U.S. patent application number 14/328949 was filed with the patent office on 2016-01-07 for plate carrier and a protective vest.
The applicant listed for this patent is David Warren. Invention is credited to David Warren.
Application Number | 20160003581 14/328949 |
Document ID | / |
Family ID | 55016771 |
Filed Date | 2016-01-07 |
United States Patent
Application |
20160003581 |
Kind Code |
A1 |
Warren; David |
January 7, 2016 |
PLATE CARRIER AND A PROTECTIVE VEST
Abstract
A plate carrier wearable by a user for housing an armor plate
comprises a plurality of hinges that connect a front portion of the
plate carrier and a back portion of the plate carrier at the
bottom; and an attachment mechanism disposed near the top of the
plate carrier and configured to adjustably secure the armor plate
inside the plate carrier.
Inventors: |
Warren; David; (Stone Ridge,
NY) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Warren; David |
Stone Ridge |
NY |
US |
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Family ID: |
55016771 |
Appl. No.: |
14/328949 |
Filed: |
July 11, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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29495839 |
Jul 3, 2014 |
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14328949 |
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29495833 |
Jul 3, 2014 |
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29495839 |
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Current U.S.
Class: |
2/2.5 |
Current CPC
Class: |
A41D 13/055 20130101;
A41D 2600/20 20130101; F41H 5/013 20130101; F41H 1/02 20130101;
A41D 13/015 20130101; A41D 29/00 20130101 |
International
Class: |
F41H 1/02 20060101
F41H001/02; A41D 13/05 20060101 A41D013/05 |
Claims
1. A plate carrier wearable by a user for housing an armor plate,
comprising: a plurality of hinges that connect a front portion of
the plate carrier and a back portion of the plate carrier at the
bottom; and an attachment mechanism disposed near the top of the
plate carrier and configured to adjustably secure the armor plate
inside the plate carrier.
2. The plate carrier according to claim 1, wherein the plate
carrier allows the armor plate to extend beyond the horizontal
edges of the plate carrier.
3. The plate carrier according to claim 1, wherein the front
portion includes a plurality of cutouts.
4. The plate carrier according to claim 1, wherein the front
portion of the plate carrier gradually reduces its configuration
from the bottom to the top when being used.
5. The plate carrier according to claim 4, wherein the
configuration at the top of the plate carrier is about half the
size of the bottom of the plate carrier.
6. The plate carrier according to claim 1, wherein the plurality of
hinges are formed by a predetermined cutout at the bottom of the
plate carrier.
7. The plate carrier according to claim 6, wherein the
predetermined cutout represents a single substantially circular
cutout.
8. The plate carrier according to claim 6, wherein the
predetermined cutout represents a single substantially rectangular
cutout.
9. The plate carrier according to claim 1, wherein the back portion
includes a plurality of shoulder harness slots and a plurality of
waist harness slots.
10. The plate carrier according to claim 9, wherein the plurality
of shoulder harness slots have an angle between about 15 degrees to
about 45 degrees relative to a horizontal direction.
11. The plate carrier according to claim 10, wherein the plurality
of shoulder harness slots have an angle of about 30 degrees
relative to the horizontal direction.
12. The plate carrier according to claim 1, wherein the back
portion includes a cutout corresponding to a wearer's chest
area.
13. The plate carrier according to claim 1, wherein the plate
carrier is capable of accommodating armor plates having different
sizes.
14. The plate carrier according to claim 1, wherein an
anti-ballistic layer is attached to the back portion.
15. The plate carrier according to claim 14, wherein a ventilation
layer is attached to the anti-ballistic layer and is configured to
provide ventilation passageways to dissipate heat generated by a
wearer.
16. The plate carrier according to claim 1, wherein the front
portion and the back portion are capable of pivoting around the
plurality of hinges like a clamshell.
17. The plate carrier according to claim 1, wherein the plate
carrier is free of any attachment slots.
18. The plate carrier according claim 1, wherein the attachment
mechanism near the top of the plate carrier represents an integral
part of the plate carrier.
19. A protective vest including at least one plate carrier of claim
1.
20. The protective vest according to claim 19, further comprising a
side panel.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of Design
Patent Application No. 29,495,839 to David Warren, titled "A plate
carrier" and filed on Jul. 3, 2014, and Design Patent Application
No. 29,495,833 to David Warren, titled "A plate carrier" and filed
on Jul. 3, 2014, the entirety of which are incorporated herein by
reference.
FIELD OF INVENTION
[0002] The invention disclosed herein relates generally to a plate
carrier and a protective vest for protecting the human torso from
ballistic impact. Specifically, the protective vest and the plate
carrier are configured to hold protective inserts with a wide range
of sizes.
BACKGROUND
[0003] Combat forces, police officers, security professionals, and
even amateurs are routinely wearing protective gear, such as
protective vests, which are designed to prevent or mitigate the
damage caused by the impact of projectiles and/or explosives and/or
by the stabbing/slashing of hand weapons. A protective vest is
typically formed primarily by two components: an outer carrier
designed to house an armor solution or a protective insert. The
armor solution or protective insert is typically in a panel form,
rigid or semi-flexible. The panels are commonly made of multi-layer
woven Kevlar if the vest is designed to provide protection against
handguns; and, for protection against more powerful weapons, such
as rifles, ceramic composites are typically used to make the panel.
Sometimes, hard steel plates are added to the body armor to enhance
the protective functions of the vest.
[0004] Traditionally, outer body armor carriers, which house the
protective inserts and form a wearable platform on a torso, are
made of nylon or cotton fabric with sewed-in pockets to receive the
protective armor solution. In the past, the outer carrier has to be
specifically tailored for each design of armor plates or panels. A
tailored design, which is suitable for a specific plate size or
contour, may not be adaptable to comfortably fit many other
different plates or body types. Knowing that there are hundreds of
armor plate designs and more than one body type, this method of
making the outer plate carrier does not provide a user with an
efficient solution when he or she needs to change armor plates from
one manufacturer to another.
[0005] In addition, conventional vests are generally very heavy due
to their full body coverage design and the use of complex
attachment systems to hold and release the armor panels. As a
result, the traditional body armor is cumbersome to properly put on
or remove from a human torso.
SUMMARY
[0006] There is a need to have a universal carrier that is capable
of receiving a wide range of armor solutions including a range of
rigid or flexible composite armor plates or panels. It is also
desirable that an improved design is lightweight with improved
functionalities, including improved ergonomics and ventilation for
a user. The present application has set forth various embodiments
of a clamshell carrier design to solve the above-identified
drawbacks of conventional plate carriers by housing armor plates
similarly like a clamshell, which has two halves connected with
each other at hinges along one side of the clamshell. The plate
carrier design includes a front portion and a back portion, which
are hinged at the base and fastened on the top. A layer of shear
thickening liquid or foam may be additionally attached to the back
portion to provide an energy absorbing gap between the plate
carrier and the torso. The shear thickening foam further reduces
backside deformation and spreads the kinetic energy over a greater
area. Additional layers may be further added to the shear
thickening form to provide ventilation passage ways between the
torso and the ambient environment. The plate carrier design may
also include relief cutouts to offer increased flexibility and
conformability.
[0007] According to an aspect of the present application, a plate
carrier houses an armor plate and is wearable by a user. The plate
carrier comprises a plurality of hinges that connect a front
portion of the plate carrier and a back portion of the plate
carrier at the bottom; and an attachment mechanism disposed near
the top of the plate carrier and configured to adjustably secure
the armor plate inside the plate carrier.
[0008] According to an embodiment of the present application, the
plate carrier allows the armor plate to extend beyond the
horizontal edges of the plate carrier.
[0009] According to another embodiment of the present application,
the front portion includes a plurality of cutouts.
[0010] According to yet another embodiment of the present
application, the front portion of the plate carrier gradually
reduces its configuration from the bottom to the top.
[0011] According to yet another embodiment of the present
application, the configuration at the top of the plate carrier is
about half the size of the bottom of the plate carrier.
[0012] According to yet another embodiment of the present
application, the plurality of hinges are formed by a predetermined
cutout at the bottom of the plate carrier.
[0013] According to various embodiments of the present application,
the predetermined cutout at the bottom of the plate carrier
represents a single substantially circular cutout or a single
substantially rectangular cutout.
[0014] According to yet another embodiment of the present
application, the back portion includes a plurality of shoulder
harness slots and a plurality of waist harness slots.
[0015] According to various embodiments of the present application,
the plurality of shoulder harness slots have an angle between about
15 degrees to about 45 degrees relative to a horizontal direction
or an angle of about 30 degrees relative to the horizontal
direction.
[0016] According to yet another embodiment of the present
application, the back portion includes a cutout corresponding to a
wearer's chest area.
[0017] According to yet another embodiment of the present
application, the plate carrier is capable of accommodating armor
plates having different sizes.
[0018] According to yet another embodiment of the present
application, an anti-ballistic layer is attached to the back
portion.
[0019] According to yet another embodiment of the present
application, a ventilation layer is attached to the anti-ballistic
layer and is configured to provide ventilation passageways to
dissipate heat generated by a wearer.
[0020] According to yet another embodiment of the present
application, the front portion and the back portion of the plate
carrier are capable of pivoting around the plurality of hinges like
a clamshell.
[0021] According to yet another embodiment of the present
application, the plate carrier is free of any attachment slots.
[0022] According to yet another embodiment of the present
application, the attachment mechanism near the top of the plate
carrier represents an integral part of the plate carrier.
[0023] According to another aspect of the present application, a
protective vest includes at least one plate carrier comprising a
plurality of hinges that connect a front portion of the plate
carrier and a back portion of the plate carrier at the bottom and
an attachment mechanism disposed near the top of the plate carrier
and configured to adjustably secure the armor plate inside the
plate carrier.
[0024] According to an embodiment, the protective vest further
comprises a side panel.
BRIEF DESCRIPTION OF DRAWINGS
[0025] Certain exemplary embodiments are described herein in
connection with the following description and the annexed drawings.
The following description and drawings are given by way of example,
and not limitation, and the claims are not intended to be limited
only to the specific details of the description and drawings.
[0026] FIG. 1 illustrates a perspective view of a protective vest
100 according to an embodiment of the present application.
[0027] FIG. 2 illustrates a perspective view of a plate carrier 200
according to an embodiment of the present application.
[0028] FIG. 3 illustrates a front view of a plate carrier 200
according to an embodiment of the present application.
[0029] FIG. 4 illustrates a back view of a plate carrier 200
according to an embodiment of the present application.
[0030] FIG. 4a illustrates a bottom view of the plate carrier 200
according to an embodiment of the present application.
[0031] FIG. 5 illustrates an armor panel secured in a plate carrier
200 according to an embodiment of the present application.
[0032] FIG. 6 illustrates a plan view of a flattened plate carrier
200 in FIG. 2 in its flattened pre-use state according to an
embodiment of the present application.
[0033] FIG. 7 illustrates a construction of the back portion of the
plate carrier 200 according to an embodiment of the present
application.
[0034] FIG. 8 illustrates a plan view of a plate carrier 800 in its
flattened pre-use state according to an embodiment of the present
application.
[0035] FIG. 9 illustrates a plan view of a plate carrier 900 in its
flattened pre-use state according to an embodiment of the present
application.
[0036] FIG. 10 illustrates a plan view a plate carrier 1000 in its
flattened pre-use state according to an embodiment of the present
application.
[0037] FIG. 11 illustrates a plan view of a plate carrier 1100 in
its flattened pre-use state according to an embodiment of the
present application.
[0038] FIG. 12 illustrates a side panel 1200 according to an
embodiment of the present application.
[0039] FIG. 13 illustrates a plate carrier 1300 in its flattened
pre-use state according to an embodiment of the present
application.
[0040] FIG. 14 illustrates the plate carrier 1300 of FIG. 13 in a
closed position according to an embodiment of the present
application.
DETAILED DESCRIPTION
[0041] Embodiments of protective vests, plate carriers, and methods
of manufacturing the same are disclosed or are apparent from and
encompassed by the description herein. Not all embodiments
disclosed herein are specifically illustrated in the drawings, but
their construction will be apparent to one of ordinary skills in
the art from the disclosure herein. Also, the specific embodiments
described below and shown in the drawings are exemplary.
[0042] The plate carrier as set forth in various embodiments of the
present application represents a universal carrier, which may
accommodate a wide range of armor panel sizes and body shapes.
According to an embodiment, the plate carrier may be used on both a
female torso and a male torso without further tailoring. The
present application provides improved designs on form, fit, and
function. According to some embodiments, the present application
provides a secure housing to hold many configurations and levels of
Small Arms Protective Inserts ("SAPI") plate armor solutions, such
as rigid ceramic, rigid steel, rigid composite, and soft composite;
mitigates backside defamation through the use of energy absorption
materials, such as shear thickening fluid and shear thickening
foam, reduces pressure by creating a natural air gap between the
carrier and the user, provides protection from secondary fragments,
shrapnel and debris, and offers rapid deployment and removal of
armor plates while providing a secure housing.
[0043] FIG. 1 illustrates a protective vest 100 according to an
embodiment of the present application. The protective vest 100
includes an anterior panel 102 and a posterior panel 104, which are
secured to each other via a harness system. The harness system may
be of any attachment means, such as straps, belts, ropes, ties,
chains, loops, buckles, hooks, or fittings, for fastening,
supporting, or restraining the panels 102 and 104. According to an
embodiment, the harness system represents a Velcro system.
According to an embodiment, the harness system includes a plurality
of shoulder straps 106 and a plurality of waist straps 108. The
panels 102 and 106 may have a predetermined contour conforming to a
general shape of an upper portion of a human torso. According to an
embodiment, the posterior panel 104 and the anterior panel 102 are
substantially similar with each other, which is contoured
regardless whether the plate carrier is used in an anterior
location or a posterior location. According to an embodiment, the
posterior panel 104 is contoured according to a general shape of
the back of a human torso, while the anterior panel 102 is
contoured according to a general shape of the front of a human
torso.
[0044] Both the anterior panel 102 and the posterior panel 104 are
used to house protective inserts with a wide range of sizes. For
example, SAPI specified by the U.S. Army may be produced in the
following sizes and weights:
[0045] Extra Small--1.27 kg (2.8 lb)|184.times.292 mm
(71/4.times.111/2 in),
[0046] Small--1.59 kg (3.5 lb)|222.times.298 mm (83/4%.times.113/4
in),
[0047] Medium--1.82 kg (4.0 lb)|241.times.318 mm (91/2.times.121/2
in),
[0048] Large--2.09 kg (4.6 lb)|260.times.337 mm (101/8.times.131/4
in), and
[0049] Extra Large 2.40 kg (5.3 lb)|280.times.356 mm (11.times.14
in).
[0050] The size of an armor plate manufactured according to the
SAPI specification may have variations up to 3.75 inches along the
horizontal direction and 3.5 inches along the vertical direction.
Traditional plate carriers with fixed pouch sizes would not be able
to accommodate armor plates with such variation in sizes. Rather,
each time a new armor plate is needed, the user has to order a new
plate carrier to fit the new armor plate.
[0051] According to an embodiment of the present application, the
plate carrier does not physically limit its housing capacity in the
horizontal direction. As shown in FIG. 1, the side edges of the
anterior panel 102 and the posterior panel 104 are open and free of
confinement means. In this way, the panels are able to house armor
plates with different horizontal dimensions. Along the vertical
direction, the panels use an attachment mechanism at the top to
secure the armor plate in position. As shown in FIG. 1, the
anterior panel 102 or the posterior panel 104 uses an adjustable
attachment mechanism 110 to secure a plate inside the panel.
According to an embodiment, the adjustable attachment mechanism may
be implanted as a stretchable Velcro system 110, as shown in FIG.
1. The adjustability of the attachment mechanism 110 allows armor
plates with various heights to be housed and secured inside the
plate carrier. It is noted that the adjustable mechanism 110 may be
implanted in any suitable means known to a person of ordinary skill
in the art, including harness, ties, straps, buckles, and
belts.
[0052] In panel 102 or panel 104, the adjustable attachment
mechanism 110 is attached to both the front portion and back
portions of that panel. Attachment areas, such as the extension
area 114, for the attachment mechanism 110 are provided. In
addition, a slot 112 is also provided at the back portion of the
panel 102 to guide and restrict the movement of the stretchable
strap 110.
[0053] According to an embodiment, both anterior panel 102 and
posterior panel 104 have a clamshell design as set forth in the
present application. The clamshell design allows a plate carrier to
be body conforming and makes the placement of armor plates in a
plate carrier or removal of armor plates from a plate carrier to be
carried out efficiently. For example, a single operation of an
attachment mechanism near the top of a plate carrier as set forth
in the present application can properly set up an armor plate in a
plate carrier.
[0054] According to another embodiment, at least one of the
anterior panel 102 or the posterior panel 104 has a configuration
as disclosed in the present application. According to an
embodiment, the protective vest 100 may further include a side
panel (not shown) to protect the side areas of the wearer. The side
panel may have a similar clamshell design as that of the anterior
panel or the posterior panel. When a side panel is used, the waist
harness system 108 attaches the side panel with the other
panels.
[0055] FIG. 2 illustrates a plate carrier 200 according to an
embodiment of the present application. The plate carrier 200 may be
used as any of the anterior panel 102 or the posterior panel 104.
The plate carrier 200 includes a front portion 214 and a back
portion 216, which are connected with each other via a plurality of
hinges 206 at the bottom of the plate carrier 200. At the top of
the plate carrier 200, the adjustable attachment mechanism 110 is
used to fasten the front portion 214 and the back portion 216
together. The side edges of the plate carrier are free of
confinements.
[0056] The plate carrier houses or holds armor panels like a
clamshell. The front portion 214 and the back portion 216 are
capable of rotating relative to each other to a limited extent
around the bottom of the plate carrier, thus widening or narrowing
the housing space inside the plate carrier 200. This adaptability
of the housing space eases the operability of the plate carrier
200. The adjustable attachment mechanism 110 is configured to
enclose and secure the armor plates. To place an armor panel inside
the plate carrier, the adjustable attachment mechanism 110 is
unfastened, i.e. at an open position. After protective inserts are
placed inside the plate carrier 200, the adjustable attachment
mechanism 110 is then fastened to corresponding attachment areas,
i.e. at its closed position. The plate, after being secured inside
the plate carrier 200, is pressed between the adjustable attachment
mechanism 110 and the bottom hinges 206 and is pressed between the
front portion 214 and the back portion 216. The friction force
along the contact areas between the armor panel and the plate
carrier is able to substantially prevent the plate from being
displaced or moved along the horizontal direction. The armor panel
is fixed vertically by the hinges 206 and straps 110, and does not
move substantially along that direction.
[0057] The hinges 206 may be made from an integral part of the
plate carrier 200. According to an embodiment, the hinges are
formed by making a cutout 208 from the bottom of the plate carrier
200. The cutout 208 may be of any shape, including circular,
rectangular, oval, elliptical, or triangle. The width of the hinges
206 are designed to provide both suitable mechanical strength to
support the weight of the plate inside the plate carrier and
flexibility of the plate carrier. The hinges 206 may be made by a
method other than a cutout method. According to an embodiment, the
hinges are formed while the plate carrier is being molded.
According to an embodiment, the hinges may be manufactured
separately from the rest of the plate carrier 200 and then attached
to the bottom of the front portion 214 or the back portion 216.
[0058] A plurality of slots 202 and 204 are provided in the plate
carrier 200 for the attachment of harness systems 106 and 108. The
slots may be provided on the back portion alone, the front portion
alone, or on both the back and front portions. According to an
embodiment as shown in FIG. 2, the slots 202 and 204 are provided
at the back portion 216 of the plate carrier 200. The plurality of
slots 202 and 204 include a plurality of shoulder harness slots 202
and waist harness slots 204. The shoulder harness slots 202 are
used for attaching a shoulder harness system 106 and are arranged
at a predetermined angle "A" relative to a horizontal direction to
follow a general contour of a user's shoulder. The angle "A" may be
between 0 to 60 degrees, preferably between 15 to 45 degrees, or
preferably about 30 degrees. The waist harness slots 204 are used
for attaching a waist harness system or a cummerbund and are
arranged in a substantially vertical direction. Both the shoulder
harness slots 202 and the waist harness slots 204 include portions
218 that are raised from adjacent areas. These raised portions 218
form clearance spaces to accommodate the thickness of corresponding
harness systems that are inserted through the clearance spaces.
[0059] The front portion 214 of the plate carrier 200 has a
gradually reducing profile from its bottom to its top to reduce
unnecessary materials. The extension portion 114 has a constant
profile, such as a rectangular shape, and represents a
configuration that provides suitable mechanical strength to the
plate carrier but does not require more than necessary materials.
According to an embodiment, the cross-section area of the extension
portion 114 may be about half the size of the cross-section area of
the bottom of the plate carrier 200. The transitional portion
between the bottom and the extension portion 114 may use any
suitable shape that provides a smooth connection therebetween.
According to an embodiment, a straight line or a curved line may be
used as a profile for the transitional area. According to an
embodiment, the transitional portion includes a beveled edge that
forms a predetermined angle "B" relative to a vertical direction.
The predetermined angle "B" may be between 1 to 60 degrees, or
preferably about 30 degrees. According to an embodiment, the
transitional portion includes a plurality of cutouts 210 at
predetermined areas to reduce the weight of the plate carrier 200.
The cutouts 210 may be of any shape such as circle, triangle,
rectangle, or oval.
[0060] The back portion 216 is proximal to a human torso and
requires a design that not only addresses the mechanical
requirements but also provides added comfort to a wearer. According
to an embodiment, the back portion 216 includes a slot 112 for
guiding and securing the adjustable attachment mechanism 110. In
the consideration of a female user, a plurality of cutouts 212 are
provided in the back portion 216 at locations corresponding to a
female's breasts or chest area. The cutouts 212 may have a circular
or oval shape that generally conforms to that of a female's breasts
or chest area. The back portion 216 also has additional layers for
reducing backside deformation of the plate carrier and for
providing ventilation passageways to a wearer, which will be
described in detail in the following sections of the present
application. According to an embodiment, when the plate carrier 200
is used to protect the back of a human torso, the back portion 216
has a plurality of cutouts 212 that conform to the contour of the
back torso.
[0061] The plate carrier 200 may be made of plastic, metal,
composite, and/or any other material that provides suitable
mechanical integrity and stiffness. According to an embodiment, the
plate carrier is made of a rigid plastic that allows for high wear
restraint and confinement for the armor plate. Rigid composites,
soft fabrics, rubber, Kevlar and other armor composites may also be
used to make the plate carrier. The manufacturing method of such a
plate carrier is well known in the art, including drape forming,
die cutting, injection molding, vacuum forming, and hot
pressing.
[0062] FIG. 3 illustrates a front view of the plate carrier 200
according to an embodiment of the present application. The plate
carrier 200 has a shoulder harness system 106 and a waist harness
system 108 installed. The adjustable attachment mechanism 110 is
fastened to the attachment area 114.
[0063] FIG. 4 illustrates a back view of the plate carrier 200
according to an embodiment of the present application. The
adjustable attachment mechanism 110 is unfastened from the back
portion 216. As shown in FIG. 4, the size of the cutouts 212 is
determined so that a remaining part 402 at the back portion 216 has
a substantially identical width as the extension area 114 of the
front portion 214 to ensure that both portions have similar
mechanical strength.
[0064] FIG. 4a illustrates a bottom view of the plate carrier 200
according to an embodiment of the present application. The plate
carrier 200 is configured to have a predetermined contour 404 that
conforms to the general shape of a female upper torso or a male
upper torso. According to an embodiment, the general contour 404
represents a shape that is generally adopted by manufacturers of
armor plates. The front panel 214 is substantially parallel to the
back panel 216, thus forming a plate carrier space with a uniform
thickness across the areas covered by the plate carrier 200.
According to an embodiment, the portion 218 does not need to be
raised. As shown in FIG. 4a, the portion 218 is at the same level
as the other portions of the back panel 216.
[0065] FIG. 5 illustrates a plate carrier housing an armor plate
according to an embodiment of the present application. The armor
plate 502 is held in a plate carrier 200 and is secured in position
by the adjustable attachment mechanism 110. The armor plate 502 is
allowed to extend beyond the horizontal edges of the plate carrier
200 as the plate carrier 102 has an open edge design along the
horizontal direction. According to an embodiment, the adjustable
attachment mechanism 110 represents substantially the only means in
the plate carrier to hold the armor plate 502. The attachment
mechanism 110 is configured to exert enough force along a suitable
area in contact with the armor plate 502 so that the friction force
substantially prevents the armor plate 502 from moving along the
horizontal direction. According to an embodiment, more than one
attachment mechanism 110 may be placed at the top of the plate
carrier to secure armor plates. The clamshell design of the plate
carriers 102 or 104 or 200 greatly simplifies the steps for
installing or removing an armor plate 502. With the clamshell
design as shown in FIG. 5, the armor plate 502 is free to be placed
inside or taken out of the plate carrier after one single operation
of the attachment mechanism 110. The front portion and the back
portion of the plate carrier are bendable and hinged at the bottom
to make additional operating rooms for a user, further easing the
installation and removal process. The clamshell design preferably
uses a limited number of hinges 206 at the bottom to ease the
operability of the plate carrier. According to an embodiment, at
least two hinges 206 are disposed at the outmost boundary of the
bottom to support the armor plate and provide flexibility of the
clamshell design.
[0066] FIG. 6 illustrates a plan view of a flattened plate carrier
200 according to an embodiment of the present application. The
plate carrier 200 has a configuration that is symmetrical relative
to a central axis 602. The material used to make the plate carrier
may be a single layer or multiple layers of material. For example,
the plate carrier 200 may be made of a single layer of a tough
plastic material. According to an embodiment, additional layers of
protective or functional materials may be further added to the
plastic material. For example, anti-ballistic fabric such as Kevlar
or Spectra may be used to cover the plastic material. Other
coatings designed to stop shrapnel may also be deposited on the
surface of the plastic material. Although FIG. 6 shows that the
plate carrier 200 is in the form of one piece of continuous sheet
material, the plate carrier 200 may be formed by many pieces or
parts without departing from the spirit of the present application.
For example, the back portion, the front portion, and the hinges
may be manufactured separately from various materials. After each
part is made, they may be assembled or attached to each other by
proper attachment or securing means including ultrasonic welding,
harness, adhesive, screws, rivets, ties, and strings. An ultrasonic
welding technique, in general, is suitable to join dissimilar or
similar materials, such as plastics. The ultrasonic welding
technique is capable of applying high-frequency ultrasonic acoustic
vibrations to selected locations of parts that are in contact with
each other under pressure to create a joint such as a solid-state
weld.
[0067] FIG. 7 illustrates a cross-section view of a back portion
212 according to an embodiment of the present application. As shown
in FIG. 7, the back portion 212 may be formed by a plurality of
layers of materials to enhance the protection against impact and/or
provide comfort to a wearer. A base layer 702 that is formed by the
same material as the other part of the plate carrier is
substantially covered by a layer of anti-ballistic armor material
704, which is further substantially covered by another layer of
functional material designed to improve ventilation to a wearer.
The layer of anti-ballistic armor material 704 may be a layer or
plural layers of Kevlar fabric and/or be a layer of a liquid armor,
also known as shear thickening fluid. According to an embodiment,
the functional material 706 has a webbed configuration that
provides air gaps or pockets between the back portion of the plate
carrier and the human body.
[0068] FIG. 8 illustrate a plan view of a plate carrier 800
according to an embodiment of the present application. The plate
carrier 800 has a front portion 802 and a back portion 806
connected with a plurality of hinges 804 at the bottom of the plate
carrier. The hinges 804 are formed by a rectangular cutout 810. The
shoulder harness slots 808 are placed on the front portion 802 of
the plate carrier.
[0069] FIG. 9 illustrates a plan view of a plate carrier 900
according to an embodiment of the present application. The plate
carrier 900 has a similar design with the plate carrier 800 except
the adjustable attachment mechanism 110. As shown in FIG. 9, the
attachment system 110 is formed by a tongue 902 in the front
portion 214 and a plurality of protrusions 908 in the back portion
216. The tongue 902 includes a plurality of perforations that are
configured to engage the protrusions 908. A plurality of slots 906
are also provided at the back portion. The tongue 902, when in an
attachment position, is placed through the slots 906, thus
preventing the tongue 902 from disengaging the protrusions 908
accidentally.
[0070] FIG. 10 illustrates a plan view of a plate carrier 1000
according to an embodiment of the present application. The plate
carrier 1000 includes a front portion 1002 and a back portion 1006
that are connected via a plurality of hinges 1004 at the bottom.
Shoulder harness slots 1008 are placed on the back portion 1006.
Both the front portion and the back portion contain no cutouts. The
front portion and the back portion both have gradually reducing
profiles from the bottom to the top. As shown in FIG. 10, a
substantially triangular shape is used as a configuration of the
plate carrier such that the bottom has a larger dimension than the
top of the plate carrier when in use.
[0071] FIG. 11 illustrates a plan view of a plate carrier 1100
according to an embodiment of the present application. The plate
carrier 1100 is similar as that of the plate carrier 1000. The
differences between the two plate carriers include that the
shoulder harness slots 1110 are placed at the front portion 1102,
which also has a plurality of perforations designed for accepting
an attachment mechanism such as MOLLE. According to an embodiment,
a substantially triangular shape is used as a configuration of the
plate carrier such that the bottom has a larger dimension than the
top of the plate carrier.
[0072] FIG. 12 illustrates a side panel 1200 according to an
embodiment of the present application. The side panel 1200 is
optional to form a functional protective vest. Without side panels
1200, a protective vest formed by only a front panel and a back
panel is still capable of protecting a wearer from projectile
impacts. The use of a side panel 1200 provides additional
protections to side areas of the human torso where the front panel
and the back panel meet each other and do not have a complete
coverage. Thus, a protective vest may be formed by a front panel, a
back panel, and two side panels. According to an embodiment of the
present application, the side panel 1200 has the same clamshell
design as disclosed in the present application. The side panel may
represent any scale down version of any of the plate carriers
described in the present application with minor modifications. As
shown in FIG. 12, the side pane 1200 includes a front part 1202 and
a back part 1204, which are connected by a plurality of hinges 1206
that are formed by a rectangular cut 1212 at the bottom of the side
plate carrier 1200. The front part 1202 includes a plurality of
cutouts 1210 to reduce weight. The side panel 1200 also includes
two waist slots 1208 for attaching a harness system, which fastens
the side plate carrier to the front panel or the back panel of a
protective vest. According to an embodiment, the side panel 1200
does not include shoulder slots or a harness system at the top of
the side panel.
[0073] FIG. 13 illustrates a plan view of a plate carrier 1300
according to an embodiment of the present application. The plate
carrier 1300 is similar with that in FIG. 6, but includes several
different embodiments. The plate carrier 1300 does not include a
plurality of slots to attach harness systems, like those slots 202,
112, and 204 in FIG. 6. Instead, the harness system of the plate
carrier 1300 represents a substantially integral part of the plate
carrier, rather than components separated from the body of the
plate carrier or components that need to be attached to the body of
the plate carrier. For example, a shoulder harness system 1304,
such as a Velcro attachment system, includes the surface loops or
hooks 1310 attached to a base layer 1312, which is formed by the
same material as that of the body and represents an integral part
of the body of the plate carrier 1300. According to an embodiment,
the plate carrier 1300, including the harness system, is made from
a single piece of material and has homogenous mechanical properties
across the body, the shoulder harness system, and the waist harness
system. The base layer 1312 may be formed at the same time the body
of the plate carrier 1300 is made by using the same process and the
same material. Thus, this design simplifies the manufacturing
process and improves the mechanical integrity of the plate carrier
1300. This design further reduces the burden of keeping an
inventory of all the parts used for a protective vest by
integrating most parts with the body of the plate carrier 1300.
Although the surface loops or hooks 1310 need to be attached to the
base layer, this attachment is relatively easy to be implemented in
a factory before a wearer receives the plate carrier. Furthermore,
this attachment does not lower the strength of the harness system
or the base layer in any noticeable manner.
[0074] The plate carrier 1300 also includes an integrated waist
harness system 1302, such as cummerbunds, in a manner similar with
the shoulder harness system 1304. The plate carrier 1300 also
includes a center harness system 1308 integrated with the body of
the plate carrier in a way similar with that of the shoulder or
waist harness systems. The harness system 1308 is disposed
substantially at the top and center portion of the plate carrier
1300 to enclose and secure an armor plate.
[0075] According to an embodiment, the plate carrier 1300 may be
made of flexible materials, such as flexible plastics or rubbers.
For example, the plate carrier 1300 may be made of Neoprene, which
has good chemical stability and maintains flexibility over a wide
temperature range.
[0076] FIG. 14 illustrates the plate carrier 1300 with a fastened
harness system 1308 according to an embodiment of the present
application. FIG. 14 depicts the side of the plate carrier that
faces an incoming projectile. As shown in FIG. 14, the center
harness system 1308 is fastened to the back portion of the plate
carrier 1300. The waist harness system 1302, such as a Velcro
system, includes hooks or loops 1402 attached to a base layer that
represents an integral part of the plate carrier 1300.
[0077] The plate carriers as set forth in various embodiments of
the present application simplify the process of properly setting up
an armor plate and improve the ease of use to a wearer. The plate
carrier may also be suitably wearable by users of various body
shapes due to the body-conforming design, in which the mechanical
part of a plate carrier is configured to conform to common body
parts of an upper human torso. Plate carriers as described in the
present application, while securing armor plates of different
sizes, are still capable of being used by different wearers with
comfort.
[0078] The particular embodiments disclosed above are illustrative
only, as the disclosed embodiments may be modified and practiced in
different but equivalent manners apparent to those skilled in the
art having the benefit of the teachings herein. Furthermore, the
claims are not intended to be limited only to the details of
construction or design herein shown, other than as described in the
claims.
[0079] It is therefore evident that the particular embodiments
disclosed above may be altered or modified and all such variations
are considered within the scope and spirit of applicable claims.
Although illustrative embodiments have been described in detail
herein with reference to the accompanying drawings, it is to be
understood that the claims are not limited to those precise
embodiments, and that various changes and modifications can be
effected therein by one skilled in the art without departing from
the scope and spirit of the claims.
* * * * *