Patent Application
20190331463
The present disclosure pertains to wearable armor, and more particularly to comfortable lightweight clothing having ballistic protection.
Body armor and helmets are known. In general, it is desirable is to make body armor and protective headwear as light and as breathable as possible and still withstand the impact of incoming projectiles. Various fabric materials have been developed to cause incoming projectiles to expend energy on the filaments of the fabric, and therefore lose the ability to penetrate the person or object being protected by the fabric. Nevertheless, traditional materials suffer from higher than desirable areal densities and thicknesses, and further have proven vulnerable to penetration or meaningful backface deformation (BFD).
With specific reference to helmets, ballistic helmets today are generally formed using a monolithic “pinwheel” design. The pinwheel design refers to preformed patterns of fabric, where the patterns include cuts or seams that are staggered when layered together to minimize structural weakness along any given seam. The layers are then assembled and secured together, such as with resin, so as to prevent the formation of folds, wrinkles or excessively thick portions.
Early single piece helmet designs have suffered from sub-par ballistic performance based upon the curve in the material. The more bend or radius in a piece of ballistic material, the worse the ballistic performance throughout the ballistic solution. Two-piece ballistic helmets have been designed as an exception to this type of singular ballistic helmet. However, such designs present challenges with regard to the gap between adjoining shell elements, and further by the recognizable staggered profile in combat situations. Enemy combatants may, for example, target personnel wearing the two-piece staggered design for strategic purposes.
With regard to body armor, military and law enforcement personnel have employed armor-enhanced under-clothing in order to protect their bodies from gunfire, shrapnel, explosive devices and other harmful ballistic objects. Even when such under-clothing is sized according to individual specifications (for example, small, medium and large), the armor-enhanced under-clothing has only a single curve and does not generally fit well, gets bunched up, prohibits smooth movement, results in undesirable gaps between body and under-clothing, has limited contact points with the body, and even hinders the withdrawal of firearms. For example, lower abdomen/groin armor components, side torso components, deltoid components, bicep components, and upper leg/thigh components all suffer from poor ergonomic design. Such disadvantages often result in poor performance and can encourage mis-use or even non-use of these protective devices.
The stiffness in body armor results from material which has a very tight weave or disposition of filaments, for example. Further, armor which comprises layers of non-woven fabric stabilized in a matrix resin, is uncomfortable, generally to the degree in which it can stop projectiles. In other words, the more uncomfortable the material, the better with which the material can stop the force of projectiles. This stopping force is a function of the material's areal density and its flexibility. For the same polymer filaments, the higher the areal density of the fabric, the lower the flexibility and breathability, which translates to greater stopping power. Further, for fabrics made up of the same filaments, the more non-woven fabric used in a protective composite fabric, the stiffer it is because the matrix resin causes it to have progressively fewer void spaces. Solid metal armor such as that worn by knights in past ages is the ultimate in stiffness and lack of void spaces, with a high areal density of the iron from which it was made. It is also infinitely stiff, having the same bending ability as any solid metal armor plate, and is therefore extremely uncomfortable.
In modern body armor, it is desirable to strike a balance between the power of the garment or fabric to stop an incoming projectile, and the degree of discomfort borne by the wearer. If the fabric has too few filaments, or if the molecular weight and denier of the filaments making up the fabric is too low, or if the fabric is too thin, there will be insufficient protection afforded the wearer. Further, as weaponry has been improved, the impact velocity and penetrating power of projectiles has continued to increase, and therefore, the stopping power of protective garments has also increased. This has been accomplished by using stronger and higher molecular weight filaments, by increasing the weight of the fabric, by using a non-woven fabric which has been stabilized by embedding the fabric in a matrix resin, and by assembling the fabric from different elements, such as both woven and non-woven fabrics, which provide different, and cumulatively superiorly effective, kinds of stopping power. However, along with this need to make the protective fabric more able to resist the penetration of high energy projectiles, it is also desired to lighten the fabric and make it more comfortable to the wearer.
In addition to the above, body armor tends to increase heat generation from the wearer's body, with perspiration contributing to the wearer's discomfort and fatigue. Currently, cooling methods for armor wearers involve radiator type cooling systems and ice packs. The radiator method's drawbacks are weight, real estate, and the need to be powered which limits its effectiveness due to limited battery life. The ice pack method is heavy, creates bulk, and turns to water that slowly heats up rendering the cooling effect very short lived.
The presently disclosed system and devices overcome the current shortcomings and more. Embodiments of the present disclosure provide a customizable, scalable, armor-enhanced under-clothing system that conforms more substantially to the user's body, providing better protection over every critical body area in different stages as selected by the user. In this way, the user can employ as much or as little of the disclosed system as desired or needed for a given anticipated threat level, incorporating suitable armor to protect the wearer against anything from light ballistics (e.g., sand) all the way up to the heaviest ballistic weaponry and fragments that might be encountered. Embodiments of the present disclosure can employ compression fabric as a base material in the top (e.g., shirt) and bottom (e.g., shorts) system elements, and further can include one or more static fabric material harnesses in the top and/or bottom elements. The material can be provided in different forms depending upon desired characteristics (e.g., wicking, fire resistance, temperature management, anti-microbial, etc.). Anti-ballistic panels of suitable material and thickness can be inserted into the static fabric material harness designed to carry the panels while preventing any undesirable bouncing effect. In embodiments, the top and bottom elements are adapted to be secured to one another using hook-and-loop fasteners or similar fasteners to facilitate comfort, intended purpose and overall fit. The presently disclosed system and devices also provide full body contact as opposed to selected point contact associated with prior devices. The presently disclosed system and devices can be provided in sleeveless, short sleeve and long sleeve shirts, shorts and pants, for example.
The present disclosure further reveals body armor and helmets that are lighter weight, easily donned and doffed, provide added comfort and maintain significant ballistic strength. The present disclosure further pertains to a cooling subsystem that can be integrated with the lightweight clothing system to keep the wearer cooler during operation.
In various embodiments, the ballistic helmet of the present disclosure is comprised of two or more pieces, has an areal density of no more than 2.10 lbs/ft2, and does not exceed a thickness of 0.44 inches while maintaining 25 millimeters, or less, backface deformation (BFD) on the helmet when subject to gunfire. In specific embodiments, the helmet pieces are provided of unidirectional material and are capable of withstanding the penetration of at least one of the following projectile types: a 9 mm, 124 grain, FMJ projectile impacting the unidirectional material at a velocity of not less than 1,400 feet per second; and a 7.62×39, 124 grain, mild steel core projectile impacting the unidirectional material at a velocity of not less than 2,400 feet per second. In various embodiments, the unidirectional material can be provided with an areal density of approximately 1.60 to approximately 2.10 pounds per square foot and can comprise not more than 15% by weight of matrix resin. Further, embodiments of the unidirectional material can comprise from approximately 85 to approximately 100 sub-plies of unidirectional material joined together by pressing, and wherein the unidirectional material passes the level III-A penetration resistance test. In various embodiments, the unidirectional material can be provided with eighty to ninety percent of the material weight in one direction.
The material employed can be nylon, aramid, or Ultra High Molecular Weight polyethylene (UHMWPE) woven or uni-directional materials, aramid fibers, ceramics, polycarbonate, plastic, aluminum, steel, titanium, or a combination of two or more such materials. The helmet can also be suitably relieved in areas where no ballistic protection is required, or where ballistic protection would otherwise impede certain functions of the helmet and the wearer's desired functional capabilities.
The multiple pieces of the helmet contribute to the performance advantage due to less curvature or bend in the material. Further, the multiple pieces can be joined without a staggered profile and with no gaps in the ballistic solution. In addition to providing multiple pieces to cover the full head of the wearer, each portion of the solution can include multiple layers for a full ballistic solution. A base shell or first layer can also be provided that includes a chin strap, pads and frame. The second layer can contain the multiple ballistic pieces and the third layer can provide a hard shell that will marry the base shell and the third layer together containing the ballistic pieces.
With regard to the armor-enhanced under-clothing according to the present disclosure, in various embodiments, ancillary body armor components are disclosed that have an areal density of no greater than 2.10 lbs/ft2 and are no thicker than 0.44 inches while not allowing more than 50 millimeters of backface deformation (BFD). The ancillary body armor components can be worn in a base-layer and under the uniform. Traditionally, body armor components are worn externally of the uniform so as to speed the donning and doffing process. The base-layer can house and “suspend” the armor components so as to be positioned correctly and comfortably with minimal movement and changing of the intended position on the body in order to enhance overall mobility, extremity movement, and survivability. In various embodiments, an advanced fabric as disclosed herein houses the armor, and this advanced fabric can comprise a compression fabric. The advanced fabric aids in the correct positioning of the ballistics and anti-fatiguing of the wearer and assists in providing an armor-enhanced under-clothing that is comfortable, easy to customize and ergonomically superior over prior devices.
With regard to cooling, the present disclosure relates, in part, to an active cooling subsystem that provides cooling via positive air pressure. The human body cools itself through the evaporation of perspiration. The cooling process is sped up and made more efficient when the perspiration is exposed to air flow, for example, like using a fan to simply move air onto a perspiring body. According to the present disclosure, positive air pressure can be provided via an external pump that pumps fluid such as air through a multitude of purposely placed perforated tubes. The tubes can be placed in and/or around a base layer and/or a spacer mesh article of clothing, allowing for comfort and unrestricted air flow from the tubing. In various embodiments, the perforated tubing can target specific areas such as the sternum of the chest and the spine region of the back where most of the blood flows in order to cool down the core temperature. According to various embodiments, multiple base layers are employed along with the cooling subsystem and ballistic inserts.
The presently disclosed subject matter now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the presently disclosed subject matter are shown. Like numbers refer to like elements throughout. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.
Example embodiments such as disclosed herein can incorporate a system having a processor and an associated memory storing instructions that, when executed by the processor, cause the processor to perform operations as described herein. The system can be embodied as a server, for example. It will be appreciated that reference to “a”, “an” or other indefinite article in the present disclosure encompasses one or more than one of the described element. Thus, for example, reference to an insert encompasses one or more inserts, reference to a base material encompasses one or more base material layers and so forth.
The arm elements 20 also include respective suitably-sized interior pockets 22 for receiving respective suitably-sized forearm ballistic panels 24. The pockets 16, 22 generally include an opening through with panels can be inserted and removed. This facilitates customization of the anti-ballistic properties of the present invention, as heavier and thicker panels may be needed for some engagements, while lighter and thinner panels may be needed for other engagements. In another embodiment, the pockets 16, 22 are constructed with panels retained therein, and then sealed so that the panels remain permanently part of the top element. The pockets can comprise a variety of materials, including compression fabric, or alternatively a static fabric material retaining greater strength and resisting movement more than compression fabric.
As shown in the embodiment of
As shown in the embodiment in
In operation, a wearer of embodiments of the presently disclosed system and devices may select a previously installed version, where ballistic panels are already selected and sewn in, or where ballistic panels are already inserted into the top and bottom elements. The selection can be made according to the wearer's size (e.g., small, medium and large). Alternatively, the wearer may select the top and bottom elements without any ballistic panels installed, put on the top and bottom elements, and then install appropriate ballistic elements in the available pockets as desired for an anticipated engagement. It will be appreciated that the pockets can be openable and sealable using hook and loop type fasteners, or other appropriate fasteners to enable quick assembly and dis-assembly. Accordingly, one aspect provides a protective clothing system with a standardized set of pockets which may or may not be fully employed for a given engagement, but which do not reduce the ergonomic design and comfortable fit, regardless of whether the pockets are filled with suitable ballistic material.
The ballistic material can comprise, for example, layers of fibers that may comprise a high molecular weight polyethylene material, an aramid fiber, a combination of high performance fibers, or a non-woven thermoplastic composite. Commercially available embodiments of the ballistic material are known as Dyneema™ and Spectrashield™, for example. Other embodiments in accordance with the present disclosure are lighter weight unidirectional material and are capable of withstanding the penetration of at least one of the following projectile types: a 9 mm, 124 grain, FMJ projectile impacting the unidirectional material at a velocity of not less than 1,400 feet per second; and a 7.62×39, 124 grain, mild steel core projectile impacting the unidirectional material at a velocity of not less than 2,400 feet per second. In various embodiments, the unidirectional material can be provided with an areal density of approximately 1.60 to approximately 2.10 pounds per square foot and can comprise not more than 15% by weight of matrix resin. Further, embodiments of the unidirectional material can comprise from approximately eighty-five to approximately one hundred sub-plies of unidirectional material joined together by pressing, and wherein the unidirectional material passes the level III-A penetration resistance test. In various embodiments, the unidirectional material can be provided with eighty to ninety percent of the material weight in one direction.
The present disclosure allows for the ballistic or other fabric inserts (e.g., as assessed by potential threat) to be sewn into or placed in a pocket or sleeve, for example. The present disclosure also protects the end user from sand, ballistic fragments, etc., as a secondary layer. In various embodiments of the present disclosure, the tops or bottoms in any configuration will cover areas that traditional body armor does not. As such, an end user can wear the top or bottoms of the present disclosure under their traditional body armor and the tops and bottoms would have extra protection in the areas that the body armor does not cover. Optionally, there may be additional protection for the lower abdominal area, arms, under arms, upper legs, etc.
As such, the presently disclosed system and devices can conceal the armor, keep the armor or protection in the correct place, allow it to fit a great range of people, allow for multiple overlap points for extreme comfort, provide interchangeable armor components in order to adjust for size, and allow the tops and bottoms in one size to adjust within the pocket or sleeve so that the same component can permit different thickness inserts to be employed.
In the embodiment as shown in
The first strap element 122 has a first strap length and is secured to the right shoulder interior surface along substantially the entire first strap length. Similarly, the second strap element 124 has a second strap length and is secured to the right shoulder interior surface along substantially the entire second strap length.
The harness element 112 further includes a chest portion 126 secured at least in part to the first 122 and second 124 strap elements and further secured to the front interior surface 108 of the top element 102. As illustrated in
The first pocket bag 130 includes a back ply portion 131 and a front ply portion 132, and can accommodate the insertion or removal of ballistic inserts. In one embodiment, the back ply portion 131 of the first pocket bag 130 is integrally formed with the back ply 128 of the chest portion, but is generally not secured to the top element 102 (except optionally at attachment points 145) and hangs freely from the chest portion. The front ply portion 132 similarly hangs freely but is not integrally formed with the front ply portion 129 of the chest portion 126 of the harness element. Rather, the front ply portion 132 of the first pocket bag 130 includes a rim 139 (illustrated by dashed arrow in
As further shown in
One or more ballistic inserts can be inserted into and removed from the second pocket bag 142 and the opening created by the two plies of the back portion 138, similar to the process described and shown in connection with the first pocket bag 130 and chest portion 126 in
As further shown in
It will be appreciated that embodiments of the protective clothing system and devices disclosed herein thus provide a customizable, scalable, armor-enhanced clothing system that conforms more substantially to the user's body, with a thinner and lighter armor profile, and with better protection over every critical body area in different stages as selected by the user. The present disclosure further provides such devices whereby the top element comprises an outer compression fabric layer with an inner non-compression fabric harness element.
With regard to the cooling sub-system of the present disclosure, positive air pressure can be provided via an external pump that pumps fluid such as air through one or more purposely placed perforated tubes. The tubes can be merged into and/or placed adjacent a base material, such as a compression fabric or spacer mesh material, allowing for comfort and unrestricted air flow from the tubing. The spacer mesh material can be embodied as three separate layers of fabric knit together, such as a face and a back connected by a monofilament yarn to produce a connecting cushion-type layer. Each layer can be knit simultaneously by a single machine. As shown in
As shown in
In various embodiments, the base material (e.g., compression fabric or spacer mesh material) has a front side and a back side. As further shown in
In some embodiments, the system employs the first base material 212, tube 305 and pump 300 and third base material 216 with one or more pockets and one or more inserts, without the second base material 214.
In various embodiments, the spacer mesh can be provided with rigid spacing inserts to increase space between the spacer mesh adjacent the user's body and the tubing. Such inserts can form a type of frame for the spacer mesh as the first base material 212, for example, and the increased space provides for additional cooling of the user during operation.
The present disclosure describes numerous embodiments, and these embodiments are presented for illustrative purposes only. These embodiments are described in sufficient detail to enable those skilled in the art to practice what is disclosed herein, and it will be appreciated that other embodiments may be employed and that structural, and other changes may be made without departing from the scope or spirit of the present disclosure. Accordingly, those skilled in the art will recognize that the presently disclosed embodiments may be practiced with various modifications and alterations. Although particular features disclosed herein can be described with reference to one or more particular embodiments or figures that form a part of the present disclosure, and in which are shown, by way of illustration, specific embodiments of the invention, it will be appreciated that such features are not limited to usage in the one or more particular embodiments or figures with reference to which they are described. The present disclosure is thus neither a literal description of all embodiments nor a listing of features of the invention that must be present in all embodiments.
This application claims the benefit of U.S. Patent Application No. 62/662,461 filed on Apr. 25, 2018, the contents of which are incorporated by reference herein in their entirety
| Number | Date | Country | |
|---|---|---|---|
| 62662461 | Apr 2018 | US |
