U.S. patent application number 12/628648 was filed with the patent office on 2011-06-02 for staple fiber conductive fabric.
Invention is credited to Gregory Russell Schultz.
Application Number | 20110126335 12/628648 |
Document ID | / |
Family ID | 44067741 |
Filed Date | 2011-06-02 |
United States Patent
Application |
20110126335 |
Kind Code |
A1 |
Schultz; Gregory Russell |
June 2, 2011 |
Staple Fiber Conductive Fabric
Abstract
A fabric for protecting a wearer thereof from an energy weapon.
The fabric is made of a plurality of coupled strands. Each strand
is made from staple fibers. At least 30% of the staple fibers are
an electrically conductive material for conducting electric current
from an energy weapon that contacts or is adjacent to the
fabric.
Inventors: |
Schultz; Gregory Russell;
(Marana, AZ) |
Family ID: |
44067741 |
Appl. No.: |
12/628648 |
Filed: |
December 1, 2009 |
Current U.S.
Class: |
2/2.5 ; 428/221;
442/181; 442/228; 442/304; 442/308; 442/316 |
Current CPC
Class: |
Y10T 442/3382 20150401;
F41H 13/0012 20130101; D04B 1/14 20130101; Y10T 442/475 20150401;
D02G 3/441 20130101; B32B 5/26 20130101; D10B 2401/16 20130101;
Y10T 442/40 20150401; F41H 5/0457 20130101; Y10T 428/249921
20150401; D10B 2501/04 20130101; F41H 1/02 20130101; F41H 5/0471
20130101; F41H 5/02 20130101; Y10T 442/30 20150401; Y10T 442/425
20150401 |
Class at
Publication: |
2/2.5 ; 428/221;
442/304; 442/308; 442/316; 442/181; 442/228 |
International
Class: |
F41H 1/02 20060101
F41H001/02; B32B 5/02 20060101 B32B005/02; D04B 21/00 20060101
D04B021/00; D04B 21/14 20060101 D04B021/14; B32B 15/02 20060101
B32B015/02; B32B 15/14 20060101 B32B015/14; D03D 15/00 20060101
D03D015/00 |
Claims
1. A fabric for protecting a wearer thereof from an energy weapon,
comprising: a plurality of coupled strands each of which comprises
coupled staple fibers, said staple fibers comprising at least 30%
electrically conductive material.
2. The fabric of claim 1, wherein said coupled strands are knit,
each of said strands comprises at least three plies each comprising
at least 50% electrically conductive staple fibers, and each of
said plies comprises a length per weight of between approximately
15,000 to 19,000 yards per pound.
3. The fabric of claim 2, wherein each of said plies comprises a
length per weight of between approximately 16,500 to 17,500 yards
per pound.
4. The fabric of claim 2, wherein said knit strands comprise a
gauge of between approximately 10 to 15.
5. The fabric of claim 4, wherein said knit strands comprise a
gauge of approximately 13.
6. The fabric of claim 4, wherein said knit strands comprise a
needle count of between approximately 65 to 95.
7. The fabric of claim 6, wherein said knit strands comprise a
needle count of between approximately 73 to 88.
8. The fabric of claim 2, wherein at least 60% of said staple
fibers of each of said strands comprise stainless steel, and at
least 30% of said staple fibers of each of said strands comprise
cotton.
9. The fabric of claim 8, wherein at least 95% of said stainless
steel staple fibers comprise a diameter of between 8 to 12 microns
and a length of between 2 to 3 inches.
10. The fabric of claim 1, wherein said coupled strands are woven
and each of said strands comprises a length per weight of between
approximately 23,000 to 27,000 yards per pound.
11. The fabric of claim 10, wherein each of said strands comprises
a length per weight of between approximately 24,500 to 25,500 yards
per pound.
12. The fabric of claim 10, wherein said woven strands comprise a
density of between approximately 160 to 200 threads per inch.
13. The fabric of claim 12, wherein said woven strands comprise a
density of between approximately 175 to 185 threads per inch.
14. The fabric of claim 10, wherein at least 40% of said staple
fibers comprise stainless steel.
15. The fabric of claim 10, wherein at least 30% of said staple
fibers comprise stainless steel, at least 30% of said staple fibers
comprise cotton, and at least 30% of said staple fibers comprise
polyester.
16. The fabric of claim 1, wherein a portion of said staple fibers
is heat resistant.
17. The fabric of claim 16, wherein a portion of said staple fibers
comprises aramid.
18. The fabric of claim 1, wherein a portion of said staple fibers
is penetration resistant.
19. The fabric of claim 18, wherein a portion of said staple fibers
comprises aramid.
20. The fabric of claim 18, wherein a portion of said staple fibers
comprises polyethylene.
21. The fabric of claim 1, wherein said electrically conductive
staple fibers are configured to conduct an electric current from
the energy weapon when the energy weapon is adjacent the
fibers.
22. The fabric of claim 1, wherein the combination of said
electrically conductive staple fibers of each of said strands is
configured to protect the wearer from the energy weapon when the
energy weapon delivers up to fifty watts of power to said
strands.
23. A garment for protecting a wearer thereof from an energy
weapon, comprising: a fabric comprising a plurality of coupled
strands each of which comprises coupled staple fibers, said staple
fibers comprising at least 30% electrically conductive
material.
24. The garment of claim 23, wherein said coupled strands are knit,
each of said strands comprises at least three plies each comprising
at least 50% electrically conductive staple fibers, and each of
said plies comprises a length per weight of between approximately
15,000 to 19,000 yards per pound.
25. The garment of claim 24, wherein said fabric comprises a first
layer of fabric, and further comprising a second layer of
electrically non-conductive fabric joined with and enclosing said
first layer of fabric, and a third layer of fabric joined with and
enclosed by said first layer of fabric, said first, second, and
third layers configured to protect a hand of the wearer, said third
layer comprising at least 10% electrically conductive material.
26. The garment of claim 25, wherein said third layer comprises at
least 15% electrically conductive material and at least a portion
of elastic material.
27. The garment of claim 25, wherein each of said plies comprises a
length per weight of between approximately 16,500 to 17,500 yards
per pound, said knit strands of said first layer of fabric comprise
a gauge of between approximately 10 to 15 and a needle count of
between approximately 65 to 95.
28. The garment of claim 24, wherein said fabric comprises a first
layer of fabric, and further comprising a second non-electrically
conductive layer of fabric joined with and enclosed by said first
layer of fabric, said first and second layers configured to protect
a torso of the wearer.
29. The garment of claim 28, wherein each of said plies comprises a
length per weight of between approximately 16,500 to 17,500 yards
per pound, said knit strands of said first layer of fabric comprise
a gauge of between approximately 10 to 15 and a needle count of
between approximately 65 to 95.
30. The garment of claim 23, wherein said coupled strands are woven
and each of said strands comprises a length per weight of between
approximately 23,000 to 27,000 yards per pound.
31. The garment of claim 30, wherein the garment comprises a
ballistic missile resistant vest, said fabric comprises a surface
facing the wearer that is positioned adjacent to a layer of
ballistic missile resistant material and another surface facing
away from the wearer that is positioned adjacent to an electrically
non-conductive outer shell.
32. The garment of claim 31, wherein each of said strands comprises
a length per weight of between approximately 24,500 to 25,500 yards
per pound, and said woven strands comprise a density of between
approximately 160 to 200 threads per inch.
33. The garment of claim 32, wherein at least 30% of said staple
fibers comprise stainless steel, at least 30% of said staple fibers
comprise cotton, and at least 30% of said staple fibers comprise
polyester.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates generally to a fabric and, more
particularly, to a fabric for protecting a wearer thereof from an
energy weapon.
[0005] 2. Description of Related Art
[0006] There are many different types of protection devices which
are used by law enforcement agents, military personnel, security
guards, and others to prevent incapacitation or death during
performance of their jobs. For example, there are "bullet-proof"
vests which typically provide protection from bullets with
ballistic panels constructed from high strength fibers such as
aramid or polyethylene. These vests may also include metal and/or
ceramic plates for protection from blunt force trauma and high
velocity projectiles. Helmets and hand-held shields are also made
from ballistic resistant material for protection from ballistic
missiles. There are also garments manufactured from heat resistant
materials such as NOMEX.RTM. aramid, which protect individuals such
as firefighters and race car drivers during performance of their
jobs.
[0007] There are also devices that provide protection from energy
weapons such as TASER.RTM. weapons manufactured by TASER
International, Inc., "stun-guns," and other electrical pulse-based
assault devices. TASER.RTM. weapons typically have two
explosive-propelled barbs and a wire connecting each barb to a
power source within a hand-held housing. When the barbs embed in a
target, the target's body completes the electric circuit between
the barbs and rapid, high voltage, low current electric pulses are
delivered to the target from the power source, thus incapacitating
the target. A "stun-gun" operates similarly, but instead of
explosive propelled barbs, a "stun-gun" typically has a housing
with two electrical leads projecting slightly from the housing.
Thus, a "stun-gun" operator must be in close proximity to
incapacitate a target.
[0008] One type of energy weapon protection device comprises a
garment having two insulating panels sandwiching a conductive
panel. When the barbs or leads of an energy weapon contact this
device, electric current flows through the conductive panel of the
protective device instead of through the target wearing the device.
Thus, the device protects the target from incapacitation typically
caused by an energy weapon.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention is directed toward a fabric for
protecting a wearer thereof from an energy weapon. The fabric
comprises a plurality of coupled strands, which are preferably
woven or knit, however, it is within the scope of the invention for
the strands to be coupled in any manner. Each of the strands has a
first, electrically non-conductive, fiber and a second,
electrically conductive, fiber which is at least partially enclosed
by the first fiber. The second fiber conducts electric current from
an energy weapon when the leads of the energy weapon contact, or
are adjacent to, the fabric, thus protecting a wearer of the fabric
from the energy weapon. The fabric is easy to manufacture because
the strands may be joined in any conventional manner, such as
weaving or knitting. Further, the coupled strands may be easily
integrated into a garment. For example, the strands may be joined
to the outer surface of a ballistic missile resistant vest, or as a
liner to the inner surface of a glove or shirt.
[0010] In a preferred embodiment, a third fiber made from an
electrically non-conductive material is intertwined with the first
fiber. The second electrically conductive fiber is at least
partially enclosed by the combination of the first and third
fibers. The first and third fibers may be made from any
electrically non-conductive material, including heat resistant or
penetration resistant materials and materials that promote moisture
wicking. It is within the scope of the invention for each strand to
have any number of fibers, and for each strand to be constructed
from fibers of different materials.
[0011] According to another embodiment of the present invention, an
energy weapon protection fabric comprises a plurality of coupled
strands, each of which comprises coupled staple fibers. At least
30% of the staple fibers are electrically conductive for conducting
electric current from an energy weapon when the leads of the energy
weapon contact, or are adjacent to, the fabric, thus protecting a
wearer of the fabric from the energy weapon. The staple fibers may
be coupled by any means known in the art, such as ring spinning,
open-end or rotor spinning, and friction spinning. Additionally,
the strands present may be coupled by any means known in the art,
including weaving or knitting. Before the present invention it was
believed that continuous electrically conductive material was
necessary to effectively protect a wearer from an energy weapon.
With the present invention it was discovered that discontinuous
electrically conductive staple fibers may be coupled together with
non-electrically conductive staple fibers in the ratios specified
herein to protect a wearer from an energy weapon. This discovery
significantly reduces the cost of producing energy weapon
protection fabrics and garments versus previous embodiments
requiring continuous electrically conductive fibers.
[0012] In another embodiment, an energy weapon protection glove
comprises a first, middle layer of fabric, a second, outer fabric
layer joined with and enclosing the first fabric layer, and a
third, inner fabric layer joined with and enclosed by the first
fabric layer. The first, middle fabric layer is knit from strands
of material containing electrically conductive fibers. Each strand
comprises at least three plies. Each of the plies comprises at
least 30% electrically conductive staple fibers, more preferably at
least 50% electrically conductive staple fibers, and most
preferably at least 60% electrically conductive staple fibers. The
electrically conductive staple fibers conduct electric current from
an energy weapon. Each of the plies may be coupled by any means
known in the art, including by twisting with an S- or Z-twist. The
second, outer fabric layer is made from electrically non-conductive
material. The third, inner fabric layer is made from knit strands
of material that contain at least 10% electrically conductive
staple fibers and preferably at least a portion of elastic
material. Most preferably, the strands of the third layer comprise
at least 15% electrically conductive staple fibers. The elastic
material of the third layer ensures that there are no gaps in the
electrically conductive material of the first, middle layer, and
the electrically conductive staple fibers of the third layer ensure
that there is a sufficient amount of electrically conductive fibers
in contact with each other to conduct the electric current of an
energy weapon.
[0013] In an alternative embodiment of the present invention, an
energy weapon protection garment for protecting a wearer's torso
comprises first and second layers of fabric joined together. The
first, outer layer of fabric comprises knit strands of material
containing electrically conductive staple fibers. Each strand
comprises at least three plies. Each of the plies comprises at
least 30% electrically conductive staple fibers, more preferably at
least 50% electrically conductive staple fibers, and most
preferably at least 60% electrically conductive staple fibers. The
electrically conductive staple fibers conduct electric current from
an energy weapon. The second, inner layer of fabric is made from
electrically non-conductive material.
[0014] In accordance with another alternative embodiment of the
present invention, a ballistic missile resistant vest comprises an
electrically non-conductive outer shell, which encloses a layer of
energy weapon protection fabric and a layer of ballistic missile
resistant material. The energy weapon protection fabric has a rear
surface adjacent to the ballistic missile resistant material and a
front surface adjacent to the outer shell. The energy weapon
protection fabric comprises a plurality of woven strands. Each of
the strands comprises at least 30% electrically conductive staple
fibers, and most preferably comprises at least 40% electrically
conductive staple fibers.
[0015] Additional aspects of the invention, together with the
advantages and novel features appurtenant thereto, will be set
forth in part in the description which follows, and in part will
become apparent to those skilled in the art upon examination of the
following, or may be learned from the practice of the invention.
The objects and advantages of the invention may be realized and
attained by means of the instrumentalities and combinations
particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a pictorial view of a vest according to the
present invention protecting the wearer thereof from the electric
current generated by an energy weapon;
[0017] FIG. 2 is a partial cut-away view of the vest of FIG. 1
showing an outer layer and a liner of the vest;
[0018] FIG. 3 is a partial cross-sectional view of the vest of FIG.
1 showing energy weapon barbs penetrating the vest;
[0019] FIG. 4 is a partial perspective view of a strand of the
liner of the vest of FIG. 1;
[0020] FIG. 5 is a partial perspective view of a fabric according
to one embodiment of the present invention;
[0021] FIG. 6 is a pictorial view of a ballistic missile resistant
vest according to one embodiment of the present invention;
[0022] FIG. 7 is a cross-sectional view of the vest of FIG. 6;
[0023] FIG. 8 is a partial perspective view of a strand of fabric
according to an alternative embodiment of the present
invention;
[0024] FIG. 9 is a partial perspective view of a strand of fabric
according to another alternative embodiment of the present
invention;
[0025] FIG. 10 is a partial perspective view of a strand of fabric
according to another alternative embodiment of the present
invention;
[0026] FIG. 11 is a pictorial view of a glove according to one
embodiment of the present invention;
[0027] FIG. 12 is a detail view of a portion of the knit liner of
the glove of FIG. 11;
[0028] FIG. 13 is a detail view of a portion of the woven liner of
the vest of FIG. 1;
[0029] FIG. 14A is a detail view of a portion of a ply of a strand
of fabric constructed from staple fibers in accordance with another
embodiment of the present invention;
[0030] FIG. 14B is a cross-sectional view of the ply of FIG. 14A
taken along the line 14B-14B;
[0031] FIG. 15 is a detail view of a portion of energy weapon
protection fabric woven from strands made from plies of staple
fibers such as shown in FIG. 14A;
[0032] FIG. 16 is a cross-sectional view of a portion of an
alternative embodiment of ballistic missile resistant vest
containing the woven fabric of FIG. 15;
[0033] FIG. 17 is a detail view of a strand of fabric containing
three plies made from staple fibers such as shown in FIG. 14A;
[0034] FIG. 18 is a pictorial view of an energy weapon protection
shirt knit from strands of fabric such as shown in FIG. 17;
[0035] FIG. 19 is a partial cross-sectional view of the shirt of
FIG. 18;
[0036] FIG. 20 is a pictorial view of an energy weapon protection
glove knit from strands of fabric such as shown in FIG. 17; and
[0037] FIG. 21 is a partial cross-sectional view of the glove of
FIG. 20.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0038] A vest according to one aspect of the present invention is
indicated generally as 10 in FIG. 1. Vest 10 is worn upon the torso
12 of a wearer 14 for protecting the wearer from an energy weapon
16. Energy weapon 16 may be any type of energy weapon known in the
art including "stun-guns" and devices manufactured by TASER
International, Inc. headquartered in Scottsdale, Ariz. Vest 10 may
also protect wearer 14 from heat or penetration from a ballistic
missile such as a bullet or cutting instrument such as a knife.
Preferably, vest 10 also wicks moisture from wearer 14. While FIG.
1 shows a vest, any type of garment configured to protect the
wearer from an energy weapon is within the scope of the present
invention including, but not limited to, gloves, shirts,
undergarments, overcoats, pants, hats, and helmets. Further, the
invention is not limited to a garment, and may consist of any of
the protective fabrics described herein.
[0039] Looking now to FIG. 2, vest 10 has an outer layer 18 and an
inner layer, or liner, 20. Preferably, outer layer 18 is
constructed from a first fabric and liner 20 is constructed from a
second fabric, although it is within the scope of the invention for
the outer layer and liner to be constructed from the same fabric.
Preferably, outer layer 18 is made from a lightweight, breathable,
and heat resistant material. Outer layer 18 is preferably made from
cotton, but may be made from any material including but not limited
to nylon, wool, polyester, polyamide, aramid, polypropylene,
olefin, or any blend thereof. Additionally, it is within the scope
of the invention for the outer layer 18 to be coated with a
material to improve its heat resistance or resistance to electric
current. As shown in FIG. 3, outer layer 18 has a front surface 22
and a rear surface 24, and liner 20 has a front surface 26 and a
rear surface 28, which is adjacent the torso of wearer 14.
Preferably liner 20 is stitched to outer layer 18 along seams
thereof, although the liner and outer layer may be joined by any
means known in the art including adhesive.
[0040] Referring now to FIG. 13, liner 20 is woven by threading a
weft strand 30a over and under alternating parallel warp strands
30b forming a weave commonly known as a plain weave. Weft strand
30a loops around the warp strands 30b at the sides of the fabric
before threading back through the warp strands above the previous
row formed by the weft strand. Although only one weft strand 30a is
shown, it is within the scope of the invention for the liner 20 to
be woven with a plurality of vertically spaced weft strands.
Further, although liner 20 is shown as a plain weave, it is within
the scope of the invention for the liner to be any type of weave
known in the art including basket, twill, or satin. Although liner
20 is preferably woven from strands 30a and 30b, the liner 20 may
also be knit from strands, such as strands 30a and 30b, or
constructed by any other means known in the art for coupling
strands.
[0041] Referring now to FIG. 4, strand 30a has intertwined first,
second, and third fibers 32, 34, and 36 respectively. Although
strand 30b is shown in FIG. 13 with a smaller diameter than strand
30a, it is within the scope of the invention for the strands to be
the same diameter or for strand 30b to have a larger diameter than
strand 30a. Strand 30b preferably has the same construction as
strand 30a and thus will not be discussed separately, however, it
is within the scope of the invention for strands 30a and 30b to be
formed from a different number of fibers or to be formed from
different types of fibers. Additionally, it is within the scope of
the invention for each of the warp and weft strands 30a and 30b, if
more than one, to have a different construction. Intertwined first
and third fibers 32 and 36 in combination enclose second fiber 34.
Although first and third fibers 32 and 36 are shown enclosing
second fiber 34, it is within the scope of the invention for a
portion of second fiber 34 to be exposed such that first and third
fibers 32 and 36 at least partially enclose second fiber 34. First
and third fibers 32 and 36 are electrically non-conductive, while
second fiber 34 is electrically conductive.
[0042] Preferably, first and third fibers 32 and 36 are cotton and
polyester respectively, although it is within the scope of the
invention for the first and third fibers to be any electrically
non-conductive fiber such as nylon, polyester, polypropylene,
olefin, wool, an aromatic polyamide fiber, commonly known as an
aramid fiber, or any other type of electrically non-conductive
fiber known in the art. In one embodiment of the present invention,
in order to provide a penetration resistant liner 20, which can
provide protection from ballistic missiles and/or cutting
instruments, either or each of first and third fibers 32 and 36 is
aramid formed from poly-paraphenylene terephthalamide, which is
sold under the trade name KEVLAR.RTM. by E.I. du Pont de Nemours
and Company ("DuPont"), or high-strength polyethylene fiber sold
under the trade name SPECTRA.RTM. by Honeywell International Inc.
In order to provide a heat resistant liner 20, either or each of
first and third fibers 32 and 36 is aramid formed from
poly(meta-phenyleneisophthalamide), which is sold under the trade
name NOMEX.RTM. by DuPont. In order to provide a penetration
resistant and heat resistant liner 20, first fiber 32 is a high
strength fiber such as KEVLAR.RTM. aramid or SPECTRA.RTM.
polyethylene, while third fiber 36 is a heat resistant fiber such
as NOMEX.RTM. aramid. In order to provide a moisture wicking liner
20, either or each of first and third fibers 32 and 36 may be
polyester. First fiber 32 may be a moisture wicking fiber such as
polyester, while third fiber 36 is a high strength fiber such as
KEVLAR.RTM. aramid or SPECTRA.RTM. polyethylene, or a heat
resistant fiber such as NOMEX.RTM. aramid. Preferably, electrically
conductive second fiber 34 is stainless steel, although it is
within the scope of the invention for the fiber to be any
electrically conductive material such as carbon fiber, copper,
aluminum, or any blend or alloy thereof.
[0043] The majority of front and rear surfaces 26 and 28 of liner
20, shown in FIG. 3, are electrically non-conductive because
electrically non-conductive first and third fibers 32 and 36
enclose electrically conductive second fiber 34, shown in FIG. 4.
However, it is within the scope of the invention for portions of
front and rear surfaces 26 and 28 to be electrically conductive if
second fiber 34 is not completely enclosed by first and third
fibers 32 and 36. Rear surface 28 is preferably electrically
non-conductive to protect wearer 14 from electric current conducted
by second fiber 34 and the heat generated therefrom. Front surface
26 is preferably electrically non-conductive to protect liner 20
and the wearer thereof from electric current if the liner 20 is
inadvertently exposed to electric current from a power source such
as a battery.
[0044] As shown in FIG. 3, energy weapon 16 has two leads 38 and 40
joined to the ends of electrically conductive wires 42 and 44.
Wires 42 and 44 are electrically joined to a power source (not
shown) that is operable to generate a voltage differential between
the two wires. Barbs 46 and 48 are joined to leads 38 and 40 for
penetrating the clothing of a target of the energy weapon 16.
Energy weapon 16 has a similar configuration as any of the devices
currently sold under the trade name TASER.RTM. by TASER
International, Inc. Although energy weapon 16 is shown with wires,
leads, and barbs, it is within the scope of the invention for vest
10 to protect wearer 14 from an energy weapon such as a "stun-gun"
(not shown), which typically comprises a housing, two leads
extending slightly from the surface of the housing, a power source
such as a battery electrically connected to the leads, and a
trigger operable to generate a voltage differential between the
leads. Vest 10 protects wearer 14 from the incapacitating effects
of a "stun-gun" (not shown) in the same manner as described below
with respect to energy weapon 16.
[0045] Typically, when both leads of energy weapon 16
simultaneously contact, or are adjacent to, a target, the target
completes the electric circuit allowing current to flow from the
power source of the weapon, through one lead, through the target,
through the other lead, and back to the power source. The electric
current temporarily incapacitates the target. Vest 10 protects the
target of energy weapon 16, because electric current flows through
at least one of the electrically conductive second fibers 34 within
strands 30a and 30b instead of flowing through the target. As shown
in FIGS. 1 and 3, when energy weapon 16 is deployed against the
wearer of vest 10, barbs 46 and 48 penetrate liner 20. If the
energy weapon generates a voltage differential between wires 42 and
44, then the electric current will flow from the power source (not
shown) of the energy weapon through wire 42 and barb 46, through at
least one electrically conductive second fiber 34 of liner 20,
through barb 48 and wire 44, and then back to the power source (not
shown). Because each electrically conductive second fiber 34 within
liner 20 has a much lower resistance to electric current than a
human body, the electric current flows through at least one
electrically conductive second fiber within liner 20 even if barbs
46 and 48 completely penetrate liner 20 and are in direct contact
with wearer 14.
[0046] Vest 10 protects wearer 14 from an energy weapon, and
incapacitation caused therefrom, even if only one lead of the
energy weapon contacts the vest, or is directly adjacent the vest,
while the other lead contacts wearer 14, or is directly adjacent
the wearer. In this situation, electric current flows from the
power source (not shown) through the lead of the energy weapon in
direct contact with, or directly adjacent, wearer 14. Then, the
current flows through the portion of the wearer between the energy
lead in contact with the wearer and vest 10 until reaching at least
one electrically conductive second fiber 34 of liner 20. Finally,
the current flows through the lead of the energy weapon in direct
contact with, or directly adjacent vest 10, and back to the power
source (not shown). Even though electric current flows through a
portion of wearer 14, vest 10 minimizes the amount of wearer's body
exposed to electric current and thus greatly reduces any
incapacitation caused by the energy weapon. It should also be
appreciated that the electric current may flow in the opposite
direction as described above.
[0047] Vest 10 also protects wearer 14 even if barbs 46 and 48 of
energy weapon 16 do not make direct contact with the liner 20, but
instead are only near or adjacent the liner. For example, if barbs
46 and 48 only partially penetrate outer layer 18, electric current
will arc from each of the barbs through the remainder of outer
layer 18 and electrically non-conductive front surface 26 of the
liner to reach at least one electrically conductive second fiber 34
within liner 20. Likewise, if a stun-gun is activated adjacent vest
10, electric current will arc from each lead of the stun gun
through the electrically non-conductive outer layer 18 and front
surface 26 to reach at least one electrically conductive second
fiber 34 within liner 20. Thus, vest 10 prevents wearer 14 from
incapacitation caused by the electric current of energy weapon 16,
or a "stun-gun" (not shown). Preferably, vest 10 is operable to
protect wearer 14 from an energy weapon capable of generating up to
twenty-six watts of power.
[0048] Referring now to FIGS. 2 and 3, outer layer 18 and liner 20
preferably each have a thickness of approximately one-sixteenth of
an inch, or a thickness approximately equal to a typical shirt or
sweatshirt. Preferably, liner 20 has a weight per area of
approximately 100 to 250 grams per square meter, and most
preferably between 150 to 200 grams per square meter, although it
is within the scope of the invention for the liner to have any
weight per area. This relatively high density weave ensures that if
energy weapon 16 is deployed on a wearer 14 of vest 10, the barbs
46 and 48 of the energy weapon will contact, or be adjacent to, the
electrically conductive fibers 34 of multiple strands 30a and 30b
within liner 20. Liner 20 is preferably woven, as shown in FIG. 13,
as opposed to knit, because vest 10 need not be flexible, as most
knit fabrics are, to comfortably fit wearer 14, and to reduce the
percentage by weight of electrically conductive fibers. Woven
fabrics require a lesser percentage by weight of electrically
conductive fibers versus electrically non-conductive fibers than
knit fabrics in order to effectively protect wearer 14 from energy
weapon 16. It is within the scope of the invention however for
liner 20 to be knit from strands such as strand 30a, shown in FIG.
4, in the manner shown in FIG. 12 and described below. Preferably,
the electrically conductive second fiber 34 of each of strands 30a
and 30b in combination is approximately 25-45% of the weight of
liner 20, and most preferably approximately 30% of the weight of
the liner.
[0049] Although vest 10 is shown with an outer layer 18 and a liner
20, the vest need not have an outer layer 18 to effectively protect
wearer 14 from energy weapon 16. Although strand 30a is shown with
two intertwined fibers 32 and 36 enclosing second fiber 34, the
strand may have any number of fibers enclosing second fiber 34,
including one fiber as shown in the alternative embodiments of
FIGS. 8 and 9 and described below, or three fibers as shown in the
alternative embodiment of FIG. 10 and described below.
[0050] Looking now to FIG. 5, a fabric 50 according to one
embodiment of the present invention is constructed from a plurality
of joined strands, such as strand 30a shown in FIG. 4, preferably
joined in a weave or knit. Like liner 20 described above in
connection with FIGS. 1-4, each strand of fabric 50 contains at
least one electrically conductive fiber, such as fiber 34 shown in
FIG. 4, which protect a wearer thereof from an energy weapon in the
same manner as described above in connection with liner 20 of vest
10, and at least one electrically non-conductive fiber at least
partially enclosing the electrically conductive fiber. Fabric 50
has a front surface 52 and a rear surface 54 which are preferably
electrically non-conductive although it is within the scope of the
invention for either or both of the front and rear surfaces 52 and
54 to be electrically conductive. Fabric 50 may be incorporated
into or affixed to any type of wearable garment, such as gloves,
shirts, pants, overcoats, hats, helmets, body armor vests, and
undergarments, or fabric 50 may be sewn as a patch onto any type of
wearable garment such as those previously described. Additionally,
fabric 50 may be used in any desirable manner to protect a human or
animal from an energy weapon. The fibers of each strand of fabric
50 may be constructed with any of the materials described above
with respect to liner 20. Further, each strand may have any number
of fibers, and the strands of fabric 50 may be joined in any manner
known in the art including weaving or knitting. Each strand of
fabric 50 may also be constructed from different numbers of fibers
or different types of fibers. Fabric 50 may also be identical to
liner 20 described above in connection with FIGS. 1-4.
[0051] Referring now to FIGS. 6 and 7, a body armor vest according
to one aspect of the present invention is shown generally as 200.
As shown in FIG. 7, vest 200 has an armor carrier 202 enclosing
armor 204. Preferably, armor carrier 202 has an opening (not shown)
for inserting and removing armor 204 therefrom. Preferably, a
zipper or hook and loop fasteners (not shown) are joined to carrier
202 adjacent the opening (not shown) for securing the armor 204
within the carrier. Carrier 202 is preferably constructed from a
lightweight, durable, flexible, breathable fabric. Carrier 202 is
preferably constructed from nylon, but may be constructed from any
material including but not limited to cotton, wool, polyester,
polyamide, aramid, olefin, any blend thereof, or any other suitable
material. Further, carrier 202 may be coated with a material to
improve the heat resistance or electrical resistance of the
carrier.
[0052] Armor 204 is preferably constructed from a lightweight
material resistant to penetration from a ballistic missile and
cutting instrument such as KEVLAR.RTM. aramid or SPECTRA.RTM.
polyethylene. Carrier 202 has an inner surface 206, which is
adjacent a wearer (not shown) of the vest, and an outer surface
208. Fabric 50, described above in connection with FIG. 5, is
joined to outer surface 208 of carrier 202 via stitching 210a,
210b, 210c, and 210d and to inner surface 206 of carrier 202 via
stitching 212a, 212b, 212c, and 212d. Although fabric 50 is shown
joined to carrier 202 with stitching, it is within the scope of the
invention for the fabric to be joined to the carrier using any
means known in the art. Fabric 50 has a front surface 52 and a rear
surface 54, which is adjacent outer surface 208 of carrier 202.
[0053] As described above with respect to FIG. 5, front and rear
surfaces 52 and 54 of fabric 50 are preferably electrically
non-conductive and fabric 50 contains electrically conductive
fibers, such as fiber 34 of strand 30, shown in FIG. 4, which
protect a wearer of vest 200 from an energy weapon. As shown in
FIG. 7, fabric 50 covers the entire outer surface 208 of carrier
202 to protect a wearer of vest 200 from an energy weapon, such as
energy weapon 16 described above and shown in FIGS. 1 and 3, or a
"stun-gun" as described above. Fabric 50 covers outer surface 208,
as opposed to covering inner surface 206, so the electric current
from an energy weapon contacting, or adjacent to, vest 200 need not
arc through carrier 202 and armor 204 to reach fabric 50. Electric
current arcing through carrier 202 and armor 204 could undesirably
raise the temperature of vest 200. Fabric 50 covers a portion of
the inner surface 206 of carrier 202 so that a portion of fabric 50
is adjacent a wearer of the vest. It is desirable to have a portion
of fabric 50 adjacent the wearer of the vest in the situation where
one lead of an energy weapon directly contacts or is adjacent the
wearer and the other lead directly contacts or is adjacent the
vest. In this scenario, electric current from the energy weapon can
flow from the lead contacting the wearer, through the wearer and
into the portion of fabric 50 adjacent the wearer without arcing
through carrier 202 and armor 204. Fabric 50 only covers a portion
of the inner surface 206 of carrier 202 to minimize the capacitance
of vest 200. If vest 200 has a high capacitance, then electric
charge stored by the vest could undesirably discharge and
potentially harm a wearer thereof.
[0054] Although in the preferred embodiment of vest 200, fabric 50
only covers the outer surface 208 of the carrier 202, it is within
the scope of the invention for fabric 50 to only cover the inner
surface 206 of the carrier 202 in spite of the potential for
electric current arcing through carrier 202 and armor 204, or for
the fabric 50 to cover both the inner and outer surfaces 206 and
208 of the carrier in spite of the potential capacitive effect of
such a construction. Additionally, it is within the scope of the
invention for fabric 50 to only cover the outer surface 208 of
carrier 202 without having any portion of the fabric adjacent the
inner surface 206 of the carrier. Further, it is within the scope
of the invention for patches of fabric 50 to be discretely joined
to either or both of the inner and outer surfaces 206 and 208 of
carrier 202 for protecting a wearer of the vest from an energy
weapon. Preferably, fabric 50, when joined to a body armor vest as
in FIGS. 6 and 7, comprises woven strands such as strands 30a and
30b shown in FIGS. 4 and 13. Each strand preferably includes two
electrically non-conductive fibers intertwined with one
electrically conductive fiber such as strand 30a shown in FIG. 4.
The two electrically non-conductive fibers are preferably a blend
of polyester and cotton, which improve the durability of the fabric
when the fabric is repeatedly exposed to cleaning products.
[0055] Looking now to FIG. 8, an alternative embodiment of strand
100 has a first fiber 102 encircling and enclosing a second fiber
104. First fiber 102 is preferably constructed from any of the
electrically non-conductive materials described above in connection
with strand 30a, and second fiber 104 is preferably constructed
from any of the electrically conductive materials described above
in connection with strand 30a. Strand 100 may replace either of
strands 30a and 30b in the construction of liner 20, shown in FIGS.
1-4, or any of the strands of fabric 50 shown in FIG. 5.
[0056] FIG. 9 shows an alternative embodiment of strand 150 which
may replace either of strands 30a and 30b in the construction of
liner 20, shown in FIGS. 1-4, or any of the strands of fabric 50
shown in FIG. 5. Strand 150 has a first fiber 152 with a hollow
core, and a second fiber 154 positioned within the hollow core of
first fiber 152. First fiber 152 is preferably constructed from any
of the electrically non-conductive materials described above in
connection with strand 30a, and second fiber 154 is preferably
constructed from any of the electrically conductive materials
described above in connection with strand 30a.
[0057] Looking now to FIG. 10, an alternative embodiment of strand
250 has three intertwined fibers 252, 254, and 256 which in
combination enclose a fourth fiber 258. Fibers 252, 254, and 256
are preferably constructed from any of the electrically
non-conductive materials described above in connection with strand
30a, and fiber 258 is preferably constructed from any of the
electrically conductive materials described above in connection
with strand 30a. In one embodiment of strand 250, fiber 252 is a
heat resistant material such as NOMEX.RTM. aramid, fiber 254 is a
material that promotes moisture wicking such as polyester, fiber
256 is a ballistic missile and penetration resistant material such
as KEVLAR.RTM. aramid or SPECTRA.RTM. polyethylene, and fiber 258
is an electrically conductive material such as stainless steel.
Strand 250 may replace either of strands 30a and 30b in the
construction of liner 20, shown in FIGS. 1-4, or any of the strands
of fabric 50 shown in FIG. 5.
[0058] Referring now to FIG. 11, a glove according to an
alternative embodiment of the present invention is indicated
generally as 300. Glove 300 has an outer layer 302 and an inner
layer or liner 304. Outer layer 302 is preferably knit from a
material such as cotton or wool, however it is within the scope of
the invention for outer layer 302 to be woven and for the outer
layer to be constructed from any material such as nylon, polyester,
polyamide, aramid, polypropylene, or olefin. Outer layer 302 and
inner layer 304 are preferably joined by stitching (not shown)
although it is within the scope of the invention for the two layers
to be joined by any means known in the art. Inner layer 304 is
preferably knit from a plurality of identical strands 306, as shown
in FIG. 12, however it is within the scope of the invention for the
inner layer 304 to be woven or made from non-identical strands.
Each strand 306 of inner layer 304 is preferably constructed in the
same manner as strand 30a, shown in FIG. 4, but may also be
constructed like strands 100, 150, or 250 shown in FIGS. 8, 9, and
10 respectively and described above. Preferably, the electrically
non-conductive fibers are cotton to improve the comfort of glove
300, however it is within the scope of the invention for the
electrically non-conductive fibers to be any of the fibers
discussed above in connection with liner 20, shown in FIGS. 1-4.
Likewise, it is within the scope of the invention for the
electrically conductive fibers to be any of the fibers discussed
above in connection with liner 20.
[0059] Liner 304 has a weight per area of approximately 250 to 300
grams per square meter, and most preferably 287 grams per square
meter. Liner 304 is preferably knit, as opposed to woven, because a
glove is preferably flexible in order to fit comfortably upon the
hand of a wearer thereof. A liner according to the present
invention constructed for a sock would also preferably be knit for
the increased flexibility over that of a woven fabric. Preferably,
the electrically conductive fibers of liner 304 are approximately
30 to 50% of the weight of the liner, and most preferably
approximately 40% of the weight of the liner. The electrically
conductive fibers for a knit liner according to the present
invention preferably represent a greater percentage of the weight
of a garment according to the present invention than a woven liner
because the spacing between the adjacent strands 306 of a knit
fabric, shown in FIG. 12, is typically greater than the spacing
between the adjacent strands 30a and 30b of a woven fabric, shown
in FIG. 13. Therefore, it is desirable to have larger electrically
conductive fibers in a knit fabric to ensure that if an energy
weapon is deployed on a wearer of the knit fabric, then the leads
of the energy weapon will contact multiple electrically conductive
fibers within the liner.
[0060] In operation, a user dons vest 10, fabric 50, vest 200, or
glove 300, shown in FIGS. 1, 5, 6, and 11 respectively, for
protection from an energy weapon, such as weapon 16, shown in FIG.
1. If the user is subjected to a voltage differential between the
two leads 38 and 40 of the energy weapon, shown in FIG. 3, then the
electrically conductive fiber 34 of each strand 30a and 30b of vest
10, the electrically conductive fibers of fabric 50, the
electrically conductive fibers of vest 200, or the electrically
conductive fibers of strands 306 of glove 300 conduct the electric
current flowing from one lead of the energy weapon to the other
lead of the energy weapon. Because the combination of the
electrically conductive fibers within the vest 10, fabric 50, vest
200, or glove 300 has a much lower electrical resistance than a
human body, no electrical current flows through the wearer of the
vest, fabric, or glove.
[0061] Further, as described above, even if only one barb 46 or 48
of energy weapon 16 contacts or is adjacent the vest, fabric, or
glove, while the other barb 46 or 48 contacts or is directly
adjacent the target of the weapon, electric current will flow from
the barb contacting or adjacent the target through the portion of
the target between the barb and the vest 10, fabric 50, vest 200,
or glove 300. Then the current flows into the electrically
conductive fibers of the vest, fabric, or glove, and into the barb
adjacent the vest, fabric, or glove. Thus, vest 10, fabric 50, vest
200, or glove 300 minimizes the incapacitating effect of an energy
weapon by minimizing the distance that electric current flows
through the target's body before the electric current reaches the
conductive fibers of the vest, fabric, or glove. It is within the
scope of the invention for vest 10, fabric 50, vest 200, or glove
300 to protect the wearer thereof from both penetrating energy
weapons, such as weapon 16 shown in FIGS. 1 and 3, and
non-penetrating energy weapons (not shown), such as a device
described above and typically referred to as a "stun-gun."
[0062] Vest 10, fabric 50, vest 200, and glove 300, when fabricated
with heat resistant fibers, penetration resistant fibers, or fibers
that promote moisture wicking also protect the wearer thereof from
heat, a ballistic missile such as a bullet, a knife, and provide
increased comfort to the wearer by wicking away perspiration.
Further, armor 204 of vest 200 provides increased protection to the
wearer thereof from penetration from a ballistic missile or cutting
instrument.
[0063] Staple Fiber Conductive Fabrics
[0064] Referring now to FIGS. 14A and 14B, a ply of thread made
from staple fibers according to an alternative embodiment of the
present invention is shown generally as 400. The ply 400 of staple
fibers comprises both electrically conductive fibers such as fiber
402 and non-electrically conductive fibers such as fiber 404. The
ply 400 is an elongate thread of staple fibers coupled by any
manner known in the art. For example, the staple fibers may be
coupled by ring spinning, open-end spinning, rotor spinning,
friction spinning, core spinning, or adhesive. Additionally, the
staple fibers making up ply 400 may undergo any other steps that
are known in the textile arts for making fabric from staple fibers.
For example, the electrically conductive and non-electrically
conductive fibers may be mixed and blended, washed, combed, carded,
drawn, and drafted before being spun or twisted into staple fiber
ply 400.
[0065] As discussed below, the ply 400 may be coupled or twisted
with other plies or strands of twisted plies in any manner such as
weaving and knitting to form fabric. For example, FIG. 15 shows ply
400 woven with other identical plies in a conventional weave
pattern to form fabric 410. Additionally, ply 400 may be knit with
other identical plies to form a knit fabric. For example, plies
such as ply 400 could be used instead of the strands 306 shown in
FIG. 12 to form a knit fabric as shown in FIG. 12. Preferably, if
ply 400 is used in a knit fabric, then the ply 400 is first twisted
with other identical plies into a strand 500 as shown in FIG. 17.
Strand 500 shown in FIG. 17 is a three ply twisted strand made of
three identical plies like ply 400 of FIG. 14A. To make strand 500
the plies 400 may be twisted in any manner known in the art
including with a Z- or S-twist. Strands such as strand 500 may be
used instead of the strands 306 shown in FIG. 12 to form a knit
fabric as shown in FIG. 12. It should be understood that the plies
and strands of the present invention may be woven or knit with any
pattern in addition to the conventional knit and weave patterns
shown in FIGS. 12 and 15, respectively. Additionally, it should be
understood that the three ply strand 500 of FIG. 17 is exemplary
only and a strand having any number of plies coupled together in
any manner may be used in accordance with the present invention.
Further, the strand 500 of FIG. 17 may be doubled or tripled by
being twisted with other identical strands 500 before being woven
or knit into a fabric.
[0066] The fabric formed with ply 400 or strand 500 in accordance
with the present invention may be formed into any type of garment
such as gloves, socks, undergarments, shirts, pants, vests,
jackets, overcoats, hats, helmets, and any other type of garment
described herein. The electrically conductive staple fibers 402
within each ply 400 making up a garment in accordance with the
present invention are operable to conduct the electric current from
an energy weapon and protect a wearer of the garment from the
effects of an energy weapon. The electrically conductive staple
fibers 402 are configured to conduct an electric current from an
energy weapon that is adjacent to the fibers 402 in a similar
manner as the electrically conductive material of vest 10 described
above. Ply 400 differs from strand 30a of vest 10, shown in FIG. 4
and described above, because ply 400 comprises electrically
conductive staple fibers, while strand 30a comprises a continuous
electrically conductive fiber 34. As is well known in the textile
arts, staple fibers typically have a length of between
approximately 0.25 inches to approximately 20 inches. Any length of
staple fibers may be used for the garments in accordance with the
present invention. Preferably, however, the staple fibers have a
length between approximately 0.4 to 10 inches, more preferably a
length between approximately 0.4 to 6 inches, and most preferably a
length between approximately 0.4 to 2.5 inches. The staple fibers
used in garments according to the present invention may also have
any diameter. To protect a wearer of a garment made from plies such
as ply 400 from an energy weapon, electric current flows from one
lead of the energy weapon to the other lead through a chain of
adjacent electrically conductive staple fibers within the
garment.
[0067] The ply 400 shown in FIGS. 14A and 14B comprises at least
30% electrically conductive staple fibers 402 to ensure that enough
electrically conductive staple fibers contact or are adjacent to
each other to conduct the current from an energy weapon, more
preferably at least 50% electrically conductive staple fibers 402,
and most preferably at least 60% electrically conductive staple
fibers. As discussed below, for different types of fabric and
garments the preferable percentage of electrically conductive
staple fibers may vary. The electrically conductive staple fibers
402 are preferably stainless steel; however, it is within the scope
of the invention for the electrically conductive staple fibers 402
to be any material including any of the electrically conductive
materials described above. The electrically non-conductive staple
fibers may be any type of material including any of the
non-electrically conductive materials described above. The
discovery of the present invention that electrically conductive
staple fibers can be mixed with non-electrically conductive staple
fibers in the ratios specified herein to protect a wearer from an
energy weapon significantly reduces the cost of producing energy
weapon protection fabrics and garments versus previous embodiments
having continuous electrically conductive fibers.
[0068] Some of the non-electrically conductive fibers 404 may
comprise a heat resistant material such as aramid, or a penetration
resistant material such as aramid or polyethylene for improving the
heat and/or penetration resistance of a fabric or garment made
according to the present invention. Commercially available types of
these heat resistant and penetration resistant materials are
described above.
[0069] Referring now to FIG. 16, a body armor vest, or ballistic
missile resistant vest, according to one embodiment of the present
invention is shown generally as 412. Body armor vest 412 includes
the woven energy weapon protection layer of fabric 410 described
above and shown in FIG. 15 that is formed from plies of staple
fibers identical to ply 400 shown in FIGS. 14A and B. Body armor
vest 412 includes an outer shell 414, which encloses woven energy
protection fabric 410 and armor, or ballistic missile resistant
material, 416. The energy weapon protection fabric 410 has an inner
surface 410a that faces a wearer of the vest 412 and an outer
surface 410b that faces away from a wearer of the vest. The inner
surface 410a of the fabric 410 is positioned adjacent to the armor
416 and the outer surface 410b is positioned adjacent to the outer
shell 414. Outer shell 414 preferably has a similar configuration
as carrier 202 of the body armor vest 200 shown in FIG. 7, and the
outer shell 414 may be made from any of the materials described
above with respect to the carrier 202. Outer shell 414 differs from
carrier 202 in that there is no layer of fabric joined to the outer
layer of outer shell 414; rather, the energy weapon protection
fabric 410 of vest 412 is positioned within outer shell 414.
Additionally, armor 416 preferably has a similar configuration as
armor 204 of the body armor vest shown in FIG. 7, and the armor 416
may be made from any of the materials described above with respect
to the armor 204.
[0070] When used in fabric 410 for vest 412, ply 400 is preferably
a single ply strand of staple fibers. The ply 400 for fabric 410
used in vest 412 preferably has a length per weight of between
approximately 20,000 to 30,000 yards per pound, more preferably
between approximately 23,000 to 27,000 yards per pound, and most
preferably between approximately 24,500 to 25,500 yards per pound,
which corresponds with a cotton count of approximately 30 on a
scale of 840 yards per pound or a denier of approximately 180. The
fabric 410 for vest 412 preferably has a density of between
approximately 160 to 200 threads per inch, more preferably between
approximately 175 to 185 threads per inch, and most preferably
approximately 180 threads per inch. Preferably, each ply 400
comprises at least 30% electrically conductive staple fibers and
more preferably at least approximately 40% electrically conductive
staple fibers to ensure that enough electrically conductive staple
fibers are in contact with each other to effectively conduct the
current from an energy weapon without harming or incapacitating a
wearer of the vest 412. Preferably, each ply 400 comprises at least
30% stainless steel staple fibers, at least 30% cotton staple
fibers, and at least 30% polyester staple fibers, and, more
preferably, each ply comprises approximately 33% stainless steel
staple fibers, approximately 30% cotton staple fibers, and
approximately 37% polyester staple fibers.
[0071] Preferably, each ply 400 of fabric 410 for vest 412 has
electrically conductive staple fibers with a length of between
approximately 0.4 to 6 inches, more preferably between
approximately 1 to 4 inches, and most preferably between
approximately 2 to 3 inches. Preferably, the electrically
conductive staple fibers of each ply 400 for fabric 410 have a
diameter of between approximately 4 to 20 microns, more preferably
a diameter of between approximately 6 to 15 microns, and most
preferably a diameter of between approximately 8 to 12 microns. In
a most preferred embodiment, 95% of the electrically conductive
staple fibers used for fabric 410 have a diameter of between 8 to
12 microns and a length of between 2 to 3 inches. The ranges for
ply length per weight, density, staple fiber length, staple fiber
diameter, and percentage electrically conductive fibers ensure that
the vest 412 will conduct the current from an energy weapon thereby
preventing incapacitation or harm to the wearer thereof.
[0072] Although vest 412 preferably includes a woven energy
protection layer of fabric 410, the vest 412 may also include an
energy protection layer of fabric knit from strands containing
staple fibers. Further, vest 412 may be woven or knit from strands
of fabric that contain more than one ply which are twisted or
coupled together by any means known in the art. The energy
protection layer 410 of vest 412 is preferably configured to
protect a wearer of the vest from an energy weapon capable of
generating up to fifty watts of power, more preferably an energy
weapon capable of generating between 10 to 50 watts of power, and
most preferably an energy weapon capable of generating between 20
to 50 watts of power. The fabric 410 may also be used in other
types of garments in addition to body armor vests, such as any of
the garments described above.
[0073] Referring now to FIGS. 18 and 19, a shirt 600 is shown in
accordance with another embodiment of the present invention. As
shown in FIG. 19, shirt 600 includes two layers of fabric, an outer
layer of energy weapon protection fabric 602 and a non-electrically
conductive inner layer of fabric 604 that is enclosed by the outer
layer 602. The two layers of fabric 602 and 604 may be joined by
any means known in the art, including stitching. The energy weapon
protection fabric 602 of shirt 600 is preferably knit from a
plurality of strands such as strand 500, which is shown in FIG. 17
and contains three plies identical to ply 400 of FIG. 14A. While
the fabric 602 may be knit in any pattern, one type of pattern that
the fabric 602 may be knit in is shown in FIG. 12. As discussed
above, strands such as strand 500 can be used to make a garment
from the knit pattern of FIG. 12 in lieu of strands 306.
[0074] Each ply 400 of strand 500 for fabric 602 preferably has a
length per weight between approximately 12,000 to 22,000 yards per
pound, more preferably between approximately 15,000 to 19,000 yards
per pound, and most preferably between approximately 16,500 to
17,500 yards per pound, which corresponds with a cotton count of
approximately 20 on a scale of 840 yards per pound. Each ply 400
also preferably comprises at least 30% electrically conductive
staple fibers, more preferably at least 50% electrically conductive
staple fibers, and most preferably at least 60% electrically
conductive staple fibers to ensure that enough electrically
conductive fibers are in contact with each other to effectively
conduct the current from an energy weapon without harming or
incapacitating a wearer of the shirt 600. Preferably, the
electrically conductive staple fibers are stainless steel; however,
any type of electrically conductive staple fibers may be used.
Preferably, the non-electrically conductive staple fibers are
cotton; however, any type of non-electrically conductive staple
fibers may be used. In a most preferred embodiment, each ply 400 of
the fabric 602 comprises approximately 60% stainless steel staple
fibers and approximately 40% cotton staple fibers.
[0075] Preferably, the knit fabric 602 has a gauge of between
approximately 10 to 15 and most preferably approximately 13. The
knit fabric 602 preferably has a needle count of between
approximately 65 to 95, and more preferably between approximately
73 to 88. The needle count used for fabric 602 preferably depends
on the size of the shirt 600 that is being made with the fabric
602. For example, the needle count for an extra small shirt is
approximately 73, the needle count for a small shirt is
approximately 78, the needle count for a medium or large shirt is
approximately 83, and the needle count for a large or extra large
shirt is approximately 88. Preferably, each ply 400 of each strand
500 knit into fabric 602 has electrically conductive staple fibers
with a length of between approximately 0.4 to 6 inches, more
preferably between approximately 1 to 4 inches, and most preferably
between approximately 2 to 3 inches. Preferably, the electrically
conductive staple fibers of each ply 400 for fabric 602 have a
diameter of between approximately 4 to 20 microns, more preferably
a diameter of between approximately 6 to 15 microns, and most
preferably a diameter of between approximately 8 to 12 microns. In
a most preferred embodiment, 95% of the electrically conductive
staple fibers used for fabric 602 have a diameter of between 8 to
12 microns and a length of between 2 to 3 inches.
[0076] Preferably, each strand 500 used to knit fabric 602 of shirt
600 has three plies of staple fibers identical to ply 400 as
described above. It is also within the scope of the invention
however for each strand 500 to have more or less than three plies.
For example, the fabric 602 may be knit from strands comprising two
three-ply strands identical to strand 500 that are twisted
together.
[0077] The non-electrically conductive fabric layer 604 may be made
from any material and most preferably is made from cotton, nylon,
wool, polyester, polyamide, or aramid. The non-electrically
conductive fabric layer 604 may also be made from a blend of
different types of materials. Preferably, the layer 604 comprises a
moisture wicking material to improve comfort to the wearer of shirt
600. The layer 604 also provides protection to the wearer of shirt
600 by spacing the wearer from the electrically conductive layer
602 when current flows through it. Preferably, fabric layer 604 is
joined with layer 602 to minimize the gaps between the knit strands
500 of fabric 602 if the shirt 600 is stretched. It is important to
minimize any gaps between the knit strands 500 of fabric 602 to
ensure that enough electrically conductive staple fibers of the
strands 500 are in contact with or adjacent to each other to
effectively conduct the current from an energy weapon.
[0078] The above specified ranges for the gauge, needle count,
staple fiber length, staple fiber diameter, percent electrically
conductive material, number of plies per strand and length per
weight for each ply also ensure that the shirt 600 will effectively
conduct current from an energy weapon to protect its wearer from
the effects of the energy weapon. In one embodiment, the layer 604
includes some elastic material such as spandex to reduce the gaps
between the knit strands 500 of layer 602. Although shirt 600
preferably includes a knit energy protection layer of fabric 602,
the shirt 600 may also include an energy protection layer of fabric
woven from strands containing staple fibers. The energy protection
layer 602 of shirt 600 is preferably configured to protect a wearer
of the shirt from an energy weapon capable of generating up to
fifty watts of power, more preferably an energy weapon capable of
generating between 10 to 50 watts of power, and most preferably an
energy weapon capable of generating between 20 to 50 watts of
power. It is also within the scope of the present invention for
layers 602 and 604 to be formed into any other type of garment
described above.
[0079] Referring now to FIGS. 20 and 21, a glove in accordance with
another embodiment of the present invention is shown generally as
700. Glove 700 is configured to protect a wearer's hand from the
incapacitating effects of an energy weapon. As shown in FIG. 21,
glove 700 includes three layers of fabric 702, 704, and 706 that
are joined together by any means known in the art including
stitching. Outer layer 702 encloses middle layer 704, which
encloses inner layer 706. The outer layer 702 is made from a
non-electrically conductive material, while each of the middle and
inner layers 704 and 706 comprise some electrically conductive
material. The middle layer 704 is preferably knit from strands such
as strand 500 shown in FIG. 17. As discussed above strand 500
comprises three twisted plies 400 each having electrically and
non-electrically conductive staple fibers. The layer 704 may be
knit in any pattern including the one shown in FIG. 12.
[0080] For middle fabric layer 704 of glove 700, each ply 400 of
strand 500 preferably has a length per weight between approximately
12,000 to 22,000 yards per pound, more preferably between
approximately 15,000 to 19,000 yards per pound, and most preferably
between approximately 16,500 to 17,500 yards per pound, which
corresponds with a cotton count of approximately 20 on a scale of
840 yards per pound. Each ply 400 also preferably comprises at
least 30% electrically conductive staple fibers, more preferably at
least 50% electrically conductive staple fibers, and most
preferably at least 60% electrically conductive staple fibers to
ensure that enough electrically conductive fibers are in contact
with each other to effectively conduct the current from an energy
weapon without harming or incapacitating a wearer of the glove 700.
Preferably, the electrically conductive staple fibers are stainless
steel; however, any type of electrically conductive staple fibers
may be used. Preferably, the non-electrically conductive staple
fibers are cotton; however, any type of non-electrically conductive
staple fibers may be used. In a most preferred embodiment, each ply
400 of the fabric 704 comprises approximately 60% stainless steel
staple fibers and approximately 40% cotton staple fibers.
[0081] Preferably, the knit fabric 704 has a gauge of between
approximately 10 to 15 and most preferably approximately 13. The
knit fabric 704 preferably has a needle count of between
approximately 65 to 95, and more preferably between approximately
73 to 88. The needle count used for fabric 704 preferably depends
on the size of the glove 700 that is being made with the fabric
704. For example, the needle count for an extra small glove is
approximately 73, the needle count for a small glove is
approximately 78, the needle count for a medium or large glove is
approximately 83, and the needle count for a large or extra large
glove is approximately 88. Preferably, each ply 400 of each strand
500 knit into fabric 704 has electrically conductive staple fibers
with a length of between approximately 0.4 to 6 inches, more
preferably between approximately 1 to 4 inches, and most preferably
between approximately 2 to 3 inches. Preferably, the electrically
conductive staple fibers of each ply 400 for fabric 704 have a
diameter of between approximately 4 to 20 microns, more preferably
a diameter of between approximately 6 to 15 microns, and most
preferably a diameter of between approximately 8 to 12 microns. In
a most preferred embodiment, 95% of the electrically conductive
staple fibers used for fabric 704 have a diameter of between 8 to
12 microns and a length of between 2 to 3 inches.
[0082] Preferably, each strand 500 used to knit fabric 704 of glove
700 has three plies of staple fibers identical to ply 400 as
described above. It is also within the scope of the invention
however for each strand 500 to have more or less than three plies.
For example, the fabric 704 may be knit from strands comprising two
three-ply strands identical to strand 500 that are twisted
together. Although glove 700 preferably includes a knit energy
protection layer of fabric 704, the glove 700 may also include an
energy protection layer of fabric woven from strands containing
staple fibers. The energy protection layer 704 of glove 700 is
preferably configured to protect a wearer of the glove from an
energy weapon capable of generating up to fifty watts of power,
more preferably an energy weapon capable of generating between 10
to 50 watts of power, and most preferably an energy weapon capable
of generating between 20 to 50 watts of power.
[0083] The non-electrically conductive fabric layer 702 may be made
from any material and most preferably is made from cotton, nylon,
wool, polyester, polyamide, or aramid. The non-electrically
conductive fabric layer 702 may also be made from a blend of
different types of materials. Preferably, layer 702 is knit;
however, it is within the scope of the invention for the layer to
be woven.
[0084] The inner fabric layer 706 preferably comprises electrically
conductive material like layer 704. Preferably, inner fabric layer
706 comprises at least 10% electrically conductive material, and
more preferably comprises at least 15% electrically conductive
material. The electrically conductive material of the inner fabric
layer 706 ensures that if there is a gap in the electrically
conductive staple fibers of middle layer 704 then there is a
sufficient amount of electrically conductive material in contact
with each other to effectively conduct the current from an energy
weapon to prevent harm or incapacitation to the wearer thereof.
Thus, if there is a gap in the electrically conductive staple
fibers of middle layer 704, current can flow from the middle layer
704 to the inner layer 706 to bypass the gap and back to the middle
layer 704.
[0085] Preferably, the electrically conductive material of inner
layer 706 is stainless steel; however, it is within the scope of
the invention for the layer 706 to comprise any type of
electrically conductive material. Preferably, the inner layer 706
also comprises elastic material such as spandex which enables the
inner layer 706 to stretch and tightly conform to the hand of a
person wearing the glove. The inner layer 706 may be woven from
single plies 400 in the same manner as fabric 410 shown in FIG. 15.
The inner layer 706 may also be knit from strands such as strand
500 shown in FIG. 17. The inner layer 706 may be knit with any
pattern known in the art including the pattern shown in FIG. 12.
Further, it is within the scope of the invention for the inner
layer 706 to be woven or knit from plies or strands comprising any
number of twisted plies or strands. The inner layer 706 is
preferably woven or knit from plies comprising staple fibers of
electrically conductive and elastic material, but it may also be
woven or knit from plies comprising continuous fibers of
electrically conductive and elastic material.
[0086] Preferably, the inner, elastic layer 706 is joined with the
middle, electrically conductive layer 704 to minimize the gaps
between the knit strands 500 of fabric 704 if the glove 700 is
stretched. The elastic material of the layer 706 assists in
reducing gaps between the knit strands 500 of layer 704. It is
important to minimize any gaps between the knit strands 500 of
fabric 704 to ensure that enough electrically conductive staple
fibers of the strands 500 are in contact with each other to
effectively conduct the current from an energy weapon. The above
specified ranges for the gauge, needle count, staple fiber length,
staple fiber diameter, percent electrically conductive material,
number of plies per strand and length per weight for each ply also
ensure that the glove 700 will effectively conduct current from an
energy weapon to protect its wearer from the effects of the energy
weapon. It is also within the scope of the present invention for
layers 702, 704, and 706 to be formed into any other type of
garment described herein.
[0087] In use, the fabric 410, vest 412, strand 500, shirt 600, and
glove 700, shown in FIGS. 15, 16, 17, 18, and 20, respectively,
operate in a similar manner to protect a wearer thereof from an
energy weapon as described above for vest 10, fabric 50, vest 200,
or glove 300, shown in FIGS. 1, 5, 6, and 11, respectively. The
fabric 410, vest 412, fabric made from strands such as strand 500,
shirt 600, and glove 700 are used to cover a portion of a wearer's
body to protect the wearer from an energy weapon, such as weapon 16
shown in FIG. 1. If the wearer of any of these garments or fabrics
is subjected to a voltage differential between the two leads 38 and
40 (FIG. 3) of the energy weapon, then the electrically conductive
staple fibers 402 of each ply 400 or strand 500 making up the
garment or fabric 410, 412, 500, 600, and 700 conduct the electric
current flowing from one lead of the energy weapon to the other
lead of the energy weapon. The electric current flows from one lead
to the electrically conductive staple fibers adjacent that lead,
through a chain of electrically conductive staple fibers in contact
with or adjacent to each other in the fabric or garment between the
two leads, and to the opposite lead of the energy weapon. Because
the combination of the electrically conductive staple fibers within
the fabric 410, vest 412, strand 500, shirt 600, and glove 700 has
a much lower electrical resistance than a human body, no electric
current flows through the wearer of the respective fabric or
garment.
[0088] Each fabric 410, vest 412, strand 500, shirt 600, and glove
700 also operates in the same manner as the vest 10, fabric 50,
vest 200, and glove 300 to protect a wearer of the fabric or
garment in the situation where one barb of an energy weapon
contacts or is adjacent to the fabric or garment and the other barb
of the energy weapon contacts or is directly adjacent to the
intended target of the weapon. Additionally, the fabric 410, vest
412, strand 500, shirt 600, and glove 700 when including heat
resistant fibers, penetration resistant fibers, or fibers that
promote moisture wicking can protect the wearer thereof from heat,
a ballistic missile, a knife, and can provide increased comfort to
the wearer in the same manner as described above for vest 10,
fabric 50, vest 200, and glove 300.
[0089] From the foregoing it will be seen that this invention is
one well adapted to attain all ends and objectives herein-above set
forth, together with the other advantages which are obvious and
which are inherent to the invention.
[0090] Since many possible embodiments may be made of the invention
without departing from the scope thereof, it is to be understood
that all matters herein set forth or shown in the accompanying
drawings are to be interpreted as illustrative, and not in a
limiting sense.
[0091] While specific embodiments have been shown and discussed,
various modifications may of course be made, and the invention is
not limited to the specific forms or arrangement of parts and steps
described herein, except insofar as such limitations are included
in the following claims. Further, it will be understood that
certain features and subcombinations are of utility and may be
employed without reference to other features and subcombinations.
This is contemplated by and is within the scope of the claims.
* * * * *