PROTECTIVE CLOTHING SYSTEM WITH COOLING SUBSYSTEM

Abstract

A protective clothing system is disclosed that provides cooling via a cooling subsystem. The cooling subsystem can incorporate one or more perforated tubes to provide positive air pressure throughout the clothing system via an external pump. In embodiments, the tubes can be positioned adjacent a spacer mesh product allowing for comfort and unrestricted air flow from the tubing. In various embodiments, the perforated tubing can target specific areas such as the sternum of the chest and the spine region of the back where most of the blood flows in order to cool down the core temperature.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Patent Application No. 62/662,461 filed on Apr. 25, 2018, the contents of which are incorporated by reference herein in their entirety

TECHNICAL FIELD

The present disclosure pertains to wearable armor, and more particularly to comfortable lightweight clothing having ballistic protection.

BACKGROUND

Body armor and helmets are known. In general, it is desirable is to make body armor and protective headwear as light and as breathable as possible and still withstand the impact of incoming projectiles. Various fabric materials have been developed to cause incoming projectiles to expend energy on the filaments of the fabric, and therefore lose the ability to penetrate the person or object being protected by the fabric. Nevertheless, traditional materials suffer from higher than desirable areal densities and thicknesses, and further have proven vulnerable to penetration or meaningful backface deformation (BFD).

With specific reference to helmets, ballistic helmets today are generally formed using a monolithic “pinwheel” design. The pinwheel design refers to preformed patterns of fabric, where the patterns include cuts or seams that are staggered when layered together to minimize structural weakness along any given seam. The layers are then assembled and secured together, such as with resin, so as to prevent the formation of folds, wrinkles or excessively thick portions.

Early single piece helmet designs have suffered from sub-par ballistic performance based upon the curve in the material. The more bend or radius in a piece of ballistic material, the worse the ballistic performance throughout the ballistic solution. Two-piece ballistic helmets have been designed as an exception to this type of singular ballistic helmet. However, such designs present challenges with regard to the gap between adjoining shell elements, and further by the recognizable staggered profile in combat situations. Enemy combatants may, for example, target personnel wearing the two-piece staggered design for strategic purposes.

With regard to body armor, military and law enforcement personnel have employed armor-enhanced under-clothing in order to protect their bodies from gunfire, shrapnel, explosive devices and other harmful ballistic objects. Even when such under-clothing is sized according to individual specifications (for example, small, medium and large), the armor-enhanced under-clothing has only a single curve and does not generally fit well, gets bunched up, prohibits smooth movement, results in undesirable gaps between body and under-clothing, has limited contact points with the body, and even hinders the withdrawal of firearms. For example, lower abdomen/groin armor components, side torso components, deltoid components, bicep components, and upper leg/thigh components all suffer from poor ergonomic design. Such disadvantages often result in poor performance and can encourage mis-use or even non-use of these protective devices.

The stiffness in body armor results from material which has a very tight weave or disposition of filaments, for example. Further, armor which comprises layers of non-woven fabric stabilized in a matrix resin, is uncomfortable, generally to the degree in which it can stop projectiles. In other words, the more uncomfortable the material, the better with which the material can stop the force of projectiles. This stopping force is a function of the material's areal density and its flexibility. For the same polymer filaments, the higher the areal density of the fabric, the lower the flexibility and breathability, which translates to greater stopping power. Further, for fabrics made up of the same filaments, the more non-woven fabric used in a protective composite fabric, the stiffer it is because the matrix resin causes it to have progressively fewer void spaces. Solid metal armor such as that worn by knights in past ages is the ultimate in stiffness and lack of void spaces, with a high areal density of the iron from which it was made. It is also infinitely stiff, having the same bending ability as any solid metal armor plate, and is therefore extremely uncomfortable.

In modern body armor, it is desirable to strike a balance between the power of the garment or fabric to stop an incoming projectile, and the degree of discomfort borne by the wearer. If the fabric has too few filaments, or if the molecular weight and denier of the filaments making up the fabric is too low, or if the fabric is too thin, there will be insufficient protection afforded the wearer. Further, as weaponry has been improved, the impact velocity and penetrating power of projectiles has continued to increase, and therefore, the stopping power of protective garments has also increased. This has been accomplished by using stronger and higher molecular weight filaments, by increasing the weight of the fabric, by using a non-woven fabric which has been stabilized by embedding the fabric in a matrix resin, and by assembling the fabric from different elements, such as both woven and non-woven fabrics, which provide different, and cumulatively superiorly effective, kinds of stopping power. However, along with this need to make the protective fabric more able to resist the penetration of high energy projectiles, it is also desired to lighten the fabric and make it more comfortable to the wearer.

In addition to the above, body armor tends to increase heat generation from the wearer's body, with perspiration contributing to the wearer's discomfort and fatigue. Currently, cooling methods for armor wearers involve radiator type cooling systems and ice packs. The radiator method's drawbacks are weight, real estate, and the need to be powered which limits its effectiveness due to limited battery life. The ice pack method is heavy, creates bulk, and turns to water that slowly heats up rendering the cooling effect very short lived.

The presently disclosed system and devices overcome the current shortcomings and more. Embodiments of the present disclosure provide a customizable, scalable, armor-enhanced under-clothing system that conforms more substantially to the user's body, providing better protection over every critical body area in different stages as selected by the user. In this way, the user can employ as much or as little of the disclosed system as desired or needed for a given anticipated threat level, incorporating suitable armor to protect the wearer against anything from light ballistics (e.g., sand) all the way up to the heaviest ballistic weaponry and fragments that might be encountered. Embodiments of the present disclosure can employ compression fabric as a base material in the top (e.g., shirt) and bottom (e.g., shorts) system elements, and further can include one or more static fabric material harnesses in the top and/or bottom elements. The material can be provided in different forms depending upon desired characteristics (e.g., wicking, fire resistance, temperature management, anti-microbial, etc.). Anti-ballistic panels of suitable material and thickness can be inserted into the static fabric material harness designed to carry the panels while preventing any undesirable bouncing effect. In embodiments, the top and bottom elements are adapted to be secured to one another using hook-and-loop fasteners or similar fasteners to facilitate comfort, intended purpose and overall fit. The presently disclosed system and devices also provide full body contact as opposed to selected point contact associated with prior devices. The presently disclosed system and devices can be provided in sleeveless, short sleeve and long sleeve shirts, shorts and pants, for example.

The present disclosure further reveals body armor and helmets that are lighter weight, easily donned and doffed, provide added comfort and maintain significant ballistic strength. The present disclosure further pertains to a cooling subsystem that can be integrated with the lightweight clothing system to keep the wearer cooler during operation.

In various embodiments, the ballistic helmet of the present disclosure is comprised of two or more pieces, has an areal density of no more than 2.10 lbs/ft², and does not exceed a thickness of 0.44 inches while maintaining 25 millimeters, or less, backface deformation (BFD) on the helmet when subject to gunfire. In specific embodiments, the helmet pieces are provided of unidirectional material and are capable of withstanding the penetration of at least one of the following projectile types: a 9 mm, 124 grain, FMJ projectile impacting the unidirectional material at a velocity of not less than 1,400 feet per second; and a 7.62×39, 124 grain, mild steel core projectile impacting the unidirectional material at a velocity of not less than 2,400 feet per second. In various embodiments, the unidirectional material can be provided with an areal density of approximately 1.60 to approximately 2.10 pounds per square foot and can comprise not more than 15% by weight of matrix resin. Further, embodiments of the unidirectional material can comprise from approximately 85 to approximately 100 sub-plies of unidirectional material joined together by pressing, and wherein the unidirectional material passes the level III-A penetration resistance test. In various embodiments, the unidirectional material can be provided with eighty to ninety percent of the material weight in one direction.

The material employed can be nylon, aramid, or Ultra High Molecular Weight polyethylene (UHMWPE) woven or uni-directional materials, aramid fibers, ceramics, polycarbonate, plastic, aluminum, steel, titanium, or a combination of two or more such materials. The helmet can also be suitably relieved in areas where no ballistic protection is required, or where ballistic protection would otherwise impede certain functions of the helmet and the wearer's desired functional capabilities.

The multiple pieces of the helmet contribute to the performance advantage due to less curvature or bend in the material. Further, the multiple pieces can be joined without a staggered profile and with no gaps in the ballistic solution. In addition to providing multiple pieces to cover the full head of the wearer, each portion of the solution can include multiple layers for a full ballistic solution. A base shell or first layer can also be provided that includes a chin strap, pads and frame. The second layer can contain the multiple ballistic pieces and the third layer can provide a hard shell that will marry the base shell and the third layer together containing the ballistic pieces.

With regard to the armor-enhanced under-clothing according to the present disclosure, in various embodiments, ancillary body armor components are disclosed that have an areal density of no greater than 2.10 lbs/ft² and are no thicker than 0.44 inches while not allowing more than 50 millimeters of backface deformation (BFD). The ancillary body armor components can be worn in a base-layer and under the uniform. Traditionally, body armor components are worn externally of the uniform so as to speed the donning and doffing process. The base-layer can house and “suspend” the armor components so as to be positioned correctly and comfortably with minimal movement and changing of the intended position on the body in order to enhance overall mobility, extremity movement, and survivability. In various embodiments, an advanced fabric as disclosed herein houses the armor, and this advanced fabric can comprise a compression fabric. The advanced fabric aids in the correct positioning of the ballistics and anti-fatiguing of the wearer and assists in providing an armor-enhanced under-clothing that is comfortable, easy to customize and ergonomically superior over prior devices.

With regard to cooling, the present disclosure relates, in part, to an active cooling subsystem that provides cooling via positive air pressure. The human body cools itself through the evaporation of perspiration. The cooling process is sped up and made more efficient when the perspiration is exposed to air flow, for example, like using a fan to simply move air onto a perspiring body. According to the present disclosure, positive air pressure can be provided via an external pump that pumps fluid such as air through a multitude of purposely placed perforated tubes. The tubes can be placed in and/or around a base layer and/or a spacer mesh article of clothing, allowing for comfort and unrestricted air flow from the tubing. In various embodiments, the perforated tubing can target specific areas such as the sternum of the chest and the spine region of the back where most of the blood flows in order to cool down the core temperature. According to various embodiments, multiple base layers are employed along with the cooling subsystem and ballistic inserts.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1 and 2 show front and back views of one embodiment of a top element as provided by the system of the present disclosure, with the top element being inverted so as to show the interior surface thereof.

FIGS. 3 and 4 show front and back views of an alternative embodiment of a top element as provided by the system of the present disclosure.

FIGS. 5 and 6 show front and back views of an alternative embodiment of a top element as provided by the system of the present disclosure.

FIGS. 7 and 8 show front and back views of an alternative embodiment of a top element as provided by the system of the present disclosure.

FIGS. 9 and 10 show front and back views of one embodiment of a bottom element as provided by the system of the present disclosure.

FIGS. 11 and 12 show front and back views of an alternative embodiment of a bottom element as provided by the system of the present disclosure.

FIGS. 13 and 14 show front and back views of an alternative embodiment of a bottom element as provided by the system of the present disclosure.

FIGS. 15 and 16 show front and back views of an alternative embodiment of a bottom element as provided by the system of the present disclosure.

FIGS. 17 and 18 show front and back views of an alternative embodiment of a bottom element as provided by the system of the present disclosure.

FIGS. 19 and 20 show front and back views of an alternative embodiment of a top element as provided by the system of the present disclosure.

FIGS. 21 and 22 show front and back views of one embodiment of a top element as provided by the system of the present disclosure.

FIG. 23 shows front and back views of a top element in accordance with one embodiment of the present disclosure.

FIG. 24 shows front and back views of an inverted top element in accordance with another embodiment of the present disclosure.

FIGS. 25 and 26 are schematic left-side view diagrams illustrating one embodiment of the chest portion and first pocket bag in accordance with the present disclosure.

FIGS. 27 through 30 show front and back views of a long sleeve shirt in accordance with aspects of the present disclosure.

FIG. 31 is a diagram illustrating a sequence of articles donned on the wearer in accordance with embodiments of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE PRESENT DISCLOSURE

The presently disclosed subject matter now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the presently disclosed subject matter are shown. Like numbers refer to like elements throughout. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.

Example embodiments such as disclosed herein can incorporate a system having a processor and an associated memory storing instructions that, when executed by the processor, cause the processor to perform operations as described herein. The system can be embodied as a server, for example. It will be appreciated that reference to “a”, “an” or other indefinite article in the present disclosure encompasses one or more than one of the described element. Thus, for example, reference to an insert encompasses one or more inserts, reference to a base material encompasses one or more base material layers and so forth.

FIGS. 1 through 31 illustrate different embodiments of the body armor aspects of the present disclosure. As shown in the embodiment of FIG. 1, the front side 14 of one embodiment of a top element 12 of the system of the present invention includes a suitably-sized interior pocket 16 within a base material 17 for receiving a suitably-sized front torso ballistic panel 18. In embodiments, the base material 17 comprises a compression fabric designed to snugly fit the wearer with 100% body contact. As such, the base material 17 provides a material with high tenacity stretch which provides muscles with a firm compression fit that lessons vibrations, reduces fatigue, and keeps muscles energized. The fabric can be formed in a knit construction, for example, using a series of gradient fibers with an open knit inner surface to create a moisture transfer environment.

The arm elements 20 also include respective suitably-sized interior pockets 22 for receiving respective suitably-sized forearm ballistic panels 24. The pockets 16, 22 generally include an opening through with panels can be inserted and removed. This facilitates customization of the anti-ballistic properties of the present invention, as heavier and thicker panels may be needed for some engagements, while lighter and thinner panels may be needed for other engagements. In another embodiment, the pockets 16, 22 are constructed with panels retained therein, and then sealed so that the panels remain permanently part of the top element. The pockets can comprise a variety of materials, including compression fabric, or alternatively a static fabric material retaining greater strength and resisting movement more than compression fabric.

As shown in the embodiment of FIG. 2, the back side 15 of the top element 12 includes a suitably-sized interior pocket 26 for receiving a suitably-sized back torso ballistic panel 28. As FIGS. 1 and 2 show the interior surface 13 of the top element, it will be appreciated that the pockets 16, 22 and 26 are on the interior and are not generally accessible from the exterior of the top element, which assists in the concealability and comfort of the present invention.

As shown in the embodiment in FIGS. 3 and 4, the top element can include epaulets 30 over the shoulder area, wherein the epaulets 30 are formed with an interior surface that forms a channel through which strap members 32 and clip members 34 can extend. The strap 32 and clip 34 members can be used to retain additional panels 36 within or over the surface of the base material 17.

FIGS. 5 and 6 show additional front 14 and back 15 sides of a top element 12 of a system embodiment, similar to those shown in FIGS. 1 and 2, respectively, with like numbers representing like elements therein. FIGS. 5 and 6 further show custom-sized interior hip-side pockets 40 within the base material for receiving a custom-sized side ballistic panel 42. Such panels 42 protect the user's side and hip areas and, similar to the front and back panels described above, provide for a snug fit which engages the wearer's body and does not, for example, protrude so far as to hinder the wearer's ability to quickly access firearms or other materials that may be attached somewhere on the wearer's outerwear.

FIGS. 7 and 8 show front 14 and back 15 sides of a sleeveless top element 12 with elements corresponding to those shown and described in connection with FIGS. 1 through 6. Other top, bottom and groin area sections can be seen in FIGS. A through G, for example.

FIGS. 9 through 18 represent different embodiments of a bottom element 50 of the present disclosure, with FIGS. 9, 11, 13, 15 and 17 representing the front side 52 of the bottom element 50 and FIGS. 10, 12, 14, 16 and 18 representing the back side 54 of the bottom element 50. The base material 55 of bottom element 50 comprises a similar material and/or the same material as the compression fabric described above with regard to base material 17 of top element 12. As represented in FIGS. 9 and 10, leg pockets 56 are provided to receive custom-sized leg protective ballistic panels 58. The panels 58 protect at least the wearer's femoral artery. The pockets 56 can comprise static material similar to that described above in connection with pockets 16, 22 in FIGS. 1-2.

FIGS. 11 and 12 show embodiments with protective elements 58 on the front 52 and back 54 sides of the bottom element 50. FIGS. 13 and 14 show embodiments similar to FIGS. 11 and 12, with the same reference elements, and with an additional crotch protective element 60 retained within a suitably-sized pocket 62 therearound.

FIGS. 15 and 16 show further enhanced embodiments of the bottom element 50 of the present disclosure, with the front side 52 showing hip guards 66 within hip pockets 64, in addition to crotch protective element 60 and leg protective panels 58 as illustrated and described above. Further, FIG. 16 shows tailbone protective element 72 within tailbone pocket 70 and gluteal protective elements 74 within gluteal pockets 76.

FIGS. 17 and 18 show embodiments of the bottom element 50 of the present disclosure in long pants-like form. Similar reference numbers apply as labeled and described above.

FIGS. 19-22 show additional embodiments of the top element 12 of the present disclosure. Outer arm internal pockets containing ballistic inserts 80, waistline internal pockets containing ballistic inserts 82 and upper torso under arm pockets containing ballistic inserts 84 are shown therein with respect to a long sleeve embodiment 85 in FIGS. 19-20 and a short sleeve embodiment 88 in FIGS. 21-22.

In operation, a wearer of embodiments of the presently disclosed system and devices may select a previously installed version, where ballistic panels are already selected and sewn in, or where ballistic panels are already inserted into the top and bottom elements. The selection can be made according to the wearer's size (e.g., small, medium and large). Alternatively, the wearer may select the top and bottom elements without any ballistic panels installed, put on the top and bottom elements, and then install appropriate ballistic elements in the available pockets as desired for an anticipated engagement. It will be appreciated that the pockets can be openable and sealable using hook and loop type fasteners, or other appropriate fasteners to enable quick assembly and dis-assembly. Accordingly, one aspect provides a protective clothing system with a standardized set of pockets which may or may not be fully employed for a given engagement, but which do not reduce the ergonomic design and comfortable fit, regardless of whether the pockets are filled with suitable ballistic material.

The ballistic material can comprise, for example, layers of fibers that may comprise a high molecular weight polyethylene material, an aramid fiber, a combination of high performance fibers, or a non-woven thermoplastic composite. Commercially available embodiments of the ballistic material are known as Dyneema™ and Spectrashield™, for example. Other embodiments in accordance with the present disclosure are lighter weight unidirectional material and are capable of withstanding the penetration of at least one of the following projectile types: a 9 mm, 124 grain, FMJ projectile impacting the unidirectional material at a velocity of not less than 1,400 feet per second; and a 7.62×39, 124 grain, mild steel core projectile impacting the unidirectional material at a velocity of not less than 2,400 feet per second. In various embodiments, the unidirectional material can be provided with an areal density of approximately 1.60 to approximately 2.10 pounds per square foot and can comprise not more than 15% by weight of matrix resin. Further, embodiments of the unidirectional material can comprise from approximately eighty-five to approximately one hundred sub-plies of unidirectional material joined together by pressing, and wherein the unidirectional material passes the level III-A penetration resistance test. In various embodiments, the unidirectional material can be provided with eighty to ninety percent of the material weight in one direction.

The present disclosure allows for the ballistic or other fabric inserts (e.g., as assessed by potential threat) to be sewn into or placed in a pocket or sleeve, for example. The present disclosure also protects the end user from sand, ballistic fragments, etc., as a secondary layer. In various embodiments of the present disclosure, the tops or bottoms in any configuration will cover areas that traditional body armor does not. As such, an end user can wear the top or bottoms of the present disclosure under their traditional body armor and the tops and bottoms would have extra protection in the areas that the body armor does not cover. Optionally, there may be additional protection for the lower abdominal area, arms, under arms, upper legs, etc.

As such, the presently disclosed system and devices can conceal the armor, keep the armor or protection in the correct place, allow it to fit a great range of people, allow for multiple overlap points for extreme comfort, provide interchangeable armor components in order to adjust for size, and allow the tops and bottoms in one size to adjust within the pocket or sleeve so that the same component can permit different thickness inserts to be employed.

In the embodiment as shown in FIGS. 23 and 24, for example, the present disclosure provides an article 100 of under-clothing, comprising a top element 102 comprising a compression fabric or spacer mesh material, with the top element 102 having front 104 and back 106 exterior surfaces, and front 108 and back 110 interior surfaces. The article 100 further includes a harness element 112 comprising, for example, a non-compression, static material secured to and extending from the front interior surface 108 to the back interior surface 110 of the top element 102. The top element 102 further includes a neck area 111 forming an opening indicated at 113, left shoulder interior 114 and exterior 116 surfaces, and right shoulder interior 118 and exterior 120 surfaces. The harness element 112 includes a first strap element 122 secured to the right shoulder interior surface 118, and a second strap element 124 secured to the left shoulder interior surface 114.

The first strap element 122 has a first strap length and is secured to the right shoulder interior surface along substantially the entire first strap length. Similarly, the second strap element 124 has a second strap length and is secured to the right shoulder interior surface along substantially the entire second strap length.

The harness element 112 further includes a chest portion 126 secured at least in part to the first 122 and second 124 strap elements and further secured to the front interior surface 108 of the top element 102. As illustrated in FIG. 23 and in the schematic drawing of FIG. 25, the chest portion 126 can be secured by sewing a seam 127 that connects the chest portion 126 to the front interior surface 108 of the top element 102. In one embodiment, the chest portion is secured to the front interior surface 108 along the upper perimeter boundary of the chest portion, which is shown along seam 127 in FIG. 23 as a substantially inverted U-shaped seam. Further, the chest portion 126 can comprise a two-ply static fabric element that provides a durable and strong material for the purposes of securely retaining ballistic-resistant material as described hereinafter. In one embodiment, the harness element comprises a static material that does not stretch. Such a material can be considered a “jersey mesh” material in accordance with one embodiment. By not stretching, any armor inserted into the pocket bag portions described herein will not be permitted to bounce around. The bouncing of armor inserts is undesirable because it can reduce effectiveness, comfort and desire for the user to employ armor. The first or back ply 128 of the chest portion 126 is retained against the top element 102 via seam 127, while the second or front ply 129 of the chest portion otherwise hangs freely over a first pocket bag portion 130 provided as part of the harness element 112.

The first pocket bag 130 includes a back ply portion 131 and a front ply portion 132, and can accommodate the insertion or removal of ballistic inserts. In one embodiment, the back ply portion 131 of the first pocket bag 130 is integrally formed with the back ply 128 of the chest portion, but is generally not secured to the top element 102 (except optionally at attachment points 145) and hangs freely from the chest portion. The front ply portion 132 similarly hangs freely but is not integrally formed with the front ply portion 129 of the chest portion 126 of the harness element. Rather, the front ply portion 132 of the first pocket bag 130 includes a rim 139 (illustrated by dashed arrow in FIG. 23, and in FIG. 26), and the rim 139 of the front ply portion, as well as the outer side edges 141 and bottom edge 143 of the first pocket bag 130 are generally not secured to the top element 102, except optionally at attachment points 145 shown in FIG. 23, which can correspond to the points of intersection of the rim 139 and outer side edges 141 of the front ply portion 132 of the first pocket bag. As shown in FIG. 26, for example, the front ply 129 of the chest portion 126 can be lifted (e.g., by hand), and the rim 139 and/or front ply 132 of the first pocket bag 130 can be pulled away from the back ply 131 so as to create an opening 133 to insert or remove a ballistic insert 135. As illustrated in FIG. 25, the rim 139 of the front ply portion 132 of the pocket bag 130 can extend above the bottom edge 121 of the front ply 129 of the chest portion 126 when both ply portions 129, 132 are in the rested position, which results in the front ply 129 of the chest portion 126 overlapping the front ply 132 of the pocket bag 130, which can thereby assist in securely retaining the ballistic insert within the open area inside the pocket bag and the chest portion. It will be appreciated that the pocket bag 130 can be a separable component that is not integrated with the chest portion of the harness element 112 but is rather connectable and disconnectable using a zipper-type connection, hook-and-loop type connection or other type of temporary connection.

As further shown in FIGS. 23 and 24, the harness element 112 includes a back portion 138 secured to the first 122 and second 124 strap elements and further secured to the back interior surface 110 of the top element 102. In one embodiment, the back portion is secured to the strap elements and the interior surface 110 of the top element 102, and the strap elements 122, 124 are secured to the interior surface 110 of the top element 102, such as by sewing a seam 140, for example. The harness element 112 further includes a second pocket bag 142. In one embodiment, the back portion 138 and the pocket bag 142 each comprise separate two-ply constructions similar to the chest portion 126 and pocket bag 130, respectively, described above. In one embodiment, and similar to the arrangement described above for the front pocket bag 130, the back ply portion of the second pocket bag 142 is integrally formed with the back ply of the back portion 138, but the second pocket bag 142 is generally not secured to the top element 102 (except optionally at attachment points 151 shown in FIG. 23) and hangs freely from the chest portion. The front ply portion of the second pocket bag 142 similarly hangs freely but is not integrally formed with the front ply portion of the back portion 138 of the harness element 112. Rather, the front ply portion of the second pocket bag 142 includes a rim similar to that shown at 139 for first pocket bag 130, and the rim of the front ply and the outer perimeter (including a bottom edge and side edges) of the second pocket bag 142 are generally not secured to the top element 102, except optionally at attachment points 151 shown in FIG. 23, which can correspond to the intersection points of the second pocket bag side edges and the rim of the front ply of the second pocket bag.

One or more ballistic inserts can be inserted into and removed from the second pocket bag 142 and the opening created by the two plies of the back portion 138, similar to the process described and shown in connection with the first pocket bag 130 and chest portion 126 in FIG. 26, for example. It will be appreciated that the pocket bag 142 can be a separable component that is not integrated with the chest portion of the harness element 112 but is rather connectable and disconnectable using a zipper-type connection, hook-and-loop type connection or other type of temporary connection.

As further shown in FIGS. 23 and 24, the top element 102 further includes a left side portion 150 comprising left side interior 152 and exterior 154 surfaces, and a right side portion 156 comprising right side interior 158 and exterior 160 surfaces, and further including a front portion 162 comprising the front interior 108 and exterior 104 surfaces. The front portion 162 of the top element 102 is releasably secured to the left side portion 150 using a left side securing element 170 and is further releasably secured to the right side portion 156 using a right side securing element 172. In one embodiment of the present invention, the left side 170 and right side 172 securing elements comprise slide fastener (i.e., Zipper™) elements, allowing the user to zip and unzip the front portion 162 from the side portions 150, 156 to allow easy access to the front pocket element 132 of the present invention.

It will be appreciated that embodiments of the protective clothing system and devices disclosed herein thus provide a customizable, scalable, armor-enhanced clothing system that conforms more substantially to the user's body, with a thinner and lighter armor profile, and with better protection over every critical body area in different stages as selected by the user. The present disclosure further provides such devices whereby the top element comprises an outer compression fabric layer with an inner non-compression fabric harness element.

With regard to the cooling sub-system of the present disclosure, positive air pressure can be provided via an external pump that pumps fluid such as air through one or more purposely placed perforated tubes. The tubes can be merged into and/or placed adjacent a base material, such as a compression fabric or spacer mesh material, allowing for comfort and unrestricted air flow from the tubing. The spacer mesh material can be embodied as three separate layers of fabric knit together, such as a face and a back connected by a monofilament yarn to produce a connecting cushion-type layer. Each layer can be knit simultaneously by a single machine. As shown in FIGS. 27 through 31, for example, a pump 300 can be secured to a tube 305 that may be perforated, such that when the pump operates, air is pressed through the tubing and exits different sections of the tubing based on the perforation therein, thereby providing an air source between the armor inserts and the base material and/or the user's skin. In various embodiments, such as shown in FIGS. 29 and 30, for example, the perforated tube 305 can be aligned with the sternum 307 of the chest and the spine region 309 of the back where most of the blood flows in order to cool down the core temperature. The tube can be provided as a flexible hollow material and the pump can operate automatically or manually. In various embodiments, the pump is battery operated.

As shown in FIG. 31, the tube 305 includes a main portion or trunk 330 and branches 307, 309 extending from the trunk 330. A splitter 333 separates the trunk 330 into the branches 307, 309 and permits air flowing from the pump 300 and trunk 330 to flow through both branches 307, 309. It will be appreciated that multiple splitters and additional branches of tubing can be employed in accordance with additional embodiments of the present disclosure. In various embodiments, the tubing is formed of a plastic or rubber material.

In various embodiments, the base material (e.g., compression fabric or spacer mesh material) has a front side and a back side. As further shown in FIG. 31, in certain embodiments, a first base material 212 can be worn by the user 250 next to the user's skin. The tube 305 and pump 300 can then be positioned over and against the first base material 212. A second base material 214 can then be positioned over and against the tubing 305. The pump 300 may lie between the first 212 and second 214 base material or may extend outwardly thereof. Regardless, the tube 305 is maintained between the first 212 and second base material 214. A third base material 216 may then be positioned over and against the second base material, according to various embodiments. The third base material 216 can be provided with one or more pockets 220, 224 to house one or more ballistic inserts 218, 222 as described above. When the third base material 216 is donned, the tube 305 is thus separated from the third base material 216 with inserts 218, 222 by the second base material 214. In this way, the tubing has adequate space and the perforations permit air flow along the path of the tubing to cool the user's body. In various embodiments, the first 212, second 214 and third 216 base material comprise compression fabric. In various other embodiments, the first 212, second 214 and third 216 base material comprise spacer mesh material. In still other embodiments, the first 212, second 214 and third 216 base material comprise compression fabric or spacer mesh material. In a specific embodiment, the first base material 212 comprises spacer mesh material and the second 214 and third 216 base material comprise compression fabric. In such embodiment, the spacer mesh material as the first base material 212 provides additional openings through which cooling air may flow to the user's skin.

In some embodiments, the system employs the first base material 212, tube 305 and pump 300 and third base material 216 with one or more pockets and one or more inserts, without the second base material 214.

In various embodiments, the spacer mesh can be provided with rigid spacing inserts to increase space between the spacer mesh adjacent the user's body and the tubing. Such inserts can form a type of frame for the spacer mesh as the first base material 212, for example, and the increased space provides for additional cooling of the user during operation.

The present disclosure describes numerous embodiments, and these embodiments are presented for illustrative purposes only. These embodiments are described in sufficient detail to enable those skilled in the art to practice what is disclosed herein, and it will be appreciated that other embodiments may be employed and that structural, and other changes may be made without departing from the scope or spirit of the present disclosure. Accordingly, those skilled in the art will recognize that the presently disclosed embodiments may be practiced with various modifications and alterations. Although particular features disclosed herein can be described with reference to one or more particular embodiments or figures that form a part of the present disclosure, and in which are shown, by way of illustration, specific embodiments of the invention, it will be appreciated that such features are not limited to usage in the one or more particular embodiments or figures with reference to which they are described. The present disclosure is thus neither a literal description of all embodiments nor a listing of features of the invention that must be present in all embodiments.

Claims

1. A clothing system, comprising:

a first base material formed for wear;

a cooling subsystem comprising: a perforated tube positionable against the first base material, and a pump configured to pump fluid through the perforated tube; and

a second base material formed for wear, wherein the second base material is positionable over the cooling subsystem.

2. The clothing system of claim 1, further comprising a third base material formed for wear, wherein the third base material comprises a pocket and wherein the third base material is positionable over the second base material.

3. The clothing system of claim 2, further comprising a ballistic insert maintained within the pocket.

4. The clothing system of claim 1, wherein the first and second base material comprise a compression fabric.

5. The clothing system of claim 2, wherein the third base material comprises a compression fabric.

6. The clothing system of claim 1, wherein the first base material comprises a spacer mesh material.

7. The clothing system of claim 6, further comprising a rigid insert secured to the spacer mesh material so as to increase space between the first base material and the perforated tube.

8. The clothing system of claim 1, wherein the perforated tube comprises a trunk and a plurality of branches extending from the trunk.

9. The clothing system of claim 1, further comprising a splitter separating the trunk into the plurality of branches.

10. The clothing system of claim 1, wherein the pump is configured to pump air through the perforated tube.

11. The clothing system of claim 3, wherein the ballistic insert comprises a unidirectional material with an areal density of approximately 1.60 to approximately 2.10 pounds per square foot.

12. The clothing system of claim 11, wherein the unidirectional material comprises from approximately 85 to approximately 100 sub-plies of unidirectional material joined together.

13. The clothing system of claim 1, wherein the first and second base material are formed for wear over a user's upper body.

14. A clothing system, comprising:

a first base material formed for wear;

a cooling subsystem comprising: a perforated tube positionable against the first base material, and a pump configured to pump fluid through the perforated tube;

a second base material formed for wear, wherein the second base material is positionable over the cooling subsystem, wherein the second base material is formed with a pocket; and

a ballistic insert maintained within the pocket.

15. The clothing system of claim 14, wherein the ballistic insert comprises a unidirectional material comprising an areal density of approximately 1.60 to approximately 2.10 pounds per square foot.

16. The clothing system of claim 15, wherein the unidirectional material comprises eighty-five or more sub-plies joined together by pressing.

17. The clothing system of claim 14, wherein the ballistic insert comprises not more than fifteen percent by weight of matrix resin.