Ballistic Vest

Some ballistic vests are constructed as a set of ballistic panels (soft armor) supported in a carrier. Many of these ballistic vests are relatively inflexible, unaccommodating to movement of the user, and thus uncomfortable. A vest that is constructed in accordance with the present invention can help to overcome those deficiencies.

The present invention relates to a ballistic vest. The invention is applicable to vest of different constructions. As representative of the invention,illustrates a vestthat is a first embodiment of the invention.

One major component of the vestis a carrier. The other main component of the vestis a plurality of ballistic panels or ballistic inserts (soft armor). In the particular vestthat is illustrated, there are four ballistic panels: a front ballistic panel, a back ballistic panel, a left side ballistic panel, and a right side ballistic panel. Other vests in accordance with the invention might have more than four ballistic panels or fewer than four ballistic panels. As described below, the ballistic panels-are inserted into the carrierafter the carrier is itself assembled; thereafter, the vestcan be donned by the user.

The carrierin the illustrated embodiment includes as its two major components a carrier outer layerand a carrier inner layer. One or both of the carrier layersandmay be made from a number of individual fabric panels that are joined together, preferably by sewing.

Assembly of the carrierpreferably starts with the carrier outer layer(). In, the outer carrier layeris viewed from the body side, that is, from the side closer to the user when being worn. The outer layerextends over all or substantially all of the exterior of the vestwhen the vestis being worn by a user. In the illustrated vest embodiment, the outer layeris not flat, but rather is three-dimensional. As such, it is made from a number of individual pieces of fabric sewn together with stitching sections. In other embodiments of the invention, the outer layercan be made from more or fewer fabric pieces, and the pieces may be joined to each other in a manner other than by sewing.

Each fabric panel of the carrier panel can utilize stretch knits or woven fabrics of varying weights and elasticity/stretch. Some fabric panels may have more elasticity/stretch than others. The fabrics may incorporate wicking, antimicrobial and/or cooling features throughout the carrier, or such features may be incorporated in strategic panel locations. One material that has been found to be suitable is the type of material that is used for cycling jerseys.

Some fabric panels of the carrierare preferably, but not necessarily, made from a different fabric than others. For example, some fabric panels may be made from a higher compression material to help keep the ballistic panels in place during movement; others may be made from a material that has less compression for ease of movement and comfort. The goal is to balance these aspects to achieve the right amount of compression to stabilize the ballistic panels while still providing a high degree of movement and comfort.

The carrier outer layer() has an upper edge, a lower edge, a left side edge, and a right side edge. (The right side edgeis to the left as viewed in, because the outer layeris viewed, in, from the body side or inside.) Two armholesandare located near the upper edge.

A right sectionof a front zipperis secured to the right side edgeof the outer layer, and a left sectionof the zipperis secured to the left side edgeof the outer layer. One preferred type of zipper that has been utilized is a separating coil zipper. Coil type zippers are known for their ability to operate under high degrees of horizontal strength, are very flexible and are the least likely to become misaligned. However, the invention contemplates that other types of zippers, and other closure technologies, may be utilized.

One step in assembly of the carrieris the addition of the front panel flapto the outer layer(). The front panel flapis secured to the inside of the outer layer, just inside the right zipper portion section, preferably by sewing. The front panel flapis formed of two layers of fabric with an open space or pocket between them; only one of these layers (the hidden layer in) is sewn to the outer layer. An openinginto this pocket runs along the right zipper section, so that a lateral portion of the front ballistic panelcan be inserted laterally into the pocket in the front panel flap, in a manner described below.

After the front panel flapis secured to the outer layer, the inner carrier layer() is secured to the outer carrier layer, preferably by sewing. Specifically, an upper edgeof the inner layeris secured along the upper edgeof the outer layer. A lower edgeof the inner layeris secured to the outer layerwith two laterally spaced stitching sectionsand, at a location upward from the lower edgeof the outer layer. A central openingis left between the stitching sectionsand. The right and left edges of the inner layerare not sewn down to the outer layer.

Two arm holesandin the inner layeroverlie the armholesand, respectively, in the outer layer, forming vest armholesandin the completed carrier. The inner layeris sewn to the outer layeraround the periphery of the vest armholesand, to secure the two carrier layers together at those locations.

The carrierat this point in the assembly process has two layers of fabric at the areas where the inner layeroverlies the outer layer. Because those two layers of fabric, the inner carrier layerand the outer carrier layer, are joined only along their respective upper and lower edges, a panel volume or panel space, designatedin the drawings, is formed between the inner layer and the outer layer. The panel spaceis bounded generally by the top edgesandof the inner and outer carrier panelsand; the right and left vest armholesand, and the bottom edgeof the inner carrier panel. The inner layercan be pulled away from the outer layerto receive and support the front and back ballistic panelsand, respectively, in the panel space, in a manner as described below.

In a further assembly step (), the right and left side panel pocketsand, respectively, are secured to the inner layer, preferably by sewing. Each one of the side panel pocketsandpreferably includes two layers of fabric material. Each side panel pocket,has a top opening, which may be closable by a zipper (not shown), to allow for insertion of its respective side ballistic panel,.

When the carrieris thus fully assembled, there are a number of openings or gaps through which the various ballistic panels can be placed into the pockets. Some of these openings or gaps are illustrated in. Specifically, the arrowillustrates an opening between the outer layerand the inner layerinto which a first lateral section of the front ballistic panelcan be inserted into the panel space. The arrowillustrates an opening between the outer layerand the inner layerinto which a second lateral section of the front ballistic panelcan be inserted into the front panel flap.

The arrowillustrates an opening into which the right side ballistic panelcan be inserted into the right side pocket. The arrowillustrates an opening into which the left side ballistic panelcan be inserted into the left side pocket. The arrowillustrates an opening into which the back ballistic panelcan be inserted upwardly into the panel space. Also shown is an openingat the left zipper sectioninto which the front panel flapcan be inserted, into the panel spacebetween the inner layerand the outer layer.

The ballistic panels can be inserted into the carrierin any selected order. One preferred order of steps is shown in. In, a first lateral sectionof the front ballistic panelis placed through the openinginto the panel spacebetween the inner carrier layerand the outer carrier layer. The first lateral sectionof the front ballistic panelis secured (suspended) in the carrierat a fixation point. This fixation may occur via a hook and loop connection, or otherwise. This fixation pointis located in the panel space, at or near the top edge of the carrier.

The fixation pointis primarily to hold the front panelin place in the carrier, in the event of a bullet impacting that area of the vest. Primarily, though, the front panelis substantially held in position in the panel spaceby a close fit within the carrier as described above, and by the bottom seam.

The back ballistic panelis inserted upward through the openinginto the panel spacebetween the inner layerand the outer layer. The back ballistic panelis secured (suspended) in the carrierat two fixation pointsand. This fixation may occur via a hook and loop connection, or otherwise. These fixation pointsandare located in the panel space, at or near the top edge of the carrier. Again, the fixation pointsandare primarily to hold the back panelin place in the carrier, in the event of a bullet impacting that area of the vest.

The left side ballistic panelis placed through the openinginto the left side panel pocket. The right side ballistic panelis placed through the openinginto the right side panel pocket. The side panel pocketsandare closed with their fasteners.

As shown in, the second lateral section or remainderof the front ballistic panelis placed through the openinginto the pocket in the front panel flap. As a result, half of the front ballistic panelis located in the panel spacebetween the outer layerand the inner layer, and the other half is contained within the front panel flap, projecting from the right side edge of the carrierat a location adjacent to but inside the right zipper section. An upper edge portionof the panelextends out of an opening in the upper corner of the front panel flap.

The user can then don the vest, in a manner as illustrated in. The user's arms are placed through the vest armholesandwhile donning the vest. The right side of the vest, with the front panel flapprojecting, is moved adjacent to the left side of the vest. The projecting front panel flapis flipped over and inserted through the opening() between the outer layerand the inner layer, along the left zipper section, thus being moved as one piece into the panel space. This action locates the front ballistic panelcompletely in the panel spacebetween the outer layerof the carrierand the inner layerof the carrier.

The second lateral sectionof the front ballistic panel(the projecting upper edge portion) is then secured (suspended) in the carrierat a fixation point. This fixation may occur via a hook and loop connection, or otherwise. This fixation pointis located in the panel space, at or near the top edge of the vest.

The zipperis zipped up, drawing the left side of the carriertogether with the right side of the carrier. In this condition, the front ballistic panelextends across the upper torso area of the user. This is a continuous placement, extending across the front zipper opening of the vest, thus providing complete front protection. The left side ballistic paneloverlies the left side of the user's torso. The right side ballistic paneloverlies the right side of the user's torso. The back ballistic paneloverlies the upper back of the user's torso.

An upper sectionof the back panelis disposed within the panel spacein the carrier, above an imaginary line() that extends laterally across the vestat a location at or just below the lower edge of the vest armholesand. The back panel upper sectionis fixed to the carrier, within the panel space, at the two fixation pointsand. These fixation pointsand(which are above the line), together with the sewn armholesand, substantially constrain lateral movement of the back panel upper sectionin the panel spacein the carrier.

In contrast, the part of the panel spacethat is below the imaginary lineand above the bottom edgeof the inner carrier panel, can be considered as being a tunnel, being open from side to side with no significant lateral obstructions. A lower sectionof the back panelextends downward from the upper sectioninto this tunnel, below the imaginary lineand below the bottom edge of the left and right armholesand. The lower sectionof the back panelis supported in the tunnelonly by the upper sectionof the back panel. The back panel lower sectionis thus substantially freer to move laterally in the tunnel portionof the panel spacethan is the upper section, as it is substantially less constrained laterally.

In the tunnel, the back panel lower sectionat least partially overlaps the left and right ballistic side panelsand. The back panel lower sectionis movable laterally relative to the left and right ballistic side panelsand

In a similar manner, a lower sectionof the front panel, disposed in the tunnel, at least partially overlaps the left and right ballistic side panels. The front panel lower sectionis movable laterally relative to the left and right ballistic side panelsand. The front panel lower sectionand the back panel lower sectionare also movable laterally relative to each other.

As thus constructed, the vestprovides numerous benefits when being worn by the user. The ability of the front panel lower sectionand the back panel lower sectionto move laterally within the tunnel portionof the carrier panel space, provides a very significant benefit. With the carrier itself being a snug fit on the user's torso, this feature allows for increased movement of the front and back ballistic panelsandwith respect to the user's torso.

The vestadjusts itself to the user's torso. The ballistic panels to some extent “self center” when the vestis donned, because of the flexible fabric and the ability of the lower portions of the front and back panelsandto move within the carrier. The ballistic panelsandcan move, or float, as the body moves. The dimensions of the various parts of the vestare selected so that the parts can move or articulate relative to one another, while staying in generally the right location as needed for protection. As a result, the vestof the present invention is both protective and comfortable.

The lower portions of the front and back panelsandare constrained laterally only by the compression of the veston the torso, the armhole blockage (the width of the carrier), and the dimensions of the various parts. The dimensions of each element, and their placement, are selected to enable this limited amount of freedom of movement (articulation) in the tunnel area, which is located at the waist of the user where it is most needed.

The elasticity of the fabric material of the carrier, especially the outer layerand the inner layer, also allows for some movement or articulation of the various ballistic panels relative to each other. Because the carrier fabric material is quite thin, the ballistic panels can lie closely against the user's torso. This structure, as a whole, compares very favorably to a typical vestthat is rigid and heavy and non-conforming.

As a result, the vestas a whole is not a rigid structure but is rather a flexible structure overall that includes relatively hard areas at the locations of the ballistic panels—with at least several inches of movement possible in many locations and in many directions. This makes the vestmuch more comfortable.

As an analogy, It might be considered that the side panelsandare like the rib cage—fixed, relatively stationary—while the front and back panelsandare like the shoulder blades—held in place generally by tendons and muscles, but able to move around somewhat relative to the rib cage. Just as the shoulder blades can move around over the rib cage, so too can the front and back panelsandmove around over the side panelsand.

Another benefit of the vestlies in the area of load distribution. Specifically, a ballistic vest can be relatively heavy for a law enforcement officer to wear, especially for an extended period of time such as an all-day shift. Also, the load (weight) of a vest is typically carried primarily by the shoulder straps of the vest, bearing down on the officer's shoulders. Together, these factors can create discomfort or pain, and can tire the wearer.

In accordance with the present invention, the vestis preferably configured and sized appropriately for the user, so that there is a snug fit on the user's torso. The material for the outer and inner carrier layersandis significantly stretchable and elastic. The resulting elasticity of the carriertends to hold the vestin place on the user's torso, thus resisting downward movement of the vest along the torso of the user. In addition, the carrieris made from a light weight, relatively inexpensive fabric and therefore can feasibly be made in a variety of sizes to fit different sized users. Thus, the desired snug fit can readily be obtained, while still allowing for the panel articulation described above. As a result, some of the load of the vestis transferred onto the core of the user. This load distribution reduces the apparent load on the shoulder and collarbone area of the user, making it more comfortable to wear the vestfor a longer period of time without tiring.

The dimensions of the carrier are designed for the individual user (different sizes), to be tight along the core and thus press the ballistic panels snugly against the core of the user's body. When this occurs, some of the load (weight) of the vest is borne by the user's core rather than the shoulders, making wearing of the vest for an extended period of time more comfortable. The ballistic panels are in their proper places for protection, when the user stands up straight. When the user bends over, the overall configuration of the carrier fabric deforms as it moves to a different position on the body. The ability of the panels to articulate (move within the carrier) enables the vest to remain comfortable, as compared to a situation in which the panels would be pushed or pulled by the carrier fabric when it moves to a different position on the body. The panels will self center or auto center as the user comes back to a standing position. Because the panels are loose, the carrier can stay snug on the user's waist and core, thus maintaining the effectiveness of this load bearing feature.

illustrate the inclusion and positioning of an optional trauma plate(hard plate) in a pocketon the carrierof the vest. The pocketis located on the outer side (strike face) of the front ballistic panel flap. The platemay be inserted before the vest is donned. The plateends up on the outside (strike side) of the front ballistic panel, which like the other ballistic panels,, andis soft armor. The pocketis preferably located so that it and the plateare centered laterally on the front of the vest.

In the first embodiment of the invention illustrated and described above, four ballistic panels are provided. The front panel and the back panel overlap each other and also overlap the side panels (see). Other embodiments are possible. In the vestshown in, for example, both the front panel and the back panel overlap the side panels, but do not overlap each other. In the vestshown in, for example, no side panels are present, as is the case with many vests, so the front and back panels overlap each other. The front panel and the back panel are configured as needed for the desired amount of overlap.

Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, the scope of the invention is limited only by the claims.