Apparatuses and wearable armor systems including electrical sources
11378360 · 2022-07-05
Assignee
Inventors
- Jacob A. Monat (Mendota Heights, MN, US)
- Joshua E. Nieman (Centerville, OH, US)
- Matthew S. Benefiel (Xenia, OH, US)
- Frank M. Zalar (Beavercreek Township, OH, US)
- Brian E. Henslee (Galloway, OH, US)
Cpc classification
F41H5/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F41H5/0414
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F41H5/0478
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
A41D13/012
HUMAN NECESSITIES
F41H5/013
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
A41D13/0015
HUMAN NECESSITIES
A41D13/00
HUMAN NECESSITIES
International classification
F41H5/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
An apparatus for an armor system includes a housing case, an interior ballistic panel, a frame, a power source, and a control unit. The housing case includes a top shell and a bottom shell, where the top shell is removably secured to the bottom shell, forming a cavity. The interior ballistic panel is removably arranged within the cavity between the top shell and the bottom shell. The frame is arranged within the cavity between the top shell and the interior ballistic panel, the frame including a compartment. The power source is arranged within the compartment of the frame, and the control unit is communicatively connected to the power source to manage operation of the power source.
Claims
1. An armor system, comprising: a ballistic housing case, comprising: a top shell; and a bottom shell secured directly to the top shell such that the ballistic housing case is environmentally sealed against dust and water intrusion; wherein the housing case is rigid, and wherein the top shell and the bottom shell form a cavity which is enclosed by the top shell and the bottom shell; a frame arranged within the cavity between the top shell and the bottom shell, the frame comprising a plurality of compartments formed by a plurality of perpendicularly arranged ribs forming the frame; a plurality of channels arranged in the ribs forming the frame, the channels formed by removal of at least a portion of the rib to form a through hole connecting adjacent compartments; a power source arranged within at least one of the plurality of compartments; and a control unit communicatively connected to the power source with wires passing through the channels arranged in the ribs to manage operation of the power source.
2. The armor system of claim 1, wherein the system further comprises an interior ballistic panel removably arranged within the cavity between the top shell and the bottom shell.
3. The armor system of claim 1, wherein the control unit is arranged within at least one compartment of the frame.
4. The armor system of claim 1, wherein the power source is a plurality of batteries comprising at least one fuse communicatively connected between the control unit and the plurality of batteries.
5. The armor system of claim 4, wherein the plurality of batteries are arranged within corresponding compartments of the plurality of compartments of the frame.
6. The armor system of claim 4, further comprising an external connector passing through the housing case and communicatively connected to the plurality of batteries and the control unit.
7. The armor system of claim 6, wherein the external connector comprises: a socket communicatively coupled to the plurality of batteries; and, a flexible power cable removably secured to the socket, wherein the flexible power cable allows current to be transmitted from the plurality of batteries to an external device.
8. The armor system of claim 1, wherein the housing case having ballistic resistance is formed from a fiber-reinforced composite material comprising reinforcement material and a polymer.
9. The armor system of claim 8, wherein the reinforcement material comprises one or more components selected from the group consisting of carbon fiber, glass fiber, aramid fiber, polypropylene fiber, polyethylene fiber, hybrid laminates, thermoplastic prepreg, or combinations thereof, and wherein the polymer comprises one of more components selected from the group consisting of polypropylene, polyethylene, polyether ether ketone, polyphenylene oxide, polyphenylene ether, polyvinylidenefluoride, epoxy, vinyl ester, polyester, polyurethane, thermoplastic elastomer, thermoset elastomer, or combinations thereof.
10. An armor system, comprising: a housing case, comprising: a top shell; and a bottom shell secured directly to the top shell such that the housing case is environmentally sealed against dust and water intrusion; wherein the housing case is rigid, and wherein the top shell and the bottom shell form a cavity which is enclosed by the top shell and the bottom shell; an interior ballistic panel removably arranged within the cavity between the top shell and the bottom shell; a plurality of longitudinally arranged ribs arranged within the cavity; a plurality of latitudinally arranged ribs arranged over the plurality of longitudinally arranged ribs, wherein the plurality of longitudinally arranged ribs are secured to the plurality of latitudinally arranged ribs, forming a plurality of compartments; wherein the plurality of longitudinally arranged ribs and the plurality of latitudinally arranged ribs are integral with one another to form a frame; a plurality of channels positioned in the latitudinally arranged ribs forming the frame, the channels formed by removal of at least a portion of the latitudinally arranged rib to form a through hole connecting adjacent compartments; a power source arranged within at least one of the plurality of compartments; and a control unit arranged within at least one of the plurality of compartments and communicatively connected to the power source with wires passing through the channels arranged in the ribs to manage operation of the power source.
11. The armor system of claim 10, wherein the power source is a plurality of batteries comprising at least one fuse communicatively connected between the control unit and the plurality of batteries.
12. The armor system of claim 11, further comprising an external connector passing through the housing case and communicatively connected to the plurality of batteries and the control unit.
13. The armor system of claim 12, wherein the external connector comprises: a socket communicatively coupled to the plurality of batteries; and, a flexible power cable removably secured to the socket, wherein the flexible power cable allows current to be transmitted from the plurality of batteries to an external device.
14. The armor system of claim 10, wherein the housing case having ballistic resistance is formed from a fiber-reinforced composite material comprising reinforcement material and a polymer.
15. The armor system of claim 14, wherein the reinforcement material comprises one or more components selected from the group consisting of carbon fiber, glass fiber, aramid fiber, polypropylene fiber, polyethylene fiber, hybrid laminates, thermoplastic prepreg, or combinations thereof, and wherein the polymer comprises one of more components selected from the group consisting of polypropylene, polyethylene, polyether ether ketone, polyphenylene oxide, polyphenylene ether, polyvinylidenefluoride, epoxy, vinyl ester, polyester, polyurethane, thermoplastic elastomer, thermoset elastomer, or combinations thereof.
16. An armor system comprising: a carrier vest; a ballistic panel holding pouch operatively arranged on the carrier vest; a housing case, comprising: a top shell; and a bottom shell secured directly to the top shell such that the housing case is environmentally sealed against dust and water intrusion; wherein the housing case is rigid, and wherein the top shell and the bottom shell form a cavity which is enclosed by the top shell and the bottom shell; an interior ballistic panel removably arranged within the cavity between the top shell and the bottom shell; a frame arranged within the cavity between the top shell and the interior ballistic panel, the frame comprising a plurality of longitudinally arranged ribs and a plurality of latitudinally arranged ribs forming a plurality of compartments within the frame; a plurality of channels positioned in the latitudinally arranged ribs forming the frame, the channels formed by removal of at least a portion of the latitudinally arranged rib to form a through hole connecting adjacent compartments; a power source arranged within the compartment of the frame; and a control unit communicatively connected to the power source with wires passing through the channels arranged in the ribs to manage operation of the power source, wherein the housing case is arranged within the ballistic panel holding pouch.
17. The armor system of claim 16, further comprising an external connector passing through the housing case and communicatively connected to the power source and the control unit.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
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DETAILED DESCRIPTION
(11) The armor system generally includes a housing case, an interior ballistic panel, a frame, a power source, and a control unit. The housing case includes a top shell and a bottom shell, where the top shell is removably secured to the bottom shell, forming a cavity. The interior ballistic panel is removably arranged within the cavity between the top shell and the bottom shell. The frame is arranged within the cavity between the top shell and the interior ballistic panel, the frame including a compartment. The power source is arranged within the compartment of the frame, and the control unit is communicatively connected to the power source to manage operation of the power source. As will be described in greater detail herein, the interior ballistic panel, frame, and power source may be easily removed from the cavity of the housing case. For example the interior ballistic panel could be removed if additional ballistics protection is not required beyond the level of ballistic protection of the housing case. Accordingly, the interior ballistic panel can replaced with a different ballistic protection panel, such as a small arms protective insert (SAPI) panel, a soft Kevlar® (E.I. du Pont de Nemours and Company, Midland, Mich.) insert, a ceramic armor panel, an ultra-high-molecular-weight polyethylene (UHMWPE) panel, a dry fiber material panel, or a composite material panel. The ceramic armor panel may be made from alumina, boron carbide, silicon carbide, or titanium diboride. The UHMWPE panel may be made from Dyneema® (DSM, Heerlen, the Netherlands) and/or Spectra® (Honeywell, Morris Plains, N.J.). The dry fiber material panel may be made of Kevlar® (E.I. du Pont de Nemours and Company, Midland, Mich.) or carbon fiber. The composite material panel may be made with Kevlar® (E.I. du Pont de Nemours and Company, Midland, Mich.) or carbon fiber. Various embodiments of the armor system will be described in greater detail herein.
(12) Referring now to
(13) Referring again to
(14) In various embodiments, the bottom shell 108 and top shell 110 may be secured together by a friction fit, a removable adhesive, or an external fabric or tape wrap, but any securement means can be used without departing from the scope of this disclosure.
(15) It is noted that the housing case 102 and/or various components thereof may be made from a variety of materials. For example, in one non-limiting embodiment, the housing case 102 is made from a fiber-reinforced composite, such as an aramid fiber (Kevlar® (E.I. du Pont de Nemours and Company, Midland, Mich.)) reinforced composite. In a further non-limiting embodiments, the housing case 102 is made from a rigid plastic such as acrylonitrile butadiene styrene (ABS) or nylon, polycarbonate, UHMWPE. It should be noted that both the bottom shell 108 and the top shell 110 have a curved profile CP1, which allows the housing case 102 to conform to the chest area of a human user. However, it should be appreciated that housing case 102 can also have a flat profile. In some embodiments, the housing case 102 is a rigid or conformal case which may be environmentally sealed against dust and water intrusion (e.g. IP67 or IP68 in accordance with the International Electrotechnical Commission standards). Additionally, the housing case 102 may be rated for MIL-STD-810 shock, vibration, and drop testing in accordance with the Institute of Environmental Sciences and Technology standards of the United States Military. The armor system 100 may be designed to provide additional ballistic protection when worn in front of or behind the interior ballistic panel 116, or may act as standalone ballistic protection (e.g. NIJ Level IIA, II, III, or IV in accordance with the National Institute of Justice standards) when worn without the interior ballistic panel 116.
(16) In some embodiments, the housing case 102 may be made from a thin, impact/ballistic resistant case material which may be a thermoplastic or thermoset resin case, with or without fiber reinforcement. A lightweight, thermally insulated, fire-resistant layer may be arranged between the interior ballistic panel 116 and the bottom shell 108 to protect a user in the event of battery thermal runaway or a fire. Example fire-resistant layers include those formed from dry fibers of Kevlar® (E.I. du Pont de Nemours and Company, Midland, Mich.), and/or carbon fibers, ceramic materials or foam.
(17) In some embodiments, the polymer materials used to make the housing case 102 can be a fiber reinforced thermoplastic or thermoset composite. Non-limiting examples of thermoplastic resin used to make the bottom shell 108 and the top shell 110 are polypropylene, polyethylene, polyether ether ketone, polyphenylene oxide, polyphenylene ether, Noryl, and polyvinylidenefluoride. Non-limiting examples of thermosetting resin used to make the bottom shell 108 and the top shell 110 are epoxy, vinyl ester, polyester, polyurethane. Non-limiting examples of fiber reinforcement materials in the composite include carbon, glass, aramid, polypropylene, polyethylene, and hybrid laminates made with multiple reinforcement materials. The fiber reinforcement used to make the composite may include various material forms, including but not limited to random mats, scrims, chopped fibers, knits, unidirectional plies, three-dimensional weaves, three-dimensional fiber preforms, plain weave fabrics, twill fabrics, harness satin fabrics, prepreg (i.e. pre-impregnated composite fibers where a thermoset polymer matrix material, such as epoxy, or a thermoplastic resin is already present), Tpreg (i.e. thermoplastic prepreg), or combinations thereof. In some embodiments, the polymer materials used to make the housing case 102 can be a fiber reinforced thermoplastic or thermoset elastomer composite. Non-limiting example of thermoplastic or thermosetting resin used to make elastomer composite for the housing case 102 are rubber, polyurea, or polyurethane.
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(23) In some embodiments, the control units 120A and 120B are printed circuit boards having one or more of the following features: flat or conformal circuit boards, overcurrent protection, overvoltage protection, undervoltage protection, a state-of-charge (SOC) measurement, a SOC indication via external LEDs 143, a state-of-health (SOH) indication via external LEDs 143 (e.g. indicating remaining battery life or capacity), a system management bus (SMBus) for SOC and SOH data and charge control, passive and/or active battery cell balancing where active cell balancing can maintain similar SOC between all batteries 124 during charging and discharging, a capability of disabling individual batteries 124 or a string of batteries 124 in the event of malfunction or damage, and optionally provide multiple output voltages to reduce/eliminate the need for downstream DC-DC converters for different voltages.
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(25) In some embodiments, the batteries 124 may be high specific energy rechargeable battery cells. Specifically, the batteries 124 may be high specific energy rechargeable lithium battery cells. The batteries 124 may also have inherent fail-safe capabilities for the following conditions per United Nations Transportation Testing for Lithium Ion and Lithium Metal Batteries (UN Manual of Tests and Criteria § 38.3): Crush, Puncture, Short circuit, Over-discharge, Over-charge, Altitude, Shock, and Vibration. Additionally, in some embodiments, the power source 122 may have a discharge capacity of 5-30 Ah, preferably 8-12 Ah, a nominal voltage of 10-36V, 10-18V, or 20-36, an total energy of 50-400, preferably 100-300 Wh, a continuous discharge of 5-30 A, and a pulse discharge of 20-120 A.
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(33) It should now be understood that embodiments described herein are directed to an armor system that generally includes a housing case, an interior ballistic panel, a frame, a power source, and a control unit. The housing case includes a top shell and a bottom shell, where the top shell is removably secured to the bottom shell, forming a cavity. The interior ballistic panel is removably arranged within the cavity between the top shell and the bottom shell. The frame is arranged within the cavity between the top shell and the interior ballistic panel, the frame including a compartment. The power source is arranged within the compartment of the frame, and the control unit is communicatively connected to the power source to manage operation of the power source. The interior ballistic panel, frame, and power source may be easily removed from the cavity of the housing case. For example, the interior ballistic panel could be removed if additional ballistics protection is not required beyond the level of ballistic protection of the housing case. Accordingly, the interior ballistic panel can replaced with a different ballistic protection panel, form a small arms protective panel, to a soft Kevlar® (E.I. du Pont de Nemours and Company, Midland, Mich.) insert.
(34) The singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
(35) It is further noted that spatially oriented terms like “top”, “bottom,” and similar are not utilized herein to limit the scope of the claimed invention or to imply that certain special orientations are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to provide relative positions of components in a commonly understood manner.
(36) Throughout this disclosure ranges are provided. It is envisioned that each discrete value encompassed by the ranges are also included. Additionally, the ranges which may be formed by each discrete value encompassed by the explicitly disclosed ranges are equally envisioned.
(37) As used in this disclosure and in the appended claims, the words “comprise,” “has,” and “include” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps.
(38) It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modification and variations come within the scope of the appended claims and their equivalents.