Flexible body armor
12435954 ยท 2025-10-07
Assignee
Inventors
Cpc classification
F41H5/0478
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
D03D15/283
TEXTILES; PAPER
F41H5/013
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F41H1/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F41H5/0485
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
D10B2321/0211
TEXTILES; PAPER
Y10T442/3472
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F41H5/0471
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F41H1/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F41H5/013
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Implementations described and claimed herein provide a ballistic filler for a flexible soft body armor and methods of manufacturing the same. In one implementation, a first portion having a first subpanel is stitched directly to a second subpanel with a stitching pattern. The first subpanel has one or more layers of woven fabric, and the second subpanel has one or more layers of unidirectional fabric. A second portion backs the first portion. The second portion has one or more layers of unstitched unidirectional fabric.
Claims
1. A flexible body armor ballistic filler comprising: a first subpanel comprising a plurality of layers of flexible ballistic woven fabric generated from a high strength yarn; a second subpanel backing the first subpanel, the second subpanel comprising a plurality of layers of unidirectional ballistic fabric generated from ultrahigh molecular weight polyethylene yarn the first subpanel stitched to the second subpanel to form a first panel; and a second panel comprising a plurality of layers of unidirectional ballistic fabric generated from ultrahigh molecular weight polyethylene yarn, the plurality of layers being stitched tougher; a third panel comprising one or more unstitched ballistic ply structures generated from the high strength yarn, wherein the first panel, the second panel and the third panel are stitched together at a proximate end and a distal end to define a ballistic filler assembly.
2. The flexible body armor ballistic filler of claim 1, wherein an edge tape is applied to the to a portion of a periphery of the ballistic filler assembly.
3. The flexible body armor ballistic filler of claim 1, wherein the ballistic filler assembly has a profile to match a ballistic plate.
4. The flexible body armor ballistic filler of claim 1, further comprises a framework that is exterior to the ballistic filler assembly.
5. The flexible body armor ballistic filler of claim 4, wherein the framework is disposed adjacent the ballistic filler assembly.
6. The flexible body armor ballistic filler of claim 4, wherein the framework provides structural integrity to the ballistic filler assembly.
7. The flexible body armor ballistic filler of claim 4, wherein the framework prevents sagging of the ballistic filler assembly.
8. The flexible body armor ballistic filler of claim 4, wherein the framework has a profile that is complimentary to the profile of the ballistic filler assembly.
Description
BRIEF DESCRIPTIONS OF THE DRAWINGS
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DETAILED DESCRIPTIONS
(11) Aspects of the present disclosure involve ballistic filler for flexible body armor insertable or otherwise deployed into ballistic gear. The ballistic fiber comprises at least a portion of woven fabric stitched directly to unidirectional laminates. In one aspect, the woven fabric is generated from ultrahigh molecular weight polyethylene (UHMWPE) fiber, which when used in conjunction with the unidirectional laminates, is effective as anti-ballistic ply structures. A ballistic arrangement of the ballistic filler includes the UHMWPE woven fabric being backed by unidirectional laminates. More specifically, the ballistic arrangement constitutes one or more regions where one or more plies of UHMWPE woven fabric are backed by one or more plies of unidirectional laminates. As used in the present disclosure, respective to each region, backed refers to plies residing closer to a wearer, and fronted refers to plies closer to a strike face of the ballistic gear. In one particular aspect, one or more of the regions comprised of UHMWPE woven fabric backed by unidirectional laminate are stitched together uniformly using a quilt pattern or some other uniform stitching pattern.
(12) To begin a detailed description of an example ballistic vest 100 for a wearer incorporating aspects of the presently disclosed technology, reference is made to
(13) As can be understood from
(14) In one implementation, the internal components 102 of the ballistic vest 100 include a flexible body armor 110, a ballistic plate 112, and a frame 114. The internal components 102 increase ballistic protection, decrease side spall and back face deformation, provide structural support to the ballistic vest 100, and/or provide other benefits. The internal components 102 are housed within the interior 104 of the ballistic vest 100 extending between a proximal end 116 and a distal end 118 and a first side 120 and a second side 122. In one implementation, the sides 120-122 are shaped to accommodate the anatomy and movement of the wearer's arms, and the proximal end 116 is shaped to accommodate the anatomy and movement of the wearer's collar and neck area.
(15) The ballistic plate 112 is a hard plate configured to provide ballistic protection against projectiles or shrapnel impacting a strike face of the ballistic plate 112. The strike face is disposed within the interior 104 towards the outer layer 106, with a back face disposed towards the inner layer 108. In one implementation, a ballistic component (not shown) wraps around at least a portion of a periphery of the ballistic plate 112 to provide additional protection against side spall created by augmentation of the ballistic plate 112. Such as ballistic component improves the structure of the interior 104 and enhances area coverage and range of motion for increased ergonomics and performance. In one implementation, such a ballistic component provides approximately one inch of additional ballistic coverage beyond a front edge of the ballistic plate 112 and approximately 0.5 inches of additional ballistic coverage beyond side edges of the ballistic plate 112.
(16) In one implementation, the frame 114 includes a body configured to improving overall load carriage performance of the ballistic vest 100 by providing a rigid platform to add weight. The frame 114 body further reduces fatigue by improving the structure of the ballistic vest 100 by retaining the flexible body armor 110 in a configuration that prevents bunching and provides support to the ballistic plate 112 to improve edge hit protection. The frame 114 is loose from or otherwise unattached to the flexible body armor 110 within the interior 104. The frame 114 absorbs and otherwise dissipates energy from an impact of a projectile against the ballistic plate 112 and/or the flexible body armor 110. The frame 114 body may be solid or have one or more openings therethrough, as shown in
(17) As can be understood from
(18) Referring to
(19) Turning to
(20) In one implementation, the stitching comprises a first set of stitching lines 402 parallel to each other and oriented in a first direction and a second set of stitching lines 404 parallel to each other and oriented in a second direction. The first direction may be perpendicular to the second direction to form a quilted square pattern. In one implementation, the first direction and the second direction are both diagonal relative to the proximal end 116 and the distal end 118. Other stitching methods and arrangements are contemplated. In one implementation, a first edge stitching 406 and a second edge stitching 408 extend around a perimeter of the first panel 200 at a distance from the edge (e.g., approximately inches and inches from the edge with +/ inches apart).
(21) Turning to
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(23) As shown in
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(25) The ballistic filler for the flexible body armor 110 provides numerous advantages over monolithic and other hybrid designs. For example, the flexible body armor 110 is comfortable, durable, flexible, lightweight, and provides increased performance, including resistance to ballistic penetration, back face deformation performance, resistance to mechanical fatigue, and resistance to fragmentation threat, and the like.
(26) In one implementation, the ballistic filler of the flexible body armor 110 has distinct regions. At least one region comprises a stitch consolidated assembly of one or more plies of woven fabric generated from ultra-high molecular weight polyethylene (UHMWPE) yarn disposed in front of one or more flexible ballistic ply structures generated from a high strength yarn.
(27) The flexible ballistic ply structures may be, for example, a resin impregnated woven fabrics, unidirectional laminates, multi-axial fabrics, and/or the like. In one implementation, the flexible ballistic ply structures can be generated using high strength yarns including, without limitation, aromatic polyamides such as poly(p-phenylene teraphthalamide), poly(metaphenylene isophthalamide), p-phenylenebenzobisoxazole, polybenzoxazole, polybenzothiazole, aromatic unsaturated polyesters such as polyethylene terephthalate, aromatic polyimides, aromatic polyamideimides, aromatic polyesteramideimides, aromatic polyetheramideimides and aromatic polyesterimides or copolymers of any of the above mentioned classes of materials, and UHMWPE, or any combination of these yarns. In another implementation, the flexible ballistic ply structures are woven fabrics generated from high strength fiber are woven structures produced using yarns containing aromatic polyamides including poly(p-phenylene teraphthalamide), poly(metaphenylene isophthalamide), p-phenylenebenzobisoxazole, polybenzoxazole, polybenzothiazole, aromatic unsaturated polyesters such as polyethylene terephthalate, aromatic polyimides, aromatic polyamideimides, aromatic polyesteramideimides, aromatic polyetheramideimides and aromatic polyesterimides or copolymers of any of the above mentioned classes of materials or any combinations of these yarns.
(28) In one implementation, at least one region of the ballistic filler of the flexible body armor 110 comprises one or more plies of unstitched ballistic ply structures generated from a high strength yarn, which may have a tenacity greater than about 7 grams/denier. The unstitched ballistic ply structures may include woven fabrics, resin impregnated woven fabrics, unidirectional laminates, or multi-axial fabrics generated from yarns containing aromatic polyamides including poly(p-phenylene teraphthalamide), poly(metaphenylene isophthalamide), p-phenylenebenzobisoxazole, polybenzoxazole, polybenzothiazole, aromatic unsaturated polyesters such as polyethylene terephthalate, aromatic polyimides, aromatic polyamideimides, aromatic polyesteramideimides, aromatic polyetheramideimides and aromatic polyesterimides or copolymers of any of the above mentioned classes of materials, and UHMWPE or any combinations of these yarns.
(29) Any one of the stitch consolidated assemblies of plies of the ballistic filler for the flexible body armor 110 is achieved using any stitching thread and any type of stitching method to achieve through-thickness connectivity of the plies, including chain stitching or lock stitching to secure all plies in the assembly together. In one implementation, a stitching pattern that is uniform across the surface of the entire assembly is used. Such a uniform stitching pattern may be, for example, a grid pattern (e.g., quilt pattern), co-linear rows of stitching, concentric circles, a spiral, and/or the like. In another implementation, the stitching pattern of any one of the stitch-consolidated assembly of plies is not uniform across the surface of the entire assembly. As described herein, the ballistic filler for the flexible body armor 110 includes a stitched consolidated region and a free ply region. In one implementation, the weight fraction of the stitch consolidated region is no greater than 50% the overall weigh of the ballistic filler. Further, the ballistic filler of the flexible body armor 110 includes at least one region of woven fabric stitched directly to unidirectional fabric.
(30) To achieve a desired level of protection, the ballistic filler for the flexible body armor 110 is configured to inhibit the complete penetration of a particular ballistic threat by overcoming the energy associated with the ballistic event. Two examples of commercially available high strength fibers routinely used to generate anti-ballistic ply structures used in ballistic filler include para-aramid fiber, such as Kevlar fiber from Dupont and Twaron fiber from Teijin, and UHMWPE, including Spectra fiber from Honeywell and Dyneema fiber from DSM.
(31) The performance of ballistic gear utilizing ply structures generated from high strength fiber is generally measured based on penetration resistance, as well as the resistance to back face deformation that can lead to blunt trauma injuries. Penetration resistance is routinely reported as the VSO, which is defined as the velocity at which a specific ballistic threat will penetrate an armor construction 50% of the time. A methodology routinely used for determining the VSO of a particular armor system against a specific threat is outlined in Mil-STD 662F VSO Ballistic test for Armor and Purchase Description FQ/PD 07-OSG, Body Armor, Multiple Threat/Interceptor Improved Outer Tactical Vest (IOTV) Generation Ill. The methodology for determining back face deformation is outlined in NIJ Standard 0101.06, Ballistic Resistance of Body Armor. As will be understood from the comparative and experimental examples provided herein, the ballistic filler for the flexible body armor 110 meets these standards and provides numerous advantages over monolithic and other hybrid designs. For example, the flexible body armor 110 is comfortable, durable, flexible, lightweight, and provides increased performance, including resistance to ballistic penetration, back face deformation performance, resistance to mechanical fatigue, and resistance to fragmentation threat, and the like.
(32) Woven fabrics generated using para-aramid fiber have long demonstrated robust ballistic performance as anti-ballistic ply structures used in flexible armor systems. Woven anti-ballistic fabrics rely on mechanical interlacing of yarns using commercial weaving equipment and are a desired when designing systems that provide flexibility, comfort, conformability, and improved breathability. Additionally, the mechanically interlocked woven fabrics are very durable, requiring no adhesives or matrix resins to create the ballistic ply structure. Woven anti-ballistic fabrics and can undergo significant flexural fatigue without losing ballistic performance. Several investigations of flexible body armor fabricated using woven para-aramid fabrics reclaimed after more than a decade of continuous use in the field have demonstrated no ballistic performance loss when compared to the performance of the same designs when first issued.
(33) While mechanical properties of UHMWPE fibers can significantly exceed those of para-aramid fibers such as Kevlar, woven fabrics generated from UHMWPE fiber have routinely been observed to underperform para-aramid fabrics. One proposition for this observation is that the low friction coefficient of UHMWPE fibers greatly facilitates slip and translation of the warp and fill yarns at the point of impact in woven constructions made therefrom during the ballistic event. This significantly reduces yarn engagement of the ballistic threat, allowing it to pass through the woven structures with limited loading of the UHMWPE yarns.
(34) Unidirectional laminates represent a second type of anti-ballistic ply structure used in the manufacture of flexible body armor systems. Unidirectional laminates are constructed from two or more layers of unidirectionally oriented high strength yarns adhesively bound together using matrix resins and optionally polymer films. The unidirectional fiber layers in the unidirectional laminate are cross-plied; having fiber direction of individual layers rotated 90 degrees relative to the neighboring layers they are laminated to. Unidirectional laminates have demonstrated improved ballistic VSO performance and improved back face deformation performance against high energy deformable projectiles such as bullet threats when compared to woven fabric systems for the same areal density. Disadvantages associated with the unidirectional laminate structure include reduced fragmentation threat resistance, increased stiffness and potentially reduced mechanical fatigue resistance when compared to woven structures generated with the same fiber.
(35) Due to the aforementioned issue associated with its use in woven constructions, the unidirectional laminate was conventionally the preferred anti-ballistic structure for UHMWPE fiber. UHMWPE has found significant commercial success in soft armor systems when used in unidirectional laminate structures. These materials are commercially available under the trade names Spectra Shield from Honeywell, or Dyneema Unidirectional from DSM. These unidirectional laminate materials are generated using tacky adhesive matrix resins capable of overcoming the low surface friction and low surface energy of the UHMWPE fiber, resulting in mechanically stable anti-ballistic structures.
(36) Hybrid designs containing woven para-aramid and either para-aramid or UHMWPE unidirectional laminates are disclosed. The hybrid designs provide improved flexibility at the expense of increased back face deformation compared to monolithic soft body armor designs comprised entirely of unidirectional laminates. Given the issues detailed above with the conventional materials, the ballistic filler of the flexible body armor 110 satisfies a long felt need in the ballistic gear industry and was developed from unexpected results. More particularly, V50 performance against deformable bullet threats and fragmentation threats in hybrid designs is largely governed by the V50 performance of the individual component materials weighted by their respective percent contribution in the hybrid design. The ballistic V50 performance of the hybrid design of the ballistic filler of the flexible body armor 110 is unexpected, among other reasons, based on the conventionally poor monolithic performance of the woven UHMWPE fabric as described above. Comparative and experimental examples are provided below to illustrate the unexpected and superior ballistic V50 performance of the flexible body armor 110.
Comparative Example 1
(37) Three 15 inch15 inch monolithic ballistic filler test panels were assemble using 32 plies of water repellent treated woven para-aramid fabric. The fabric was generated with 500 d Kevlar KM2 Plus fiber having a plain weave construction with 28 ends per inch in the warp direction, and 28 picks per inch in the fill direction. The basis weight of the fabric was 3.61 oz/yd2. The areal density of the ballistic filler test panels was 0.80 lbs/ft2. The filler panels were stitched along corners with Kevlar stitching thread to secure plies in place during testing. Each of the three panels was tested to determine the V50 against the Remington 9 mm FMJ bullet threat based on the testing protocol outlined in Purchase Description FQ/PD 07-05G, Body Armor, Multiple Threat/Interceptor Improved Outer Tactical Vest (IOTV) Generation Ill. The average of the V50s measured for the three replicate panels was 1486 ft/s.
Comparative Example 2
(38) Three 15 inch15 inch monolithic ballistic filler test panels were assemble using 15 plies of woven UHMWPE fabric. The fabric was generated with 288 denier Dyneema UHMWPE fiber having a 5/1 twill weave construction with 21 ends per inch in the warp direction, and 20 picks per inch in the fill direction. The basis weight of the fabric was 8.50 oz/yd2 The fabric thickness was 19.8 mils and 0.50 mm. The fabric was supplied by JPS Composites of Greenville, SC as fabric style 17517. The areal density of the ballistic filler test panels was 0.84 lbs/ft2. The filler panels were stitched along corners with Kevlar stitching thread to secure plies in place during testing. The average of the measured 9 mm FMJ bullet V50s for the three replicate panels was 469 ft/s.
Comparative Example 3
(39) Three 15 inch15 inch monolithic ballistic filler test panels were assemble using 18 plies of UHMWPE unidirectional laminate. The unidirectional laminate was supplied by DSM under the trade name Dyneema SB117. The basis weight of the Dyneema SB117 was 6.37 oz/yd2. The filler panels were stitched along corners with Kevlar stitching thread to secure plies in place during testing. The areal density of the ballistic filler test panels was 0.80 lbs/ft2. The average of the measured 9 mm FMJ bullet V50s for the three replicate panels was 1997 ft/s.
Comparative Example 4
(40) Three 15 inch15 inch hybrid ballistic filler panels were assemble using the 500 d woven Kevlar fabric described in example 1, and the Dyneema SB117 unidirectional laminate described in example 3. The hybrid design consisted of a front (strike face) region comprising 7 plies of the 500 d woven Kevlar fabric quilt stitched to 4 plies of the Dyneema SB117 using Kevlar thread in 2 inch diagonal square stitching pattern. The quilted region was backed by 10 plies of Dyneema SB117 and the filler panels were stitched along corners with Kevlar stitching thread to secure plies in place during testing. The weight percent of woven Kevlar fabric in this design was 22.1 wt %. The areal density of the ballistic filler test panels was 0.81 lbs/ft2. Each of the three panels was tested to determine the V50 against the Remington 9 mm FMJ bullet threat. The average of the V50s measured for the three replicate panels was 1863 ft/s.
Experimental Example
(41) Three 15 inch15 inch hybrid ballistic filler panels were assemble using the woven Dyneema UHMWPE fabric described in Comparative Example 2, and the Dyneema SB117 unidirectional laminate described in example 3. The hybrid design consisted of a front (strike face) region comprising 3 plies of the woven Dyneema UHMWPE fabric 500 d Kevlar fabrics quilt stitched to 4 plies of the Dyneema S8117 using Kevlar thread in 2 inch diagonal square stitching pattern. The quilted region was backed by 10 plies of Dyneema S8117 and the filler panels were stitched along corners with Kevlar stitching thread to secure plies in place during testing. The weight percent of woven UHMWPE fabric in this design was 21.4 wt %. The areal density of the ballistic filler test panels was 0.81 lbs/ft2. Each of the three panels was tested as before to determine the V50 against the Remington 9 mm FMJ bullet threat. The average of the V50s measured for the three replicate panels was 1880 ft/s. These results indicate improved average 9 mm FMJ V50 performance over that of Comparative Example 4 having similar ply arrangement, and roughly the same areal density and woven fabric content. This result is unanticipated based on the poor monolithic 9 mm FMJ V50 performance of the woven UHMWPE fabric panels presented in Comparative Example 2.
(42) While the present disclosure has been described with reference to various implementations, it will be understood that these implementations are illustrative and that the scope of the disclosure is not limited to them. Many variations, modifications, additions, and improvements are possible. More generally, implementations in accordance with the present disclosure have been described in the context of particular examples. Functionality may be separated or combined in blocks differently in various implementations of the disclosure or described with different terminology. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure as defined in the claims that follow.