Flexible Ballistic Headwear

Abstract

A ballistic garment includes a plurality of flexible ballistic sheets. Each of the plurality of flexible ballistic sheets defines at least one slit. Opposite edges of the plurality of flexible ballistic sheets at the at least one slit are positioned in overlap such that each of the plurality of flexible ballistic sheets is curved. The plurality of flexible ballistic sheets are nested together, and the plurality of flexible ballistic sheets are mounted together to collectively form a flexible headcap.

Claims

1. A ballistic garment, comprising: a plurality of flexible ballistic sheets, each of the plurality of flexible ballistic sheets defining at least one slit, opposite edges of the plurality of flexible ballistic sheets at the at least one slit positioned in overlap such that each of the plurality of flexible ballistic sheets is curved, wherein the plurality of flexible ballistic sheets are nested together, and the plurality of flexible ballistic sheets are mounted together to collectively form a flexible headcap.

2. The ballistic garment of claim 1, wherein the opposite edges of each of the plurality of flexible ballistic sheets defines an overlap joint, the plurality of flexible ballistic sheets are nested together in a stack, and the overlap joint of each the plurality of flexible ballistic sheets is offset from the overlap joint of adjacent ballistic sheets within the stack of flexible ballistic sheets.

3. The ballistic garment of claim 1, wherein a thickness of the flexible headcap formed by the plurality of flexible ballistic sheets is no less than four millimeters and no greater than eight millimeters.

4. The ballistic garment of claim 1, wherein the plurality of flexible ballistic sheets comprises no less than fifteen flexible ballistic sheets.

5. The ballistic garment of claim 1, wherein each of the plurality of flexible ballistic sheets comprises ultra-high-molecular-weight polyethylene fibers.

6. The ballistic garment of claim 1, wherein the flexible headcap conforms to the NIJ Type Ma standard.

7. The ballistic garment of claim 1, wherein the flexible headcap formed by the plurality of flexible ballistic sheets covers anterior, lateral, and posterior skull bones when the flexible headcap is on a wearer.

8. The ballistic garment of claim 1, wherein the plurality of flexible ballistic sheets are distributed three-hundred and sixty degrees around an interior of the flexible headcap.

9. The ballistic garment of claim 1, wherein the flexible headcap is sized for receipt within a hat.

10. The ballistic garment of claim 1, wherein the plurality of flexible ballistic sheets are mounted together by adhesive or thermal bonding.

11. A ballistic garment, comprising: a plurality of flexible ballistic sheets, each of the plurality of flexible ballistic sheets defining at least one slit, opposite edges of the plurality of flexible ballistic sheets at the at least one slit positioned in overlap such that each of the plurality of flexible ballistic sheets is curved, wherein the plurality of flexible ballistic sheets comprises no less than fifteen flexible ballistic sheets, the plurality of flexible ballistic sheets are nested together, and the plurality of flexible ballistic sheets are thermally bonded together to collectively form a flexible headcap.

12. The ballistic garment of claim 11, wherein the opposite edges of each of the plurality of flexible ballistic sheets defines an overlap joint, the plurality of flexible ballistic sheets are nested together in a stack, and the overlap joint of each the plurality of flexible ballistic sheets is offset from the overlap joint of adjacent ballistic sheets within the stack of flexible ballistic sheets.

13. The ballistic garment of claim 11, wherein a thickness of the flexible headcap formed by the plurality of flexible ballistic sheets is no less than four millimeters and no greater than eight millimeters.

14. The ballistic garment of claim 11, wherein each of the plurality of flexible ballistic sheets comprises ultra-high-molecular-weight polyethylene fibers.

15. The ballistic garment of claim 11, wherein the flexible headcap conforms to the NIJ Type Ma standard.

16. The ballistic garment of claim 11, wherein the flexible headcap formed by the plurality of flexible ballistic sheets covers anterior, lateral, and posterior skull bones when the flexible headcap is on a wearer.

17. The ballistic garment of claim 11, wherein the plurality of flexible ballistic sheets are distributed three-hundred and sixty degrees around an interior of the flexible headcap.

18. The ballistic garment of claim 11, wherein the flexible headcap is sized for receipt within a hat.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures.

[0027] FIG. 1 is a top, plan view of a flexible ballistic sheet, in a flat configuration, according to an example embodiment of the present subject matter.

[0028] FIG. 2 is a side, elevation view of the example flexible ballistic sheet of FIG. 1.

[0029] FIG. 3 is a top, plan view of the example flexible ballistic sheet of FIG. 1, in a folded configuration.

[0030] FIG. 4 is a side elevation view of the example flexible ballistic sheet of FIG. 3.

[0031] FIG. 5 is a perspective view of a flexible headcap formed from a plurality of the example flexible ballistic sheets of FIG. 3.

[0032] FIG. 6 is a section view of the example flexible headcap of FIG. 4 taken along the 6-6 line in FIG. 5.

[0033] FIG. 7 is an exploded view of a fabric cap according to an example embodiment of the present subject matter with the example flexible headcap of FIG. 4 shown removed from an interior of the example fabric cap.

[0034] FIG. 8 is a front elevation view of a flexible headcap according to an example embodiment of the present subject matter.

DETAILED DESCRIPTION

[0035] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0036] When introducing elements of the present disclosure or the preferred embodiment(s) thereof, the articles a, an, the and said are intended to mean that there are one or more of the elements. As used herein, the terms includes and including are intended to be inclusive in a manner similar to the term comprising. Similarly, the term or is generally intended to be inclusive (i.e., A or B is intended to mean A or B or both). Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as about, approximately, and substantially, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. For example, the approximating language may refer to being within a ten percent (10%) margin.

[0037] FIG. 1 is a top, plan view of a flexible ballistic sheet 10 according to an example embodiment of the present subject matter. In FIG. 1, flexible ballistic sheet 10 is shown in a flat configuration. Thus, e.g., as shown in FIG. 2, flexible ballistic sheet 10 may be generally planar in the flat configuration. Conversely, as shown in FIGS. 3 and 4, flexible ballistic sheet 10 may folded or deformed from the flat configuration, e.g., into a semispherical or other suitable shape. For instance, flexible ballistic sheet 10 may be folded from the flat configuration into a hat shape. As discussed in greater detail below, flexible ballistic sheets 10 may be stacked to form a flexible headcap 100 (FIG. 5) when flexible ballistic sheet 10 is in the folded configuration shown in FIGS. 3 and 4. Moreover, flexible ballistic sheet 10 may advantageously include features for forming the flexible headcap 100 without sizable gaps. Thus, flexible headcap 100 may be used as to protect the skull and brain of a wearer. For example, flexible headcap 100 may be worn alone or below a cap, hat, scarf, etc., and the flexible headcap 100 may limit or prevent projectiles from penetrating the skull so that underlying brain tissue is thereby protected.

[0038] Turning back to FIGS. 1 and 2, flexible ballistic sheet 10 may be formed from a fiber material that is resistant to penetration by projectiles, such as bullets. As an example, flexible ballistic panel 10 may be constructed of or with a fabric having one or more of ultra-high-molecular-weight polyethylene fibers and para-aramid fibers. In certain example embodiments, the ultra-high-molecular-weight polyethylene fibers may be Dyneema? or Spectra? brand fibers, and the para-aramid fibers may be Kevlar? brand fibers. The ultra-high-molecular-weight polyethylene fibers and para-aramid fibers may be woven together to form the flexible ballistic sheet 10. The fiber material within flexible ballistic sheet 10 may be more comfortable for extended wear relative to hard armor panels.

[0039] Flexible ballistic sheet 10 may have a circular or oval shape in the flat configuration. For example, flexible ballistic sheet 10 may be cut from a roll of ballistic fabric to form ballistic sheet 10 from the roll of ballistic fabric. Flexible ballistic sheet 10 may also include at least one slit 14. In the example embodiment shown in FIG. 1, ballistic sheet 10 includes four (4) slits 14. However, it will be understood that flexible ballistic sheet 10 includes other numbers of slits 14 in alternative example embodiments depending upon the desired shaped for flexible ballistic sheet 10 in the folded configuration. For example, flexible ballistic sheet 10 may include one (1) slit 14, two (2) slits 14, three (3) slits 14, five (5) slits 14, six (6) slits 14, or more.

[0040] Flexible ballistic sheet 10 may be cut to form slits 14. Slits 14 may extend from an outer edge 16 of flexible ballistic sheet 10 towards a center 18 of flexible ballistic sheet 10. Thus, e.g., flexible ballistic sheet 10 may be cut at the outer edge 16 towards the center 18 of flexible ballistic sheet 10 to form slits 14. Slits 14 may be straight or curved. For instance, slits 14 may be straight or curved from the outer edge 16 towards the center 18 of flexible ballistic sheet 10. A length of slits 14, e.g., from outer edge 16 towards the center 18 of flexible ballistic sheet 10 may be no less than twenty-five millimeters (25 mm) and no greater than one hundred and fifty millimeters (150 mm), such as no less than thirty millimeters (30 mm) and no greater than one hundred and twenty-five millimeters (125 mm), such as no less than fifty millimeters (50 mm) and no greater than one hundred millimeters (100 mm).

[0041] As shown in FIG. 2, flexible ballistic sheet 10 may have a first surface 13 positioned opposite a second surface 15 on flexible ballistic sheet 10. Thus, first surface 13 may be spaced from second surface 15, and first surface 13 may also face opposite second surface 15 on flexible ballistic sheet 10. First and second surfaces 13, 15 may be spaced apart by a thickness TS of flexible ballistic sheet 10. The thickness TS of flexible ballistic sheet 10 may be no less than two hundred microns (200 ?m) and no greater than six hundred microns (600 ?m), such as no less than two hundred microns (200 ?m) and no greater than six hundred microns (600 ?m). The slits 14 may extend through the thickness TS of flexible ballistic sheet 10, e.g., between first and second surfaces 13, 15.

[0042] Turning to FIGS. 3 and 4, flexible ballistic sheet 10 is shown in the folded configuration. Flexible ballistic sheet 10 may be folded or deformed from the flat configuration into the folded configuration. For instance, flexible ballistic sheet 10 may have opposite edges 22, 24 at each slit 14, and the opposite edges 22, 24 at each slit 14 may be positioned in overlap to form an overlap joint 20 at each slit 14. By positioning the opposite edges 22, 24 at slits 14 in overlap the flexible ballistic sheet 10 may be curved in the folded configuration, e.g., rather than planar as in the in the flat configuration. For example, as shown in FIG. 4, semispherical or other suitable shape when the opposite edges 22, 24 at slits 14 are positioned in overlap to form the overlap joints 20. Thus, e.g., the overlap of opposite edges 22, 24 at slits 14 may be greater at the outer edge 16 of flexible ballistic sheet 10 than towards the center 18 of flexible ballistic sheet 10. In such a manner, flexible ballistic sheet 10 may be shaped to form headwear as discussed in greater detail below.

[0043] Turning now to FIGS. 5 and 6, a plurality of flexible ballistic sheets 10 may be nested together and mounted to one another to collectively form a flexible headcap 100 from multiple flexible ballistic sheets 10. Moreover, each of the flexible ballistic sheets 10 may be in the folded configuration, e.g., such that the opposite edges 22, 24 at slits 14 are positioned in overlap to form the overlap joints 20 (FIGS. 3 and 4). Thus, as shown in FIG. 6, the flexible ballistic sheets 10 may be nested together in a stack 110.

[0044] The stack 110 of flexible ballistic sheets 10 may include a suitable number of flexible ballistic sheets 10. In example embodiments, the stack 110 of flexible ballistic sheets 10 may include no less than ten (10) flexible ballistic sheets 10, such as no less than twelve (12) flexible ballistic sheets 10, such as no less than fifteen (15) flexible ballistic sheets 10, such as no less than seventeen (17) flexible ballistic sheets 10, such as no less than twenty (20) flexible ballistic sheets 10. In example embodiments, the stack 110 of flexible ballistic sheets 10 may include no greater than thirty (30) flexible ballistic sheets 10, such as no greater than twenty-five (25) flexible ballistic sheets 10, such as no greater than twenty-two (22) flexible ballistic sheets 10, such as no greater than twenty (20) flexible ballistic sheets 10. Such number of flexible ballistic sheets 10 within the stack 110 may advantageously assist with limiting or preventing penetration of flexible headcap 100 by projectiles, such as bullets, while also providing comfortable protection during extended wear of flexible headcap 100, e.g., within a hat.

[0045] The stack 110 may have a thickness TSS between opposite end flexible ballistic sheets 10, e.g., between an outer flexible ballistic sheet 32 at an outer surface 102 of flexible headcap 100 and an inner flexible ballistic sheet 34 at an inner surface (not shown) of flexible headcap 100. The inner surface of flexible headcap 100 may face towards a wearer of flexible headcap 100, and the outer surface 102 of flexible headcap 100 may face away from the wearer of flexible headcap 100 when flexible headcap 100 is on the wearer. The thickness TSS of stack 110 (e.g., and thus flexible headcap 100) may be no less than two millimeters (2 mm) and no greater than twenty millimeters (20 mm), such as no less than three millimeters (3 mm) and no greater than fifteen millimeters (15 mm), such as no less than four millimeters (4 mm) and no greater than eight millimeters (8 mm). Such sizing of the TSS of stack 110 may advantageously provide comfortable protection during extended wear of flexible headcap 100, e.g., within a hat.

[0046] The flexible ballistic sheets 10 may be mounted together in a suitable manner to form the flexible headcap 100. For instance, flexible ballistic sheets 10 may be mounted together by adhesive or thermal bonding, such as by heating flexible ballistic sheets 10 such that adjacent flexible ballistic sheets 10 melt together. It will be understood that flexible ballistic sheets 10 may include a film over the woven ultra-high-molecular-weight polyethylene fibers and/or para-aramid fibers that may be melted together to heat bond the adjacent flexible ballistic sheets 10.

[0047] Flexible headcap 100 may be configured to protect against assaults with handguns and may also be suitable for extended daily wear. Thus, flexible headcap 100 may be worn by law enforcement officers while executing their daily duties. Flexible headcap 100 may provide three hundred and sixty degrees (360?) of head protection while also being comfortable to wear, e.g., relative to rigid helmets or other ballistic headwear.

[0048] Flexible headcap 100 may include multiple layers of strong, ballistic-resistant flexible sheets 10 that engage and deform a projectile in order to spreading a force of the projectile over a larger portion of flexible headcap 100, relative to an undeformed projectile. Flexible headcap 100 can absorb energy from the deforming projectile and stop the projectile before the projectile completely penetrates the flexible headcap 100. In certain example embodiments, flexible headcap 100 may conform to the NIJ Type Ma standard and thus protect against penetration by the bullets described in such standard. Thus, e.g., flexible headcap 100 may stop 0.357 SIG and 0.44 Magnum ammunition fired from longer barrel handguns.

[0049] As shown in FIG. 8, flexible ballistic sheets 10 may also be oriented within flexible headcap 100 such that overlap joints 20 of adjacent flexible ballistic sheets 10 are offset or misaligned within flexible headcap 100. Thus, e.g., as shown in FIG. 8, an overlap joint 120 of a first one of flexible ballistic sheets 10 may be offset from an overlap joint 122 of a second one of flexible ballistic sheets 10 that is adjacent the first one of flexible ballistic sheets 10 within the stack 110. In addition, an overlap joint 124 of a third one of flexible ballistic sheets 10 may be offset from the overlap joint 122 of the second one of flexible ballistic sheets 10 that is adjacent the third one of flexible ballistic sheets 10 within the stack 110, e.g., and also offset from the overlap joint 120 of the first one of flexible ballistic sheets 10 within the stack 110. As an example, the overlap joints 20 of adjacent flexible ballistic sheets 10 may be offset by no less than fifty millimeters (50 mm), such as no less than twenty-five millimeters (25 mm), such as no less than ten millimeters (10 mm), e.g., at outer edges 16 of flexible ballistic sheets 10. Such relative positioning of the flexible ballistic sheets 10 within stack 110 may advantageously assist with limiting or preventing penetration of flexible headcap 100 by projectiles, such as bullets, e.g., by aligning the overlap joint 120 of each flexible ballistic sheet 10 with a continuous (non-slit) portion of adjacent flexible ballistic sheets 10.

[0050] Flexible headcap 100 formed from flexible ballistic sheets 10 may be disposed within headwear in order to protect the skull and brain of a wearer. For example, as shown in FIG. 7, flexible headcap 100 may be disposed within headwear, such as a cap, hat, scarf, etc., and the flexible headcap 100 may prevent projectiles from penetrating the skull so that underlying brain tissue is thereby protected. In FIG. 7, a fabric cap 200 is shown. Flexible headcap 100 may be positioned within fabric cap 200. Moreover, a wearer may insert flexible headcap 100 within fabric cap 200. An interior of fabric cap 200 may be shaped complementary to flexible headcap 100, Moreover, an inner surface of fabric cap 200 may be shaped complementary to outer surface 102 of flexible headcap 100. Flexible headcap 100 in fabric cap 200 may protect a wearer of fabric cap 200 from brain damage due to projectiles, such as bullets.

[0051] Fabric cap 200 may be constructed to match the appearance of known headwear, such as a baseball cap, a casquette, a combination cap, a boonie hat, a patrol cap, a ranger hat, etc. Thus, e.g., fabric cap 200 may be constructed of various fabric panels stitched together. Fabric cap 200 may include one or more of para-aramid fibers, polyester fibers, cotton fibers, wool fibers, etc. As may be seen from the above, fabric cap 200 may have a covert and unassuming appearance. Thus, fabric cap 200 with flexible headcap 100 therein may be worn to provide protection from brain damage due to projectiles, such as bullets, while also avoiding the aggressive or militaristic appearance of known helmets.

[0052] Within fabric cap 200, a top portion 106 of flexible headcap 100 may be positioned adjacent a top portion 202 of fabric cap 200, and a bottom edge 108 of flexible headcap 100 may be positioned adjacent a bottom portion 204 of fabric cap 200. Thus, e.g., flexible headcap 100 may be distributed in a generally semi-spherical pattern within a corresponding portion of fabric cap 200. In particular, flexible headcap 100 may be distributed three-hundred and sixty degrees (360?) around an interior of fabric cap 200, e.g., in a plane that is perpendicular to an axis between the top and bottom portions 202, 204 of fabric cap 200. In such a manner, e.g., flexible headcap 100 may be positioned in fabric cap 200 to cover anterior, lateral and posterior skull bones when fabric cap 200 on a wearer.

[0053] As shown in FIG. 3, flexible headcap 100 may be removable from fabric cap 200. Thus, e.g., flexible headcap 100 may be removed from fabric cap 200 to allow cleaning of fabric cap 200, replacement of flexible headcap 100, etc. In alternative example embodiments, flexible headcap 100 may be attached to (e.g., sewn, adhered, riveted, etc.) fabric cap 200 such that flexible headcap 100 are not removable from fabric cap 200.

[0054] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.