Abstract:
A flexible, multi-functional, multi-ply material mix and device, capable of providing ballistic protection are herein presented. The device and material herein presented provide multiple electronic and ballistic functionality integrated into a soft body armor that is lighter in weight and more comfortable to wear than previously available alternatives.

Description:
RELATED APPLICATIONS 
       [0001]    This Application claims the benefit of the filing date of U.S. Provisional Application No. 61/316,426 filed on Mar. 23, 2010, the entire contents of which are incorporated by reference hereto. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The disclosed subject matter relates to ballistic protection for military personnel. More particularly, the disclosed subject matter relates to a body armor made of integrated, multi-functional components designed to reduce the overall weight while increasing agility and durability; and to a flexible, multi-functional, multi-ply material mix capable of providing ballistic protection. 
         [0004]    2. Brief Description of Related Art 
         [0005]    Current soldier body armors are made of multiple layers of ballistic fabric, such as KEVLAR® brand fabric, that protect the torso from pistol shots. The addition of ceramic ballistic plates into pockets in the soft armor front, back and sides provides protection to the torso from high velocity rifle ammunition. However, such body armor may be unavoidably cumbersome, weighing up to 30 lbs when fully fitted with the ballistic plates. Adding batteries, cabling&#39;, radios, computers, GPS, and sundry other electronic devices to such a soldier system would add a further weight burden and may add to the cumbersome nature of a soldier&#39;s equipage. 
       SUMMARY OF THE INVENTION 
       [0006]    A need exists, therefore, for improved ballistic protection and for a body armor system having layers of flexible materials that provide electronic and ballistic functionality integrated into a soft body armor solution. 
         [0007]    In one embodiment, the disclosed subject matter relates to a flexible, multi-functional body armor device comprising an outer cover material facing a threat side, an inner cover material facing a skin of a user, the inner cover material being peripherally fastened to the outer cover material so as to form an inner compartment, a non-conductive flexible ballistic outer layer disposed within the inner compartment, the non-conductive flexible ballistic outer layer having a plurality of conductive ballistic antenna fibers weaved therein and at least one smart connector operatively connected to the plurality of conductive ballistic antenna fibers. 
         [0008]    In another embodiment, the disclosed subject matter relates to a flexible, multi-functional, multi-ply material mix capable of providing ballistic protection, the flexible, multi-functional, multi-ply material mix having a first layer with antenna fibers weaved therein, a second layer of insulating fibers, the first layer overlaying the second layer. A third layer of ground plane EMI shield fibers, the second layer overlaying the third layer. A fourth layer of flexible electronics and hybrid power storage, the third layer overlaying the fourth layer. A fifth layer of insulating fibers, the fourth layer overlaying the fifth layer. A sixth layer of power and data distribution fibers, the fifth layer overlaying the sixth layer. A seventh layer of insulating fibers, the sixth layer overlaying the seventh layer. An eighth layer of ground plane EMI shield plies, the seventh layer overlaying the eighth layer. A ninth layer of ballistic fibers, the eighth layer overlaying the ninth layer and a tenth layer of thermal electric generator fibers, the ninth layer overlaying the tenth layer. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Embodiments will be better understood from the detailed description given below and by reference to the attached drawings in which: 
           [0010]      FIG. 1  is a cross-sectional view of the multi-ply material mix; 
           [0011]      FIG. 2  is a schematical exploded view of a ballistic vest; 
           [0012]      FIG. 3   a  is a frontal view of a full body armor; and 
           [0013]      FIG. 3   b  is a dorsal view of a full body armor. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0014]    Current soldier equipage is federated, with individual stand-alone components. This federated architecture results in duplication of subcomponents, inefficiencies and added weight. A particular concern is the proliferation of electronic systems that have to be carried by the modern war fighter, each with batteries that are usually different in design and function, resulting in a significant weight burden in spare batteries alone. 
         [0015]    Referring to  FIG. 1 , a preferred arrangement of the multi-ply material mix  100  is shown. The multi-ply material mix  100  has a threat side which is closest to the outer plies  105 , and a skin side, which is farthest from the outer plies  105 . The outer plies  105  can be made of non-conductive, flexible ballistic fibers  105   a . Such fibers  105   a  can include, but are not limited to, KEVLAR® brand fibers, DYNEEMA® brand fibers, and various ultrahigh molecular weight polyethylene (UHMW-PE) fibers, including, but not limited to, TENSYLON® brand fibers. In addition to the preceding sample fibers, the outer plies  105  can also include Carbon Nano-Tube (CNT) fibers. 
         [0016]    The outer plies  105  can also include conductive ballistic fibers  105   b  weaved therein. It is preferred that these conductive ballistic fibers  105   b  are weaved in such a way as to be closest to the threat side of the multi-ply material mix  100 . Such arrangement allows these conductive ballistic fibers  105   b  to provide antennae reception and transmission capabilities. The conductive ballistic fibers  105   b  can have multiple arrangements within the outer plies  105 . For instance, in one embodiment the conductive ballistic fibers  105   b  can be spread equally throughout the surface area of the outer plies  105 , while in other embodiments the conductive ballistic fibers  105   b  can be localized within certain regions of the outer plies  105 , such as areas covering the shoulders and neckline of a garment, such as, but not limited to, a vest. 
         [0017]    Below the outer plies  105 , toward the skin side, the multi-ply material mix  100  can include at least one layer of insulator plies  110 . These insulator plies  110  can be made using non-conductive ballistic fibers, which can include, but are not limited to, KEVLAR® brand fibers, DYNEEMA® brand fibers and TENSYLON® brand fibers. The insulator plies  110  can provide additional ballistic protection to a user. Furthermore, the arrangement of the insulator plies  110 , within the multi-ply material mix  100  can vary. For instance, in one embodiment there can be a single layer of insulator plies  110 , while in other embodiments there may be two or more layers of insulator plies  110 , thereby providing increased ballistic protection to a user. 
         [0018]    Below the layer of insulator plies  110 , toward the skin side, the multi-ply material mix  100  can include a layer of shield plies  115 . The shield plies  115  functions as an EMI shield layer and can be made of conductive ballistic materials, including, but not limited to, CNT fibers. In some embodiments the multi-ply material mix  100  can have a single layer of shield plies  115 , while in other embodiments the multi-ply material mix  100  can have two or more layers of shield plies  115 . 
         [0019]    Below the layer of shield plies  115 , toward the skin side, the multi-ply material mix  100  can include an electronics and power storage layer  120 . The electronics and power storage layer  120  can be made from a number of available flexible electronics. These applications include, but are not limited to, RF electronics, general purpose processing electronics and power management electronics. 
         [0020]    Below the layer of electronics and power storage  120 , toward the skin side, the multi-ply material mix  100  can include a layer of power and data distribution plies  125 . The power and data distribution plies  125  can be made of conductive ballistic materials, including but not limited to, TENSYLON® brand fiber and CNT fibers. 
         [0021]    Below the layer of power and data distribution plies  125 , toward the skin side, the multi-ply material mix  100  can include a layer of thermal electric generator plies  130 . The layer of thermal electric generator plies  130  can be made of a mixture of both conductive ballistic and non-conductive ballistic fibers. The conductive ballistic fibers can include, but are not limited to, CNT fibers, while the non-conductive ballistic fibers can include, but are not limited to, KEVLAR® brand fibers, DYNEEMA® brand fibers and TENSYLON® brand fibers. Further, the ratio of conductive ballistic fibers to non-conductive ballistic fibers in the layer of thermal electric generator plies  130  can vary. 
         [0022]    The multi-ply material mix  100  can be used in the construction of body armor, such as the armored vest depicted in  FIG. 2  and/or the full body armor depicted in  FIG. 3 . However, the multi-ply material mix  100  is not limited in its use to such applications. In fact, the multi-ply material mix  100  can be used in the construction of other equipment including, but not limited to, tents, clothing, etc. Further, the ballistic properties of the multi-ply material mix  100  can be strengthened by adding additional ballistic plies  140  as desired. 
         [0023]    The several layers of the multi-ply material mix  100  can be held together through different fastening mechanisms, including, but not limited to stitching and gluing. 
         [0024]    Referring to  FIG. 2 , a ballistic vest  200  embodiment of the multi-ply material mix is shown. In this embodiment, the multi-ply material mix (not shown) can be easily incorporated into a ballistic vest  200 , which in one embodiment can be shaped like a human torso, having a front side and a back side. The ballistic vest  200  includes an outer cover  205  and an inner cover (not shown), which are peripherally sewn to create an inner compartment (not shown) in which the multi-ply material mix (not shown) is disposed. Accordingly, the ballistic vest  200  is capable of providing a user ballistic protection, while at the same time providing a number of integrated capabilities. 
         [0025]    For instance, the ballistic vest is capable of providing integrated antennae transmission and reception capabilities by incorporating antennae fibers  210 . In one embodiment, the antennae fibers  210  can be made out of conductive ballistic fibers located on the outer plies (not shown) multi-ply material mix (not shown), the antennae fibers  210  can be positioned near the shoulder area of the ballistic vest  200 , where they can most effectively provide the user, antennae transmission and reception capabilities. In other embodiments, the antennae fibers  210  can be positioned around the neck line of the ballistic vest, or wrap around the shoulder blade area of the ballistic vest  200 . Preferably, the antennae fibers  210  are placed directly below the outer cover  205 , so as to improve performance. Because the multi-ply material mix (not shown) incorporates a number ballistic fibers, the ballistic vest  200  is capable of providing 360° ballistic protection. 
         [0026]    The arrangement of the fibers in the multi-ply mix can modified to meet the requirements of different applications. For instance, in the vest  200  embodiment, additional CNT fibers  220 , which provide increased ballistic protection, can be placed to protect sensitive areas, such as those covering the vital organs of user. 
         [0027]    The ballistic vest  200  can also be equipped with a region of power and data distribution fibers  230 . These power and data distribution fibers  230  can be both conductive ballistic and non-conductive ballistic fibers. Additionally, the power and data distribution fibers  230  can be arranged virtually anywhere on the ballistic vest  200 , and are therefore not restricted in placement to any given region within the ballistic vest  200 . In other embodiments, additional ballistic protection can also be provided by incorporating non-conductive ballistic fibers (not shown). These non-conductive ballistic fibers can include, but are not limited to, KEVLAR® brand fibers, DYNEEMA® brand fibers and TENSYLON® brand fibers. 
         [0028]    The ballistic vest  200  is also capable of harnessing and storing energy in a power storage unit  240 . For instance, in one embodiment conductive ballistic fibers can channel harnessed energy (i.e. thermal energy) for storage in a power storage unit  240 . Power and data distribution fibers  230  can then be used to access the power storage unit  240  and make this power available to external devices via smart connectors  270 . In some embodiments, the power storage unit  240  may be capable to store up to 96 hours of usable power. 
         [0029]    As was noted above, data and power transfer to and from the ballistic vest  200  can be achieved by incorporating smart connectors  270 , including, but not limited to, SNAP Net® brand connectors. These smart connectors  270  come in a variety of snap geometries and therefore allow for the integration of a variety of applications, including, but not limited to, USB devices, RF antennas and various other electronic devices. Further, the placement of the smart connectors  270  is not limited to the shoulder area, as the smart connectors  270  may be placed virtually anywhere on the ballistic vest  200 . 
         [0030]    Additionally, the ability to transmit power from the power storage unit  240  via the power and data distribution fibers  230  allows the ballistic vest  200  to be fitted with additional electronic devices, including but not limited to, small single-board computers  290  such as GUMSTIX® brand computers and SAINT® brand handheld devices  260 . 
         [0031]    Further, the ballistic vest  200  can be equipped with any desired number of storage compartments  250 . These storage compartments  250  can be constructed out of the same materials as the ballistic vest  200 , and therefore provide a convenient means to store and transport cargo without compromising safety. The cargo can vary depending on the application and may include land mobile radio units  280 , handheld devices  260 , single-board computers  290 , etc. Additionally, the storage compartments  250  can be placed in any desired location on the ballistic vest  200 . 
         [0032]    The ballistic vest  200  can also be equipped with an EMI shield  293 . The EMI shield  293  can be made of ballistic fibers, including, but not limited to, CNT fibers. These ballistic fibers provide a great degree of flexibility and exhibit reduced weight, compared to traditional metal EMI shield applications. Accordingly, the ballistic vest  200  can be fitted with an EMI shield  293  throughout the vest, thereby providing 360° magnetic radiation protection, without increasing ballistic vest  200  weight and while retaining ballistic vest  200  flexibility. In other embodiments, additional layers of EMI shield  293  can be disposed in areas of the ballistic vest  200  that protect vital organs. For example, in one embodiment, additional EMI shield  293  layers can be disposed in the frontal section of the ballistic vest  200 , while in other embodiments additional EMI shield  293  layers can be disposed in the dorsal section of the ballistic vest  200 . 
         [0033]    The ballistic vest  200  can also be fitted with a layer of flexible electronics  295 . The flexible electronics  295  layer can be distributed through the ballistic vest  200 . The flexible electronics  295 , can include, but are not limited to RF electronics, general purpose processing and power management electronics. 
         [0034]    Referring to  FIGS. 3   a  and  3   b , a full body ballistic armor  300  embodiment of the multi-ply material mix is shown. That is the in addition to protecting the anterior  310  and posterior  320  regions of the torso, the multi-ply material mix (not shown) can be use to provide full body ballistic protection including, the head  330 , upper limbs  340  and lower limbs  350 . Because of the high flexibility and reduced weight (compared to traditional federated ballistic materials) the bull body ballistic armor  300  provides improved mobility without compromising threat protection. 
         [0035]    It is to be understood, that the above-described arrangements are intended solely to illustrate the application of the principles of the disclosed subject matter. Numerous modifications and alternative arrangements may be devised by those skilled in the art without departing from the spirit and scope of the disclosed subject matter in the present Application. Accordingly, the appended claims are intended to cover such modifications and alternative arrangements. Thus, while the disclosed subject matter of the present Application has been described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiments, it will be apparent to those skilled in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made without departing from the principles and concepts set forth herein.