U.S. patent application number 15/257745 was filed with the patent office on 2017-07-13 for personal tactical system.
This patent application is currently assigned to Tyr Tactical, LLC. The applicant listed for this patent is Tyr Tactical, LLC. Invention is credited to Jason Beck.
Application Number | 20170199011 15/257745 |
Document ID | / |
Family ID | 57914915 |
Filed Date | 2017-07-13 |
United States Patent
Application |
20170199011 |
Kind Code |
A1 |
Beck; Jason |
July 13, 2017 |
PERSONAL TACTICAL SYSTEM
Abstract
Implementations described and claimed herein provide a personal
tactical system configured to be worn by an individual for
protection against threats. In one implementation, the personal
tactical system includes one or more internal components disposed
in an interior formed by an outer layer and an inner layer. The
internal components include a flexible body armor, a ballistic
plate, a ballistic frame, and/or a ballistic plate cover.
Inventors: |
Beck; Jason; (Peoria,
AZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Tyr Tactical, LLC |
Peoria |
AZ |
US |
|
|
Assignee: |
Tyr Tactical, LLC
Peoria
AZ
|
Family ID: |
57914915 |
Appl. No.: |
15/257745 |
Filed: |
September 6, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/US2016/040989 |
Jul 5, 2016 |
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15257745 |
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14497508 |
Sep 26, 2014 |
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PCT/US2016/040989 |
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14497486 |
Sep 26, 2014 |
9435614 |
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14497508 |
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13161322 |
Jun 15, 2011 |
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14497486 |
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62188595 |
Jul 3, 2015 |
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61883140 |
Sep 26, 2013 |
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61883121 |
Sep 26, 2013 |
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61384560 |
Sep 20, 2010 |
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61355089 |
Jun 15, 2010 |
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62289089 |
Jan 29, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A41D 1/04 20130101; F41H
5/013 20130101; F41H 1/02 20130101; F41H 5/0485 20130101; F41H
5/0471 20130101; F41H 5/0478 20130101 |
International
Class: |
F41H 1/02 20060101
F41H001/02; A41D 1/04 20060101 A41D001/04; F41H 5/04 20060101
F41H005/04 |
Claims
1. A tactical system comprising: an inner layer; an outer layer
disposed opposite the inner layer and forming an interior, the
outer layer comprising a composite fabric; one or more load
carriage points disposed along the outer layer; a first layer of
the composite fabric disposed at the one or more load carriage
points, the first layer comprising a woven synthetic fabric, the
first layer facing outwardly in a direction away from the inner
layer; and a second layer of the composite fabric backing the first
layer at the one or more load carriage points, the second layer
comprising a woven fabric of para-aramid fibers, an attachment of
the first layer to the second layer providing a structural support
to the one or more load carriage points.
2. The tactical system of claim 1, wherein the woven synthetic
fabric is nylon having a weight of at least 200 denier and the
woven fabric of para-aramid fibers of the second layer has a weight
of at least 100 denier and an aerial density of at least 3 ounces
per square yard.
3. The tactical system of claim 1, wherein the attachment of the
first layer to the second layer includes at least one of:
laminating the first layer to the second layer under heat pressure
using a thermoplastic bonding agent; or using an adhesive.
4. The tactical system of claim 1, wherein the one or more load
carriage points includes at least one of a pouch, a pocket, a
corner, or a seam.
5. The tactical system of claim 1, wherein the outer layer and the
inner layer are deployed in at least one of: a tactical vest; a
tactical garment; or tactical equipment.
6. The tactical system of claim 1, wherein the outer layer is
exposed to an outside environment.
7. The tactical system of claim 1, wherein the weight of the first
layer is 500 denier and the weight of the para-aramid fibers is 200
denier.
8. The tactical system of claim 1, wherein the weight of the first
layer is less than 1000 denier and the weight of the para-aramid
fibers is less than 1200 denier.
9. A tactical system comprising: an outer layer exposed to an
outside environment, the outer layer comprising a composite fabric;
one or more load carriage points disposed along the outer layer; a
first layer of the composite fabric disposed at the one or more
load carriage points, the first layer comprising a woven synthetic
fabric, the first layer facing the outside environment; and a
second layer of the composite fabric backing the first layer at the
one or more load carriage points, the second layer comprising a
woven fabric of para-aramid fibers, an attachment of the first
layer to the second layer providing a structural support to the one
or more load carriage points.
10. The tactical system of claim 9, wherein the woven synthetic
fabric is nylon having a weight of at least 200 denier and the
woven fabric of para-aramid fibers of the second layer has a weight
of at least 100 denier and an aerial density of at least 3 ounces
per square yard.
11. The tactical system of claim 9, wherein the attachment of the
first layer to the second layer includes laminating the first layer
to the second layer under heat pressure using a thermoplastic
bonding agent.
12. The tactical system of claim 9, wherein the weight of the first
layer is 500 denier and the weight of the para-aramid fibers is 200
denier.
13. The tactical system of claim 9, wherein the weight of the first
layer is less than 1000 denier.
14. The tactical system of claim 9, wherein the weight of the
para-aramid fibers is less than 1200 denier.
15. The tactical system of claim 9, wherein the aerial density of
the para-aramid fibers is less than 10 ounces per square yard.
16. The tactical system of claim 9, wherein the weave of the
para-aramid fibers has at least 40 fibers per inch in a warp
direction and at least 40 fibers per inch in a fill direction.
17. The tactical system of claim 9, wherein the weave of the
para-aramid fibers has a warp yarn density in excess of 100 percent
and a fill yarn density in excess of 75 percent.
18. The tactical system of claim 9, wherein the weave of the
para-aramid fibers has filament crossovers of at least 50 million
filament crossovers per square inch.
19. The tactical system of claim 9, wherein the filament crossovers
are less than 90 million filament crossovers per square inch.
20. The tactical system of claim 9, wherein the para-aramid fibers
have a tensile strength of at least 2000 MPa and an elastic modulus
of at least 60 GPa.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of Patent
Cooperation Treaty Application No. PCT/US2016/040989, entitled
"Female Protective Vest" and filed on Jul. 5, 2016, which claims
priority under 35 U.S.C. .sctn.119 to U.S. Provisional Application
No. 62/188,595, entitled "Female Protective Vest" an filed on Jul.
3, 2015. The present application is further a continuation-in-part
of U.S. patent application Ser. No. 14/497,508, entitled "Ballistic
Vest System with a Ballistic Ridge Component" and filed on Sep. 26,
2014, which claims priority under 35 U.S.C. .sctn.119 to U.S.
Provisional Application No. 61/883,140, entitled "Ballistic Vest
System with a Ballistic Ridge Component" an filed on Sep. 26, 2013.
The present application is further a continuation-in-part of U.S.
patent application Ser. No. 14/497,486, entitled "Ballistic Vest
System with a Ballistic Vein Component" and filed on Sep. 26, 2014,
which claims priority under 35 U.S.C. .sctn.119 to U.S. Provisional
Application No. 61/883,121, entitled "Ballistic Vest System with a
Ballistic Vein Component" an filed on Sep. 26, 2013. The present
application is further a continuation-in-part of U.S. patent
application Ser. No. 13/161,322, entitled "High Performance
Composite Fabric" and filed on Jun. 15, 2011, which claims priority
under 35 U.S.C. .sctn.119 to U.S. Provisional Application No.
61/384,560, entitled "Kevlar Backed Nylon Tactical Material" and
filed on Sep. 20, 2010 and to U.S. Provisional Application No.
61/355,089, entitled "High Performance Composite Fabric" and filed
on Jun. 15, 2010.
[0002] The present application further claims priority under 35
U.S.C. .sctn.119 to U.S. Provisional Application No. 62/289,089,
entitled "Flexible Body Armor" and filed on Jan. 29, 2016.
[0003] Each of the above-referenced applications is incorporated by
reference herein in its entirety.
TECHNICAL FIELD
[0004] Aspects of the present disclosure relate to personal
tactical systems and more particularly to tactical vests and other
tactical devices configured to be worn by an individual for
protection against threats.
BACKGROUND
[0005] Tactical systems, including vests, carriers, belts,
cummerbunds, ballistic accessories (e.g., shoulder protection,
pouches, abdomen protection, groin protection, leg protection,
bicep/deltoid upper arm protection, etc.) and the like, are worn by
a human or animal to protect against penetration to the body from
ballistic projectiles and shrapnel from explosions, as well as to
absorb the impact force caused by such threats. Conventional
systems typically achieve a compromise at best, sacrificing at
least one of performance, longevity, comfort, mobility, protection,
and the like to attain another. It is with these observations in
mind, among others, that various aspects of the present disclosure
were conceived and developed.
SUMMARY
[0006] Implementations described and claimed herein address the
foregoing problems by providing a personal tactical system. In one
implementation, a tactical system includes one or more internal
components disposed in an interior formed by an outer layer and an
inner layer. The internal components include at least one of a
flexible body armor, a ballistic plate, a ballistic frame, or a
ballistic plate cover. Other implementations are also described and
recited herein. Further, while multiple implementations are
disclosed, still other implementations of the presently disclosed
technology will become apparent to those skilled in the art from
the following detailed description, which shows and describes
illustrative implementations of the presently disclosed technology.
As will be realized, the presently disclosed technology is capable
of modifications in various aspects, all without departing from the
spirit and scope of the presently disclosed technology.
Accordingly, the drawings and detailed description are to be
regarded as illustrative in nature and not limiting.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0007] FIG. 1 is a front view of an example tactical system in the
form of a tactical vest with internal components shown.
[0008] FIG. 2 is a perspective view of the tactical vest of FIG.
1.
[0009] FIG. 3 shows a back view of the tactical vest of FIG. 1.
[0010] FIG. 4 shows a side perspective view of the tactical vest of
FIG. 1 with a cummerbund belt buckle released.
[0011] FIG. 5 illustrates an example outer layer of the tactical
system.
[0012] FIG. 6 depicts an example ballistic plate of the tactical
system.
[0013] FIG. 7 shows a perspective view of an example ballistic
plate cover of the tactical system.
[0014] FIG. 8 illustrates the ballistic plate cover engaged to the
ballistic plate.
[0015] FIG. 9 is a perspective view of another example ballistic
plate cover of the tactical system.
[0016] FIG. 10 is a perspective view of another example ballistic
plate cover of the tactical system.
[0017] FIG. 11A and 11B show front perspective and back perspective
views of the ballistic plate cover of FIG. 10.
[0018] FIG. 12 illustrates example panels of a ballistic filler for
a flexible body armor, including a first panel, a second panel, and
a third panel.
[0019] FIG. 13 illustrates the first panel of the ballistic filler,
including a first subpanel of woven fabric and a second subpanel of
unidirectional laminates.
[0020] FIG. 14 depicts the first panel of the ballistic filler with
the first subpanel stitched directly to the second subpanel.
[0021] FIG. 15 shows the second panel of the ballistic filler
formed from a plurality of stitched layers of unidirectional
laminates.
[0022] FIG. 16 illustrates the third panel of the ballistic filler
formed by a plurality of layers of unidirectional laminates.
[0023] FIG. 17 depicts a ballistic arrangement of the ballistic
filler, including the first panel backed by the second panel, which
is backed by the third panel.
[0024] FIG. 18 shows the ballistic filler with the first panel, the
second panel, and the third panel connected using closure
stitching.
[0025] FIG. 19 illustrates edge tape applied to a portion of a
periphery of the ballistic filler for heat sealing.
[0026] FIG. 20 illustrates example operations for manufacturing a
ballistic filler.
[0027] FIG. 21 shows a front view of an example flexible body armor
with a female shape.
[0028] FIG. 22 illustrates the ballistic plate displaced at an
angle relative to the flexible body armor of FIG. 21.
[0029] FIG. 23 shows a perspective cut-away view of the flexible
body armor of FIG. 21.
[0030] FIG. 24 illustrates example operations for manufacturing a
tactical vest with a female shape.
[0031] FIG. 25 illustrates an example frame disposed adjacent to
the flexible body armor.
[0032] FIGS. 26 and 27 each show another example frame.
DETAILED DESCRIPTION
[0033] Aspects of the present disclosure involve personal tactical
systems configured to be worn or otherwise used by an individual
for protection against threats, including ballistic projectiles and
shrapnel from explosions. In one aspect, internal components,
including a ballistic plate, a ballistic plate cover, flexible body
armor, and/or a frame, are disposed in an interior of the tactical
system. The interior is formed between an outer layer and an inner
layer.
[0034] The presently disclosed technology relates generally to
personal tactical systems. The various example implementations are
described herein in the context of a tactical vest. It will be
appreciated, however, that the presently disclosed technology is
applicable in the context of other tactical systems, including, but
not limited to, other tactical vests, carriers, belts, cummerbunds,
tactical accessories (e.g., shoulder protection, pouches, abdomen
protection, groin protection, leg protection, bicep/deltoid upper
arm protection, etc.) and the like.
[0035] To begin a detailed description of an example personal
tactical system 100 in the form of a tactical vest, reference is
made to FIG. 1-4. In one implementation, the tactical system 100
includes one or more internal components 102 insertable or
otherwise disposed in an interior 104 of the tactical system 100.
The internal components 102 of the tactical system 100 include a
flexible body armor 110, a ballistic plate 112, a ballistic frame
114, and/or the like. The internal components 102 increase
ballistic protection, decrease side spall and back face
deformation, and provide structure to the tactical system 100,
among other advantages. The interior 104 may be, for example, a
pocket or similar enclosure formed by an outer layer 106 and an
inner layer 108 of the tactical system 100. In some implementations
the tactical system 100 includes one or more intermediate layers
between the outer layer 106 and the inner layer 108.
[0036] As shown in FIG. 1, the outer layer 106 is exposed to an
outside environment and is distal from the inner layer 108 to the
wearer of the tactical system 100. Stated differently, the inner
layer 108 faces the wearer and the outer layer 106 faces away from
the wearer. In one implementation, the outer layer 106 is made from
a lightweight hybrid material with superior abrasion, tear, and
fire resistance characteristics, while providing load carriage
support and improved durability, particularly in high-wear areas,
such as corners, edges, seams, and exposed areas. The lightweight
hybrid material of the outer layer 106 may be, for example, a
laminate of 500-denier nylon and 200-400-denier para-aramid fibers
in an ultra-tight weave. In one implementation, the inner surface
108 is made from a material that is antimicrobial and fire
resistant treated.
[0037] In the context of a tactical vest, the tactical system 100
includes a front carrier 124 and a back carrier 126 each extending
between a proximal end 116 and a distal end 118 and between a first
side 120 and a second side 122. In one implementation, the sides
120-122 are shaped to accommodate the anatomy and movement of the
wearer's arms, and the proximal end 116 is shaped to accommodate
the anatomy and movement of the wearer's collar and neck area.
[0038] Further, the front carrier 124 may be shaped to accommodate
the anatomy of a female wearer. As such, in one implementation, the
front carrier 124 has a carrier female shape formed by an upper
portion, a set of lateral portions, and a lower portion. The
carrier female shape permits a full range of motion by and provides
support to the female wearer, while maximizing comfort. The back
carrier 126 similarly includes an upper back portion and a lower
back portion adapted to maximize comfort without inhibiting motion
of the female wearer.
[0039] In one implementation, the tactical system 100 includes a
front carrier pocket 134 extending from or otherwise attached to
the front carrier 124. The front carrier pocket 134 may define the
interior 104 be adapted to receive and hold one or more of the
internal components 102.
[0040] For example, the ballistic plate 112 may be disposed within
the front carrier pocket 134 with a strike face oriented away from
the wearer and a back face oriented towards the towards the inner
layer 108. The ballistic plate 112 is a hard plate configured to
provide ballistic protection against projectiles or shrapnel
impacting a strike face of the ballistic plate 112.
[0041] A ballistic plate cover may wrap around at least a portion
of a periphery of the ballistic plate 112 to provide additional
protection against side spall created by augmentation of the
ballistic plate 112. Such a ballistic plate cover further improves
the structure of the front carrier pocket 134 and enhances area
coverage and range of motion for increased ergonomics and
performance, while providing additional ballistic coverage beyond a
front edge of the ballistic plate 112 and beyond side edges of the
ballistic plate 112. In one implementation, the ballistic plate
cover provides approximately one inch of additional ballistic
coverage beyond a front edge of the ballistic plate 112 and
approximately 0.5 inches of additional ballistic coverage beyond
side edges of the ballistic plate 112.
[0042] In addition, the tactical system 100 may include a ballistic
flap that covers an opening to the front carrier pocket 134 and is
configured to cover and protect the bottom portion of the ballistic
plate 112 when disposed within the front carrier pocket 134. The
ballistic flap may be made from a soft armor material similar to
the flexible body armor 110 that, in combination with the ballistic
plate cover, assists in preventing side spall and backside
deformation along the bottom portion of the ballistic plate 112. In
one implementation, the tactical system 100 includes a soft armor
liner that extends along the peripheral edge of the front carrier
pocket 134 to provide further protection to the ballistic plate
112. The soft armor liner may be sewn along a peripheral edge of
the front carrier pocket 134 such that the soft armor liner at
least substantially covers a peripheral edge of the ballistic plate
cover when the ballistic plate 112 is disposed within the front
carrier pocket 134. In some implementations, the soft armor liner
may be a strip of soft armor material (e.g., similar material to
the outer layer 106), while in other implementations the soft armor
liner may substantially or completely line the interior of the
front carrier pocket 134.
[0043] The flexible body armor 110 may be disposed in the front
carrier pocket 134 behind the ballistic plate 112 on the back face
side to provide additional protection and force absorption. In one
implementation, the flexible body armor 110 is made from a
ballistic fiber comprising at least a portion of woven fabric
stitched directly to unidirectional laminates. The woven fabric is
generated from ultrahigh molecular weight polyethylene (UHMWPE)
fiber, which when used in conjunction with the unidirectional
laminates, is effective as anti-ballistic ply structures. A
ballistic arrangement of the ballistic filler includes the UHMWPE
woven fabric being backed by unidirectional laminates. More
specifically, the ballistic arrangement constitutes one or more
regions where one or more plies of UHMWPE woven fabric are backed
by one or more plies of unidirectional laminates. As used in the
present disclosure, respective to each region, "backed" refers to
plies residing closer to a wearer, and "fronted" refers to plies
closer to a strike face of the outer layer 106. In one
implementation, one or more of the regions comprised of UHMWPE
woven fabric backed by unidirectional laminate are stitched
together uniformly using a quilt pattern or some other uniform
stitching pattern.
[0044] A ballistic frame 114 may be disposed within the front
carrier pocket 134 behind or in front of the flexible body armor
110. The ballistic frame 114 includes a body configured to improve
overall load carriage performance of the front carrier pocket 134
and the tactical system 100 by providing a rigid platform to add
weight. The frame body further reduces fatigue by improving the
structure of the tactical system 100 by retaining the flexible body
armor 110 in a configuration that prevents bunching and provides
support to the ballistic plate 112 to improve edge hit protection.
The ballistic frame 114 is loose from or otherwise unattached to
the flexible body armor 110 within the front carrier pocket 134.
The ballistic frame 114 absorbs and otherwise dissipates energy
from an impact of a projectile against the ballistic plate 112
and/or the flexible body armor 110. The ballistic frame 114 body
may be solid or have one or more openings therethrough. The inner
layer 108 may include one or more pads 132 to enhance comfort and
further dissipate forces generated from an impact. The pads 132 may
be sized and shaped to mirror the openings in the ballistic frame
114.
[0045] In one implementation, the back carrier 126 includes a
releasable back panel 148, which may be used to releasably connect
to or otherwise secure one or more protective devices and/or to
integrate with other tactical devices. The back carrier 148 may
include a back carrier pocket within, adjacent to, or in place of
the releasable back panel 148 to receive and hold one or more
internal components 102. In one implementation, the releasable back
panel 148 is releasably engaged to the back carrier 126 with a
zipper assembly.
[0046] The front carrier 124 is connected to the back carrier 126
at the proximal end 116 and/or the distal end 118. In one
implementation, the front carrier 124 is connected to the back
carrier 126 at the distal end 118 with a cummerbund having a first
cummerbund portion 128 and a second cummerbund portion 130. It will
be appreciated, however, that a belt, straps, or other side
connections may supplement or be used in place of the cummerbund.
One or more of the cummerbund sections 128 and 130 may be connected
to the front carrier 124 using a cummerbund buckle 140 disposed
within a pocket.
[0047] In one implementation, the front carrier 124 is connected to
the back carrier 126 at the proximal end 116 with shoulder
portions, including a first shoulder strap 136 and a second
shoulder strap 138. The shoulder straps 136 and 138 may each be
adjustable. For example, the first shoulder strap 136 and the
second shoulder strap 138 may each loop through a shoulder buckle
forming an adjustment portion. The adjustment portions may be
secured, for example, using paired hook and loop fasteners. In one
implementation, the shoulder straps 136 and 138 each include a
shoulder pad with a low to enhance comfort and provide additional
load distribution.
[0048] In the context of a tactical vest, the tactical system 100
may include a cutaway system permitting single-handed release. In
one implementation, the cutaway system includes a plurality of
buckles, which when released permit the tactical vest to be easily
and quickly removed. The plurality of buckles may include, for
example, the shoulder buckles 142 and 144 and the cummerbund
buckle(s) 140. In one implementation, the plurality of buckles are
connected to a quick-release tab 146 via corresponding wires. When
the quick-release tab 146 is pulled, each of the plurality of
buckles is automatically disengaged, facilitating the removal of
the tactical vest. The cutaway system may be reengaged and the
tactical vest reassembled by reengaging the plurality of buckles.
In one implementation, the wires are housed within the interior 104
and in communication with the buckles using one or more pockets or
openings.
[0049] In one implementation, each of the plurality of buckles are
connected to the cutaway system via one or more wires to release
the buckles upon pulling of the quick-release tab 146. For example,
the cummerbund buckle 140 may include a female buckle portion and a
male buckle portion. The female buckle portion includes an opening
adapted to receive a body of the male buckle portion and slots to
releasably engage buckle arms of the male buckle portion. In one
implementation, a releasing member is connected to a wire of the
cutaway system and configured to displace the buckle arms. When the
quick-release tab 146 is pulled, the wires of the cutaway system
are displaced, which displaces the releasing member and in turn the
buckle arms, thereby disengaging the male buckle portion from the
female buckle portion. The shoulder buckles 142 and 144 may include
similar features and functionality.
[0050] For a detailed description of the outer layer 106, reference
is made to FIG. 5. In one implementation, the outer layer 106 is a
composite of a first layer 204 facing an outside environment 200
and a second layer 206 facing in a direction 202 inwardly toward
the interior 104. Stated differently, the first layer 206 is backed
by the second layer 206. The first layer 204 and the second layer
206 form a lightweight hybrid material with superior abrasion,
tear, and fire resistance characteristics that provides load
carriage support and improved durability, particularly in load
carriage points 208, such as corners, edges, seams, high wear
areas, and exposed areas.
[0051] In one implementation, the first layer 204 is a synthetic
fabric outer layer. For example, the first layer 204 may be a nylon
fabric, such as a high-performance Nylon-6,6. The weight of the
nylon fabric of the first layer 204 may be between approximately
200 and 1000 denier, and in one particular example implementation,
the weight is about 500 denier.
[0052] The second layer 206 may be a backing layer made from a high
strength, damage resistant material. More particularly, the second
layer 206 may be made of high tenacity polymer fibers, including,
but not limited to, aramid fibers, para-aramid fibers, para-aramid
synthetic fibers, high performance polyethylene fibers, and/or
other materials having a high tensile strength-to-weight ratio.
Examples of materials from which the second layer 206 may be made
include, without limitation: Kevlar.RTM., Twaron, terephthaloyl
chloride (TCI), and high molecular weight polyethylene (HMWPE).
Other suitable materials include polybenzobisoxazole fibers (PBO),
ballistic nylon, and/or heat resistant aramid fiber products such
as Nomex.RTM. and Protera.RTM. fabrics. The fibers of the second
layer 206 may have a tensile strength greater than about 2000 MPa
(or greater than about 7 grams per denier) and an elastic modulus
greater than about 60 GPa.
[0053] In one implementation, high performance polymer fibers for
the second layer 206 are utilized in the form of a woven fabric,
including for example woven fabrics generally used for repelling
and trapping hand driven sharp objects such as knives, awls, shanks
and the like. An exemplary woven fabric for the second layer 206
may be constructed from yarn of anywhere between about 100 and 1200
denier and aerial densities in the range of 3 to 10 ounces per
square yard ("OSY"). For example, fabrics constructed of yams in
the 200 to 300 denier range, and aerial densities in the 3 to 4 OSY
range may be used where the tactical system 100 is a ballistic
accessory, such as a pouch, small duffel, backpacks, or the like.
Alternatively, where the tactical system 100 is heavier, such as a
large suitcase or equipment bag, larger yams in the 700 to 1200
denier range and densities in the 7 to 10 OSY range may be used. In
one particular example implementation where the tactical system 100
is a tactical vest, the first layer 204 is made from a 500-denier
nylon and the second layer 206 is made from 200-400-denier
para-aramid fibers.
[0054] The woven fabric of the second layer 206 may be formed of a
relatively tight, puncture resistant weave, comprising, for
example, at least 40 fibers per inch in a first (warp) direction
and at least 40 fibers per inch in a second (fill) direction. In
one implementation, the second layer 206 comprises a weave with
between 60 and 72 fibers per inch in both the warp and fill
directions. In addition, the fabric of the second layer 206 may be
formed by tightly weaving multi-filament yarns to obtain a warp
yarn "density" or "cover" in excess of 100 percent at the center of
the fill yarn and a fill yarn density or cover in excess of 75
percent as measured between two warp ends. Such ultra-tight weaves
may comprise in excess of 100 fibers per inch in the warp and fill
directions and filament crossovers in the range of about 50,000,000
(fifty million) filament crossovers per square inch up to
90,000,000 (ninety million) filament crossovers per square
inch.
[0055] In one example, the second layer 206 is Dupont.TM.
Kevler.RTM. Correctional.TM., which is an extremely tight weave
utilizing filaments one fourth the size of comparable materials.
Another suitable commercially available material is a woven
puncture resistant product sold under the trademark TURTLESKIN by
Warwick Mills, Inc., of New Ipswich, N.H. The weight of the second
layer 206 may range between approximately 200 and 300 denier where
the tactical system 100 includes lightweight personal gear such as
packs and pouches and between approximately 500 and 1000 denier
where the tactical system 100 includes larger, heavier articles,
such as large suitcases and equipment duffels.
[0056] In one implementation, the first layer 204 and the second
layer 206 are consolidated into a unitary composite fabric using
any suitable technique such as lamination, bonding, stitching,
and/or the like. Suitable bonding methods include, for example, the
use of various types of adhesives, such as air-drying adhesives,
chemically setting adhesives, radiation activated adhesives such as
ultraviolet (UV) activated dental adhesives, hot-melt adhesives,
and pressure sensitive adhesives. An adhesive may be pre-applied on
at least one of the first layer 204 or the second layer 206 or
separately introduced during a lamination process. In one
implementation, the first layer 204 and the second layer 206 are
laminated under heat and pressure using a solid, polymer based
thermoplastic adhesive, such as a polyamide, polyester, elastomeric
urethane, or polyolefin polymer. For example, the first layer 204
may be laminated to the second layer 206 using a dry, non-woven
mat, or web of a polymer-based thermoplastic or other thermoplastic
adhesives. The first layer 204 and the second layer 206 and the
thermoplastic adhesive may be supplied from respective adjacent
spools and fed through a laminating machine with the thermoplastic
web sandwiched between the first layer 204 and the second layer
206.
[0057] As noted above, the first layer 204 and the second layer 206
may also be consolidated using various types of Pressure Sensitive
Adhesives, also referred to as "PSA"s. PSAs are distinguished from
most other types of adhesives in that they bond on contact, rather
than through a solidifying process such as evaporation, chemical
reaction, or melting. PSAs are usually based on an elastomer
compounded with a suitable tackifier (e.g., a rosin ester). The
elastomers may include those based on natural rubber, Nitriles,
Butyl rubber, Acrylics, Styrene block copolymers, vinyl ethers,
Ethylene-vinyl acetate, and various silicon rubbers. In one
implementation, the PSA comprises an acrylic adhesive such as a
permanent assembly tape or an acrylic sheet.
[0058] The strength of the second layer 206 makes the composite
material of the outer layer 106 particularly beneficial in the load
carriage points 208 of the tactical system 100. Examples of the
load carriage points 208 include, without limitation, comers of
ammunition pouches, fragmentation pouches, radio communication
pouches, armor pockets in armor plate carriers, and/or load
carriage points. In ballistic vests and ballistic armor carriers
the outer layer 106 also increases longevity and strength of load
carriage points 208, particularly once the outer layer 106 is sewn
through. Seams can be further strengthened by folding the seam over
to double or triple thickness prior to stitching. In addition, any
tears or de-laminations in the first layer 204 of the outer layer
106 can be temporarily field repaired by re-attaching the damaged
first layer 204 to the intact second layer 206 using a fast setting
adhesive such as Cyanoacrylate liquid adhesive. Alternatively, if
portions of the first layer 204 are missing or worn away making
re-attachment impractical, the intact second layer 206 can instead
simply be left exposed, and if desired, temporarily disguised using
a suitably colored paint or ink marker.
[0059] Although the composite fabric of the outer layer 106 has
been described primarily in terms of the first layer 204 and the
second layer 206, the outer layer 106 may comprise additional or
different layers. For example, the outer layer 106 may comprise a
plurality of outer layers similar to the first layer 204, or a
plurality of backing layers similar to the second layer 206, or
multiple layers of each. In addition, the layers may be arranged in
various configurations, such as two backing layers of the second
layer 206 on one side of a single outer layer of the first layer
204, or a sandwich configuration with an outer layer of the first
layer 204 on either side of one or more backing layers of the
second layer 206. The composite fabric of the outer layer 106 may
also be combined with various other material layers, such as a
liner made of a breathable or insulative type of fabric or
material. The additional materials may be consolidated or attached
to the first layer 204 and/or the second layer 206 using any of the
above described methods and materials. Further, various other
combinations of layers and materials are contemplated as
foreseeable, and intended to fall within the scope of the high
performance composite fabric of the outer layer 106.
[0060] Turning to FIG. 6, in one implementation, the ballistic
plate 112 includes a body with a strike face 300 disposed opposite
a back face 302. A peripheral edge 304 extends along a periphery of
the body between the strike face 300 and the back face 302. A
non-peripheral area 306 of the ballistic plate 112 extends from a
center of each of the strike face 300 and the back face 302 towards
a peripheral area disposed near the peripheral edge 304.
[0061] As can be understood from FIGS. 7-11B, in one
implementation, a ballistic plate cover 400 may wrap around at
least a portion of the peripheral area of the ballistic plate 112
to provide additional protection against back face deformation
and/or side spall created by augmentation of the ballistic plate
112. Back face deformation occurs when a ballistic projectile
impacts the strike face 300 and causes the back face 302 to deform
or bulge outwardly. Side spall occurs when a ballistic projectile
impacts the peripheral area of the ballistic plate 112 such that
shrapnel from the ballistic projectile impact and/or debris of
material from the impacted portion of the ballistic plate 112
potentially penetrates the flexible body armor 110 and/or injure
the wearer.
[0062] The ballistic plate cover 400 further enhances area coverage
and range of motion for increased ergonomics and performance, while
providing additional ballistic coverage beyond the ballistic plate
112 in a direction outward from the strike face 300 and in a
direction outward from the peripheral edge 304. In one
implementation, the ballistic plate cover 400 provides
approximately one inch of additional ballistic coverage beyond the
strike face 300 and approximately 0.5 inches of additional
ballistic coverage beyond the peripheral edge 304.
[0063] The ballistic plate cover 400 includes a body extending from
a proximal end 402 to a distal end 404. The body of the ballistic
plate cover 400 may be made from a polyethylene material or other
types of thermoplastic materials. For example, the body of the
ballistic plate cover 400 may be made from a stretchable and
elastic spandex material reinforced with a unidirectional and/or
aramid material.
[0064] In one implementation, the body of the ballistic plate cover
400 includes a peripheral portion including side portions 406
extending proximally to a top portion 414. The peripheral portion
may have a variety of shapes mirroring a shape of the peripheral
edge 304 of the ballistic plate 112. For example, the peripheral
portion may extending linearly and taper inwardly in a proximal
direction. More particularly, the peripheral portion 406 may
include the side portions 406 extending parallel to each other and
then tapering inwardly at tapered portions 412 until reaching the
top portion 414. The peripheral portion includes an inner
peripheral surface 410.
[0065] In one implementation, the body of the ballistic plate cover
400 includes a back portion 416 connected to the peripheral
portion. For example, the back portion 416 may be connected at an
edge of the peripheral portion, such that the back portion 416 is
disposed inwardly from the side portions 406, the tapered portions
412, and/or the top portion 414.
[0066] The back portion 416 includes an inner back surface 418. In
one implementation, the inner back surface 418 is disposed at an
angle relative to the inner peripheral surface 410. For example,
the inner back surface 418 and the inner peripheral surface 410 may
be disposed perpendicularly to each other. The inner back surface
418 and the inner peripheral surface 410 collectively form a
receiving portion 420, such as an open-ended slot or a channel,
configured to receive the body of the ballistic plate 112. In one
implementation, the receiving portion 420 releasably engages the
ballistic plate 112. In another implementation, the receiving
portion 420 is secured to the ballistic plate 112 with an adhesive
or similar engaging mechanisms.
[0067] As shown in FIG. 8, in one implementation, the receiving
portion 420 engages the ballistic plate 112, such that at least a
portion of the peripheral edge 304 is covered. In the example shown
in FIG. 8, the peripheral portion of the ballistic plate cover 400
covers side portions and a proximal portion of the peripheral edge
304 with a distal portion left exposed. Further, the receiving
portion 420 may engage the ballistic plate 112 such that at least a
portion of the peripheral area of the strike face 300 and/or the
back face 302 is covered. In the example shown in FIG. 8, the back
portion 416 covers at least a portion of the peripheral area of the
back face 302 along the portions of the peripheral edge 304 covered
by the peripheral portion of the ballistic plate cover 400.
[0068] As can be understood from FIG. 9, in one implementation, the
body of the ballistic plate cover 400 further includes a bottom
portion 422 of the peripheral portion disposed opposite the top
portion 414 and a front portion 424 disposed opposite the back
portion 416. The front portion 424 is connected to the peripheral
portion. For example, the front portion 424 may be connected at an
edge of the peripheral portion, such that the front portion 424 is
disposed inwardly from the side portions 406, the tapered portions
412, and/or the top portion 414 and parallel to the back portion
416.
[0069] The front portion 424 includes an inner front surface 426
facing the inner back surface 418. In one implementation, the inner
front surface 426 is disposed at an angle relative to the inner
peripheral surface 410 and parallel to the inner back surface 418.
For example, the inner back surface 418 and the inner front surface
424 may each be disposed perpendicularly to the inner peripheral
surface 410. The inner back surface 418, the inner front surface
424, and the inner peripheral surface 410 collectively form the
receiving portion 420.
[0070] As can be understood from FIG. 9, in one implementation, the
receiving portion 420 engages the ballistic plate 112, such that an
entirely of the peripheral edge 304 is covered. Further, the
receiving portion 420 may engage the ballistic plate 112 such that
an entirety of the peripheral area of the strike face 300 and/or
the back face 302 is covered. In the example of FIG. 9, the back
portion 416 covers an entirety of the peripheral area of the back
face 302 and the front portion 424 covers an entirety of the
peripheral area of the strike face 300. In one implementation, the
body of the ballistic plate cover 400 defines an opening 428
exposing the non-peripheral area 306 of the ballistic plate
112.
[0071] Turning to FIGS. 10-11B, in one implementation, the body of
the ballistic plate cover 400 further includes one or more middle
portions 430 extending between the top portion 414 and the bottom
portion 414. The middle portion 430 may be engaged to the inner
back surface 418 and/or the inner front surface 424. The middle
portion 430 provides further structural support to maintain the
ballistic plate 112 within the receiving portion 420 of the
ballistic plate cover 400.
[0072] As discussed herein, the body of the ballistic plate cover
400 may have a variety of shapes, including, but not limited to,
rectangular, circular, elliptical, triangular, polygonal, angles,
contoured, and/or the like. In the example shown in FIG. 10-11B,
the body of the ballistic plate cover 400 has a rectangular shape
with the peripheral portion including side portions 406 extending
linearly between the top portion 414 and the bottom portion 422.
Portions or an entirety of the body of the ballistic plate cover
400 may be made from aramid/unidirectional material and/or a
stretchable fabric composite material and may be stitched or
otherwise connected or be of unitary construction. In one
implementation, the ballistic plate cover 400 includes a soft armor
padding disposed in one or more places and made from a similar
material to the flexible body armor 110.
[0073] For a detailed description of an example of the flexible
body armor 110, reference is made to FIGS. 12-20. As can be
understood from FIG. 12, in one implementation, ballistic filler
for the flexible body armor 110 includes a first panel 500 having a
first subpanel 502 and a second subpanel 504, a second panel 506,
and a third panel 508.
[0074] Referring to FIG. 13, in one implementation, the first panel
500 of the ballistic filler of the flexible body armor 110 includes
the first subpanel 502 as a plurality of layers of woven fabric
generated from UHMWPE fiber and a second subpanel 504 as a
plurality of layers of unidirectional laminate. In one particular
implementation, the first subpanel 502 comprises three layers 510
of JPS 17517 woven fabric, and the second subpanel 504 comprises
four layers 512 of SB117 unidirectional laminates. Tape 514 holds
the layers 510 of the first subpanel 502 together and holds the
layers 512 of the second subpanel 504 together.
[0075] Turning to FIG. 14, in one implementation, the first
subpanel 502 is stitched directly to the second subpanel 504 to
form the first panel 500. The first subpanel 502 is backed by the
second panel 504. Tape 516 disposed at one or more of the edges may
hold the first subpanel 202 to the second subpanel 204 during
stitching.
[0076] In one implementation, the stitching comprises a first set
of stitching lines 518 parallel to each other and oriented in a
first direction and a second set of stitching lines 520 parallel to
each other and oriented in a second direction. The first direction
may be perpendicular to the second direction to form a quilted
square pattern. In one implementation, the first direction and the
second direction are both diagonal relative to the proximal end 116
and the distal end 118. Other stitching methods and arrangements
are contemplated. In one implementation, a first edge stitching 522
and a second edge stitching 524 extend around a perimeter of the
first panel 500 at a distance from the edge (e.g., approximately %
inches and % inches from the edge with +/-1/8 inches apart).
[0077] Turning to FIG. 15, the second panel 506 of the ballistic
filler for the flexible body armor 110 is shown. In one
implementation, the second panel 506 is formed from a plurality of
layers 526 of unidirectional laminates. In one implementation, the
plurality of layers 526 is fifteen layers of SB115. The plurality
of layers 526 may be held together with tape 528 for stitching. In
one implementation, the stitching comprises a first stitching line
530 and a second stitching line 532. The stitching lines 530 and
532 form an "X" shape across the plurality of layers 526 from the
proximal end 116 to the distal end 118, with the ends spaced an
equal distance such that if the proximal and distal end points of
the stitching lines 530 and 532 were joined a rectangle would be
formed.
[0078] FIG. 16 illustrates the third panel 508 of the ballistic
filler for the flexible body armor 110 formed by a plurality of
layers 534 of unidirectional laminates. In one implementation, the
plurality of layers 534 is two layers of SB117. The plurality of
layers 534 are not sewn and are held together with tape 536 for
combining with the first panel 500 and the second panel 506.
[0079] As shown in FIG. 17, a ballistic arrangement of the
ballistic filler for the flexible body armor 110, includes the
first panel 500 backed by the second panel 506, which is backed by
the third panel 508, such that the subpanel 502 of the woven fiber
is the layer most proximal to the strike face towards the outer
layer 106. FIG. 18 illustrates the ballistic filler for the
flexible body armor 110 with the first panel 500, the second panel
506, and the third panel 508 connected using proximal closure
stitching 538 and distal closure stitching 540 disposed at the
proximal end 116 and the distal end 118, respectively. In one
implementation, the closure stitching 538 and 540 comprises two
passes of three inch O/C 1.5 inches left and right. As shown in
FIG. 19, edge tape 542 may be applied to a portion of a periphery
of the ballistic filler for the flexible body armor 110 for heat
sealing.
[0080] FIG. 20 illustrates example operations 600 for manufacturing
a ballistic filler for the flexible body armor 110. In one
implementation, an operation 602 forms a first panel comparison a
first subpanel of woven fabric and a second subpanel of
unidirectional laminate. An operation 604 stitches the first
subpanel to the second subpanel. An operation 606 stitches a
plurality of layers of unidirectional laminate to form a second
panel, and an operation 608 forms a third panel from a plurality of
layers of unidirectional laminate. An operation 610 forms a
ballistic filler from the first panel, the second panel, and the
third panel, and an operation 612 stitches the ballistic filler at
a primal end and a distal end. An operation 614 applies edge tape
to at least a portion of a periphery of the ballistic filler, and
an operation 616 heat seals the ballistic filler to form the
flexible body armor 110.
[0081] The ballistic filler for the flexible body armor 110
provides numerous advantages over monolithic and other hybrid
designs. For example, the flexible body armor is comfortable,
durable, flexible, lightweight, and provides increased performance,
including resistance to ballistic penetration, back face
deformation performance, resistance to mechanical fatigue, and
resistance to fragmentation threat, and the like.
[0082] In one implementation, the ballistic filler of the flexible
body armor 110 has distinct regions. At least one region comprises
a stitch consolidated assembly of one or more plies of woven fabric
generated from UHMWPE yarn disposed in front of one or more
flexible ballistic ply structures generated from a high strength
yarn.
[0083] The flexible ballistic ply structures may be, for example, a
resin impregnated woven fabrics, unidirectional laminates,
multi-axial fabrics, and/or the like. In one implementation, the
flexible ballistic ply structures can be generated using high
strength yarns including, without limitation, aromatic polyamides
such as poly(p-phenylene teraphthalamide), poly(metaphenylene
isophthalamide), p-phenylenebenzobisoxazole, polybenzoxazole,
polybenzothiazole, aromatic unsaturated polyesters such as
polyethylene terephthalate, aromatic polyimides, aromatic
polyamideimides, aromatic polyesteramideimides, aromatic
polyetheramideimides and aromatic polyesterimides or copolymers of
any of the above mentioned classes of materials, and ultra high
molecular weight polyethylene, or any combination of these yarns.
In another implementation, the flexible ballistic ply structures
are woven fabrics generated from high strength fiber are woven
structures produced using yarns containing aromatic polyamides
including poly(p-phenylene teraphthalamide), poly(metaphenylene
isophthalamide), p-phenylenebenzobisoxazole, polybenzoxazole,
polybenzothiazole, aromatic unsaturated polyesters such as
polyethylene terephthalate, aromatic polyimides, aromatic
polyamideimides, aromatic polyesteramideimides, aromatic
polyetheramideimides and aromatic polyesterimides or copolymers of
any of the above mentioned classes of materials or any combinations
of these yarns.
[0084] In one implementation, at least one region of the ballistic
filler of the flexible body armor 110 comprises one or more plies
of unstitched ballistic ply structures generated from a high
strength yarn, which may have a tenacity greater than about 7
grams/denier. The unstitched ballistic ply structures may include
woven fabrics, resin impregnated woven fabrics, unidirectional
laminates, or multi-axial fabrics generated from yarns containing
aromatic polyamides including poly(p-phenylene teraphthalamide),
poly(metaphenylene isophthalamide), p-phenylenebenzobisoxazole,
polybenzoxazole, polybenzothiazole, aromatic unsaturated polyesters
such as polyethylene terephthalate, aromatic polyimides, aromatic
polyamideimides, aromatic polyesteramideimides, aromatic
polyetheramideimides and aromatic polyesterimides or copolymers of
any of the above mentioned classes of materials, and ultra high
molecular weight polyethylene or any combinations of these
yarns.
[0085] Any one of the stitch consolidated assemblies of plies of
the ballistic filler for the flexible body armor 110 is achieved
using any stitching thread and any type of stitching method to
achieve through-thickness connectivity of the plies, including
chain stitching or lock stitching to secure all plies in the
assembly together. In one implementation, a stitching pattern that
is uniform across the surface of the entire assembly is used. Such
a uniform stitching pattern may be, for example, a grid pattern
(quilt pattern), co-linear rows of stitching, concentric circles, a
spiral, and/or the like. In another implementation, the stitching
pattern of any one of the stitch-consolidated assembly of plies is
not uniform across the surface of the entire assembly. As described
herein, the ballistic filler for the flexible body armor 110
includes a stitched consolidated region and a free ply region. In
one implementation, the weight fraction of the stitch consolidated
region is no greater than 50% the overall weigh of the ballistic
filler. Further, the ballistic filler of the flexible body armor
110 includes at least one region of woven fabric stitched directly
to unidirectional fabric.
[0086] As can be understood from FIGS. 21-24, the flexible body
armor 110 may be generated for the natural shape of a female
wearer, while providing a full range of motion and support and
eliminating excess compression on the breast tissue.
[0087] As can be understood from FIGS. 21 and 22, in one
implementation, a female shape 700 of the flexible body armor 110
is formed from an upper portion 702, a set of lateral portions 704
and a lower portion 706. The set of lateral portions 704 connect
the upper portion 702 to the lower portion 706.
[0088] In one implementation, the upper portion 702 includes a set
of upper side edges 716 each extending distally from a top edge
714. The upper side edges 716 may further extend along a contour to
enhance ergonomics and accommodate the anatomy of a female wearer.
For example, the upper side edges 716 may each extend inwardly from
the top edge 714 in a direction generally towards a central axis
730 extending from the proximal end 116 of the flexible body armor
110 to the distal end 118. The top edges 714 are connected by a
center edge 710, which may be a contoured. In one implementation,
the center edge 710 contours distally from each of the top edges
714 until reaching a central point. The top edges 714 may contour
from the upper side edges 716 into the center edge 710.
[0089] In one implementation, each of the upper side edges 716 is
connected to the lateral portion 704 at an upper valley 718. An
edge of each of the lateral portions 704 extends from the upper
valley 718 in a direction generally outwardly away from the central
axis 730 to a lower valley 722. In one implementation, each of the
lateral portions 704 includes a lateral peak 720. The edge of each
of the lateral portions 704 may include a first edge extending from
the upper valley 718 to the lateral peak 720 and a second edge
extending from the lateral peak 720 to the lower valley 722. The
first edge, lateral peak 720, and the second edge may extend
outwardly at angle along a line, forming a generally straight line
angling from the upper valley 718 to the lower valley 722. In
another implementation, the first edge contours from the upper
valley 718 to the lateral peak 720, and the second edge contours
from the lower valley 722 to the lateral peak 720.
[0090] The lower portion 706 is connected to the upper portion 702
with the set of lateral portions 704. In one implementation, the
lower valleys 722 of the lateral portions 704 connect to a set of
outwardly extending edges 724 of the lower portion 706. Stated
differently, the lower valley 722 connects the second edge of the
lateral portion 704 to the outwardly extending edge 724. The
outwardly extending edges 724 may each be disposed at an angle
relative to lower side edges 726 of the lower portion 706 and
extend outwardly from the lower valleys 722 to the lower side edges
726. In one implementation, the lower side edges 726 each extend
distally from the outwardly extending edges 724 to a bottom edge
712, which may extend horizontally between the lower side edges
726.
[0091] Each of the lateral portions 704 may include lateral darts
extending from the edge of the lateral portion 704 inwardly and
distally. In one implementation, the lateral darts form cup
portions 728. As can be understood in FIG. 22, the lateral darts
are each adapted to displace a ballistic hard plate 300 to
eliminate excess compression on the breast tissue of the female
wearer. The lateral darts displace a proximal end the body of
ballistic plate 112 in a direction away from the inner surface 108
of the front carrier 124 and the flexible body armor 110 (i.e., a
direction away from the wearer). As such, a central axis 732 of the
ballistic plate 112 is disposed at an angle relative to the central
axis 730 of the flexible body armor 110. The front carrier 124 may
similarly incorporate the female shape 700, such that the ballistic
plate 112 is maintained in the front carrier pocket 134 in an
orientation generally parallel to the body of the wearer,
preventing projectiles from moving through the ballistic protection
into the body of the wearer, while eliminating compression on the
breast tissue by displacing the proximal end of the ballistic plate
112 outwardly.
[0092] Turning to FIG. 23, in one implementation, the one or more
panels 708 includes a first panel 734 having one or more layers and
a second panel 736 having one or more layers. The first panel 734
includes an inner surface 738 and the second panel 736 has an inner
surface 740. In one implementation, the lateral darts are each
formed from one or more raised pleats. For example, a first raised
pleat 42 may be formed along the inner surface 738 of the first
panel 734, and a second raised pleat 744 may be formed along the
inner surface 740 of the second panel 736. The raised pleats 742
and 744 may each extend from a center area 746 of a respective cup
portion 728 to a periphery 750. In one implementation, the raised
pleats 742 and 744 form free space 748 of the cup portion 728
between the first panel 734 and the second panel 736. The raised
pleats 742 and 744 may each be formed using a plurality of sewing
lines extending from the center area 746 to the periphery 750. In
one implementation, the lateral darts formed from the raised pleats
742 and 744 extend from the center area 746 to an edge of the
lateral portion 704 of the flexible body armor 110 disposed between
the upper valley 718 and the lower valley 722. After the raised
pleats 742 and 744 are formed, the first panel 734 may be attached
to the second panel 736, for example, using sewing, lamination
(e.g., with an adhesive,) to form the flexible body armor 110.
[0093] FIG. 24 illustrates example operations 800 for manufacturing
a female tactical vest. In one implementation, an operation 802
forms a front carrier having an upper portion connected to a lower
portion with opposing lateral darts. An operation 804 forms a first
panel from a plurality of layers of ballistic material. An
operation 806 stitches a plurality of sewing lines along the first
panel to form a first set of raised pleats, which may include one
or more raised pleats. An operation 808 forms a second panel from a
plurality of layers of ballistic material. An operation 810
stitches a plurality of sewing lines along the second panel to form
a second set of raised pleats, which may include one or more raised
pleats. An operation 812 stitches or otherwise attaches the first
panel to the second panel with the first set of raised pleats
oriented relative to the second set of raised pleats to form a cup
in a soft ballistic armor. An operation 814 orients the soft
ballistic armor along the front carrier, for example, in an
interior of the front carrier.
[0094] Turning to FIGS. 25-27, it will be appreciated that the
ballistic frame 114 may be disposed behind or in front of and loose
from the flexible body armor 110 within the interior 104. The
ballistic frame 114 includes a frame body 900 configured to improve
overall load carriage performance of the tactical system 100 by
providing a rigid platform to add weight. The frame body 900 may be
disposed loose or secured within the interior 104 to provide
structural support to the outer layer 106, the inner layer 108,
and/or other aspects of the tactical system 100. In one
implementation, the frame body 900 is configured to support a load.
The frame body 900 reduces fatigue by improving the structure of
the tactical system 100 by retaining the flexible body armor 110 in
a configuration that prevents bunching and provides support to the
ballistic plate 112 to improve edge hit protection. The frame body
900 may be made from a polyethylene material, an ABS plastic
material, an aramid fiber material, and/or other ballistics force
dissipating material.
[0095] The ballistic frame 114 is unattached to the flexible body
armor 110 within the interior 104, such as the front carrier pocket
134 where the tactical system 100 is a tactical vest. The ballistic
frame 114 absorbs and otherwise dissipates energy from an impact of
a projectile against the ballistic plate 112 and/or the flexible
body armor 110. The ballistic frame 114 may be disposed in the
interior 104 together with the flexible body armor 110 or without
the flexible body armor 110.
[0096] In one implementation, the flexible body armor 110 is
disposed within the interior 104 of the tactical system 100 and
made from a force dissipating material. The ballistic frame 114 is
disposed within the interior of the ballistic vest adjacent to and
detached from the soft body armor component. The ballistic frame
114 may be disposed within the interior 104 between the outer layer
106 and the flexible body armor 110 or between the inner layer 108
and the flexible body armor 110. Stated differently, the ballistic
frame 114 may be backed by the flexible body armor 110 or the
flexible body armor 110 may be backed by the ballistic frame
114.
[0097] The ballistic frame 114 thus provides an additional
protective layer to the flexible body armor 110 in some
implementations, further dissipating the forces generated by the
impact of a ballistic projectile and/or shrapnel against the
flexible body armor 110. Another aspect of the ballistic frame 114
is a structural component that provides a framework to the tactical
system 100 that is exterior to the flexible body armor 110 and
provides structural integrity and prevents sagging of the outer
layer 106 and other portions of the tactical system 100.
[0098] The frame body 900 may be solid or have one or more openings
902 therethrough. The openings 902 may have a variety of shapes
including, but not limited to, circular, rectangular, elliptical,
triangular, hexagonal, star, trapezoidal, angled, and/or contoured.
The openings 902 may be symmetrical along at least one axis 906 of
the frame body 900. For example, the openings 902 may include a
first set of openings vertically aligned and a second set of
openings vertically and/or horizontally aligned, with the first set
of openings and the second set of openings being symmetrical.
[0099] The frame body 900 may have a variety of shapes, for
example, asymmetrical, symmetrical, circular, square, rectangular,
hexagonal, contoured, angled, and/or polygonal. The frame body 900
may be planar or extend along one or more angles or curves.
Further, the frame body 900 may be sized and shaped based on a
coverage area for protecting the wearer. The coverage area may
include a deltoid area, a bicep area, a neck area, a yoke area, a
collar area, and/or an extremity area.
[0100] In one implementation, the frame body 900 extends between a
peripheral edge shaped based on ergonomics of the wearer and/or to
mirror a shape of the flexible body armor 110 and/or the ballistic
plate 112. For example, the frame body 900 may have a shape similar
to the female shape 700. The peripheral edge may include a bottom
edge 910 connected to a top edge 912 with a set of side edges 908.
In one implementation, a width of the frame body 900 tapers
proximally toward the top edge 912. Stated differently, the
peripheral edge may include tapered edges 914 connecting the side
edges 908 to the top edge 912. In another implementation, the side
edges 908 extend proximally beyond the top edge 912 and peaks 916
curve to connect to the side edges 908 to the top edge 912.
[0101] While the present disclosure has been described with
reference to various implementations, it will be understood that
these implementations are illustrative and that the scope of the
disclosure is not limited to them. Many variations, modifications,
additions, and improvements are possible. More generally,
implementations in accordance with the present disclosure have been
described in the context of particular examples. Functionality may
be separated or combined in blocks differently in various
implementations of the disclosure or described with different
terminology. These and other variations, modifications, additions,
and improvements may fall within the scope of the disclosure as
defined in the claims that follow.
* * * * *