COMPOSITE BODY ARMOR

Abstract

Apparatus for protecting an individual from oncoming projectiles comprises a hardened steel plate; a support member supporting the hardened steel plate against the body of the individual; a plastic member; and an armor fiber secured to the plastic member, the armor fiber and said plastic member forming an interface layer, the interface layer being secured to the hardened steel plate at a position where the hardened steel plate is positioned between the interface layer and the body of the individual to be protected.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Provisional Patent Application No. 62/077168, filed Nov. 7, 2014, and provisional patent application No. 62/056483 filed Sep. 27, 2014, the disclosures of which are hereby incorporated herein by reference.

TECHNICAL FIELD

The invention relates to apparatus and methods for providing a measure of protection from handheld weapons to personnel in peacekeeping, policing and combat roles.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

(Not applicable)

BACKGROUND OF THE INVENTION

Today, a growing part of the globe is becoming increasingly unstable and dangerous. Military personnel and police officers are exposed to greater risks as stabilizing forces attempt to maintain peace and combat terrorists who favor surprise and ambush-style guerilla tactics. Much of modern combat takes place in urban environments where the norm is that engagements take place at extremely close range, often with combatants intermixed with a civilian population. This means that military and police are often attacked by surprise and often by unseen forces. This also means that adversary fire can originate from all directions and in rapid succession, resulting in the human body needing to withstand multiple impacts within a short period of time, sometimes on the order of a few seconds.

The problem is complicated by the proliferation of increasingly high powered rounds and the weaponry to deliver projectiles of unprecedented power. Due to such increased power, the trend has been toward heavier protective gear, and AR500 steel plates have seen increased use. However, despite the relative effectiveness of AR500 steel, protective gear incorporating the same is very heavy, compared to that made from other materials, such as Kevlar® fabrics, ceramic plates and the like. Accordingly, there exists a need for more formidable body armor protection having relatively low weight to keep personnel safe while still enabling them to do their jobs under such conditions, but without carrying excessive weight.

The National Institute of Justice certifies body armor at various protective levels with a standard that defines an armor plate's protective capability. Most armor used by police and military fall into the category of NIJ Level IIIA, NIJ Level III, or NIJ Level IV. NIJ Level IIIA is certified to stop large caliber pistol rounds such as a 0.44 magnum, which are very powerful handgun rounds but not as powerful as most rifle rounds. NIJ Level III is a higher rating than NIJ Level IIIA and is certified to stop the more powerful, but non-armor piercing, rifle rounds such as the 7.62 mm steel jacketed bullets common to most military assault rifles. NIJ Level IV is an even higher rating than the NIJ Level III and is certified to stop the even more powerful 0.30 caliber armor piercing rifle rounds commonly found in sniper rifles. These rounds have the same diameter projectiles as their less powerful non-armor piercing counterparts, but tend to travel faster due to the use of more or more powerful propellant, or have solid steel cores which increase the likelihood of penetrating armor.

Modern body armor is commonly available in a soft or flexible form fashioned into vests or jackets or even full armored suits, as well as in the form of hard “trauma” or “ballistic” plates. Ballistic plates are sized to protect a specific portion of the human body, typically 10″×12″ to protect the chest area, but can be of any size. Ballistic plates are held in position over vital areas when they are inserted into ballistic plate pockets typically found in modern body armor. It is also common to see ballistic plates inserted into tactical vests or “plate carriers” as they are often called. Plate carriers are unarmored vests or harnesses that are typically made from nylon or similar material and incorporating pockets to hold ballistic plates, as well as other design features to provide for the attachment of gear or equipment. Vests do not offer as much protection as full body armor combined with ballistic plates, however only using the ballistic plates for protection of the torso, the most critical vital areas are protected and substantial weight savings are achieved.

Ballistic plates can be made out of a number of materials. Flexible plates, for example, are commonly made of high tensile strength densely woven fibers, such as those sold under the trademark Kevlar or ultrahigh molecular weight polyethylene fibers sold under the trademarks Spectra and Dyneema. Rigid plates may comprise steel, or, or, alternatively, a variety of ceramic based materials may be employed. Ceramic based materials may include such compounds as aluminum oxide and silicon carbide. Ceramic ballistic plates are the most common and are produced in many countries and under many different names.

Fibrous ballistic plates, such as those made of poly-para-phenylene teraphthalamide (e.g. Kevlar®) fibers, have the advantage of being very light weight for the protection provided. They absorb energy and stop bullets by the mechanism of the stretching of the fibers. Common “bulletproof” vests such as those comprising Kevlar® material function in this manner. Typically, protective articles made of Kevlar® do not provide protection above NH Level IIIA. Because protective gear made of Kevlar® is not rigid, when a bullet hits, but does not penetrate the Kevlar®, percussive impact energy can still pass through to the body causing secondary damage as the Kevlar® bends, stretches and displaces to absorb the bullet's impact. Kevlar® also has the disadvantage of a limited shelf life as the fibers can break down due to wear and tear, or environmental ultraviolet exposure. Kevlar® can also be easily cut by debris or shrapnel.

Steel ballistic plates can be very strong, and the thicker the steel, the stronger the ballistic plate becomes. Steel is a heavy material, however, and it is very uncommon for steel ballistic plates to exceed NH Level III due to the weight of a sufficiently thick steel plate. Steel stops bullets by being rigid enough and thick enough to deflect incoming bullets and fragments, or shatter an incoming bullet into shrapnel. Steel does not break down as easily under normal environmental exposure compared to Kevlar®, but can still suffer marginal deterioration due to rust. A more serious shortcoming is the likelihood of bullets (or bullet fragments) being deflected from steel ballistic plates after impact. This can pose a risk of secondary injury if the ricocheted fragment hits an individual in an unarmored part of the body.

Ceramic ballistic plates provide a great deal of protection for their weight and are commonly produced to NH Level IIIA, NIJ Level III, and, significantly, NIJ Level IV standards. Ceramic ballistic plates may comprise a variety of materials, but aluminum oxide and silicon carbide are the most common.

Ceramic based trauma plates absorb the energy of and, when effective, stop or greatly reduce impact speeds of bullets using an ablative/fracture process. The relative functions of the ablative (ballistic impact energy is dissipated through the loss of armor material) and fracture (ballistic impact energy is dissipated through fracturing of armor material) characteristics may be varied in the material design.

Although this dual ablative/fracture energy absorption mechanism allows ceramic ballistic plates to stop very powerful bullets, it has the disadvantage that every impact weakens the armor. Moreover, damage is propagated from the point of impact. This means that after the first shot, every additional bullet is more likely than the previous to punch through a ceramic ballistic plate, especially if it hits close to the location of a previous impact.

Perhaps more seriously, even “micro” impacts, stresses and concussions from nearby explosions, and general wear and tear will deteriorate ceramic armor. Even more serious damage and degradation of the armor capability of a ceramic ballistic plate will be done by low impact concussion, such as that due to ballistic and non-ballistic debris. Thus, damage can cause small fractures and weaken the ceramic ballistic plate over time. Such damage may not be visible to the eye. Accordingly, ceramic ballistic plates can be weakened without the wearer knowing that protection has been compromised. This resulted putting the wearer at increased risk. Because of this risk it is common for ceramic ballistic plates to be regularly x-ray scanned to check for deterioration. The US Military regularly cycles out older ceramic ballistic plates every 3 years or so, even if the ceramic ballistic plate has never seen combat.

Although most commonly used by the military, ceramic ballistic plates are the most expensive option for protection, partly because of the initial cost of the material and partly because of the cost of a proper retirement schedule.

Given the above limitations of conventional constructions, ambush tactics and the use of explosives, which are commonplace in modern urban combat, creates a need for a ballistic plate that does not easily break down through concussive impact and general wear and tear. A need exists for a ballistic plate that can withstand long term use in less than ideal conditions, and will provide maximum protection from multiple hits for a reasonable weight, and not require any special care or maintenance to insure reliability.

SUMMARY OF THE INVENTION

In accordance with the invention, a protective armor plate is provided. This is achieved through the use of a composite trauma plate with a steel base for strength, combined with an absorption layer to dissipate ballistic impact energy, and both contained within a protective encasement layer. The absorption layer may comprise Kevlar® para-aramid synthetic fiber. Other materials, such as polyparaphenelyne benzobisthiazole film, a liquid crystal-like material similar to Kevlar® may also be employed in accordance with the present invention. It is contemplated that such film may be formed by calendaring, extruding and/or tentering to form a layer with good uniaxial strength, that individual layers may be laminated with their uniaxial directions of strain oriented in a plurality of directions, for example every 45°.

The inventive protective device protects an individual from oncoming projectiles and comprises a substantially rigid member having a length and a width sufficient to overlie a portion of the body of the individual to be protected. The substantially rigid member has a front side oriented toward an incoming projectile and a reverse or back side in facing relationship to the portion of the body of the individual to be protected. The substantially rigid member is configured to spread out energy from the incoming projectile to a plurality of points on the portion of the body of the individual to be protected. An energy absorbing member is supported by a support member on the substantially rigid member at a position where energy from an oncoming projectile is transferred to and absorbed by the energy absorbing member.

BRIEF DESCRIPTION THE DRAWINGS

The operation of the invention will become apparent from the following description taken in conjunction with the drawings, in which:

FIG. 1 is a cross-sectional view of an armor plate constructed in accordance with the present invention;

FIG. 2 is a cross-sectional view of the foundation layer in an embodiment of the present invention;

FIG. 3 illustrates in cross-section the interface layer in an embodiment of the present invention;

FIG. 4 is a cross-sectional view according to the present invention of an alternate embodiment of an interface layer;

FIG. 5 illustrates in cross-section still another alternative embodiment of the present invention;

FIG. 6 illustrates in cross-section yet still another embodiment of the inventive protective plate;

FIG. 7 illustrates in cross-section yet another embodiment of the invention;

FIG. 8 illustrates in cross-section still yet another alternative embodiment of the present invention;

FIG. 9 illustrates an alternative embodiment of the present invention generally comprising a multilayer sandwich protective plate;

FIG. 10 illustrates in perspective a pair of plates as they would be positioned around the chest during use;

FIG. 11 illustrates the shape of a typical armored plate;

FIGS. 12-49 schematically depict alternative embodiments employing of the invention;

FIGS. 50-53 schematically depict improved methods for applying a protective encasement layer to better weather seal an armor plate;

FIG. 54 illustrates an improved method for applying spall protection;

FIG. 55 illustrates an improved method for applying Kevlar reinforcement; and

FIGS. 56 and 57 schematically illustrate a further alternative embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, an overview of an armor piercing resistant composite hard ballistic plate constructed in accordance with the invention may be understood. The inventive and armor piercing resistant composite hard ballistic plate 10 comprises a first plate which functions as a foundation layer 12, the second plate which functions as an interface layer 14, and an encapsulation layer 16. Foundation layer 12 has an outer foundation layer surface 18 and an inner foundation layer surface 20, which layers are parallel to one another. Interface layer 14 is meant to receive the initial impact of an incoming projectile, whereas foundation layer 12 rests against the chest of the individual wearing the vest in which ballistic plate 10 is held. Foundation layer 12 is made from a rigid material, for example hardened steel such as ¼ inch thick AR500 steel in the preferred embodiment, although other rigid materials, or combinations of materials, such as rigid metals, polymers, ceramics and laminates. Such materials can also be used to form a desired shape, in the case of the embodiment illustrated in FIG. 1 being a flat member 10 inches by 12 inches. This may be slightly curved off the vertical plane to comfortably fit atop a surface on the left or right side of the torso of the human body.

Interface layer 14 is made from non-rigid layers of materials intended to reduce the velocity of an incoming projectile and help trap fragmentation and ricochets within its layers, for example Kevlar and rubber in the preferred embodiment, although layers of other non-rigid materials, including but not limited to foam, woven carbon fiber and polymers such as ultra high molecular density polyethylene, as well as polyparaphenelyne benzobisthiazole film may be used. Interface layer 14 comprises an outer interface layer surface 22 and an inner interface layer surface 24 which are, for example, parallel to one another.

Inner interface layer surface 24 is affixed to outer foundation layer surface 18 using an adhesive 26, thus connecting interface layer 14 to foundation layer 12 forming a composite hard plate assembly 28. Composite hard plate assembly 28 is encased within an encapsulation layer 16. Encapsulation layer 16 protects and environmentally seals composite hard plate assembly 28, and is made out of a rubberized material in the preferred embodiment, but any preferably watertight environmentally sealing material the does not substantially degrade over time is appropriate.

Referring to FIG. 2, a detailed understanding of a preferred embodiment of foundation layer 12 may be understood. In this embodiment, foundation layer 12 comprises a rigid base 30 and a shock absorbing layer 32. Rigid base 30 comprises an outer base surface 34 and an inner base surface 36. Rigid base 30 is made from a rigid material, for example ¼ inch thick AR500 steel in the preferred embodiment, although other rigid materials, or combinations of materials, such as rigid metals, polymers, and laminates can also be used. Shock absorbing layer 32 comprises an outer shock absorbing layer surface 38 and an inner shock absorbing layer surface 40. Shock absorbing layer 32 helps to diffuse impact energy against a human body and is made from a compressible material, for example ⅛″ foam rubber in the case of the preferred embodiment, but can be made from any compressible polymer.

Outer shock absorbing layer surface 38 is affixed to inner base surface 36 using an adhesive 42 in such a configuration that, optionally, no part of outer shock absorbing layer surface 38 or inner base surface 36 are exposed. Interface layer 14 is affixed to outer base surface 34 by adhesive 26 to complete formation of composite hard plate assembly 28. As in the FIG. 1 embodiment, composite hard plate assembly 28 is encased within an encapsulation layer 16 for environmental protection.

Referring to FIG. 3, a detailed understanding of interface layer 14 may be understood. Interface layer 14 comprises a compression layer 44, a fibrous mesh layer 46, and an entrapment layer 48, which underlies encapsulation layer 16. Entrapment layer 48 may be made of a high friction polymer and have a thickness of ⅛ inch. Compression layer 44 comprises an inner compression surface 50 and an outer compression surface 52 which are optionally parallel to one another. Compression layer 44 is made out of a compressible material, for example ⅜″ rubber in the preferred embodiment, but can also be made using, but not limited to varying thicknesses of foam, foam rubber, neoprene, or any compressible polymer. Inner compression surface 50 affixes to outer foundation layer surface 18 by means of adhesive 26.

Fibrous mesh layer 46 comprises an outer mesh surface 54 and an inner mesh surface 56 which may be roughly parallel to one another. Inner mesh surface 56 is affixed to outer compression surface 52 using adhesive 26, in such a way that fibrous mesh layer 46 is positioned atop, optionally rubber, compression layer 44. Fibrous mesh layer 46 is made out of a mesh or weave of high tensile strength fibers, such as Kevlar in the disclosed embodiment, though other high tensile strength polymers such as, but not limited to, ultra high molecular density polyethylene, or high tensile strength non polymer fibers such as, but not limited to, carbon fibers. Fibrous mesh layer 46 may be made of a polymeric material which stretches when absorbing impact energy from an incoming bullet. Compression layer 44 supports fibrous mesh layer 46 during a bullet impact and assists with energy dissipation.

Entrapment layer 48 comprises an outer entrapment surface 58 and an inner entrapment surface 60 which are parallel to one another. Inner entrapment surface 60 is affixed to outer mesh layer 54 using adhesive 26 such that entrapment layer 48 is positioned atop fibrous mesh layer 46. Entrapment layer 48 is made out of a high friction polymer, such as dense rubber in the preferred embodiment, though entrapment layer 48 could be made out of other durable, high friction polymers such as, but not limited to, a dense foam or foam rubber. Entrapment layer 48 helps protect fibrous mesh layer 46 from incidental and non-ballistic damage as well as prevents wear and tear.

Entrapment dimples 62 are affixed to outer entrapment surface 58, and in the preferred embodiment are made from the same dense rubber used in entrapment layer 48 and integrally made with entrapment layer 48, but could be made out of other high friction polymers such as, but not limited to, a dense foam rubber. Dimples 62 cause incoming bullets and projectiles that connect with entrapment surface 58 to interact differently due to an uneven surface as opposed to a smooth surface.

FIG. 4 is a similar but alternate embodiment of interface layer 14 found in the embodiment of FIGS. 1-3. Where practicable, in the various disclosed embodiment, parts having similar or analogous functions are numbered with numbers which are multiples of 100 different from corresponding or analogous parts in other embodiments.

Referring to FIG. 4, a detailed understanding of an interface layer 114 may be understood. Interface layer 114 comprises a number of compression layers 144, a number of fibrous mesh layers 146, and an entrapment layer 148. Compression layers 144 comprise inner compression surfaces 150 and outer compression surfaces 152 which are parallel to one another. Compression layers 144 are made out of a compressible material, for example ⅛″ rubber in the alternate embodiment, but can also be made using, but not limited to varying thicknesses of foam, foam rubber, rubber, or any compressible polymer. A bottom inner compression surface 151 affixes to outer foundation layer surface 118 by means of adhesive 126.

Fibrous mesh layers 146 comprise outer mesh surfaces 154 and inner mesh surfaces 156 which are parallel to one another. Inner mesh surfaces 156 are affixed to outer compression surfaces 152 using adhesive 126, in such a way that fibrous mesh layers 146 are positioned atop compression layers 144. Additionally, inner compression surfaces 152 are affixed to outer mesh surfaces 156 below, thus creating multiple layers. Fibrous mesh layers 146 are made out of a mesh or weave of high tensile strength fibers, such as Kevlar in the preferred embodiment, though other high tensile strength polymers such as, but not limited to, ultra high molecular density polyethylene, or high tensile strength non polymer fibers such as, but not limited to, carbon fibers. Fibrous mesh layers 146 stretch when absorbing impact energy from an incoming bullet. Compression layers 144 support fibrous mesh layers 146 during a bullet impact and assist with energy dissipation.

Entrapment layer 148 comprises an outer entrapment surface 158 and an inner entrapment surface 160 which are parallel to one another. Inner entrapment surface 160 is affixed to upper outer mesh layer 155 using adhesive 126 such that entrapment layer 148 is positioned atop fibrous mesh layer 146. Entrapment layer 148 is made out of a high friction polymer, such as dense rubber in the preferred embodiment, though entrapment layer 148 could be made out of other durable, high friction polymers such as, but not limited to, a dense foam or foam rubber. Entrapment layer 148 helps to protect fibrous mesh layer 146 from incidental and non-ballistic damage as well as to prevent excessive wear and tear.

Entrapment dimples 162 are affixed to outer entrapment surface 158, and in the preferred embodiment are made from the same dense rubber used in entrapment layer 148, but could be made out of other high friction polymers such as, but not limited to, a dense foam rubber. Dimples 162 cause incoming bullets and projectiles that connect with entrapment surface 158 to interact differently due to an uneven surface as opposed to a smooth surface.

Referring to FIG. 5, an overview of another alternate preferred embodiment of an armor piercing resistant composite hard ballistic plate 210 may be understood. An armor piercing resistant composite hard ballistic plate 210 comprises a foundation layer 212, an interface layer 214, and an encapsulation layer 216. Foundation layer 212 is made from a rigid material, for example ¼ inch thick AR500 steel in the alternate preferred embodiment, although other rigid materials, or combinations of materials, such as rigid metals, polymers, and laminates can also be used to form a desired shape, in the case of the alternate preferred embodiment being a flat member 10 inches by 12 inches which is slightly curved to comfortably fit atop a surface of a torso of a human body, such as the chest. Foundation layer 212 comprises an outer foundation layer surface 218 and an inner foundation layer surface 220 which are parallel to one another.

Interface layer 214 is made from non-rigid layers of materials intended to reduce the velocity of an incoming projectile and help trap fragmentation and ricochets within its layers, for example Kevlar and rubber in the alternate preferred embodiment, although other non-rigid materials including but not limited to foam, carbon fiber, and polymers such as ultra high molecular density polyethylene may be used. Interface layer 214 comprises an outer interface layer surface 222 and an inner interface layer surface 224 which are parallel to one another.

Inner interface layer surface 224 is affixed to outer foundation layer surface 218 using an adhesive 226, thus connecting interface layer 214 to foundation layer 212 forming a composite hard plate assembly 228. Composite hard plate assembly 228 is encased within an encapsulation layer 216. Encapsulation layer 216 protects and environmentally seals composite hard plate assembly 228, and is made out of a rubberized material in the preferred embodiment, but any watertight environmentally sealing material the does not degrade in the elements would be used.

Composite hard plate assembly 228 is provided with an raised labeling system 230 made from, in the alternate preferred embodiment, a rubberized material, similar to the rubberized material referenced in embodiment 1-3 entrapment layer 48, but can be made out of other durable, high friction polymers such as, but not limited to, a dense foam or foam rubber. Raised labeling system 230 is affixed to outer interface layer surface 222, using adhesive 226, such that embossed labeling system 230 protrudes from, and is distinguishable from, composite hard plate assembly 228, such that a clearly visible three dimensional embossing effect 232 is created which is distinguishable through encapsulation layer 216, and may portray a symbol, alphanumeric designation or the like.

Hidden within encapsulation layer 216 is a radio-frequency identification chip 234, which is affixed to a side surface 236 of composite hard plate assembly 228, by means of adhesive 216, such that radio-frequency identification chip 234 does not come in contact with, either outer interface layer surface 222, or inner foundation layer surface 220, thus reducing the odds of radio-frequency identification chip 234 being damaged should multiple armor piercing resistant composite hard ballistic plates 210 be stacked one upon another. Radio-frequency identification chip 234 is coupled with a unique identification 238 that distinguishes any particular armor piercing resistant composite hard ballistic plate 210 from other similar armor piercing resistant composite hard ballistic plates 210. The coupling of radio-frequency identification chip 234 with unique identification 238 allows individual armor piercing resistant composite hard ballistic plates 210 to be scanned electronically for purposes such as inventory control and tracking.

Chip 234 may be an active RFID chip, a passive RFID chip, or any other device capable of acting as a transponder. While passive ISAM band chips operating in the 865-868 MHz range in Europe and the 902-928 MHz range in North America are low in cost, typically in the range of $0.15 each, other technologies may be more appropriate, including active devices, devices operating in the 3 to 10 GHz range, devices acting in lower microwave frequency ranges, UHF devices of the type operating in the range of about 433 MHz, as well as high-frequency and low-frequency devices. Choice depends upon cost, range desired, and data speed required. However, in accordance with the invention, relatively slow data speeds will likely provide substantially acceptable functionality.

Referring to FIG. 6, an overview of an alternate armor piercing resistant composite hard ballistic plate may be understood. An armor piercing resistant composite hard ballistic plate 310 comprises a foundation layer 312, an interface layer 314, and an encapsulation layer 316. Foundation layer 312 is made from a rigid material, for example ¼ inch thick AR500 steel in the preferred embodiment, although other rigid materials, or combinations of materials, such as rigid metals, polymers, and laminates can also be used to form a desired shape, in the case of the preferred embodiment being a flat member 10 inches by 12 inches which is slightly curved to comfortably fit atop a surface of a torso of a human body. Foundation layer 312 comprises an outer foundation layer surface 318 and an inner foundation layer surface 320 which are parallel to one another.

A spallguard 313 is coupled to foundation layer 312, spallguard 313 encompassing foundation layer 312 on all sides, by weld 315, which is a tack weld in the preferred embodiment, but can alternatively be another type of weld such as, but not limited to, a continuous weld or an intermittent weld, at angle 317 away from outward foundation layer surface 318, a 40 degree angle in the preferred embodiment, though any angle such that projectiles sliding across outer foundation layer surface 318 impact spallguard 313 and get stopped or deflected in an outwardly direction away from outer foundation layer surface 318, would work. Spallguard 313 has an inward spallguard surface 319 and an outward spallguard surface 321 that are parallel to one another and consistent with angle 317.

Interface layer 314 is made from non-rigid layers of materials intended to reduce the velocity of an incoming projectile and help trap fragmentation and ricochets within its layers, for example Kevlar and rubber in the preferred embodiment, although other non-rigid materials including but not limited to foam, carbon fiber, and polymers such as ultra high molecular density polyethylene may be used. Interface layer 314 comprises an outer interface layer surface 322 and an inner interface layer surface 324 which are parallel to one another.

Inner interface layer surface 324 is affixed to outer foundation layer surface 318, and outer spallguard surface 321, using an adhesive 326, curved to match angle 317, thus connecting interface layer 314 to foundation layer 312 and spallguard 313, forming a composite hard plate assembly 328. Composite hard plate assembly 328 is encased within an encapsulation layer 316. Encapsulation layer 316 protects and environmentally seals composite hard plate assembly 328, and is made out of a rubberized material in the preferred embodiment, but any watertight environmentally sealing material that doesn't degrade in the elements would be used.

Referring to FIG. 7, an overview of an alternate armor piercing resistant composite hard ballistic plate may be understood. An armor piercing resistant composite hard ballistic plate 410 comprises a foundation layer 412, an interface layer 414, and an encapsulation layer 416. Foundation layer 412 is made from a rigid material, for example ¼ inch thick AR500 steel in the preferred embodiment, although other rigid materials, or combinations of materials, such as rigid metals, polymers, and laminates can also be used to form a desired shape, in the case of the preferred embodiment being a flat member 10 inches by 12 inches which is slightly curved to comfortably fit atop a surface of a torso of a human body. As in the case of the other embodiments, thicker steel plate may be used and will result in better protection against incoming rounds. Foundation layer 412 comprises an outer foundation layer surface 418 and an inner foundation layer surface 420 which are parallel to one another.

A spallguard 413 is coupled to foundation layer 412, spallguard 413 encompassing foundation layer 412 on all sides, by weld 415, which is a tack weld in the preferred embodiment, but can alternatively be another type of weld such as, but not limited to, a continuous weld or an intermittent weld, at angle 417 away from outward foundation layer surface 418, a 40 degree angle in the preferred embodiment, tough any angle such that projectiles sliding across outer foundation layer surface 418 impact spallguard 413 and get stopped or deflected in an outwardly direction away from outer foundation layer surface 418, would work. Spallguard 413 has an inward spallguard surface 419 and an outward spallguard surface 421 that are parallel to one another and consistent with angle 417.

Interface layer 414 is made from non-rigid layers of materials intended to reduce the velocity of an incoming projectile and help trap fragmentation and ricochets within its layers, for example Kevlar and rubber in the preferred embodiment, although other non-rigid materials including but not limited to foam, carbon fiber, and polymers such as ultra high molecular density polyethylene may be used. Interface layer 414 comprises an outer interface layer surface 422 and an inner interface layer surface 424 which are parallel to one another, and with interface layer thickness 425 such that outer interface layer surface 422 is flush with the outer most portion of spallguard 413.

Inner interface layer surface 424 is affixed to outer foundation layer surface 318, and outer spallguard surface 421, using an adhesive 426, said inner interface layer surface 424 curved to match angle 417, thus connecting interface layer 414 to foundation layer 412 and spallguard 413, forming a composite hard plate assembly 428. Composite hard plate assembly 428 is encased within an encapsulation layer 416. Encapsulation layer 416 protects and environmentally seals composite hard plate assembly 428, and is made out of a rubberized material in the preferred embodiment, but any watertight environmentally sealing material the does not degrade in the elements would be used.

Referring to FIG. 8, an overview of an alternate preferred embodiment of an armor piercing resistant composite hard ballistic plate 510 may be understood. An armor piercing resistant composite hard ballistic plate 510 comprises foundation layers 512 with peripherally overlapping edges, a foundation bonding matrix 513, an interface layer 514, and an encapsulation layer 516. Foundation layers 512 are made from multiple pieces of rigid material, for example ¼ inch thick AR500 steel in the alternate preferred embodiment, although other rigid materials, or combinations of materials, such as rigid metals, polymers, and laminates can also be used to form a desired shape, in the case of the alternate preferred embodiment being a complex curve.

Foundation layers 512 are encapsulated by foundation bonding matrix 513 which serves to couple individual foundation layers 512 to one another forming a contiguous bonded foundation layer 515. Contiguous bonded foundation layer 515 comprises an outer foundation layer surface 518 and an inner foundation layer surface 520 which may or may not be parallel depending on the desired complex shape.

Interface layer 514 is made from non-rigid layers of materials intended to reduce the velocity of an incoming projectile and help trap fragmentation and ricochets within its layers, for example Kevlar and rubber in the alternate preferred embodiment, although other non-rigid materials including but not limited to foam, carbon fiber, and polymers such as ultra high molecular density polyethylene may be used. Interface layer 514 comprises an outer interface layer surface 522 and an inner interface layer surface 524 which are parallel to one another.

Inner interface layer surface 524 is affixed to outer foundation layer surface 518 using an adhesive 526, thus connecting interface layer 514 to foundation layer 512 forming a composite hard plate assembly 528. Composite hard plate assembly 528 is encased within an encapsulation layer 516. Encapsulation layer 516 protects and environmentally seals composite hard plate assembly 528, and is made out of a rubberized material in the preferred embodiment, but any watertight environmentally sealing material the does not degrade in the elements would be used.

FIG. 9 illustrates an alternative embodiment of the present invention generally comprising a multilayer sandwich protective plate 610 of padding 611, ceramic 615, shock absorbing layer 617, foundation layer hardened steel plate 612, an interface layer 614, fibrous mesh layer 646 and encapsulation layer 616.

Padding 611 may comprise any suitable padding material, such as compressed fibers, soft foam rubber, feathers, or any other material which would suffice to absorb the shock of impact between the chest of the wearer and the ceramic plate 615. Ceramic plate 615 may be made of any material conventionally used to make ceramic bullet protective plates, as detailed above. Shock absorbing layer 617 may be made of any material suitable to protect ceramic plate 615 from shocks that might be transmitted by the foundation layer hardened steel plate after it has been impacted by projectile. Such material may be relatively dense foam rubber. Foundation layer hardened steel plate 612 may be a relatively thin layer of AR 500 hardened steel, for example 0.25 inches, or even 0.125 inches. Interface layer 614 may be made of any material suitable to absorb projectiles impacting multilayer sandwich protective plate 610, for example foam rubber. Fibrous mesh layer 646 may be made of any suitable material, such as woven Kevlar fiber. Like in the other embodiments, the amount of fiber may be comparable to that used in conventional all fiber so-called bulletproof vests. Encapsulation layer 616 may be made of hard rubber to provide the encapsulation function of the encapsulation layers of the other embodiments described herein, and would be made of similar materials.

The inventive multilayer sandwich protective plate 610 may be made using the techniques described above in connection with the other embodiments, and which are generally employed in assembling the various embodiments of the invention disclosed herein.

The multilayer sandwich protective plate 610 has the advantage of lighter weight compared to the other embodiments. More particularly, part of the strength of protective plate 610 is provided by the AR 500 hardened steel plate 612. The other primary protective layer is ceramic plate 615. The weight of the combination is somewhat lower than an all steel plate. However, the multilayer sandwich protective plate 610 does not suffer from the problem of microfracture degradation, in so far as it is protected by shock absorbing layer 617 from vibrations caused by impacts of projectiles against steel plate 612. Thus, impacts on steel plate 612 all have minimal effect on the integrity of ceramic plate 615, unless steel plate 612 is shattered, in which case ceramic plate 615 provides a backup protective function.

FIG. 10 illustrates a pair of plates 10 as they would be positioned around the chest of a wearer, and which may incorporate any of the above structures. FIG. 11 shows an alternative approach where a single protective member constructed in accordance with the present invention is essentially placed over the center of the chest of the wearer and substantially covers the chest of the user to the extent usually provided in the prior art.

In accordance with the invention, it has been discovered that, remarkably, soft rounds traveling at sufficient velocity, after impacting armor, for example personal protection body armor, appear to be transferring momentum through a substantially inelastic collision and causing hardened AR500 steel to fracture in a circular pattern, allowing the bullet and a bullet shaped piece of AR500 steel to break through and advance toward the individual being protected. Four sets of tests with numerous samples in each group were conducted as are detailed below. Except where otherwise specified, foundation plates and foundation plate components, made of steel or aluminum used in the tests detailed herein were performed on 6″×8″ test sample plates. All AR500 steel plates tested were ¼″ thick and the aluminum thickness, either ¼″ or ⅛″ depending on the test, as detailed herein. The aluminum employed in the fabrication of the various embodiments described herein is referred to as 5052 aluminum plate and is available from numerous distributors. Typically, fabrication begins with large plates having a width dimension of 48 inches, and a length dimension of either 96 inches or 120 inches. Kevlar® layers manufasctured by Infinity Composites in Ashtabula, Ohio were employed in fabricating the various embodiments described herein. The Kevlar® fiber used was in the form of large rolls of woven material. The fibers used to make the material are produced by Dupont. Kevlar® fibers comprise an aramid fiber that is used by manufacturers who weave the fabric into various patterns. The Kevlar fabric is given a specification corresponding to the particular weight of the material in a square yard. In accordance with the invention, the heaviest known material, which has a specification of 14 ounces, was employed. The pattern of the weave to produce the roll of Kevlar fiber employed in the embodiments disclosed herein is identified by the manufacturer as a 90 degree, 4 strand, overlapping weave. Generally, such material is provided in roll form, 50 inches wide and 150 yards in length. Tests were conducted using 5.56×45 mm, 55 grain, copper full metal jacket lead ball rounds, travelling in excess of 3200 ft/sec. These rounds were chosen because they are a non-armor piercing bullet that was discovered by the inventors to be consistently punching through bare ¼ inch AR500 steel plates. As used in this specification, the term “bare” refers to a plate of AR 500 steel without laminations of Kevlar, aluminum or other material on either side.

Test Group 1:

Test Group 1 involved Samples consisting of ¼″ AR500 steel plates with varying amounts of Kevlar and foam layers affixed atop a the plate to determine how effective various soft interface layer combinations are at reducing bullet penetration. Samples involving six layers of Kevlar outperformed Samples involving two layers of Kevlar. Furthermore, Samples incorporating more foam outperformed Samples incorporating less foam. This was a surprising result in so far as the foam has minimal stopping power. However, in accordance with the invention, it is postulated that it may be possible that thicker foam allows greater stretching of the Kevlar with concomitant greater energy absorption. Effectiveness of the structure under test was determined by measuring the size of the exit hole on the back end of the plate. A smaller exit hole was viewed as indicative of less damage than a larger exit hole. In every case, however, the bullet was able to completely penetrate the Sample to some degree. Additionally, in every case, all of the spall and debris was captured by the interface layer indicating that front facing 2 layers of Kevlar affixed atop a ⅛″ layer of foam affixed atop the front face of a ¼″ AR500 steel plate was sufficient to prevent secondary damage from spall and debris. By the front of a plate or plate assembly is meant the side of the plate upon which a round is incident. Back of the plate would be adjacent the body of the individual being protected. Typical structures tested comprised 1) an interface layer forming the front of the plate and received the first impact from an incoming round, and 2) a foundation layer) secured to and supporting the interface layer) designed to bear against the torso of an individual being protected. We were surprised at how well the rubberized encasement layer, in this case Plastidip, was able to hold together and, for the most part, even appeared to reseal itself after initial penetration by the bullet. This indicates a greater survivability of a soft interface layer than previously expected.

Referring to FIG. 12 it can be seen how Samples were tested, and their structure, which may be said generally to comprise an encapsulation or encasement layer 16 which envelops a target Sample 10 which protects an individual 11. Encasement layer 16 may comprise Plastidip®, a plastic material manufactured by Plastidip International. Encasement layer 16 may be applied by spraying, brushing or dipping. Optionally, encasement layer 16 may be deposited over a dimpled foam plastic strike face deposited, or positioned and glued over surface 22 of interface layer 14. Contained within the encasement layer, each Sample comprises an interface layer affixed atop a foundation layer, with the foundation layer comprising ¼″ AR500 steel plate. The only difference between Samples was the composition of the interface layer, the interface layer being a layer in the armor assembly which interacts with incoming bullets prior to an incoming bullets interaction with the foundation layer. All Samples were shot with a 5.56×45 lead bullet traveling in excess of 2800 ft/sec. For the purposes of testing, “Sample” is meant to designate a inch by inch armor plate section with full thickness constituent elements constructed for test purposes. This armor plate section is believed to simulate the operation of full size personal body armor, and further believed, with a high degree of confidence, to be at least a reliable indicator of the relative strengths and weaknesses of full size armor. The various samples in the examples disclosed in the specification were tested by mouthing the sample armor plate portion structures as targets. All rounds, unless otherwise indicated, were fired from a distance of approximately fifteen meters. No repeated rounds to the same plate, or the same location, unless otherwise indicated, were fired.

Referring to FIG. 13, Sample A (interface layer comprising 6 layers of Kevlar affixed atop ¼″ foam) with the foundation layer comprising ¼″ AR500 steel plate fired upon with a 5.56×45 lead bullet resulted in complete penetration, that is relatively poor protection. In this embodiment, as in all the other embodiments illustrated in FIGS. 13-49, Kevlar fabric of the type detail below was used. Likewise, in this embodiment, as well as all other embodiments illustrated in FIGS. 13-49, all layers of material (whether Kevlar, steel, aluminum, foam, plastic, or other material) were secured to each other with using glue as specified herein.

Referring to FIG. 44, Sample B: (interface layer comprising 2 layers of Kevlar affixed atop ⅛″ foam with the foundation layer comprising ¼″ AR500 steel plate when fired upon by a 5.56×45 lead bullet resulted in complete penetration or relatively poor protection.

Referring to FIG. 45, Sample C: (interface layer comprising two sublayers affixed atop one another, each sublayer comprising one layer of Kevlar 101 affixed atop a ⅛″ thick layer of foam 102 affixed atop a foundation layer 103 comprising ¼″ AR500 steel plate when fired upon by a 5.56×45 lead bullet resulted inrelatively poor protection.

Referring to FIG. 46, Sample D: (interface layer comprising 2 sub layers affixed atop one another, sub layers comprising two layers of Kevlar 101 affixed atop ⅛″ foam layer 102 with the foundation layer 103 comprising ¼″ AR500 steel plate when fired upon by a 5.56×45 lead bullet resulted in relatively poor protection.

Referring to FIG. 47, interface layer comprising 1 layer of Kevlar 104 affixed atop ⅛″ foam 105 affixed atop 2 layers of Kevlar affixed atop ⅛″ foam affixed atop 1 layer of Kevlar 104 with the foundation layer comprising ¼″ AR500 steel plate, when fired upon by a 5.56×45 lead bullet resulted in relatively poor protection.

Referring to FIG. 48, Sample F (interface layer comprising 6 layers of Kevlar affixed atop ½″ foam with the foundation layer comprising ¼″ AR500 steel plate when fired upon by a 5.56×45 lead bullet resulted in complete penetration (but with a small hole) and thus relatively poor protection.

Referring to FIG. 49, Sample G: (interface layer comprising 6 layers of Kevlar affixed atop ¾″ foam with the foundation layer comprising ¼″ AR500 steel plate, when fired upon by a 5.56×45 lead bullet resulted in complete penetration but with a small hole and thus relatively poor protection.

Test Group 1 Conclusion: This test (described in connection with FIGS. 13, 44 -49 was initiated when it was discovered that lead core bullets traveling in excess of 2800 feet/second pose a significant risk to AR500 steel plate foundation layers. It is believed that the inelastic collision in soft lead rounds transfers momentum more completely to the surface of the AR500 steel which, at sufficient bullet velocities causes the stand-alone ¼″ AR500 steel to fracture and fail in a relatively clean circle of the same size as the deformed lead bullet. In the case of each of the samples, 7.62×39 and 7.62×54 steel core bullets (as opposed to the lead core bullets) were defeated. Samples using more foam performed better than similar Samples using less foam probably because the thicker foam in the interface (front) layer allows Kevlar to stretch more before the bullet hits the foundation (which is in contact with body of person being protected) layer. What was surprising was that the various constructions of the interface layer, even constructions that had passed level 4 armor piercing 30.06 (steel core) tests, still were not able to prevent a 5.56 lead core bullet traveling in excess of 2800 ft/sec from penetrating the ¼″ AR500 steel foundation layer. As a result of this discovery, it was concluded that a stronger interface layer or a reinforced foundation layer would be required to defeat soft lead rounds traveling in excess of 2800 ft/sec.

In all of the tests described in Test Groups 1 and 2, the various components were adhered to each other using a 3M aerosol spray automotive, although it is expected that a wide range of adhesives will function with substantially equal effectiveness.

Test Group 2:

Test Group 2 involved Samples consisting of combinations of solid sheets of ABS plastic and Kevlar with variations in thickness and placement on the face and/or back of the AR500 steel. 3/16″ ABS plastic layers were used for this test, and layers were laminated to one another to achieve varying thickness ABS plastic layers. This allowed testing a more rigid interface layer as well as a reinforced foundation layer. It was discovered that a reinforced foundation layer could prevent the fracturing of the steel, or in the case of steel failure, catch the penetrating bullet and steel debris, thus preventing total penetration of the Sample.

It was discovered that additional layers of ABS plastic in the interface layer reduced penetration but alternating layers of Kevlar and ABS plastic in the interface layer was required to most effectively prevent penetration. It was also observed that bullet impacts lead to the separation of the various layers and that ABS plastic or the combination of ABS plastic and Kevlar were good at catching spall. All Samples were shot with a 5.56×45 lead bullet traveling in excess of 2800 ft/sec.

Referring to FIG. 14, Sample 2.1-A (foundation layer (position reversed to be put in front to receive first impact of incoming round) comprising ¼″ AR500 steel affixed atop 3 layers of 3/16″ ABS plastic backing): Projectile from a 5.56×45 lead bullet resulted in penetrated AR500 steel layer but did not penetrate ABS plastic backing—partial success.

Referring to FIG. 15, Sample 2.1-B (foundation layer (position reversed to be put in front to receive first impact of incoming round) comprising ¼″ AR500 steel affixed atop 6 layers of 3/16″ ABS plastic backing). The projectile from a 5.56×45 lead bullet penetrated AR500 steel layer but did not penetrate ABS plastic backing—partial success.

Referring to FIG. 16 Sample 2.1-C (interface layer comprising 3 layers of 3/16″ ABS plastic affixed atop foundation layer comprising ¼″ AR500). The projectile from a 5.56×45 lead bullet penetrated this construction—relatively poor protection.

Referring to FIG. 17 Sample 2.1-D (interface layer comprising 6 layers of 3/16″ ABS plastic affixed atop foundation layer comprising ¼″ AR500 steel). The projectile from a 5.56×45 lead bullet penetrated this construction with reduced damage—relatively poor protection.

Referring to FIG. 18 Sample 2.2-A (interface layer comprising 3 layers of 3/16″ ABS plastic, each layer of plastic being encircled by a single ply Kevlar wrapping, interface layer assembly being affixed atop foundation layer comprising ¼″ AR500 steel foundation layer). The projectile from a 5.56×45 lead bullet penetrated this construction thus resulting in a rating of relatively poor protection.

Referring to FIG. 19, Sample 2.2-B (interface layer comprising 6 layers 3/16″ ABS plastic, each layer of plastic being encircled by a single ply Kevlar wrapping, interface layer assembly being affixed atop foundation layer comprising ¼″ AR500 steel). The projectile from a 5.56×45 lead bullet penetrated the interface layer, but the bullet did not penetrate AR500 steel resulting in a rating of complete success.

Referring to FIG. 20, Sample 2.3-A (interface layer comprising 3 layers of 3/16″ ABS plastic, each layer of plastic being encircled by a single ply Kevlar wrapping, interface layer assembly being affixed atop foundation layer, foundation layer comprising ¼″ AR500 steel affixed atop 3 layers of 3/16″ ABS plastic backing). The projectile from a 5.56×45 lead bullet penetrated AR500 steel layer but did not penetrate ABS plastic backing—partial success.

Referring to FIG. 21, Sample 2.3-B (interface layer comprising 6 layers of 3/16″ ABS plastic, each layer of plastic being encircled by a single ply Kevlar wrapping, interface layer assembly being affixed atop a foundation layer comprising ¼″ AR500 steel affixed atop 3 layers of 3/16″ ABS plastic backing). The projectile from a 5.56×45 lead bullet penetrated interface layer, but the bullet did not penetrate the AR500 steel for a rating of complete success.

Test Group 2 Conclusion: A sufficiently durable interface layer can reduce bullet velocities to prevent lead bullets traveling in excess of 2800 ft/sec from penetrating a ¼″ AR500 steel foundation. Additionally, when considering partial success it is shown that semi-rigid ablative material not reinforced with Kevlar, such as plastic, performs better when placed behind ¼″ AR500 steel than in front of ¼″ AR500 steel. Additionally, when considering complete success (¼″ AR500 steel not being penetrated), Kevlar reinforced plastic performs better when placed in the interface layer in front of ¼″ AR500 steel than when placed behind. As a result of this work, it is believed that plastic in front of the steel will help protect the steel from being penetrated because the plastic will reduce bullet velocity. Plastic behind the steel is also useful because it can catch a bullet that penetrates the steel and other fragments, but may not reinforce the steel sufficiently to prevent the steel from being penetrated. More particularly, semirigid plastic without Kevlar in the interface layer was found not to reinforce the ¼″ AR500 steel foundation layer with sufficient tensile strength to prevent the steel from fracturing under the strain of a lead bullet traveling in excess of 2800 ft/sec.

Test Group 3:

Test Group 3 involved testing a variety of foundation layers comprising AR500 steel encased in a variety of polyurethane based hard plastics. AR500 steel combined with reinforcements encased in plastic was also tested. Finally, test samples comprising prototype yellow and red plates reinforced with aluminum were tested. In all cases, test samples comprising a plastic encasement showed varying degrees of degradation in the hard plastic encasement after just a single shot. Best results were yielded by the samples reinforced with aluminum. All samples were shot with a 5.56×45 lead bullet traveling in excess of 2800 ft/sec.

Referring to FIG. 22, Sample 3-A (¼″ AR500 steel plate encased within Smooth Cast 380 Plastic made by Reynolds Advanced Materials, plastic thickness being ¼″ on the front and side with ½″ thickness on the back) 5.56 lead bullet penetrated the relatively brittle plastic in this sample and shattered plastic—relatively poor protection.

Referring to FIG. 23 Sample 3-B (¼″ AR500 steel plate encased within Smooth Cast 385 Plastic made by Reynolds Advanced Materials, plastic thickness being ¼″ on the front and side with ½″ thickness on the back) 5.56 lead bullet exploded front covering, partially penetrated ¼″ AR500 steel but was caught in the back plastic. Sample would not survive a second hit.—limited success. Smooth Cast 385 appears to be a stronger plastic but still too brittle to be used to encase armor.

Referring to FIG. 24 Sample 3-C (¼″ AR500 steel plate encased within Task 18 Plastic made by Reynolds Advanced Materials, plastic thickness being ¼″ on the front and side with ½″ thickness on the back) 5.56 lead bullet blew off front plastic but did not penetrate ¼″ AR500 steel. Back plastic cracked and this test sample may not have survived a second hit, thus yielding a rating of limited success. It is believed that the effectiveness of this arrangement, lacking as it did any conventional bullet proofing fiber was a result of flexure of the AR 500 steel plate and resulting stretching of the half-inch thick layer of Task 18 Plastic, which stretching acted to spread the energy from the impact of the lead projectile over the entire plastic half-inch thick back layer. It is noted that a single layer of AR 500 steel, by comparison, was discovered by the inventors to be weak enough to be pierced by a lead round. Such flexing of the steel plate and associated stretching of a back layer secured to the back of the steel plate (with its absorption of the impact of the projectile) is described below.

Referring to FIG. 25, Sample 3-D (¼″ AR500 steel plate encased within Task 21 Plastic, plastic thickness being ¼″ on the front and side with ½″ thickness on the back) 5.56 lead bullet penetrated this test sample, but with no shattering of plastic—relatively poor protection.

Referring to FIG. 26, Sample 3-E (interface layer comprising three layered steel grill (glued to each other and other components of the protective plate), grill layer made from a 16 gauge mild steel barbeque grill material with ¼″ diamond shaped holes, holes evenly spaced ⅛″ apart across the entire grill surface, each grill layer offset slightly such that there was no clear path through the grill without interacting with part of the grill, affixed atop foundation layer comprising ¼″ AR500 steel plate, interface layer and foundation layer encased within Smooth Cast 385 Plastic, plastic thickness being ¼″ on the front and side with ½″ thickness on the back) 5.56 lead bullet penetrated interface layer but was sufficiently deflected that bullet did not penetrate ¼″ AR500 steel plate. The layers were affixed to each other using glue as described herein. Front plastic immediately above impact area was shattered but there was no damage to back plastic. Sample remains functional. Mild steel grill noticeably altered bullet trajectory and noticeably reduced damage to Smooth Cast 385 plastic compared with Sample 3-B where no grill was used.—success.

Referring to FIG. 27 Sample 3-F (¼″ AR500 steel plate, wrapped in and glued to an 18 gauge wire mesh with ½″ separations between wires, encased within Task 18 Plastic, plastic thickness being ¼″ on the front and side with ½″ thickness on the back). A 5.56 lead bullet penetrated Sample but plastic held together and did not break apart as in the case of Sample 3-C which also used Task 18 Plastic.—relatively poor protection. However, rebar effect successful since it was shown to improve the strength of the plastic encasement and prevent plastic from breaking apart.

Referring to FIG. 28 Sample 3-G (foundation layer comprising ¼″ AR500 steel plate affixed atop ¼″ aluminum plate, foundation encased within Smooth Cast 385 Plastic, plastic thickness being ¼″ on the front and side with ½″ thickness on the back) 5.56 lead bullet exploded front covering, and partially penetrated ¼″ AR500 steel and blew out the back plastic. Sample not suitable to survive repeated hits given the amount of damage observed from a single hit, however bullet was stopped.—limited success.

Referring to FIG. 29, Sample 3-H (interface layer comprising 3 layered steel grill, each grill layer offset slightly such that there was no clear path through the grill without interacting with part of the grill, affixed atop foundation layer comprising ¼″ AR500 steel plate affixed atop ¼″ aluminum plate, foundation layer wrapped in a 18 gauge wire mesh with ½″ separations between wires, interface layer and foundation layer encased within Task 21 Plastic, plastic thickness being ¼″ on the front and side with ½″ thickness on the back) 5.56 lead bullet trajectory was altered by grill interface layer and did not penetrate ¼″ AR500 steel plate. No damage to plastic encasement layer and target suitable to survive repeated hits.—complete success.

Referring to FIG. 30 Sample 3-I (Interface layer, comprising dimpled foam affixed atop 6 layers of Kevlar affixed atop ¼″ foam, interface layer affixed atop foundation layer, comprising ¼″ AR500 steel plate affixed atop ¼″ aluminum.) 5.56 lead bullet penetrated ¼″ AR500 steel plate but did not penetrate ¼″ aluminum.—partial success. 5.56 bullet shot at back of plate penetrated aluminum but did not penetrate ¼″ AR500 steel plate.—partial success. Comparing to the embodiment of FIG. 21, suggests the importance of depth allowing Kevlar to stretch and perhaps the importance of higher density material providing that depth, although the environment of FIG. 21 effectively has 12 layers of Kevlar. However, comparing to the FIG. 20 embodiment, where the projectile penetrated AR500 steel layer but did not penetrate ABS plastic backing—partial success.

Referring to FIG. 31 Sample 3-J (Interface layer, comprising dimpled foam affixed atop two layers of Kevlar affixed atop ⅛″ foam, interface layer affixed atop foundation layer, comprising ¼″ AR500 steel plate affixed atop ⅛″ aluminum.) 5.56 lead bullet penetrated interface layer but did not penetrate ¼″ AR500 steel plate.—complete success. This result suggests the importance of initial impact absorption by relatively weak materials such as dimpled foam which one would have no expectation of being able to stop the projectile, but which at high incoming projectile speeds may be very effective energy absorbers. A 5.56 bullet shot at the back of the plate penetrated the aluminum but did not penetrate ¼″ AR500 steel plate.—partial success. This result again suggests the importance of initial deformable or shatterable layers absorbing energy of an incoming projectile rioted in fact with the rigid AR 500 steel plate.

Test 3 Conclusion: Unreinforced rigid plastic is not ideal for encasement layer as it will not likely survive repeated hits without reinforcement. (Rigid plastic encasement is also too heavy compared to other possible solutions). As a result of a combination of deflection and energy absorption, the steel grill configuration can affect bullet trajectory, greatly improving survivability of foundation layer. Aluminum backing is capable of supporting foundation layer in conjunction with a weaker interface layer, but needs to be secured in a stronger fashion than just 3M adhesive. This is suspected because the ¼″ aluminum should have performed better than the ⅛″ aluminum as it is a stronger material, yet it is suspected that it partially separated during impact, thus reducing support of the ¼″ AR500 steel. Further tests should confirm whether this result was an anomaly or if there are other forces at work making ⅛″ aluminum superior to ¼″ aluminum. The best strength to weight ratio will likely be achieved by some combination of a Kevlar+foam interface layer affixed to a steel and aluminum foundation layer.

Test Group 4:

Test Group 4 involved testing of various configurations incorporating AR500 steel, aluminum, Kevlar, foam, and/or rubberized encasement.

Referring to FIG. 32a Sample 4-A (interface layer comprising 8 sub-interface layers affixed atop one another, (each sub-interface layer comprising a sheet of polyurethane and Kevlar composite which is available on the market. Affixed atop a 0.03″ sheet of polycarbonate affixed atop a 0.06″ sheet of Ultra High Molecular Weight Polyethylene (UHMWP) FIG. 32b) affixed atop a sheet of polyurethane enhanced Kevlar. The interface layer is affixed atop a foundation layer comprising a ¼″ AR500 steel plate.): 5.56×45 lead bullet penetrated interface layer but did not penetrate AR500 steel—complete success. 7.62×54R 185 grain FMJ steel bullet penetrated interface layer but did not penetrate AR500 steel plate—complete success. It is believed that the reason for the effectiveness of this product is a consequence of the ability of the Kevlar fibers and more particularly, the Kevlar polyurethane composite to stretch and absorbed energy. The polycarbonate backing may improve effectiveness by deforming and fracturing allowing energy to be absorbed by the Kevlar composite.

Referring to FIG. 33a Sample 4-B (interface layer comprising 8 sub-interface layers affixed atop one another, each sub-interface layer (schematically illustrated in FIG. 33b) comprising a sheet of Kevlar (the same Kevlar material used in all of the samples tested) affixed atop a 0.03″ sheet of polycarbonate affixed atop a 0.06″ sheet of Ultra High Molecular Weight Polyethylene (UHMWP) affixed atop a sheet of Kevlar. Interface layer was affixed atop a foundation layer comprising a ¼″ AR500 steel plate). A 5.56×45 lead bullet penetrated the interface layer but did not penetrate AR500 steel giving a conclusion of complete success. 7.62×54R 185 grain FMJ steel, bullet penetrated interface layer but did not penetrate AR500 steel plate—complete success. As in all the other sample test described herein, all layers, whether Kevlar, polymers, enhanced polymers, plastic, etc. were glued to each other (except where the nature of material formation inherently provided adhesion, i.e. in the case of Plasticdip and Smooth Cast products) using the automotive adhesive specified herein.

Referring to FIG. 34 Sample 4-C (interface layer comprising 3 sheets of 0.06″ ultra high molecular weight polyethylene affixed atop a foundation layer comprising a ¼″ AR500 steel plate affixed atop 4 layers of 0.06″ ultra high molecular weight polyethylene. An encasement layer comprising 2 overlapping layers of Kevlar wraps around the test sample.): 5.56×45 lead bullet penetrated interface layer but did not penetrate AR500 steel—complete success. 7.62×54R 185 grain full metal jacket steel bullet penetrated interface layer but did not penetrate AR500 steel plate—complete success.

Referring to FIG. 35a, the inventive personnel protecting plate 810 of Sample 4-D comprises a foundation layer 812, comprising ¼″ AR500 steel. Foundation layer 812 is contained within an encasement layer. The encasement layer comprises two front overlapping layers of Kevlar secured by glue to the steel AR 500 plate forming foundation layer 812 and was further wrapped around the steel AR 500 plate. In similar fashion, two layers of Kevlar 814b are glued to each other and to the back of foundation layer 812. A 5.56×45 lead bullet penetrated interface layer but did not penetrate AR500 steel, giving this construction a rating of complete success. A 7.62×54R 185 grain full metal jacket steel bullet 811 penetrated the interface layers of Kevlar 814a but did not penetrate the AR500 steel plate again yielding a rating of complete success against a full metal jacket steel projects.

Referring to FIG. 35b, it is believed that the favorable result is substantially provided by back Kevlar layers 814b by their being stretched as a result of deformation steel foundation layer 812 by incoming projectile 811. More particularly, when projectile 811 hits a portion, perhaps the central portion, of AR 500 steel foundation layer 812, that portion tends to move forward, but surrounding portions of the rest of the plate to stay in place because of their inertia. In this respect, the weight of the steel compared to the stiffness of the plate helps result in deformation. However, this deformation is largely elastic at the moment of the initial impact. During this elastic deformation process, the flexure of AR 500 steel foundation layer 812 results in its back surface 815 having a greater circumference than its front surface 817. Accordingly, back Kevlar layers 814b are stretched, and in stretching absorb the energy of incoming projectile 811.

Is believed that increasing the number of layers of Kevlar adhered to the back surface 815 of AR 500 steel foundation layer 812 will increase the amount of energy which can be absorbed, until a point where the number of layers is so large that they impede the necessary amount of flexure necessary to both absorbed energy and allow AR 500 steel foundation layer 812 to flex and not break.

Referring to, Sample 4-E (interface layer comprising 2 layers of Kevlar affixed atop ⅛″ layer of foam, interface layer affixed atop a foundation layer comprising ¼″ AR500 steel plate affixed atop ⅛″ aluminum plate, the two layers of Kevlar in the interface layer wrapping around the back of the foundation layer.): 5.56×45 lead bullet penetrated interface layer but did not penetrate AR500 steel—complete success. 7.62×54R 185 grain full metal jacket (FMJ) steel bullet penetrated interface layer but did not penetrate AR500 steel plate—complete success. 30.06 lead bullet completely penetrated target—relatively poor protection.

Referring to FIG. 37 Sample 4-F (interface layer comprising 2 layers of Kevlar affixed atop ⅛″ layer of foam, interface layer affixed atop a foundation layer comprising ¼″ AR500 steel plate affixed atop ¼″ aluminum plate, the two layers of Kevlar in the interface layer wrapping around the back of the foundation layer.): 5.56×45 lead bullet penetrated interface layer but did not penetrate AR500 steel—complete success. 7.62×54R 185 grain FMJ steel bullet penetrated interface layer but did not penetrate AR500 steel plate—complete success. 30.06 lead bullet penetrated interface layer but did not penetrate AR500 steel plate—complete success.

Sample 4-F was shot from behind by a 30.06 lead bullet (¼″ aluminum affixed atop ¼″ AR500 steel) and bullet completely penetrated the target -relatively poor protection, perhaps because the foam was impressed and prevented the two layer Kevlar on the front of the plate from stretching and absorbing energy.

Referring to FIG. 38 Sample 4-G the interface layer comprised two layers of Kevlar affixed atop ⅛″ aluminum plate affixed atop ⅛″ layer of foam, interface layer affixed atop a foundation layer comprising ¼″ AR500 steel plate, the two layers of Kevlar in the interface layer wrapping around the back of the foundation layer. A 5.56×45 lead bullet penetrated the interface layer but did not penetrate the AR500 steel for a rating of complete success. A 7.62×54R 185 grain FMJ steel bullet penetrated the interface layer but did not penetrate the AR500 steel plate—complete success. 30.06 lead bullet partially penetrated target—relatively poor protection. The failure of this material to protect against a lead projectile can be understood as a result of the structure not providing any support which allows the Kevlar to stretch. More particularly, the Kevlar is directly glued to aluminum which prevents it from stretching until the aluminum has been penetrated.

Referring to FIG. 39, in the case of Sample 4-H (interface layer comprising two layers of Kevlar affixed atop ⅛″ aluminum plate affixed atop ⅛″ layer of foam, interface layer affixed atop a foundation layer comprising ¼″ AR500 steel plate affixed atop ⅛″ aluminum plate, the two layers of Kevlar in the interface layer wrapping around the back of the foundation layer), a 5.56×45 lead bullet penetrated the interface layer but did not penetrate the AR500 steel for a rating of complete success. A 7.62×54R 185 grain FMJ steel bullet penetrated the interface layer but also did not penetrate AR500 steel plate for a rating of complete success.

Referring to FIG. 40, in the case of sample 4-I (interface layer comprising 2 layers of Kevlar affixed atop ⅛″ aluminum plate affixed atop ⅛″ layer of foam, interface layer affixed atop a foundation layer comprising ¼″ AR500 steel plate affixed atop ¼″ aluminum plate, the two layers of Kevlar in the interface layer wrapping around the back of the foundation layer), a 5.56×45 lead bullet penetrated interface layer but did not penetrate AR500 steel for a rating of complete success. Hey 7.62×54R 185 grain FMJ steel bullet penetrated the interface layer but did not penetrate AR500 steel plate for a rating of complete success. However, a 30.06 lead bullet completely penetrated Sample 4-I for a rating of relatively poor protection.

Test 4 Conclusion: Soft interface layer affixed atop a rigidly reinforced foundation layer with Kevlar wrapped entirely around Sample is the most promising protection compared to weight and thickness for defeating soft lead rounds. Utilizing a tight Kevlar wrap around the foundation layer greatly increases the strength of the foundation layer as well as long term durability. A primary concern seems to be keeping Kevlar tightly wrapped when used behind the foundation layer as that promotes stretching and energy absorption by the Kevlar behind the foundation layer and also does a better job of holding everything in place securely. Earlier tests generally involving shock absorption at the front end in the form of a grill or even plastic also seems to make a difference in reducing bullet impact energy. A stronger interface layer and a stronger foundation layer both are effective ways of stopping high velocity bullets. Given that tests have shown several methods that will stop a high velocity bullet, the lighter weight option would be preferable. This is more about finding the right balance between interface layer and foundation layer options.

Test Group 5:

Test Group 5 involved further work with the goal of optimization testing of foundation layer configurations comprising ¼″ AR500 steel, possible inclusion of aluminum, and varying amounts of Kevlar. Samples were tested against 5.56×45 lead bullets as well as tested against 30.06 lead bullets with all bullets traveling in excess of 2800 ft/sec. Each Sample was first shot with the 30.06 lead bullet and then shot with the 5.56 lead bullet. The goal of this test was to determine the lightest and least expensive method of construction required to achieve a desired strength. Samples were weighed to compare against a raw ¼″ AR500 steel plate of equivalent size weighting 3 lb 7 oz.

A duplicate set of samples were made for use in optimizing armor against high powered armor piercing rounds traveling in excess of 2800 ft/sec but at this time, the armor piercing test against these samples has not yet been completed. It is theorized that since lead bullets cause greater damage against AR500 steel based armors compared to damage from armor piercing ammunition, if an armor stops a lead bullet traveling in excess of 2800 ft/sec, then the same AR500 steel based armor should also be able to stop an equivalent caliber armor piercing bullet in excess of 2800 ft/sec.

Referring to FIG. 41a Sample 5-A, which with all its components weighed 3 lb 14 oz, comprised ¼″ AR500 steel plate with one sheet of Kevlar 914 (FIG. 41b). Kevlar sheet 914 as a generally cross shaped figuration with a central portion 914a substantially matching in shape and size of the plate to be covered. Four portions 914b have substantially the same size and shape. In accordance with the invention, the central portion is glued to the front of AR 500 steel plate 912. Portions 914b are wrapped around and secured by being glued in position overlying the back of plate 912. Thus, a single sheet of Kevlar 914 provides a single layer of Kevlar over the front of plate 912 and four layers of couple are completely covering the back of plate 112. Repeating the process by tightly wrapping a second sheet 914 to the back of plate 912 with the first sheet 914 already glued to it and overlapping completely over the front with four portions 914b results in a sample with a total of 5 layers of Kevlar on the front and 5 layers on the back under tension. Under test, a 30.06 lead bullet penetrated this Sample, scoring relatively poor protection. 5.56 lead bullet did not penetrate ¼″ AR500 steel plate which was a successful outcome.

FIG. 42 shows Sample 5-B which had a weight of 4 lb 7 oz. It comprised substantially similar to that of FIG. 41, except for the addition of a third piece of Kevlar tightly wrapping from front to back and overlapping completely over the back 4 times, a fourth piece of Kevlar tightly wrapping from front to back and overlapping completely over the back 4 times, and a fifth piece of Kevlar tightly wrapping from back to front and overlapping completely over the front four times. The resulting structure containing a total of seven layers of Kevlar on the front and 14 layers of Kevlar on the back under tension). Upon being impacted with a 30.06 lead bullet the ¼″ AR500 steel plate was penetrated but the projectile was partially caught in the Kevlar backing giving a rating of limited relatively poor protection. Accordingly, it was concluded that 14 layers of Kevlar caused excessive rigidity and stretching of the Kevlar with the associated absorption of energy did not occur to a sufficient extent. 5.56 lead bullet did not penetrate ¼″ AR500 steel plate, presenting a rating of complete success.

Referring to FIG. 43 Sample 5-C at a weight of 4 lb 7 oz. Its construction was similar to that of FIG. 41 except for the addition of an aluminum plate. The foundation layer comprised ¼″ AR500 steel plate affixed atop ⅛″ aluminum plate, foundation layer being enclosed by Kevlar with 1 piece of Kevlar tightly wrapping from front to back and overlapping completely over the back 4 times with a second piece of Kevlar tightly wrapping from back to front and overlapping completely over the front 4 times, Sample containing a total of 5 layers of Kevlar on the front and 5 layers on the back under tension): 30.06 lead bullet partially penetrated ¼″ AR500 steel plate but was caught by the ⅛″ aluminum plate incurring only minor denting. Sample can withstand multiple hits as long as no two bullets strike the exact same spot—partial success. 5.56 lead bullet did not penetrate ¼″ AR500 steel plate—complete success.

Compared to the FIG. 41 embodiment, substantial additional strength was achieved sufficient to withstand an incoming letter 30.06 projectile. It is believed that tightly wrapping the Kevlar layers promoted transfer of energy to the aluminum layer, which even though it was only 0.125 inches thick and substantial beneficial effect on the outcome. The thinness of the aluminum may be promoting stretching of the aluminum conforming to flexure of the steel plate in response to the tendency of the steel plate to increase its back circumference and stretch layers behind it.

Test 5 Conclusion: A tight wrap of Kevlar can reinforce ¼″ AR500 steel well enough to withstand the 5.56 lead bullet. A sufficient amount of Kevlar could stop the 30.06 bullet from completely penetrating the Sample, but probably cannot ever be a strong enough reinforcement to prevent the ¼″ AR500 steel plate from being penetrated. Additionally, ⅛″ aluminum backing is sufficient to prevent total penetration of the 30.06 bullet when foundation layer is tightly wrapped in Kevlar, weighing less and costing less to produce than an all Kevlar reinforcement solution. Tightly wrapping foundation layer in Kevlar appears to greatly improve the strength of foundation layer materials and prevents foundation layer materials from separating when receiving incoming bullets.

The above work appeared to indicate that it is important to overlap layers of Kevlar so that there are no exposed seams on the back and that layers reinforce each other.

OVERALL CONCLUSIONS

Given certain market limitations in space, weight, and cost, when it comes to personal body armor trauma plates, it appears that the thinnest, lightest, and least costly method for stopping both armor piercing, steel, and lead bullets is to utilize a combination of interface layer affixed atop a foundation layer, with interface layer and foundation layer encapsulated within an encasement layer. However, testing is planned to confirm whether protection is being provided by front or back layers of Kevlar. A preferred embodiment comprises the layers providing protection covered by a single all-around ply of Kevlar to keep all elements in place. In accordance with a particularly preferred embodiment, such Kevlar will be use with a foundation layer comprising steel and aluminum layers, including most preferably embodiments with steel in the front. Tests putting aluminum in front appeared to indicate that it is preferable to position an aluminum layer behind a steel. Moreover, flexure of the forward facing steel layer into an arcoate shape with resultant stretching of the aluminum layer is believed to be a particularly effective strategy for absorbing energy and distributing it over the entire layer.

Optimal Outer Encasement Layer: Plastidip over dimpled foam since it adequately weather seals the armor plate and, for the most part, tends to self seal when penetrated by most bullets (probably due to the bullet heat melting the foam and plastidip causing it to reform over the hole. It is contemplated that this outer encasement layer will overlie multiple plies of Kevlar encasing the steel/aluminum-steel foundation plate.

Optimal interface Layer: Interface layer comprising two components, a primary interface layer affixed atop a secondary interface layer, primary interface layer comprising 1-2 layers of Kevlar affixed atop ⅛″-¼″ foam, with Kevlar wrapping around the sides and partially around the back of armor plate, and secondary interface layer comprising layers of Kevlar tightly wrapping around foundation layer. The primary interface layer helps reduce bullet velocity and catches any debris and spall that bounces back through the secondary interface layer. The main function of the secondary interface layer, comprising a Kevlar wrap which surrounds the foundation layer, is to help hold foundation layer elements together under tension so foundation layer elements don't separate when absorbing damage, thus greatly enhancing strength. Being part of the interface layer, the Kevlar wrap also assists with catching spall and debris and, to some degree, helps reduce bullet velocity, though reducing bullet velocity may not be the most important of the Kevlar wrap.

To the extent possible it is preferable to alternate directions of wrapping so that a solid piece of Kevlar lays across any overlaps and seams. Two overlapping Kevlar wraps are sufficient but additional wraps will enhance strength and durability. Additional layers also serve as a stronger safety net in case the foundation layer is breached by a bullet as most of the bullet's velocity will have been absorbed by that point. Orienting the Kevlar fiber in different directions is also advantageous. This, combined with wrapping the Kevlar such that there is no uncovered (which would create a weak spot) yields superior protection. This can be implemented in various ways. For example, if one starts a wrap on one edge, one should wrap all the way around, overlap, and finish on the opposite edge so that there is no exposed seam. Furthermore, having additional Kevlar behind the plate not only reinforces the plate (the tensile strength helps prevent the steel plate from fracturing and holds everything together) but in the event that a bullet does penetrate the steel foundation layer, the Kevlar backing catches the bullet

Optimal Foundation Layer: It has been demonstrated that ¼″ AR500 steel plate affixed atop a ⅛″ aluminum plate is sufficient to stop a 30.06 lead bullet traveling in excess of 2800 ft/sec and would provide the lightest and least expensive foundation layer. Foundation layers, referring to the rigid layer of solid plates towards the back of the armor, are desirably made of metal such as AR500 steel and aluminum, though durable plastics that won't shatter upon receiving a high velocity impact are also an option. The combination of a ¼″ AR500 steel plate backed by ⅛″ or thicker aluminum appears to be preferred from along the various sample configurations tested. A ¼″ AR500 steel plate affixed atop a ¼″ aluminum plate will increase cost (double material cost for aluminum but the same labor cost) and weight but will improve the durability of the foundation layer with regard to multiple hits in the same location. Strength added by aluminum plates exceeding ¼″ thickness will not be significant compared to the additional weight, thickness, and cost to produce when attempting to stop common bullets ranging in diameter from 5.56 mm through 7.62 mm.

It should be noted that NIJ Level 4 certification levels were achieved without the use of aluminum reinforcement in the foundation layer and plates reinforced with aluminum are also expected to pass NIJ Level 4. It is also likely that a thinner interface layer will still allow for the inventive armor to achieve NIJ Level 4, given the inclusion of aluminum in the foundation layer.

Optimal Curve: A flat armor plate allows for a better bonding of the materials comprising the foundation layer as there will be no gap between the AR500 steel plate and the aluminum plate. A flat armor plate allows for a tighter Kevlar wrap and a more consistent production quality. Curve to better fit the human body can be achieved by employing a piece of foam comprising a flat surface facing the armor plate and a concave surface facing the human body. This method also allows utilization of varying sizes of foam for different body types. Additionally, foam will help reduce impact trauma.

It is understood that variations from the disclosed embodiments may be made by those of ordinary skill in the art. Such variations may include, for example different foam, rubber, or additions to the Kevlar such as polyurethane or spray on plastics such as truck bedliner to improve rigidity. Additional tests will focus on reducing weight, perhaps through the use of less Kevlar, or the use of alternative materials to the AR500 steel. When protecting non-vital areas of the body, it may not be necessary to stop all high caliber bullets, but rather focus on absorbing damage from debris and shrapnel using reduced weight materials, and, accordingly, inventive structures which are not at the highest protection levels may be preferred. It may also be possible to build lighter armor that, instead of stopping all bullets, stops only the most common bullets used by expected adversaries (such as the 7.62×39 bullet used in the AK47) allowing for a lighter weight and thinner steel used in the foundation layer.

Optimal Configuration Summary

A foundation layer, whether a single AR500 steel plate or several materials used in conjunction therewith, is, in accordance with what is currently believed to be the best mode of the invention, preferably contained within a tight Kevlar wrap which extends completely around the foundation layer, most preferably with substantial overlap, for example over the back of the foundation layer. When utilizing a foundation layer comprising multiple components, best results may often be achieved when foundation layer components are arranged such that incoming bullets first encounter the strongest material first, for example a layer of Kevlar supported by a flexible material which allows the Kevlar to stretch and begin to absorb impact energy. Other materials in the foundation layer then serve as support for the strongest layer, perhaps acting as both a reinforcement to the first layer, and also serving as a safety net should an incoming bullet penetrate the first layer.

The inventive interface layer may desirably comprise a fibrous mesh, such as Kevlar, over an ablative polymer layer, such as foam, rubber, or plastic. The inventive interface layer should they also advantageously include a Kevlar layer that tightly wraps around the outer surface of the foundation layer, ideally in several directions, thus providing additional strength and support. Augmenting Kevlar with a polymer coating such as polyurethane makes the Kevlar more rigid and demonstrates some benefit by not allowing Kevlar fibers to separate as easily.

Encapsulation layer should comprise a softer, less rigid, weatherproof polymer material, such as Plastidip, truck bedliner, or cast plastic or rubber. It is important that encapsulation material not be brittle as the primary purpose is to protect inner layers from wear and tear, not stop bullets. A durable soft rubberized material seems to work best.˜˜˜

Referring to FIG. 50, an improved armor encasement dipping method may be understood. A cloth ribbon assembly 710 comprising an outer ribbon 712, an inner ribbon 714, a hook loop 716 and a stitching fold 718, is coupled to foundation layer 720 comprising an outer foundation surface 722, an inner foundation surface 724, and a foundation edge 726, using an adhesive 728, forming a combined foundation assembly 730. Outer ribbon 712 is affixed to outer foundation surface 722 using adhesive 728. Inner ribbon 714 is affixed to inner foundation surface 724. To prevent separation of ribbon assembly 710 from foundation layer 720, stitching fold 718 is positioned at foundation corner 732, foundation corner 732 being the intersection of inner foundation surface 724 and foundation edge 726, where outer ribbon 712 leaves no empty space wrapping across foundation edge 726 before affixing to outer foundation surface 722. Ribbon assembly 710 is made from material strong enough to support the weight of combined foundation assembly 730. Hook loop 716 creates a hook encirclement space 734 which is large enough to allow a dipping hook 736 to be easily inserted into hook encirclement space 734 during an encasement layer dipping process 738.

Referring to FIG. 51, a preferred method for an encasement layer dipping process 738 may be understood. An armor plate assembly 740 comprises combined foundation assembly 730, which may or may not have been augmented by other previously mentioned processes, prior to encasement layer dipping process 738. Dipping hook 736 is inserted into hook encirclement space 734 with an orientation such that armor plate assembly 740 hangs from and below dipping hook 736, such that dipping hook 736 is solely supporting the weight of armor plate assembly 740. Dipping hook 736 is positioned such that armored plate assembly 740 is suspended above encasement material container 742, said encasement material container 742 having a top oriented opening 744, said opening 744 being large enough for armor plate assembly 740 to pass through and said encasement material container 742 being large enough for armor plate assembly 740 be lowered entirely inside encasement material container 742 without making contact with any sides or bottom. Encasement material container 742 is filled with encasement material 746 to a dept sufficient that armor plate assembly 740 can be completely submerged armor plate assembly 740 is fully lowered inside of encasement material container 742.

Referring to FIG. 52, an alternate preferred method for an encasement layer dipping process 748 may be understood. Much as in encasement layer dipping process 738, armor plate assembly 740 comprises combined foundation assembly 730, comprising at least one additional ribbon assembly 710. The ribbon assemblies 710 are spaced to evenly distribute the weight of armor plate assembly 740 when being suspended below dipping hooks 736. In a method similar to that described in FIG. 202, dipping hooks 736 are inserted into hook encirclement spaces 734 with an orientation such that armor plate assembly 740 hangs from and below dipping hooks 736, such that dipping hooks 736 are solely supporting the weight of armor plate assembly 740. Dipping hooks 736 are positioned such that armored plate assembly 740 is suspended above encasement material container 742, with the encasement material container 742 having a top orientated opening 744, the opening 744 being large enough for armor plate assembly 740 to pass through and said encasement material container 742 being large enough for armor plate assembly 740 be lowered entirely inside encasement material container 742 without making contact with any sides or bottom. Encasement material container 742 is filled with encasement material 746 to a dept sufficient that armor plate assembly 740 can be completely submerged armor plate assembly 740 is fully lowered inside of encasement material container 742.

Depending on the composition of above mentioned encasement material 742, and the composition of adhesive 728, adverse reactions between encasement material 742 and adhesive 728 can occur which can weaken or break down adhesive 728. In order to prevent this occurrence, a plastic wrapping process 750 is applied to armor plate assembly 740 prior to dipping process 738. Tests have shown that, in every instance, this prevents any potential breakdown of adhesive 728 and additionally requires less encasement material 742 to be used, thus reducing overall weight by a small amount.

Referring to FIG. 53, a preferred method for plastic wrapping process 750 may be understood. Plastic wrapping process 750 is a process by which armor plate assembly 740, comprising an inner armor plate assembly surface 752 and an outer armor plate assembly surface 754 is encased within inner plastic wrap 756 and outer plastic wrap 758. Inner plastic wrap 756 and outer plastic wrap 758 can be made from any thin and flexible plastic sheet, although in the preferred embodiment, common kitchen plastic wrap is used. Because common kitchen plastic wrap tends to adhere to itself, no adhesive is required prior to dipping process 738. Inner plastic wrap 756 is affixed to inner armor plate assembly surface 752 with excess material being wrapped around onto outer armor plate assembly surface 754. Next, outer plastic wrap 758 is affixed to outer armor plate assembly surface 754 with excess material being wrapped around onto inner armor plate assembly surface 752, forming a wrapped armor plate assembly 760.

In certain circumstances, spall protection may be crucial for stopping bullet fragments from ricocheting after being deflected or shattered by armor plate assembly 740. Such fragments are known as spall. While the fundamental elements of armor plate assembly 740 are already effective at stopping most spall, tests have shown that this can be improved by having a final spall wrap 762. Such a final spall wrap 762 can provide an additional layer of spall protection which wraps around the sides in order to stop sideways deflection. In the preferred embodiment, Kevlar is used. It is also desirable to optimize the geometry of spall wrap 762 to minimize material to reduce weight.

Referring to FIG. 54, a preferred method for spall protection wrapping may be understood. Spall wrap 762 is made from a durable fibrous mesh material, such as Kevlar in the preferred embodiment, comprising a center spall guard 764 and a number of spall guard tabs 766, the number of spall guard tables 766 corresponding to the specific geometry of a given armor plate assembly 740, numbering 6 spall guard tabs 766 in the preferred embodiment. Spall guard 764 is affixed to outer foundation surface 722 by means of adhesive 728, with an orientation such that the entire outer foundation surface 722 is exactly covered by spall guard 764. Spall tabs 766 protrude beyond outer foundation surface 722 in such a way that spall tabs 766 may wrap behind combined foundation assembly 730 and are affixed to inner foundation surface 724 by means of adhesive 728.

Referring to FIG. 55, a preferred method for applying a Kevlar reinforcement wrap 768 to a foundation layer 720 may be understood. Foundation layer 720, in the case of a preferred embodiment, is shaped to fit a typical human torso and comprises a top edge 770, a bottom edge 772, a right edge 774, a left edge 776, a right shoulder edge 778, and a left shoulder edge 780. In a preferred embodiment, a vertical Kevlar reinforcement wrap 782 is affixed to foundation layer 720, by means of adhesive 728, in a vertical orientation such that the wrap crosses the outer foundation surface 722, wraps behind to cross the inner foundation surface 724, and then wraps around to cross the outer foundation surface 722 a second time. A second vertical Kevlar reinforcement wrap 782 is also affixed atop the first vertical Kevlar reinforcement wrap 782 for additional strength. The two vertical Kevlar reinforcement wraps 782 are applied in opposing directions such that the two vertical Kevlar reinforcement wraps 782 support one another. Next, two left shoulder reinforcement wraps 784 and two right shoulder reinforcement wraps 786 are affixed to foundation layer 720, by means of adhesive 728, such that left shoulder reinforcement wraps 784 and right shoulder wraps 786 begin in the middle of outer foundation surface 722, wrap across right edge 774 and left edge 766 respectively, and around to inner foundation surface 724. Finally, three horizontal reinforcement wraps 788 are affixed to foundation layer 720, by means of adhesive 728, in a horizontal orientation such that each horizontal reinforcement wrap crosses the outer foundation surface 722, then wraps behind to cross the inner foundation surface 724, and then wraps around to cross the outer foundation surface 722 once again. The horizontal reinforcement wraps 788 alternate beginning and ending on either the right edge 774 or the left edge 776, with each of the three horizontal reinforcement wraps 788 atop one another for additional strength, The three horizontal reinforcement wraps 788 are applied in opposing directions such that each horizontal reinforcement wrap 788 supports one another.

Turning next to FIGS. 56 and 57, a further alternative embodiment of the inventive personnel protecting plate 1010 is illustrated. In this embodiment, a foundation plate is formed by a 0.25 inch thick AR 500 steel plate 1012 which is adhered to a 0.125 inch aluminum plate 1011. A T-shaped Kevlar sheet as illustrated in FIG. 57 forms a front Kevlar layer 1001, a rear pair of Kevlar layers 1002 and 1003, and a third rear Kevlar layer 1004. The Kevlar sheet of FIG. 57 is applied to the foundation plate formed by steel layer 1012 and aluminum layer 1011 by gluing the central portion 1001 of the Kevlar sheet to the front of the foundation plate. Portions 1002 and 1003 are then wrapped around the foundation plate and sequentially glued to the back of the foundation plate. Next third layer of Kevlar 1004 is wrapped around foundation plate aluminum back 1011 and glued in place by being adhered to portion 1003. Additional rigidity may be insured by extending the dimension of portions 1002, 1003, and 1004 to include extension portions 1005, 1006 and 1007. Extension portions 1005, 1006 and 1007 may be wrapped around the edge of the foundation plate and glued over the Kevlar covering the front of the foundation plate. Following this, a 0.25 inch layer of foam, rubber or ABS plastic may be applied to the front face of Kevlar 1001. Finally the entire assembly is covered with a Kevlar encasement 1016. In this embodiment, foam 1008 serves the function of allowing Kevlar front face 1016 to deform in response to an incoming projectile 1017.

While illustrative embodiments of the invention have been described, it is noted that various modifications will be apparent to those of ordinary skill in the art in view of the above description and drawings. Such modifications are within the scope of the invention which is limited and defined only by the following claims.

Claims

1. A protective device for protecting an individual from oncoming projectiles, comprising:

(a) a substantially rigid member having a length and a width sufficient to overlie a portion of the body of the individual to be protected, said substantially rigid member having a front side oriented toward an incoming projectile and a reverse side in facing relationship to said portion of the body of the individual to be protected, said substantially rigid member being configured to spread out energy from said incoming projectile to a plurality of points on said portion of the body of the individual to be protected;

(b) an energy absorbing member; and

(c) a support member for supporting said energy absorbing member on said substantially rigid member at a position where energy from an oncoming projectile is transferred to and absorbed by said energy absorbing member.

2. Apparatus as in claim 1, wherein the energy absorbing member comprises an energy absorbing material which deforms resiliently and/or non-resiliently in response to applied force.

3. Apparatus as in claim 2, wherein said substantially rigid member is elastic, and the energy absorbing member is supported adjacent the reverse side of said substantially rigid member, whereby an increase in dimension of said reverse side of said substantially rigid member in response to flexure of said substantially rigid member being hit by an incoming projectile hitting said front side of said substantially rigid member, causes an increase in dimension in said energy absorbing member.

4. Apparatus as in claim 1, further comprising a spacing member positioned over and secured to said front side of said substantially rigid member, and wherein the energy absorbing member is secured in place disposed over said spacing member, whereby incoming projectiles impacting said energy absorbing member deform said energy absorbing member and proceed into the space occupied by said spacing member before said incoming projectiles can directly impact said substantially rigid member.

5. Apparatus as in claim 1, wherein the energy absorbing member is secured in place disposed over said substantially rigid member, whereby incoming projectiles impacting said energy absorbing member deform said energy absorbing member before said incoming projectiles can directly impact said substantially rigid member.

6. Apparatus as in claim 1, wherein the energy absorbing member is secured in place disposed over the front of said substantially rigid member.

7. Apparatus as in claim 1, wherein said energy absorbing member comprises a material selected from the group consisting of Kevlar, Nomex and other aramid fibers, and Spectra, Dyneema and other ultrahigh molecular weight polyethylene fibers; and said substantially rigid member is selected from the group consisting of metal plate and ceramic armor plate.

8. Apparatus as in claim 1, wherein the energy absorbing member comprises a first energy absorbing fiber structure which deforms resiliently and/or non-resiliently in response to applied force and wherein said substantially rigid member is elastic, and the energy absorbing member is supported adjacent the reverse side of said substantially rigid member, whereby an increase in dimension of said reverse side of said substantially rigid member in response to flexure of said substantially rigid member being hit by an incoming projectile hitting said front side of said substantially rigid member, causes an increase in dimension in said energy absorbing member, and wherein said support member comprises a second energy absorbing fiber structure, said first energy absorbing fiber structure being integral with said second energy absorbing fiber structure, said first energy absorbing fiber structure and said second energy absorbing fiber structure being formed by winding or wrapping a single energy absorbing fiber fabric around said substantially rigid member.

9. Apparatus as in claim 1, further comprising a foam spacing member positioned over and secured to said front side of said substantially rigid member, and wherein the energy absorbing member is secured in place disposed over said spacing member, whereby incoming projectiles impacting said energy absorbing member deform said energy absorbing member and proceed into the space occupied by said spacing member before said incoming projectiles can directly impact said substantially rigid member.

10. Apparatus as in claim 1, further comprising a solid polymeric spacing member positioned over and secured to said front side of said substantially rigid member, and wherein the energy absorbing member is secured in place disposed over said spacing member, whereby incoming projectiles impacting said energy absorbing member deform said energy absorbing member and proceed into the space occupied by said spacing member before said incoming projectiles can directly impact said substantially rigid member.

11. Apparatus as in claim 1, wherein the energy absorbing member comprises a metallic energy absorbing material which deforms resiliently and/or non-resiliently in response to applied force, and wherein said substantially rigid member is elastic, the energy absorbing member being supported adjacent the reverse side of said substantially rigid member, whereby an increase in dimension of said reverse side of said substantially rigid member in response to flexure of said substantially rigid member being hit by an incoming projectile hitting said front side of said substantially rigid member, causes an increase in dimension in said energy absorbing member.

12. Apparatus as in claim 1, further comprising a spacing member positioned over and secured to said front side of said substantially rigid member, and wherein a first portion of the energy absorbing member is secured in place disposed over said spacing member, whereby incoming projectiles impacting said energy absorbing member deform said energy absorbing member and proceed into the space occupied by said spacing member before said incoming projectiles can directly impact said substantially rigid member, and wherein a second portion of the energy absorbing member is supported adjacent the reverse side of said substantially rigid member, whereby an increase in dimension of said reverse side of said substantially rigid member in response to flexure of said substantially rigid member being hit by an incoming projectile hitting said front side of said substantially rigid member, causes an increase in dimension in said energy absorbing member.

13. Apparatus as in claim 1, further comprising a second substantially rigid member oriented at an angle between 20 degrees and 100 degrees to said substantially rigid member, said substantially rigid members being made of steel.

14. Apparatus as in claim 1, wherein said substantially rigid member comprises AR500 steel or the equivalent.

15. A protective device for protecting an individual from oncoming projectiles, as in claim 1, wherein said energy absorbing member wraps around said substantially rigid member and said support member for supporting said energy absorbing member and said energy absorbing member are formed by a single member wrapped around said substantially rigid member substantially without any slack.

16. A protective device for protecting an individual from oncoming projectiles, as in claim 15, wherein said energy absorbing member has a T configuration formed by a central portion and three arms.

17. A protective device for protecting an individual from oncoming projectiles, as in claim 15, wherein said energy absorbing member has a cross configuration formed by a central portion and four arms.

19. A protective device for protecting an individual from oncoming projectiles, as in claim 15, wherein said energy absorbing member comprises Kevlar® or another aramid synthetic fiber, or a high strength film such as polyparaphenelynebenzobisthiazole film, or ultrahigh molecular weight polyethylene fiber.

20. A protective device for protecting an individual from oncoming projectiles, as in claim 1, wherein said energy absorbing member comprises metal wire mesh-like material.