Abstract:
A method is disclosed for making a bullet and fragmentation resistant vest. The method may include layering the following materials, in the following order, to create a pre-sewing ballistic pack: two layers of a Barrday TWF2006 and Twaron 2040 basket weave, ten layers of Barrday U600 four ply, and eleven layers of Dyneema SB21. The method may also include sewing at least one bar tack into the pre-sewing ballistic pack to create a pre-heat-treatment ballistic pack. The method may further include maintaining the pre-heat-treatment ballistic pack at a temperature of between about 65 and about 73 degrees Celsius at about one atmosphere for about 45 minutes to create a completed ballistic pack. The method may additionally include covering the completed ballistic pack to create a covered ballistic pack, and inserting the covered ballistic pack into a carrier vest.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to both Provisional U.S. Patent Application No. 61/434,297 filed Jan. 19, 2011, entitled “BULLET AND FRAGMENTATION RESISTANT VESTS AND LAYERED FABRICS” and Provisional U.S. Patent Application No. 61/434,301 filed Jan. 19, 2011, entitled “SYSTEMS AND METHODS FOR CERTIFICATION, DISTRIBUTION, MAINTENANCE, AND REWARRANTY OF TACTICAL VESTS.” The entire disclosures of both of the aforementioned Provisional U.S. Patent Applications are hereby incorporated by reference, for all purposes, as if fully set forth herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    This invention relates generally to bullet and fragmentation resistant fabrics. More specifically, the invention relates to bullet and fragmentation resistant vests, and flexible versions thereof 
         [0003]    Typical bullet and fragmentation resistant vests as known in the art are rigid. 
         [0004]    This makes them uncomfortable, and sometimes impractical, for end users who may often need the maximum possible freedom of movement in life threatening situations. 
         [0005]    Embodiments of the instant invention provide solutions to these and other problems. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0006]    In one embodiment, a method for making a bullet and fragmentation resistant vest is provided. The method may include layering the following materials, in the following order, to create a pre-sewing ballistic pack: two layers of a Barrday TWF2006 and Twaron 2040 basket weave; ten layers of Barrday U600 four ply; and eleven layers of Dyneema SB21. The method may also include sewing at least one bar tack into the pre-sewing ballistic pack to create a pre-heat-treatment ballistic pack. The method may also include maintaining the pre-heat-treatment ballistic pack at a temperature of between about 65 and about 73 degrees Celsius at about one atmosphere for about 45 minutes to create a completed ballistic pack. The method may further include covering the completed ballistic pack to create a covered ballistic pack. The method may additionally include inserting the covered ballistic pack into a carrier vest. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0007]    The present invention is described in conjunction with the appended figures: 
           [0008]      FIG. 1  shows construction of one embodiment of the invention for an NIJ level IIIA ballistic pack; 
           [0009]      FIG. 2  shows a ballistic pack with all layers assembled and a bar tack sewn in; 
           [0010]      FIG. 3  shows a block diagram of a method of the invention for certifying, distributing, maintaining, and rewarranting tactical vests; and 
           [0011]      FIG. 4  shows a computer interface involved for a vest donation system of the invention. 
       
    
    
       [0012]    In the appended figures, similar components and/or features may have the same numerical reference label. Further, various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components and/or features. If only the first numerical reference label is used in the specification, the description is applicable to any one of the similar components and/or features having the same first numerical reference label irrespective of the letter suffix. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0013]    Embodiments of the present invention provide bullet and fragmentation resistant vests and layered fabrics, as well as methods for their construction. The vests of the invention may consist of multiple subcomponents, including, merely by way of example, a carrier vest and ballistic packs. The carrier vest may include carrier sections which accept insertion of ballistic packs, with the ballistic packs providing the bullet and fragmentation resistant properties of the vest. These vests may be concealable beneath other clothing, and may be provided in various shapes, sizes, layer packages, colors, and with different markings per standard specifications, or in some instances, user specification. Layered fabrics, for example, blankets and construction materials for bullet and fragmentation resistant structures, both stationary (i.e., buildings) and mobile (i.e., vehicles), may also be provided by the invention in the same manner as ballistic packs of the invention. 
         [0014]    In some embodiments, vests may have two carrier sections, one on the front of the vest and one on the back of the vest, each accepting a ballistic pack to protect vital organs of the wearer from the front and back. In other embodiments, vests may include any number of ballistic packs, possibly to protect the sides and/or groin of the wearer. 
         [0015]    In one embodiment of the invention, the construction of a ballistic pack may include the combination of multiple layers of materials. In some embodiments, the layers may merely be laid onto one another to await further processing. In other embodiments, these layers may be adhered together initially, either partially or wholly across the surface area of each material. In these or other embodiments, the materials will include at least both aramid and polyethylene based fabrics. 
         [0016]    The layers may further be sewn together. In some embodiments, a bar tack may be sewn down the vertical centerline of the ballistic pack, through all layers. In other embodiments, only certain layers may be sewn through. A horizontal bar tack may be located at each end of the vertical bar tack, near the top and bottom of the ballistic pack. In other embodiments, other stitching may be provided, perhaps around the edges of the ballistic pack, either partially or completely. 
         [0017]    After assembly of the layers of the ballistic pack, the resulting ballistic pack may be heat treated for a certain time at a certain temperature. In one embodiment, the temperature may be between about 65 degrees Celsius and about 73 degrees Celsius for a period of about 45 minutes at about one atmosphere of pressure. In an exemplary embodiment, the temperature may be about 69 degrees Celsius for a period of about 45 minutes at about one atmosphere of pressure. Heat treatment may result in better flexibility of the ballistic pack than prior to the heat treatment. 
         [0018]    In other embodiments, the temperature, duration, and pressure of the heat treatment may be adjusted to suit manufacturing constraints or efficiencies. Merely by way of example, pressure may be increased and the duration decreased to increase production speed. Furthermore, in some embodiments, heat may be applied to a ballistic pack in a vacuum. 
         [0019]    After heat treatment, the ballistic pack may be allowed to cool via normal convective heat transfer in room temperature until the ballistic pack itself is at room temperature. The ballistic pack may then be covered in rip stock material, and be ready for insertion into a carrier vest. 
         [0020]    Labels and/or embroideries may be applied to both the ballistic pack cover and the carrier vest. Applicable National Institute of Justice (NIJ) standards, such as 0101.06 may be adhered to regarding such labeling/embroideries. Hook and loop fasteners (i.e., Velcro) may be provided to access/close the carrier sections, as well as for shoulder and waist straps to secure the vest to the wearer. 
         [0021]    Turning to  FIG. 1 , the construction  100  of one embodiment of the invention for an NIJ level IIIA ballistic pack is provided. NIJ level I, IIA, II, and III ballistic packs may be provided by varying the numbers of layers of one or more of the different types of materials discussed below. NIJ level IV vests may be provided by the addition of ceramic, steel, or other plates to the vests described herein. Whenever a material is described by a trade name, equivalent materials of the same and/or similar composition as of the date of this application may also be assumed as applicable to the same application. 
         [0022]    Construction  100  may include, starting at the outer strike face, a first layer  303  and second layer  306  of Barrday TWF2006, Twaron 2040, 1500 denier (grams/9,000 meters), 2×2 basket weave material. A similar material may be used in place of Barrday TWF2006. Twaron 2040 is a poly paraphenylene terephthalamide (Kevlar) or similar material. In other embodiments, different numbers of layers may be used in addition to, or in place of, first layer  303  and second layer  306 . 
         [0023]    Construction  100  may further include intermediate layers  309  of Barrday U600. Barrday U600 is a mulit-ply fabric of unidirectional polyethalyne poly paraphenylene terephthalamide (Kevlar) or similar materials, where four plys are set at 0°, 90°, 0°, and 90° between polyethanlene films or similar materials. This embodiment is shown as having ten intermediate layers  309 . In other embodiments, different numbers of layers may be used in addition to, or in place of, intermediate layers  309 . 
         [0024]    Construction  100  may further include backside layers  312  of Dyneema SB21. Dyneema SB21 is a unidirectional polyethalyne or similar material. This embodiment is shown as having  11  backside layers  312 . In other embodiments, different numbers of layers may be used in addition to, or in place of, backside layers  312 . 
         [0025]      FIG. 2  shows a ballistic pack  200  with all the layers assembled and bar tack  403  sewn in. Bar tack  403  may have a minimum of seven stitches per inch. The horizontal portions of bar tack  403  may be about two inches long and be located about one inch from the top and bottom edges of the ballistic pack. The vertical portion of the bar tack  403  may run between the horizontal bar tacks, and be substantially centered on the vest and horizontal bar tacks. The thread used for the bar tack may be made from any of the aforementioned materials or other similar materials. 
         [0026]    After completion, when the ballistic packs are inserted into the carrier vest, the vest may maintain a degree of flexibility hereto unknown in the art. This flexibility may allow the vest to be rolled up onto itself (similar to that of a traditional sleeping bag), and stored in a bag or other container in such a manner. This greater degree of flexibility will translate during actual use of the vest into greater comfort, flexibility, and operator performance for the user. 
         [0027]    Turning to  FIG. 3 , a method  300  of the invention for certifying, distributing, maintaining, and rewarranting tactical vests is shown. Certification may be the process of determining that a particular tactical vest meets applicable standards, for example National Institute of Justice (NIJ) standards. Distribution may be the process of delivering tactical vests to end users. Maintenance may be the process of cleaning, repairing, and/or replacing used tactical vests (generally referred to as refurbishment). Rewarranting may be the process of reinsuring that refurbished tactical vests still meet the standards under which they were certified. A tactical vest may refer to any ballistic vest configured to be bullet and/or stab resistant. 
         [0028]    At block  103 , a request may be received to supply one or more tactical vests. The request may be to supply an individual vest or a plurality of vests. In some embodiments, the request may come from the end user of the vest or vests, while in other embodiments a third party may request the vest or vests be supplied to the end user. Examples of end users requesters may be police departments and/or military units. Examples of third party requesters may be friends or relatives of an end user. 
         [0029]    The request may be a purchase request or a lease request. In the case of a purchase request, a flat total fee may be collected for delivery of the vest. In the case of a lease requests, a flat partial fee may be collected for delivery of the vest, and continuing lease payments (later occurring partial fees) may be collected for an ongoing basis (i.e. weekly, monthly, quarterly, yearly, etc.). Also, if the request is for a lease, the number of vests requested for simultaneous use may be included in the least request. 
         [0030]    In embodiments where a lease of a vest or vests is requested, the lease may be modeled around the anticipated life cycle of the vests. For example, if the life cycle of the vests is anticipated to be 2 to 3 years, the lease term may be set at that length. In this model, the manufacturer/distributor would maintain ownership of the vests, while the lessee would maintain possession of the vests until the end of the lease term, or the occurrence of an impact incident. 
         [0031]    At either the end of the lease term, or the occurrence of an impact incident, whichever occurs first, the vests would be returned to the manufacturer/distributor for maintenance and refurbishment as described herein. A new or refurbished vest would then be issued by the lessor to the lessee under the terms of the original lease agreement unless a new or modified lease agreement is reached between the parties. In some embodiments, a lease agreement will have a term coextensive with the life cycle of the vest. In other embodiments, a lease agreement will have a term shorter or greater than the life cycle of the vest. 
         [0032]    In some embodiments, the lease may specify that the risk associated with an impact incident requiring replacement/refurbishment of a vest be assumed by the lessor, while in other embodiments, the lease may specify that the risk be assumed by the lessee. Which party assumes the risk would dictate whether the cost to replace a vest on which an impact incident occurs is covered by the manufacturer/distributor, or by the lessee. 
         [0033]    In any case, the types of vests requested may also be included in the request. For example, the armor level/standard of the vests may be specified (e.g., NIJ Type I, IIA, II, IIIA, III, or IV standards). Additional markings on the vest, besides certification and/or trademark markings may also be specified. Personalization of the vest or vests via markings or other indicia of appearance (color, cut, etc.) may also be requested. The terms “tactical vest” or “vest,” as used herein may generally refer to a carrier vest having one or more ballistic packs inserted into portions of the carrier vest. Thus, any marking or personalization of the vest may affect either one or both of the carrier vest and/or the ballistic packs. 
         [0034]    At block  106 , if the request is for a lease, the required number of vests for the end user may be calculated. The total number of required vests may be the number of vests required for simultaneous use plus an additional number of rotational vests. The additional number of rotational vests (possibly a single vest), may equal the number of vests that at any one time may be returned to the supplier for rewarranting and maintenance, as will be discussed below. Other factors that may affect the number of required rotational vests for any specific order may depend on the number of different size vests ordered, as backups may be necessary in proportion to the sizes ordered. 
         [0035]    The additional number of rotational vests may also include backup vests in case a vest worn by a user is involved in an impact incident, for example, being struck by a knife or other melee weapon, bullet, and/or other significant impact force, which would necessitate removal of the vest from operational use. Thus, in the above manner, the end user may be supplied with enough vests for simultaneous use and to account for vests rotated out of, or otherwise removed from, simultaneous use, such than any individual end user within the ordering organization will not be without a vest for any period of time. 
         [0036]    At block  109 , inventory is checked to determine if the requested number and type of vests is available. Some aspects of the request may be customizations that can be applied to stock vests, while other aspects of the request may require certain types of stock vests. The inventory may be computerized and may be checked against all the requirements of the request. A database may be provided during and post-manufacturing that tracks vests and/or vest subcomponents individually via an RFID or other electronic tag present in each vest and subcomponent. Such tracking may extend to end users of the vests and tracking systems used by those end users. 
         [0037]    At block  112 , if the inventory check at block  109  identified the inventory as being sufficient to supply the requests, the requisite vests are pulled from stock. At block  115 , if the inventory check identified the inventory as being insufficient to supply the requests, a manufacturing request detailing the needed vests is formulated and forwarded to a manufacturing unit for the remainder (or total) of vests specified by the request. When a vest is manufactured, either to fulfill a request or to provide stock for inventory, the vest is certified, possibly under one of the standards described above. 
         [0038]    At block  118 , the vests are received from inventory and/or manufacturing. At block  121 , the vests are customized as detailed in the request. Block  121  may include sub-processes. At block  124 , the ballistic packs may be marked/personalized. At block  127 , the carrier vest may be marked/personalized. At block  130 , the ballistic packs may be loaded into the carrier vest. 
         [0039]    At block  133 , outtake of the vests may be documented. The information documented may be uploaded to the tracking database described above, and may include information on the end user of the vests, the shipment method used to transport the vests, insurance information regarding the shipper and/or shipment, as well as information on the vests themselves, for example any quality check information regarding the vests (a final quality check may be made on the order of vests insuring that the order will be properly fulfilled). An RFID or other electronic tag reader may be used at this point in the method, as with all operations in the method, to facilitate data entry into the database. 
         [0040]    At block  136 , the vests are shipped to the end user. In the case of organizational end users, those end users may continue to track their internal usage of the vests. This usage may be combined with the tracking information stored in the manufacturer and/or supplier&#39;s tracking database, or may be kept separately. For example, vests may be checked out and in to individual user within the organization, and this information tracked. The total number of vests shipped to the end user may or may not include the rotational vests, which may be shipped at a later date when that number of vests are due for maintenance and/or rewarranting. Backup vests may, however, be included in the initial shipment. 
         [0041]    At block  139 , at some point in the future, a vest may be returned to the manufacturer/distributor from an end user. This may occur due to a regularly scheduled maintenance interval, concerns about the integrity of the vest, and/or because the vest was involved in an impact incident. In some embodiments, the manufacturer/distributor may send paper or electronic notification that interval inspection/maintenance is due for specific vests. 
         [0042]    At block  142 , the vest may be inspected. Both the carrier vest and the ballistic packs may be examined by trained technicians to identify any mechanical failures and/or degradations which would increase the chance of a mechanical failure in the future. After the inspection, a decision is made at block  145  as to the disposition of the vest. 
         [0043]    At block  148 , disposition may involve disposing of the vest if it is beyond repair. At block  151 , disposition may involve merely cleaning the vest. At block  154 , disposition may involve repairing the vest. 
         [0044]    Block  154  repairs may include fabric repair to the carrier vest, replacement of the carrier vest, repair or replacement of ballistic pack coverings, and/or replacement of one or more of the ballistic packs in the carrier vest. Block  148  disposal may include recycling of available materials from the vest, and/or destruction of a portion or all of the vest components. 
         [0045]    At block  157 , tracking information may be updated in the database such that the any procedures performed at blocks  148 ,  151 ,  154  are recorded. Tracking information may be updated for the vest as a complete entity, as well as for the individual components of the vest (carrier vest and/or ballistic packs). This allows a history to be built for the lifespan of all vests and components produced and distributed through the system. In the case of disposal of the vest at block  148 , final disposition will be recorded at block  157  such that it will be known that any destroyed components should not be later found in another tactical vest. In an y case, RFID or other electronic means may be used to correlate actual disposition with electronic tracking of the history of a vest or vest subcomponents. 
         [0046]    At block  160 , if the vest or vests are beyond repair, new vests are acquired from inventory and/or the manufacturing unit. They are customized at block  163  in a similar manner to block  121  such that the new vest matches the configuration of the vest it is replacing. 
         [0047]    At block  166 , the vests are rewarranting as repaired and/or replaced. Rewarranty may include an inspection of the vest to insure that it still meets the standards to which the original vest was certified for. In one embodiment, the rewarranty may be an internal verification by the manufacturer that the vest is up to the certification standard specified. In another embodiment, the rewarranty may be vis-à-vis the manufacturer and the end user, with the manufacturer providing a written statement to that effect to the end user. In yet other embodiments, the recertification process may be the same as the original certification process (all originally manufactured vests may be certified at the point of manufacture). 
         [0048]    At block  169 , outtake of the vests may be documented. This process may be substantially similar to block  133 . At block  172 , the vests are shipped to the end user. This process may be substantially similar to block  136 . 
         [0049]    In some embodiments, an additional means of requesting a tactical vest may be provided to replace the process at block  103  in  FIG. 1 . This process may allow for people with an interest in an individual operator or group of operators to provide a tactical vest to those operator(s). For example, the below described system may allow family, friends, and/or a community involved with a police officer or military operator to group together to donate a tactical vest to the operator. 
         [0050]    Turning to  FIG. 4 , a computer interface  400  involved in such a system is provided. Interface  400  may allow users to input a personnel identifier  203  which calls up a graphical display  206  showing the donation status for the particular individual. Graphical display  206  may be broken into pieces  209 , possibly in the form of jig-saw puzzle pieces, that show the current donations, and the remaining donations required to provide the necessary funding to provide the tactical vest to the operator. A piece display  212  may show how many pieces  209  have been purchased, how many remain outstanding, and the cost per piece  209 . A payment display  215  may provide a means for a user to submit payment for individual pieces  209 . 
         [0051]    Once all pieces have been paid for, and the graphical display shows a completed picture or puzzle, the manufacturer/distributor may use method  300  to distribute the vest to the end user. In some embodiments the manufacturer may note on computer interface  400  that the vest has been subsidized by either the manufacturer/distributor or other entity, reducing the cost of individual pieces on the graphical display. In other embodiments, computer interface  400  may note that the manufacturer/distributor or other entity is matching purchases of pieces  209  (i.e., the manufacturer will pay for or cover the cost of a piece for every piece purchased). 
         [0052]    The above description provides exemplary embodiments only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the above description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing one or more exemplary embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as so set forth. 
         [0053]    Specific details were given in the previous description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, systems, processes, and other elements in the invention may have been shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known processes, structures, and techniques may have been shown without unnecessary detail in order to avoid obscuring the embodiments. 
         [0054]    Also, it is noted that individual embodiments may be described as a process which is depicted as a flowchart, a flow diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process may be terminated when its operations are completed, but could have additional steps not discussed or included in a figure. Furthermore, not all operations in any particularly described process may occur in all embodiments. 
         [0055]    Furthermore, embodiments of the invention may be implemented, at least in part, either manually or automatically. Manual or automatic implementations may be executed, or at least assisted, through the use of machines, hardware, software, or any combination thereof. 
         [0056]    The invention has now been described in detail for the purposes of clarity and understanding. However, it will be appreciated that certain changes and modifications may be practiced within the scope of previously described embodiments.