WEARABLE BODY ARMOR

Abstract

The present invention provides a wearable body armor suit, comprising a plurality of body armor components that are connected together by an impact-resistant material, wherein the impact-resistant material comprises Vectran™ or woven chain mail, and wherein the body armor components are formed of carbon fiber or liquid crystal polymer fiber that is woven or formed into a platen. The platen is molded or curved to accommodate the shape of a body part being covered by the body armor component, for localized and directed protection of strategically important body parts.

Description

RELATED APPLICATIONS

This application claims the benefit of the priority of U.S. Provisional Patent Application No. 61/155,888 filed on Feb. 26, 2009, the content of which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present invention relates generally to body armor, and more particularly to body armor that is shaped and interconnected with articulation points to cover and protect strategically important parts of the body of a wearer, while providing flexibility and comfort.

DESCRIPTION OF THE RELATED ART

Most active wear clothing, fabrics, garments, and accessories are generally of minimal effectiveness and of limited comfort. Garments and accessories made of conventional materials that are touted as puncture, laceration, abrasion and/or impact resistant are nearly unwearable, or at least suffer from bulkiness, denseness, rigidity, and, most importantly, ineffectiveness.

Conventional body armor is bulky, cumbersome, and uncomfortable to wear. In some cases, conventional body armor is tailored to stop blunt-force objects such as bullets, but may be ineffective against other threats such as needles, knives, teeth, glass or other objects. Further, conventional body armor is not well adapted to strategically important parts of the body other than the chest of the wearer.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

The present invention is directed toward a wearable body armor suit that provides a wearer near-complete coverage and protection from threatening objects.

In various embodiments of the invention, the body armor suit is a modular suit made from armor components as well as high strength, protective fibers, fabrics and materials. The minor components can be formed of carbon fiber, liquid crystal polymer fiber, or any other strong, resilient fiber, or combination thereof, that is woven or formed into a platen. The platen can be molded or curved to accommodate the shape of a body part being covered by the component, for localized and directed protection of strategically important body parts. The fabrics may be formed of high-strength fibers that can be incorporated with other materials to produce comfortable garments and accessories that are resistant to laceration, abrasion, impact and puncture. The body armor suit may be employed for (i) marine use including water sports and activities such as scuba diving, surfing, kite boarding, rescue divers, and (ii) military use for impact-resistant clothing, upholstery and accessories.

One embodiment of the invention provides a wearable body armor suit, comprising a plurality of body armor components that are connected together by an impact-resistant material, wherein the impact-resistant material comprises Vectran™ or woven chain mail, and wherein the body armor components are formed of carbon fiber or liquid crystal polymer fiber that is woven or formed into a platen. The platen is molded or curved to accommodate the shape of a body part being covered by the body armor component, for localized and directed protection of strategically important body parts.

Other features and aspects of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the features in accordance with embodiments of the invention. The summary is not intended to limit the scope of the invention, which is defined solely by the claims attached hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention, in accordance with one or more various embodiments, is described in detail with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict typical or example embodiments of the invention. These drawings are provided to facilitate the reader's understanding of the invention and shall not be considered limiting of the breadth, scope, or applicability of the invention. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale.

FIGS. 1A-1G illustrate various front and side views of a plurality of components of a body armor suit, in accordance with the principles of the invention.

FIG. 2 illustrates a front view of a portion of a body armor suit for an arm of a wearer, with heavy-duty articulation, in accordance with the principles of the invention.

The figures are not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be understood that the invention can be practiced with modification and alteration, and that the invention be limited only by the claims and the equivalents thereof.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

The present invention is directed toward a wearable body armor suit. The suit includes multiple components that are connected together by a heavy-duty articulation point or by impact-resistant material, such as Vectran™, woven chain mail, or the like. The armor components can be formed of carbon fiber, liquid crystal polymer fiber, or any other strong, resilient fiber, or combination thereof, that is woven or formed into a platen. The platen can be molded or curved to accommodate the shape of a body part being covered by the component, for localized and directed protection of strategically important body parts.

In some embodiments, the components of the wearable body armor suit are modular and selectively detachable. In other embodiments, these components are not detachable. According to some embodiments of the invention, the components of the wearable body armor suit are detachably or fixedly connected to a base clothing layer. In particular, the base clothing layer may be formed as a conventional body suit to which the components are attached either inside or outside of the body suit. The various body armor components are attached to the body suit such that when the wearable body armor suit is worn by a wearer, the body armor components are positioned over the strategically important locations of the wearer's body. In this manner, each body armor component protects a strategically important area of the body.

Various combinations of body armor components may be employed in different body armor embodiments based upon the intended application. By way of example, only the front portion of the body armor may be employed in woodshop applications, and the body and leg body armor may optionally be excluded or included in the body armor configuration. As another example, only the arm portions of the body armor may be employed in a butcher application. In a further example, only the leg components of the body armor may be employed in a baggage handler application.

FIGS. 1A-1G illustrate various front and side views of a plurality of components of a body armor suit, in accordance with the principles of the invention. The body armor components may be formed of carbon fiber or liquid crystal polymer fiber that is woven or formed into a platen. The platen is molded or curved to accommodate the shape of a body part being covered by the component, for localized and directed protection of strategically important body parts.

FIG. 1A depicts a front view of vest component 10 of the body armor suit adapted to cover the chest and back of the wearer's body. In the illustrated embodiment, a groin protector 15 may be selectively detached from the vest component 10, for example using snaps, straps, hook and loops fasteners or other conventional means. Alternatively, the groin protector 15 may be permanently affixed or sewn onto the vest component 10. The vest component 10 may feature raised projections/ribs 20 at selected locations to provide stiffness and/or additional protection from impacts.

FIG. 1B illustrates the backside of the vest component 10 for protecting the back of the wearer. The backside may also include projections 20 for additional stiffness and/or protection from impacts to particularly vulnerable areas of the wearer's anatomy. In some embodiments, the vest component may comprise three layers including an outer metal layer featuring raised projections 20, a middle layer, and an inner layer of protective fabric. The middle layer may comprise a material such as polycarbonate or sorbothane, which tend to distribute the load 90 degrees with respect to the impact. The inner layer of protective fabric may comprise Vectran™ or any other protective fiber or fabric described herein.

FIGS. 1C and 1D illustrate front and side views, respectively, of an arm component 30 of the body armor suit. Specifically, the arm component 30 includes an upper arm sleeve 35 and a lower arm sleeve 40 that may be attached via a hinge 45 such that the arm sleeves 35, 40 may pivot with respect to one another in accordance with the natural bending of the wearer's arm. Some embodiments of the arm component 30 may not include a hinge between the sleeves 35, 40; instead, the sleeves 35, 40 may be detachably attached via snaps, straps, hoop and loop fasteners, or other conventional means. In further embodiments, the sleeves 35, 40 may be fixed attached or sewn together.

In the illustrated embodiment, the arm sleeves 35, 40 are substantially tubular elements that are contoured to fit the natural shape of the wearer's arm. The arm sleeves 35, 40 further include an opening 50 along the length of the arm sleeves 35, 40, thereby allowing the wearer to easily insert his arm into the sleeves 35, 40. After arm insertion, the sleeves 35, 40 may be tightened onto the arm using adjustable straps 55. The sleeves 35, 40 may further comprise cutout areas to permit improved articulation and range of motion of the wearer's arms.

FIGS. 1E-1G illustrate side front and back views of, respectively, of a leg component 60 of the body armor suit. Specifically, the leg component 60 includes an upper leg sleeve 65 and a lower leg sleeve 70 that may be attached via a hinge 75 such that the leg sleeves 65, 70 may pivot with respect to one another in accordance with the natural bending of the wearer's leg. Some embodiments of the leg component 60 may not include a hinge between the sleeves 65, 70. In such embodiments, the sleeves 65, 70 may be detachably attached via snaps, straps, hoop and loop fasteners, or other conventional means. In further embodiments, the sleeves 65, 70 may be fixed attached or sewn together.

In the illustrated embodiment, the leg sleeves 65, 70 are substantially tubular elements that are contoured to fit the natural shape of the wearer's leg. The leg sleeves 65, 70 also include an opening 80 along the length of the sleeves 65, 70, thereby allowing the wearer to easily insert his leg into the sleeves 65, 70. After leg insertion, the sleeves 65, 70 may be tightened onto the leg using adjustable straps 85. The leg sleeves 65, 70 may further comprise cutout areas to permit improved articulation and range of motion of the wearer's legs. Some embodiments of the leg component 60 may further include a foot section 90 that may be selectively attached and detached from the lower leg sleeve 70, for example using snaps, straps, hook and loop fasteners, or other conventional means. Alternatively, the foot section 90 may be fixedly attached or sewn onto the lower leg sleeve 70.

FIG. 2 illustrates a front view of a portion of a body armor suit 100 for an arm of a wearer, with heavy-duty articulation, in accordance with the principles of the invention. In particular, the arm component features an upper arm sleeve 110 that is pivotably attached to a lower arm sleeve 115 by way of heavy-duty articulation comprising a series of overlapping plates 125 that permit the arm sleeves 110, 115 to pivot with respect to one another in accordance with the natural bending of the wearer's arm. The body armor components may also be connected together by an impact-resistant material such as Vectran™ or woven chain mail.

With further reference to FIG. 2, an impact-resistant material that is also flexible may be employed to attach the overlapping plates 125 to one another and to the upper and lower arm sleeves 110, 115, to provide further body protection while permitting sufficient articulation between plates 125. The impact-resistant material may comprise Vectran™ or any other impact-resistant material described herein. In addition, the sleeves 110, 115 further comprise cutout areas to permit improved articulation and range of motion of the wearer's arms. These cutout areas reveal the base clothing layer 130 that is disposed generally underneath the body armor. As stated, the base clothing layer 130 may be formed as a conventional body suit to which the body armor components are attached either inside or outside of the body suit. In the illustrated embodiment, the armor components are disposed on the outside of the base clothing layer 130.

In the embodiments of FIGS. 1 and 2, the body armor components may comprise titanium, steel, hardened aluminum, or any other metal that can be sufficiently formed and hardened. The resultant body armor components are spring-loaded such that they fit snugly yet flexibly about the wearer's anatomy. By way of example, one body armor embodiment may feature an outer body armor shell made of titanium and an inner protective shell made from stainless steel or hardened aluminum. In the event that the body armor is struck by a bullet, the bullet may crack and penetrate the hard titanium outer shell. However, under such circumstances, the more ductile inner shell would catch the bullet such that it does not penetrate the wearer's body.

In embodiments featuring an inner layer of impact-resistant material, the material may comprise Vectran™ or any other impact-resistant material described herein. As such, the inner layer of impact-resistant material provides further protection for the wearer against impacts including sharp edges that may penetrate between body armor components. The inner layer of impact-resistant material may be bonded or sewn to the body armor components and/or middle layer using an adhesive. Alternatively, the impact-resistant material may be attached via snaps, straps, hook and loop fasteners, or other conventional means.

Protective Fibers

According to some embodiments of the invention, the impact-resistant material used to form the inner layer of protection may comprise a meta-aramid fiber, such as Nomex™. Meta-aramid fibers are dry spun and generally exhibit: (i) high tenacity (tensile stress when expressed as force per unit linear density of the unstrained specimen), (ii) high modulus (the ratio of change in stress—in force per unit linear density or force per unit area of the original specimen—to change in strain—i.e. percentage contraction or elongation of the specimen—following removal of crimp from the specimen being tested), and (iii) high heat resistance. Additionally, meta-aramid fibers provide heat and flame resistance, anti-static behavior, and resistance to industrial oils, solvents, oxidation, and most chemicals. In some implementations, a meta-aramid fiber is formed into a fabric and used as a primary barrier in garments and accessories. Such a meta-aramid fiber may be combined with other fibers and materials to achieve desired effects in accordance with various embodiments of the invention.

According to further embodiments of the invention, the impact-resistant material comprises a para-aramid fiber, such as Kevlar™ or Twaron™. Para-aramid fibers are dry-wet or wet spun, and exhibit very high tenacity, high modulus and high heat resistance. Other embodiments may include a protective fiber in the form of a liquid crystal polymer fiber such as Vectran™. Liquid crystal polymer fibers are dry spun, and exhibit high strength, high modulus, and high heat resistance, as well as high resistance to moisture and chemicals. Further, liquid crystal polymer fibers generally retain these properties in hostile environments. Other example fibers that can be used as a protective fiber include, but are not limited to, polyphenylenebenzimidazole (PBI), polybenzoxazole (PBO), and polyethylene.

According to various exemplary protective fabrics set forth herein, each protective fiber is made in 100-2500 denier filament, with an exemplary weight of about 200-600 denier. Each protective fabric comprises one or more protective fibers that are woven, knitted or otherwise formed into a fabric (hereinafter “protective fabric”). In implementations where two or more protective fibers are employed, each protective fiber can have the same denier. Alternatively, protective fibers of different deniers can be used. By way of example, two or more protective fibers can be woven or knitted into separate protective fabrics and combined in layers or patterns of layers. One or more layers of protective fabrics can be bonded, glued, stitched, or fused together, or bonded, glued, stitched or fused to a base garment or accessory material such as neoprene, cotton, nylon, or the like. A selected layer of fabric may be adjusted to various biases with the other layers. Flipping selected layers in the stack can be desirable to achieve certain desired properties. Additionally, two or more of the materials described herein for making a protective fiber may be blended together to form a yarn, which is then turned into a knit or weave. Such materials include, but are not limited to, Vectran™ (liquid crystal polymer), Nomex™ (meta-aramid), Kevlar™ (para-aramid), Twaron™ (para-aramid), nylon, olefin, s-glass, elastic, spandex, polyethylene, diamond tough nylon, Zylon™ (thermoset polyurethane synthetic polymer material), Technora™ (aromatic copolyamid), Spectra™ (extended-chain polyethylene) and metallic fibers.

Knit Types/Weave Types

According to various embodiments of the invention, protective fabrics are made of protective fibers knitted into a fabric. In further embodiments, protective fibers may be woven, braided, or otherwise formed into a fabric. In knitted configurations, a protective fabric is formed of a circular-knit or flat-knit jersey stitch, in which the loops of plain stitching intermesh in only one direction. A jersey-style protective fabric can be formed to be stretchable in two directions. In other implementations, a protective fabric is formed of a terry knit, i.e. having uncut loops of protective fiber on one or both sides. A protective fabric can be ribbed, crimped, flat, double knitted, or ring spun. In specific implementations, a protective fiber may be produced in 2″-30″ tubular form, or 4″-60″ flat form. Such a protective fiber may have a produced weight of approximately 0.5-1.5 lbs. per square yard.

Fabrics/Composition

The protective fabrics described herein can be formed to exhibit specific properties, such as being stretchable in four-ways or two-ways, or alternatively to be stiff and inelastic. In some implementations, a protective fiber can be interwoven or integrated with elastic or other stretchable material for added flexibility, or with one or more other protective fibers to produce a protective fabric with specific combinations of properties such as strength and flame resistance.

Products

According to various embodiments of the invention, wearable body armor may include, but is not limited to, uniforms, vests, flightsuits, jackets, coveralls, gear bags, pouches, pockets, harnesses, webgear, hats, helmets, headgear, shoes, skate shoes, socks, booties, cuffs, armbands, gloves, belts, and other items.

Method of Manufacture

According to some embodiments, method of manufacturing wearable body armor comprises the steps of: (i) forming an outer metal layer featuring raised projections; (ii) forming a middle layer and attaching the middle layer to a body side of the outer metal layer; and (iii) forming an inner layer of impact-resistant material and attaching the inner layer to a body side of the middle layer. The middle layer may comprise a material such as polycarbonate or sorbothane, which tend to distribute the load 90 degrees with respect to the impact. The inner layer of impact-resistant material may comprise Vectran™ or any other impact-resistant material described herein. Forming the inner layer of impact-resistant material may comprise forming a protective fiber, cutting the protective fiber, and knitting or weaving the fibers to form the protective fabric. The impact-resistant material may be formed using a blend of two or more materials selected from the group consisting of, liquid crystal polymer, meta-aramid, para-aramid, nylon, olefin, s-glass, elastic, spandex, polyethylene, diamond tough nylon, polyphenylenebenzimidazole, polybenzoxazole, thermoset polyurethane synthetic polymer material, aromatic copolyamid, and extended-chain polyethylene. Each of the protective layers may include fibers having a tensile strength of at least 3 GPa and a modulus of at least 70 GPa.

The impact-resistant material may be formed by knitting or weaving the fibers into an interlocking knitted fabric having a weight of 200-600 denier. Suitable knits and weaves include without limitation, V-bed, terry, jersey, rib knit, double knit interlock, Rochelle, and other knits and weaves. Additionally, the impact-resistant material may feature a combination of knits and weaves. The material is then quilted into multiple softly or semi-connected layers. This semi-loose assembly of softly or semi-connected layers is useful in ‘trapping’ and defeating sharp edged objects like sharks teeth, bullets and shrapnel. The quilted material is then cut into pattern shapes or panels and incorporated into or onto the garment in a manner such as those mentioned herein. The layers of protective material are loosely fused together by stitching, molding or layering in with a soft flotation material such as foam, gel or other thin buoyant material. The protective quilted material can be a simple pattern of shapes with small gaps between the panels to allow flexibility of the substrate material. Alternatively, the protective quilted material can be patterned to replicate the appearance of human musculature, again with gaps between the sections (for flexibility of the substrate material), giving the wearer of the suit a very fit athletic appearance.

The protective fabrics described herein can be assembled by a cut and sew operation. Cutting can be achieved by mechanical operations such as using knife blades. In some embodiments, heat cutting may be employed whereby a cutting blade is heated to a temperature above the zero-strength temperature of the fiber. The resultant fabric can include texture or patterns. The fabric may also be manufactured to exhibit other features such as ultraviolet protection, dynamic toughness, good flex fatigue. In addition, the fabric may be easy to splice, cut or bond with other fabrics or materials.

Although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead can be applied, alone or in various combinations, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.

Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.

The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated examples. These illustrations and their accompanying description should not be construed as mandating a particular architecture or configuration.

Claims

1. A wearable body armor suit, comprising:

a plurality of body armor components that are connected together by an impact-resistant material.

2. The wearable body armor suit of claim 1, wherein the impact-resistant material comprises Vectran™ or woven chain mail.

3. The wearable body armor suit of claim 1, wherein the body armor components are formed of carbon fiber or liquid crystal polymer fiber that is woven or formed into a platen.

4. The wearable body armor suit of claim 3, wherein the platen is molded or curved to accommodate the shape of a body part being covered by the body armor component, for localized and directed protection of strategically important body parts.

5. The wearable body armor suit of claim 1, wherein the body armor components are modular and selectively detachable.

6. The wearable body armor suit of claim 1, wherein the body armor components are detachably or fixedly connected to a base clothing layer.

7. The wearable body armor suit of claim 6, wherein the base clothing layer is formed as a conventional body suit to which the body armor components are attached.

8. The wearable body armor suit of claim 1, wherein the body armor components include a vest component adapted to cover a chest and back of a wearer's body.

9. The wearable body armor suit of claim 8, further comprising a groin protector that is selectively detachable from the vest component.

10. The wearable body armor suit of claim 8, wherein the vest component includes raised projections at selected locations to provide stiffness and additional protection from impacts.

11. The wearable body armor suit of claim 8, wherein the vest comprises three layers including an outer metal layer featuring raised projections, a middle layer, and an inner layer of protective fabric.

12. The wearable body armor suit of claim 11, wherein the middle layer comprises polycarbonate or sorbothane for distributing a resultant load 90 degrees with respect to an impact.

13. The wearable body armor suit of claim 11, wherein the inner layer of protective fabric comprises Vectran™.

14. The wearable body armor suit of claim 1, wherein the body armor components include an arm component including an upper arm sleeve and a lower arm sleeve attached via a hinge such that the arm sleeves may pivot with respect to one another.

15. The wearable body armor suit of claim 14, wherein the upper arm sleeve is pivotably attached to the lower arm sleeve by way of heavy-duty articulation comprising a series of overlapping plates that permit the arm sleeves to pivot with respect to one another.

16. The wearable body armor suit of claim 1, wherein the body armor components include a leg component including an upper leg sleeve and a lower leg sleeve attached via a hinge such that the leg sleeves may pivot with respect to one another.

17. The wearable body armor suit of claim 1, wherein the body armor components comprise titanium, steel, and/or hardened aluminum.

18. The wearable body armor suit of claim 1, wherein the body armor components comprise an outer body armor shell made of titanium and an inner protective shell made from stainless steel or hardened aluminum.