The second fabric portion comprises stretchable fabric configured to cover a lower torso region of the user's body underneath the body armor.
Implementations of this aspect may include one or more of the following additional features. The first fabric portion may be formed from low stretch woven fabric. The woven fabric can include a double weave construction (e.g., for increased insulation and/or decreased air permeability, such as for colder weather applications). The low stretch woven fabric is selected from the group of materials consisting of: synthetic yarns and/or fibers (e.g., polyester, nylon, etc.), natural yarns and/or fibers (e.g., cotton and/or wool), and specialty yarns and/or fibers (e.g., flame retardant yarns and/or fibers, including m-aramid (such as those sold by E.I. duPont under the trademark NOMEX®), melamine, flame retardant cotton, flame retardant nylon, a flame retardant treated cotton/nylon blend, modacrylic, and combinations thereof). The first fabric portion may be comprised of yarns and/or fibers resistant to melting and dripping when exposed to a flame or high temperatures. The first fabric portion has predetermined air permeability, e.g., the first fabric portion has predetermined air permeability in the range of between about 0 CFM to about 200 CFM, preferably between about 5 CFM to about 100 CFM, more preferably, between about 20 CFM and about 40 CFM. The second fabric portion may be formed from synthetic yarns and/or fibers (e.g., nylon, polyester, polypropylene, and combinations thereof), natural yarns and/or fibers, and/or combinations thereof. The second fabric portion may be comprised of flame retardant yarns and/or fibers (e.g., m-aramid, flame retardant treated cotton, acrylic, and combinations thereof). In some cases, the second fabric portion includes yarns and/or fibers resistant to melting and dripping when exposed to fire or high heat (e.g., cotton, wool, acrylic, and combinations thereof). The second fabric portion may be comprised of a fabric with one-way or two-way stretch. The second fabric portion has plated jersey, double knit, single jersey knit, single face terry loop in plated construction, or single face terry loop in non-plated construction. In some cases, the plated jersey construction can include a combination of nylon yarns and cotton yarns, wherein the nylon yarns are shown predominantly on the technical face of the fabric and the cotton yarns are shown predominantly on the technical back of the fabric. Alternatively, the plated jersey construction can include a combination of m-aramid yarns (e.g., NOMEX® yarns) and cotton yarns, wherein the m-aramid yarns are shown predominantly on the technical face of the fabric and the cotton yarns are shown predominantly on the technical back of the fabric. The second fabric portion has a plated jersey construction including a combination of a first set of m-aramid yarns and a second set of m-aramid yarns, wherein the first set of m-aramid yarns are shown predominantly on the technical face of the fabric and the second set of m-aramid yarns are shown predominantly on the technical back of the fabric. The second fabric portion has a plated jersey construction including a combination of m-aramid yarns and wool yarns, wherein the m-aramid yarns are shown predominantly on the technical face of the fabric and the wool yarns are shown predominantly on the technical back of the fabric. The second fabric portion has a plated jersey construction including a combination of nylon yarns and wool yarns, wherein the nylon yarns are shown predominantly on the technical face of the fabric and the wool yarns are shown predominantly on the technical back of the fabric. Preferably, the second fabric portion is comprised of wicking fabric, e.g. POWER DRY® textile fabric, as manufactured by Malden Mills Industries, Inc. of Lawrence, Mass. Spandex yarn can be included in the second fabric portions to form a fitted garment with enhanced resistance to folding, creases and bulging. The second fabric portion has denier gradient, i.e. relatively finer dpf on an outer surface of the fabric and relatively more coarse dpf on an inner surface of the fabric, for encouraging flow of liquid sweat from the inner surface of the second fabric portion to the outer surface of the second fabric portion (i.e., for better water management). The second fabric portion has predetermined air permeability, e.g., the second fabric portion may have predetermined air permeability greater than about 100 CFM. The second fabric portion has single face plated construction. Preferably, the single face plated construction includes a sinker loop surface, which defines the inner surface of the second fabric portion. The sinker loop surface can have raised sinker loop finish, velour (napped) finish, cut loop velour finish, or un-napped loop form. The sinker loop surface defines a plurality of discrete inner regions of loop yarn including one or more first discrete inner regions having first inner pile height, and defines one or more other discrete inner regions having contrasting inner pile height relatively greater than the first inner pile height, wherein the one or more first discrete inner regions of loop yarn, together with the one or more other discrete inner regions, define air channels between the user's skin and an opposed inner base surface of the fabric, thereby to facilitate ventilation and to reduce the number of contact points with the user's skin. The air channels comprise a plurality of vertical channels, horizontal channels, diagonal channels, or combinations thereof. The air channels may include a plurality of intersecting channels. The plurality of discrete inner regions of loop yarn are disposed in a pattern corresponding to one or more predetermined regions of the user's body. The plurality of discrete inner regions of loop yarns may be disposed on a front surface of the second fabric portion, on a back surface of the second fabric portion, or on both a front and a back surface of the second fabric portion. In some cases, the second fabric portion includes a double face fabric. The double face fabric can include a first surface defining an inner surface of the second fabric portion, the inner surface defining a plurality of discrete inner regions of loop yarn including one or more first discrete inner regions having first inner pile height, and defining one or more other discrete inner regions having contrasting inner pile height relatively greater than the first inner pile height, wherein the one or more first discrete inner regions of loop yarn, together with the one or more other discrete inner regions, define inner air channels between the user's skin and an opposed inner base surface of the fabric, thereby to facilitate ventilation and to reduce the number of contact points with the user's skin. The double face fabric still further comprises a second surface defining an outer surface of the second fabric portion, the outer surface defining a plurality of discrete outer regions of loop yarn, the discrete outer regions of loop yarn including one or more first discrete outer regions having first outer pile height, and one or more other discrete outer regions having contrasting outer pile height relatively greater than the first outer pile height, wherein the discrete outer regions of loop yarn, together with the one or more other discrete outer regions, define outer air channels between an inner surface of the body armor and an opposed outer base surface of the fabric, thereby to facilitate ventilation and to reduce the number of contact points with the inner surface of the body armor. The inner and/or outer air channels may comprise a plurality of vertical channels, horizontal channels, diagonal channels, or combinations thereof. The inner and/or out air channels may include a plurality of intersecting channels. The plurality of discrete inner regions of loop yarn may be disposed in a pattern corresponding to one or more predetermined regions of the user's body. The plurality of discrete inner and outer regions of loop yarn may be disposed on a front surface of the second fabric portion, a back surface of the second fabric portion, or both.
In another aspect, a battlefield garment system comprises a body armor element and an under-armor garment. The under-armor garment comprises a first textile fabric portion including low stretch fabric configured to cover an upper torso region of a user's body, the first textile fabric portion covering a first body region left exposed by the body armor element and extending into a second body transition region covered by the body armor element. The under-armor garment further comprises a second textile fabric portion comprising stretchable fabric configured to cover a lower torso region of the user's body underneath the body armor element.
Preferred implementations of this aspect may include one or more of the following additional features. The first textile fabric portion is configured to cover the user's shoulder regions and extends below the elbows down towards the user's wrists defining a pair of fabric arms. At least one of the fabric arms includes a pocket configured to carry ammunition. The first textile fabric portion has woven construction. The first textile fabric portion is treated with durable water repellent (DWR), camouflage and/or infrared radiation reduction. The second textile fabric portion comprises fibers of stretch and/or elastic material incorporated in the fabric. The second textile fabric portion includes a raised inner surface. The raised inner surface may be finished as raised sinker loop surface, velour surface, cut loop velour surface, or un-napped loop form. The raised inner surface defines one or more discrete inner regions of loop yarn including one or more first discrete inner regions having first inner pile height, and one or more other discrete inner regions having contrasting inner pile height relatively greater than the first inner pile height, wherein the one or more first discrete inner regions, together with the one or more other discrete inner regions, defines inner air channels between the user's skin and an opposed inner base surface of the fabric, thereby to facilitate ventilation, and to reduce the number of contact points with the user's skin. The first inner pile height is low pile, no pile or a combination thereof. The contrasting inner pile height is high pile, low pile, or combinations thereof. Preferably, the first discrete inner regions having first inner pile height comprise loop yarn formed to low pile height of between about 1.0 mm to about 3.0 mm. The other discrete inner regions comprise loop yarn formed to pile height in the range of greater than about 2.0 mm up to about 6.0 mm. The inner air channels comprise a plurality of vertical channels, horizontal channels, diagonal channels, or combinations thereof. The plurality of discrete inner regions of loop yarn correspond to one or more predetermined regions of the user's body selected from the group consisting of: spinal cord area, spine, back area, upper back area, lower back area, front chest area, breast area, and abdominal area. The discrete inner regions of loop yarn can be disposed on a front surface of the second textile fabric portion, on a back surface of the textile fabric portion, or on both a front surface and a back surface of the textile fabric portion. The second fabric portion may also include a raised outer surface. Preferably, the raised outer surface defines one or more discrete outer regions of loop yarn, the discrete outer regions of loop yarn including one or more first discrete outer regions having first outer pile height, and one or more other discrete outer regions having contrasting outer pile height relatively greater than the first outer pile height, wherein the one or more first discrete outer regions, together with the other discrete outer regions, define outer air channels between an inner surface of the body armor element and an opposed outer base surface of the fabric, thereby to facilitate ventilation and reduce the number of contact points with the inner surface of the body armor element. The first outer pile height may be low pile, no pile or a combination thereof, and preferably a pile height of about 1.0 mm to about 3.0 mm. The contrasting outer pile height may be high pile, low pile or a combination thereof, and preferably in the range of greater than about 2.0 mm up to about 6.0 mm. The outer air channels may comprise a plurality of horizontal and vertical channels. The plurality of inner and outer regions of loop yarn may be disposed on a front surface of the second textile fabric portion, a back surface of the second textile fabric portion, or on a front surface and a back surface of the second textile fabric portion.
In yet another aspect, a method of forming an under body armor hybrid fabric battlefield garment comprises the steps of: forming a first fabric portion corresponding to an upper torso region of a user's body from low stretch or no stretch fabric, wherein the first fabric portion covers a first body region left exposed by the body armor and extends into a second body transition region covered by the body armor; forming a second fabric portion corresponding to a lower torso region of the user's body from stretchable fabric, wherein the second fabric portion is configured to cover a lower torso region of the user's body underneath the body armor, and joining together the first and second fabric portions to form the hybrid fabric battlefield garment.
Preferred implementations of the method may include one or more of the following additional features. The step of forming the second fabric portion comprises combining yarns and/or fibers selected from the group consisting of: synthetic yarns and/or fibers, natural yarns and/or fibers, and combinations thereof to form a knit fabric. The step of forming the second fabric portion comprises combining yarns and/or fibers to form plated jersey fabric, double knit fabric, or single jersey knit fabric. The step of forming the second fabric portion comprises combining yarn and/or fibers to form single face plated fabric with plated sinker loop. Preferably, forming the single face fabric comprises finishing a first surface of the single face plated fabric to form one or more discrete inner regions of loop yarn, including, forming one or more first discrete inner regions having first inner pile height, and forming one or more other discrete inner regions having contrasting inner pile height relatively greater than the first inner pile height, wherein the one or more first discrete inner regions, together with the one or more other discrete inner regions, define inner air channels between the user's skin and an opposed inner base surface of the fabric, thereby to facilitate ventilation and to reduce the number of contact points with the user's skin. The first surface of the single face plated fabric may define an inner surface of the second fabric garment. The one or more discrete inner regions of loop yarn may be formed in a pattern corresponding to one or more predetermined regions of the user's body. The discrete inner regions of loop yarn may be disposed on a front surface of the second textile fabric portion, or on a back surface of the second fabric portion, or on a front surface and a back surface of the second fabric portion. The step of forming the second fabric portion comprises combining yarns and/or fibers to form double face fabric. In some cases, forming the double face fabric comprises finishing an inner surface of the double face fabric to form one or more discrete inner regions of loop yarn forming one or more first discrete inner regions having first inner pile height, and forming one or more other discrete inner regions having contrasting inner pile height relatively greater than the first inner pile height, wherein the one or more first discrete inner regions, together with the one or more other discrete inner regions, define inner air channels between the user's skin and an opposed inner base surface of the fabric, thereby to facilitate ventilation and to reduce the number of contact points with the user's skin. Forming the double face fabric further comprises finishing an outer surface of the double face fabric to form one or more discrete outer regions of loop yarn, forming one or more first discrete outer regions having first outer pile height, and one or more other discrete outer regions having contrasting outer pile height relatively greater than the first outer pile height, wherein the one or more first discrete outer regions, together with the other discrete outer regions, define outer air channels between an inner surface of the body armor and an opposed outer base surface of the fabric, thereby to facilitate ventilation and to reduce the number of contact points with the inner surface of the body armor. The inner surface of the double face fabric may define an inner surface of the second fabric garment, and the outer surface of the double face fabric defines an outer surface of the second fabric garment. The discrete inner and outer regions of loop yarn may be disposed on a front surface of the second fabric portion, or on a back surface of the second fabric portion, or on both a front and a back surface of the second fabric portion.
An under-the-armor battlefield garment is many times employed as the only garment layer, which requires it to serve the wearer as an outer layer, where left exposed by the body armor, as well as an inner layer underneath regions covered by the body armor. Therefore, there is need for an under-the-armor battlefield garment equipped to serve multiple requirements such as providing a tough, durable, low stretch or no stretch outer layer, and a comfortable, stretchable inner layer that provides adequate ventilation.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
Referring to
Referring still to
As illustrated in
In addition, second fabric portion 14 may be finished, as described above, on both inner and outer surfaces for enhanced thermal insulation. For example,
Referring to
Additionally,
A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. For example, the second fabric element may be produced by any procedure suitable for combining yarns and/or fibers to create regions with contrasting pile heights and/or regions of no pile. For improved stretch, the second fabric portions may have fibers of stretch and/or elastic material incorporated into the stitch yarn. The first and second fabric portions may have predetermined air permeability. For example, the first fabric portion may have predetermined air permeability of about 0 CFM to about 200 CFM, and the second fabric portion may have predetermined air permeability greater than about 100 CFM. Accordingly, other embodiments are within the scope of the following claims.
