Patent Publication Number: US-10782103-B2

Title: Multi-layer multi-impact ballistic body armor and method of manufacturing the same

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. Utility application Ser. No. 14/054,260 which was filed on Oct. 15, 2013, which also claims the benefit of U.S. Provisional Application No. 61/767,536 filed Feb. 21, 2013. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to body armor. More specifically, and without limitation, this invention relates to multi-layer body armor which is capable of sustaining multiple ballistic impacts. 
     BACKGROUND OF INVENTION 
     Body armor is old and known in the art. Since the dawn of time, warriors and soldiers have clad themselves with protective clothing and apparatuses in an attempt to shield their bodies from injury. Initially, this armor was made of naturally occurring materials such as animal skins, leathers, bamboo, wood and combinations thereof While this early armor was certainly better than no armor at all, it had its disadvantages. Namely, this armor was difficult to work with, it was heavy and bulky and it did not provide much protection to higher levels of impact. 
     A substantial improvement to body armor occurred with the discovery of metals and the development of manufacturing methods to manipulate metal. Body armor made of metal afforded substantial improvements to impact resistance over the prior armor. While metallic body armor has extremely high impact resistance, it comes at the cost of being extremely heavy. 
     In the modern era, tightly woven composite fabrics were developed and implemented for use as body armor. The most well-known is Kevlar® which is a registered trademark for a para-aramid synthetic fiber developed by DuPont in 1965. Kevlar® is flexible and has a high tensile strength-to-weight ratio which is 5 times stronger than steel on an equal weight basis. While Kevlar® is strong, lightweight and flexible Kevlar® has its deficiencies. Namely, body armor made of Kevlar® is ineffective at stopping multiple impacts as the material becomes compromised after the first impact. In addition, while Kevlar® may be effective at stopping smaller handgun rounds, Kevlar provides little protection against higher-velocity and higher-impact projectiles such as rifle rounds. A generic name for Kevlar®-type materials is aramid, which is used herein. 
     Therefore, despite the advances in body armor, problems still remain. 
     Thus it is a primary object of the invention to provide body armor that improves upon the state of the art. 
     Another object of the invention is to provide body armor that is lightweight. 
     Yet another object of the invention is to provide body armor that is low cost to manufacture. 
     Another object of the invention is to provide body armor that can sustain multiple ballistic impacts. 
     Yet another object of the invention is to provide body armor that can sustain high ballistic impacts. 
     Another object of the invention is to provide body armor that breaks a projectile apart when the projectile hits the body armor. 
     Yet another object of the invention is to provide body armor stops a projectile when the projectile hits the body armor. 
     Another object of the invention is to provide body armor that is comfortable to wear. 
     Yet another object of the present invention is to provide body armor that has multiple layers that perform different functions when struck by a projectile. 
     Another object of the invention is to provide body armor that is durable. 
     These and other objects, features, or advantages of the present invention will become apparent from the specification, claims and drawings. 
     SUMMARY OF THE INVENTION 
     Multi-impact multi-layer body armor is presented. In one arrangement, the body armor has a first layer which is a single layer of covering material such as Tac-Tex or polyester which serves as the strike face of the body armor. The second layer, is a ballistic ceramic plate formed of a plurality of smaller ceramic tiles that are bonded together using an adhesive binder. These individual ceramic tiles are arcuately curved, which when the individual ceramic tiles are bonded together form a larger curved plate. The third layer, positioned behind and connected to the ceramic plate is a plurality of aramid layers, which in one arrangement are formed of approximately eleven layers of Dupont Kevlar® XP. The fourth layer, positioned behind and connected to the aramid layers, is a rigid backing plate, which in one arrangement is formed of approximately thirty-six layers of ultra high molecular weight polyethylene, which in one arrangement are formed of Honeywell Spectra Shield® II. These layers are hot pressed together with an adhesive to form a single unitary rigid piece. The fifth layer, a single layer of covering material such as Tac-Tex or polyester, serves as the rear covering material. Because the ceramic plate is slightly small than the other layers, a foam layer is positioned around the exterior edges of the ceramic plate. In addition, foam piping is positioned around the exterior edge of the combined layers. A fabric band is positioned around the exterior edge of all the layers and connects the first layer to the last layer thereby sealing the body armor. Thus, an improved body armor is presented which is inexpensive to produce, light, durable and can sustain multiple impacts. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is perspective blown-up view of the body armor. 
         FIG. 2  is a plan view of a portion of an armor plate formed of a plurality of individual hexagonal ceramic tiles positioned in end-to-end alignment. 
         FIG. 3  is a plan view of a portion of an armor plate formed of two layers of a plurality of individual hexagonal ceramic tiles positioned in end-to-end alignment, the dual layers providing additional protection from a projectile passing between a seam in the individual hexagonal ceramic tiles. 
         FIG. 4  is a perspective and exploded view of an alternative embodiment of body armor. 
         FIG. 5  is a plan view of the back side of a plurality of small curved ceramic tiles aligned to form an armor plate, the arrangement showing a staggered arrangement of a plurality of rows, and the use of corner tiles as well as partial side tiles. 
         FIG. 6  is a perspective view of a mold used to apply pressure, vacuum and/or heat to form components of the body armor, such as the armor plate, the rigid backing plate and/or finish the assembly of the entire body armor. 
         FIG. 7  is a perspective blown up view of an armor plate formed on a mold and positioned within a vacuum bag, the armor plate being formed of a plurality of curved square tiles with a layer of structural adhesive positioned on the top side and bottom side of the ceramic tiles, and a release film positioned over the top of the assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to the drawings, body armor  10  is presented. Body armor  10  has a front side  12  also known as the impact side or strike face, a back side  14  opposite the front side  12 , a left side  16 , a right side  18 , a top side  20  and a bottom side  22 . Body armor  10  is comprised of a plurality of layers. While body armor  10  is of a generally constant thickness, body armor  10  slightly arcuately curves from front  12  to back  14 , so as to provide a better ergonomic fit for the user. In addition, while in one arrangement body armor, when viewed from the front  12  is generally square or rectangular, in another arrangement, the upper corners are chamfered or rounded, so as to provide additional freedom of motion for the user&#39;s arms. In another arrangement, the bottom corners are also chamfered or rounded, or alternatively, body armor  10  takes any shape desired, such as round, oval, or any other geometric shape or shapes. 
     A first embodiment of the body armor  10  is as follows. 
     First Layer  24 —Exterior Ballistic Fiber 
     The first layer  24  or cover layer of body armor  10  is a layer of ballistic fiber. The first layer  24  provides the exterior surface of the body armor  10 . This first layer  24  of ballistic fiber may comprise of only a single layer of material, or alternatively this layer of ballistic fiber  24  may comprise two, three or more layers of ballistic fiber which are stacked on top of one another. The number of layers of ballistic fiber and the thickness of each of these layers can be increased or decreased depending on the application. As the layers become thicker and the number of layers increase, so does the ability of the first layer  24  to stop impacts. In the event that a plurality of layers are used, they are either bonded to one another to form a single sheet with the use of adhesive, heat, pressing, stitching, gluing, welding or any other process; or alternatively, each of these layers are not bonded to one another and instead are merely positioned in overlapping condition with one another. 
     In one arrangement ballistic fiber  24  is a sheet, or a plurality of sheets of ultra-high-molecular-weight (UHMW) material or ultra-high-molecular-weight-polyethylene (UHMWPE). UHMWPE is a subset of the thermoplastic polyethylene. Also known as high-modulus polyethylene, (HMPE), or high-performance polyethylene (HPPE), it has extremely long chains, with a molecular weight usually between 2 and 6 million. UHMWPE is a type of polyolefin. It is made up of extremely long chains of polyethylene, which all align in the same direction. It derives its strength largely from the length of each individual molecule (chain). Van der Waals bonds between the molecules are relatively weak for each atom of overlap between the molecules, but because the molecules are very long, large overlaps can exist, adding up to the ability to carry larger shear forces from molecule to molecule. Each chain is bonded to the others with so many Van der Waals bonds that the whole of the inter-molecule strength is high. In this way, large tensile loads are not limited as much by the comparative weakness of each Van der Waals bond. When formed to fibers, the polymer chains can attain a parallel orientation greater than 95% and a level of crystallinity from 39% to 75%. In contrast, Kevlar derives its strength from strong bonding between relatively short molecules. 
     The simple structure of the molecule also gives rise to surface and chemical properties that are rare in high-performance polymers. For example, the polar groups in most polymers easily bond to water. Because olefins have no such groups, UHMWPE does not absorb water readily, nor wet easily, which makes bonding it to other polymers difficult. For the same reasons, skin does not interact with it strongly, making the UHMWPE fiber surface feel slippery. In a similar manner, aromatic polymers are often susceptible to aromatic solvents due to aromatic stacking interactions, an effect aliphatic polymers like UHMWPE are immune to. Since UHMWPE does not contain chemical groups (such as esters, amides or hydroxylic groups) that are susceptible to attack from aggressive agents, it is very resistant to water, moisture, most chemicals, UV radiation, and micro-organisms. 
     In one arrangement, the UHMWPE used for the first layer  24  is Tac-Tex™ Ballistic Fiber manufactured by TAC International Corp. It is advertised that Tac-Tex™&#39;s shock intensity is 15 times that of high-quality steel, the impact energy absorption is 2.6 times aramid. Tac-Tex™ is lightweight and flexible. One benefit to using Tac-Tex™ over Kevlar® is that while Tac-Tex™ is not as strong as Kevlar® in some ways, Tac-Tex™ is lighter. Alternatively, first layer  24  is formed of any other high strength material such as an aramid like Kevlar®, Nomex®, Technora® or Kevlar® XP. 
     Kevlar® is the well-known trademark for DuPont&#39;s material formed of Poly-paraphenylene terephthalamide. Kevlar is synthesized in solution from the monomers 1,4 phenylene-diamine (paraphenylendiamine) and terephthaloyl chloride in a condensation reaction yielding hydrochloric acid as a byproduct. The result has liquid crystalline behavior, and mechanical drawing orients the polymer chains in the fiber&#39;s direction. 
     Hexamethylphosphoramide (HMPA) was the solvent initially used for the polymerization, but for safety reasons, DuPont replaced it by a solution of N-methyl-pyrrolidone and calcium chloride. Kevlar (poly paraphenylene terephthalamide) production is expensive because of the difficulties arising from using concentrated sulfuric acid needed to keep the water-insoluble polymer in solution during its synthesis a spinning. Several grades of Kevlar are available: (1) Kevlar K-29—in industrial applications, such as cables, asbestos replacement, brake linings, and body/vehicle armor; (2) Kevlar K49—high modulus used in cable and rope products; (3)Kevlar K100—colored version of Kevlar; (4) Kevlar K119—higher-elongation, flexible and more fatigue resistant; (5) Kevlar K129—higher tenacity for ballistic applications; (6) Kevlar AP—has 15% higher tensile strength than K-2; (7) Kevlar XP—lighter weight resin and KM2 plus fiber combination; (8) Kevlar KM2—enhanced ballistic resistance for armor applications, Kevlar® XP or another Kevlar or aramid is hereby contemplated for this use as the first layer  24  as well. 
     Alternatively, the first layer  24  is made of a non-ballistic material, such as cloth, felt, canvas, flannel, denim, polyester, nylon, plastic or any other material, which while not having substantial impact resistance, is useful in covering the body armor  10 , holding the interior layers of body armor  10  together, and making the body armor  10  comfortable for wear and use. In addition, the outer layer can serve to keep the body armor  10  clean and dry, and be easily washed. 
     In one arrangement, a padding material  25  is positioned behind and/or connected to first layer  24 . Padding material  25  is any material which is compressible, soft or absorbs shocks. In one arrangement, padding material  25  provides some cushioning so as to make the body armor more comfortable to wear and use. Alternatively, padding material  25  may also be water or moisture absorptive, so as to absorb sweat from use, thereby also making the body armor  10  more comfortable to wear and use. 
     Second Layer  26 —Ballistic Fiber 
     Second layer  26  of body armor  10  is positioned behind the first layer  24 . The second layer  26  may be made of the same material as first layer  24  or cover layer, or alternatively second layer  26  may be made of a different material as the first layer  24 . The second layer  26  may be made of a single layer of material or a plurality of layers of material. 
     In one arrangement which has been tested with success, second layer  26  comprises 4 or 5 layers of Tac-Tex™ which amount to about 1/16 to ⅛ to 3/16 of an inch in thickness. In this arrangement, the layers of Tac-Tex™ are cut to shape and stacked in overlapping condition to one another. These layers are either bonded to one another to form a single sheet of material with the use of adhesive, heat, pressing, stitching, gluing, welding or any other process; or alternatively, each of these layers are not bonded to one another and instead are merely positioned in overlapping condition with one another. More or less layers of material are hereby contemplated to increase or decrease the impact resistance of body armor  10  such as 1-3 layers, 5-10 layers, 10-20 layers, 20-30 layers, 30-40 layers, 40-50 layers, or more. Other thicknesses have also been contemplated including 1/32″, 3/32″ 5/32″, 7/32″, ¼″, 9/32″, 5/16″, 11/32″, ⅜″ 13/32″, 7/16″, 15/32″, ½″, 17/32″, 9/16″, 19/32″, ⅝″, 21/32″, 11/16″, 23/32″, ⅗″, 25/32″, 13/16″, 27/32″, ⅞″, 29/32″, 15/16″, 31/32″ and 1″ or more. 
     Alternatively, any other ballistic material such as aramid or any Kevlar® is used for the second layer  26 . Alternatively, more than one material is used for the second layer  26 , such as using a layer of Tac-Tex, followed by a layer of Kevlar®, followed by a layer of Tac-Tex, and so on; or alternatively two layers of Tac-Tex are followed by two layers of Kevlar®, and so on. As such, any combination of layers of ballistic material are hereby contemplated for second layer  26 . 
     In one arrangement, second layer  26  is merely positioned in overlapping condition behind first layer  24  without being connected directly to one another. Alternatively, first layer  24  and second layer  26  are bonded to one another with the use of adhesive, heat, pressing, stitching, gluing, welding or any other process. 
     Third Layer  28 —Armor Plate 
     Third layer  28  of body armor  10  is positioned behind the first layer  24  and second layer  26 . Third layer  28  is a hard armor plate. 
     In one arrangement, third layer is a hard ceramic armor plate made of any form of ceramic material such as Alumina Silicon, Aluminum Oxide (Al 2 O 3 ) ceramic tile, hot pressed boron carbide and/or silicon carbide which is useful in stopping and/or breaking up projectiles. In one arrangement, the ceramic plate is formed of a single unitary ceramic plate. Alternatively, the overall ceramic plate is formed of a plurality of smaller ceramic tiles  30  which are bonded together. 
     In the arrangement wherein the armor plate  28  is formed of a plurality of smaller ceramic tiles  30 , the smaller ceramic tiles  30  are positioned in end-to-end alignment with one another, or in overlapping condition with one another, either in one single layer or, for added protection, in a plurality of layers in a mold  32  made of steel, metal or any other suitable material which is contoured and sized in the desired overall shape for the armor plate  28 . Once the small ceramic tiles  30  are properly aligned, an adhesive is coated over the small ceramic tiles  30 . Once fully coated, the mold  32  and ceramic plate is baked, which melts the adhesive which flows over, through and in-between the small ceramic tiles  30  thereby smoothing the exterior surface and binding the small ceramic tiles  30  together into a single plate. For additional bonding, pressure is added to the mold, and/or the adhesive is pressurized. In one arrangement, the adhesive is put over the exterior and interior surfaces of the combined individual ceramic tiles  30  in a single or multiple thin sheet. Once heated and/or pressurized, the adhesive flows into and around the small ceramic tiles  30 . 
     One manufacturer of suitable ceramic tiles  30  is Ceradyne, Inc. of Costa Mesa, Calif. which produces Aluminum Oxide, boron carbide and silicon carbide plates and tiles. Another manufacturer of ceramic plates and tiles is CerCo, LLC of Shreve, Ohio which produces aluminum oxide with magnesium oxide plates and tiles. However, any other manufacturer of ballistic ceramic plates and tiles which are suitable for this application are hereby contemplated. 
     In one arrangement, the individual ceramic tiles  30  are symmetrical 6-sided hexagons having a flat front face  12  and a flat back face  14  which extend in planar parallel spaced relation. Each side of these hexagon tiles are straight. When assembled, the edges of each hexagon plate are positioned in end-to-end flush mating arrangement so as to ensure that no space is left between adjacent ceramic tiles  30 . (See  FIG. 2 ). To provide additional protection, and to ensure that no projectile passes between the seam of two tiles, a second layer of ceramic tiles  30  is positioned in overlapping, but offset condition. (See  FIG. 3 ). In an alternative arrangement, these hexagonal tiles are curved. 
     Other shaped tiles are also hereby contemplated, including triangle, square, rectangular, pentagon, heptagon, octagon, star, trapezoid, diamond, round, oval, or any other shape. Shapes which flushly engage its equal to form a seamless array work well as they engage one another and prevent seams. 
     In one arrangement tiles having a thickness of ¼″ have been tested with success. Although other thicknesses are also hereby contemplated including 1/32″, 1/16″, 3/32″ ⅛″, 5/32″, 3/16″, 7/32″, ¼″, 9/32″, 5/16″, 11/32″, ⅜″ 13/32″, 7/16″, 15/32″, ½″, 17/32″, 9/16″, 19/32″, ⅝″, 21/32″, 11/16″, 23/32″, ⅗″, 25/32″, 13/16″, 27/32″, ⅞″, 29/32″, 15/16″, 31/32″, 1″; or an inch plus any of these thicknesses; or the like. In the event that two layers are used in overlapping and/or offset condition, the thickness of each layer is halved. 
     In the arrangement where hexagon tiles are used, hexagons having a length of 1&amp;¼″ from point-to-point have been used with success. However, any other point-to-point sized hexagons are hereby contemplated, including ¼″, ½″, ¾″, 1″, 1&amp;½″, 1&amp;¾″, 2″, 2&amp;¼″, 2&amp;½″, 2&amp;¾″, 3″, 3&amp;¼″, 3&amp;½″, 3&amp;¾″, 4″ or the like. Similarly, when square or rectangular tiles are used, while 2″ tiles have been used with success, measured from side-to-side, any other side-to-side sized square or rectangular tiles are hereby contemplated, including ¼″, ½″, ¾″, 1″, 1&amp;¼″ 1&amp;½″, 1&amp;¾″, 2&amp;¼″, 2&amp;½″, 2&amp;¾″, 3″, 3&amp;¼″, 3&amp;½″, 3&amp;¾″, 4″ or the like. 
     Using a plurality of smaller tiles  30 , as opposed to a single unitary ceramic plate, provides a number of substantial advantages. Namely, when a projectile hits a single unitary plate, the projectile tends to shatter the entire plate, thereby compromising the single unitary ceramic plate after the first hit, which reduces or eliminates the ceramic plate&#39;s ability to stop a second, third, or fourth round. When a plurality of ceramic tiles  30  are used, only the tiles  30  which are actually stricken by the projectile are compromised, leaving the remaining tiles  30  in pristine condition to prevent other projectiles. In addition, by using a plurality of ceramic tiles  30 , the body armor  30  can be arcuately bent so as to form a more comfortable body armor for use. Alternatively, the individual ceramic tiles  30  are arcuately curved themselves. 
     In the arrangement wherein hexagonal small tiles  30  are used approximately 20-30 tiles are hereby contemplated for use in a single layer, doubled for dual layers, and so on. However, any other amount of tiles are hereby contemplated, such as 1-10, 10-15, 15-25, 30-40, 40-50, 50-60, 60-70, 70-80, 80-90, 90-100, or more, or any range inbetween. In the arrangement wherein square or rectangular small tiles  30  are used approximately 15-25 tiles are hereby contemplated for use in a single layer, doubled for dual layers, and so on. However, any other amount of tiles are hereby contemplated, such as 1-10, 10-15, 20-30, 30-40, 40-50, 50-60, 60-70, 70-80, 80-90, 90-100, or more, or any range inbetween. As the size of the body armor  10  increases, so does the number of tiles required. 
     Fourth Layer  34 —Ballistic Fiber 
     The forth layer  34  is another layer of ballistic fiber. The fourth layer  34  may be made of the same material as first layer  24  and/or second layer  26 , or may be made of a different material than either the first layer  24  or second layer  26 . The fourth layer  34  may be made of a single layer of ballistic fiber or made of multiple layers of ballistic fiber. 
     In one arrangement, the fourth layer  34  is made of multiple layers of Kevlar® XP. It is hereby contemplated that the fourth layer is made of many layers, from 2 layers up to or 100, or 200, or 300, or 400 or any amount inbetween, or more layers of ballistic fiber. However 35-40 layers of Kevlar® XP have been tested with success, which amount to about 1/16 to ⅛ to 3/16 of an inch in thickness. Other thicknesses have also been contemplated including 1/32″, 3/32″ 5/32″, 7/32″, ¼″, 9/32″, 5/16″, 11/32″, ⅜″ 13/32″, 7/16″, 15/32″, ½″, 17/32″, 9/16″, 19/32″, ⅝″, 21/32″, 11/16″, 23/32″, ⅗″, 25/32″, 13/16″, 27/32″, ⅞″, 29/32″, 15/16″, 31/32″ and 1″ or more. 
     In this arrangement, the multiple layers of ballistic fiber are cut to the same dimensions and laid in flat-overlapping condition with one another. The layers are either counted by hand or by machine to ensure that the appropriate number of layers are used. Alternatively, the layers are weighed to ensure the appropriate number of layers are used. 
     Fifth Layer  36 —Polyethylene Fiber 
     The fifth layer  36  is layer of polyethylene fiber. The fifth layer is in one arrangement made of a polyethylene fiber that is strong, thin, light, flexible, and has good impact resistance as well as good energy dispersal characteristics. Spectra® and/or Spectra Shield® fiber manufactured by Honeywell has been tested with success as the fifth layer  36 . 
     Spectra® or Spectra Shield® fiber is a bright white polyethylene fiber that is produced using a gel-spinning process. Pound-for-pound, it is 15 times stronger than steel, more durable than polyester and has a specific strength that is 40 percent greater than aramid fiber. Polyethylene is a remarkably durable plastic. Spectra® is one of the world&#39;s strongest and lightest fibers. The gel-spinning process and subsequent drawing steps allow Spectra fiber to have a much higher melting temperature (150° C. or 300° F.) than standard polyethylene. 
     Spectra® displays outstanding toughness and extraordinary visco-elastic properties, Spectra® fiber can withstand high-load strain-rate velocities. Light enough to float, it also exhibits high resistance to chemicals, water, and ultraviolet light. It has excellent vibration damping, flex fatigue and internal fiber-friction characteristics, and Spectra fiber&#39;s low dielectric constant makes it virtually transparent to radar. 
     In one arrangement a plurality of polyethylene fiber layers are placed in overlapping condition with one another. It is hereby contemplated that the fifth layer  36  is comprised of several layers up to hundreds of layers of polyethylene fiber including 10, 20, 30, 40, 50, 75, 100, 200, 300, 400, 500, 600, 700, 800, 900, 1,000 or more layers or any amount inbetween. The layers are either counted by hand or by machine to ensure that the appropriate number of layers are used. Alternatively, the layers are weighed to ensure the appropriate number of layers are used. 
     In one arrangement several hundred layers of polyethylene fiber have been tested in Level III body armor that amount to approximately ½″ thick, Level IV body armor has been tested having a polyethylene fiber layer that amount to approximately ¾″ thick. 
     Joining of Fourth Layer  34  and Fifth Layer  36   
     In one arrangement, once cut and stacked, the fourth layer  34  and fifth layer  36  are positioned in overlapping condition. Next, the fourth layer  34  and fifth layer  36  are coated with or dipped into a bonding adhesive and placed into a hot press. Pressure and heat are used to bond the plurality of layers together. The bonding adhesive is forced around and throughout the plurality of layers forcing the air pockets out of the layers and compressing the layers together. Once cooled and hardened, resulting product is a single unitary rigid piece  38  that is formed in the desired shape that has a forward side which is comprised of a plurality of layers of a ballistic fiber, and a rearward side formed of a plurality of layers of polyethylene fiber. In an alternative arrangement, the fourth layer  34  and the fifth layer  36  are joined only by adhesive and not hot pressed. 
     Joining the Ceramic Plate  28  with the Rigid Piece  38   
     Once the fourth layer  34  and fifth layer  36  are joined together to form the rigid piece  38 , the rigid piece  38  is connected to the back side  14  of the ceramic armor plate. Adhesive is placed on the back side  14  of the armor plate  28  and/or on the front side  12  of the rigid piece  38 . Next the armor plate  28  and the rigid piece  38  are positioned in a mold in overlapping condition and stamped together. This stamping process uses pressure, heat and adhesive to bind the two layers  28 ,  38  into a single unitary piece. 
     Joining the Second Layer  26  to the Ceramic Plate  28   
     In one arrangement, second layer  26  is merely positioned in overlapping condition in front of ceramic plate  28  without being connected directly to one another. Alternatively, once the ceramic plate  28  is formed and the second layer  26  is formed, the two can be joined together by placing adhesive on the back side  14  of the second layer  26  and/or on the front side  12  of the ceramic plate  28 . The armor plate  28  and the second layer  26  are positioned in a mold in overlapping condition and stamped together to improve bonding. This stamping process uses pressure, heat and adhesive to bind the two layers  26 ,  38  into a single unitary piece. This joining can occur before or after the ceramic plate  28  is joined with the rigid piece  38 . 
     Sixth Layer  40 —Exterior Ballistic Fiber 
     The sixth layer  40  is like the first layer  24  and provides the exterior surface of the body armor  10 , as well as some protection. This sixth layer  40  is made of ballistic fiber, such as Tac-Tex™ as is described herein and may comprise of only a single layer of material, or alternatively may comprise two, three or more layers of ballistic fiber which are stacked on top of one another. The number of layers of ballistic fiber and the thickness of each of these layers can be increased or decreased depending on the application. As the layers become thicker and the number of layers increase, so does the ability of the sixth layer  40  to stop impacts. In the event that a plurality of layers are used, they are either bonded to one another to form a single sheet with the use of adhesive, heat, pressing, stitching, gluing, welding or any other process; or alternatively, each of these layers are not bonded to one another and instead are merely positioned in overlapping condition with one another. 
     In one arrangement, sixth layer  40  is merely positioned in overlapping condition behind rigid piece  38  without being connected directly to one another. Alternatively, sixth layer  40  and rigid piece  38  are bonded to one another with the use of adhesive, heat, pressing, stitching, gluing, welding or any other process. 
     Alternatively, the sixth layer  40  is made of a non-ballistic material, such as cloth, felt, canvas, flannel, denim, polyester, nylon, plastic or any other material, which while not having substantial impact resistance, is useful in covering the body armor  10 , holding the interior layers of body armor  10  together, and making the body armor  10  comfortable for wear and use. In addition, the outer layer can serve to keep the body armor  10  clean and dry, and be easily washed. 
     Joining the First Layer  24  To the Sixth Layer  40   
     In one arrangement, the first layer  24  and the sixth layer  40  extend beyond the borders of the other components of body armor  10 . This flange area  42  of first layer  24  and sixth layer  40  are then joined together by any means known in the art such as stitching, gluing, welding or any other means thereby sealing body armor  10  and locking or clam-shelling the other components of body armor  10  therebetween. Once the first layer  24  and sixth layer  40  are joined together, the excess material is cut away for aesthetic and comfort purposes. 
     Alternatively, the first layer  24  and sixth layer  40  are formed of the same piece of material which is simply wrapped around the other components of body armor  10 . Once wrapped around the other components of body armor  10 , this single piece of material is then connected to itself, as is described above, and the excess is removed. In this arrangement a single seam is located in the center of the back side  14  of the body armor  10 . 
     Joining All Layers Together 
     In another arrangement, all layers described herein, are placed in a mold and pressed together with pressure, heat and adhesive. The pressure and heat activates the adhesive and binds all layers together. This inter-layer cohesion, or the cohesion between each layer, creates a single, albeit multilayered piece of body armor, which improves the strength and impact resistance of the body armor  10 . 
     Foam Piping 
     A layer of piping  44  is positioned around the exterior periphery of all layers. This piping  44  is made of any compressible material such as foam, rubber, Styrofoam, gel, or any other flexible and compressible material. Piping provides an amount of give and cushion to the edge of body armor  10  which improves the comfort of wearing body armor  10 . 
     In Operation 
     In operation, body armor  10  is placed in the vest of user. Upon impact from a bullet or other projectile, the bullet engages and likely passes through the exterior surface of the vest and impacts the strike face or first layer  24  of body armor  10 . Upon initial impact, the first layer  24  of ballistic material, which is in one arrangement Tac-Tex™, begins the initial velocity brake of the projectile in motion. This begins the absorption of the kinetic energy of the bullet by the body armor  10  and begins to deform the bullet. Next, the bullet begins to engage the multiple layers ballistic material which form the second layer  26  which are positioned directly behind the first layer  24 . Each additional layer of ballistic material provides additional protection and supports the absorption of kinetic energy from the bullet and causes additional deformation of the bullet. Next, the bullet engages the hard ceramic armor plate  28  which continues the absorption and dispersion of kinetic energy from the bullet. The ceramic armor plate  28  also serves to break the bullet into pieces thereby reducing the kinetic energy of each individual piece. The ceramic armor plate  28  also breaks apart when struck by the bullet. 
     When because the ceramic armor plate  28  is formed of a plurality of smaller ceramic tiles  30  when the bullet engages any one of these smaller ceramic tiles  30  the impacted small ceramic plate  30  cleaves, shatters and breaks apart as does the bullet. However, because the ceramic plate  28  is made of a plurality of smaller ceramic tiles  30 , the adjacent smaller tiles  30  do not break apart. The other smaller ceramic tiles  30  are fully able to stop additional bullets as they themselves have not been impacted. This is a substantial improvement over the prior art which consists of only a single unitary solid ceramic plate, which when struck by a bullet, the entire plate shatters, leaving little to no protection from other bullets. 
     Also, in the event that the bullet strikes the intersection of two or more smaller ceramic tiles  30 , the bullet shatters the smaller ceramic tiles  30  that it strikes, but it does not pass through. Due to the strong adhesion between adjacent ceramic tiles  30 , as well as the small ceramic tiles  30  being bonded to layers on both the front  12  and the back side  14 , the bullet does not pass through, and shatters the tiles it strikes, while shattering itself and leaving the remaining portions of the body armor intact. 
     For additional protection from a strike at the intersection of two smaller ceramic tiles  30 , there are two or more layers of small ceramic tiles  30  positioned in overlapping and offset condition. In this way, there are no seams for the bullet to pass through. 
     Next, after striking the ceramic layer, the bullet engages the rigid piece  38 . First the bullet engages the fourth layer  34  which comprises a plurality of layers of ballistic fiber which are bonded together, such as 35-40 layers of Kevlar® XP which begins the rapid absorption of kinetic energy and velocity from the bullet. Next the bullet engages the fifth layer  36  which comprises a plurality of layers of polyethylene fiber which are bonded together, such as several hundred layers Spectra® which stops all of the bullet&#39;s motion and displaces the remaining kinetic energy into its fibers. The sixth layer  40  of ballistic fiber, such as a single layer of Tec-Tex, acts as a final stop against any remaining force and displaces the remaining blunt force trauma. 
     Test Results 
     April, 2012: One hit from a 55 gr FMJ .223 DPMS AR-15 on a Level III plate. One additional hit from a 168 gr 30-06 round. 
     May, 2012 Two hits from a 55 gr FMJ .223 DPMS AR-15 on a Level III plate. Two additional hits from a 165 gr .308 DPMS AR-10. Two additional hits from a GLOCK 21 .45 
     One hit on a Level IV plate with a 7mm Remington Magnum BDL. One hit from a 260gr 12 gauge shotgun slug. Nine hits from armor penetrating Homady .40 rounds. 
     Two hits on a Level IV with a Remington .300 WinMag 168gr FMJ rounds from 250 yards. 
     The Level III body armor plate will stop all small arms munitions including 7.62 mm, 5.56 mm, .223, .308 and other assorted rifle munitions and is also rated to take one hit from a .30-06. 
     The Level IV body armor plate will stop all small arms munitions including 7.62 mm, 5.56 mm, .223, .308 and other assorted rifle munitions and is also tested against a point blank 12 gage shotgun, a .300 Winchester Magnum, a .30-06 among many other high powered munitions. 
     Differences Between Level III and Level IV Armor 
     Level III body armor is rated and tested to stop all small arms munitions such as .45, .357, .44, .40, 9 mm. The Level III body armor was tested against the following rifle rounds .30-06 (only 1 hit rated. Tested on 04/2012 against a 165 gr round at 2,900 fps), .223 (2 hit rated), .308 (2 hit rated). The level IV body armor is also rated and tested to stop all of the above as the following rifle and shotgun rounds, .30-06 (1 hit tested using a steel core round), .223 (8 hit rated using 55gr FMJ rounds), .308 (2 hit rated from a DPMS Panther AR-10), 12 gauge 260 gr slug (tested point blank), .300 168gr Winchester Magnum FMJ (2 round tested). 
     Level III body armor has approximately ¾″ of overall thickness, and Level IV body armor has approximately 1″ of overall thickness. The ceramic plate  30  of the Level III body armor is made of smaller hexagonal tiles (such as 1&amp;¼″ tip-to-tip), whereas the Level IV body armor is made of slightly larger square tiles (such as 2″ squares). Also, the Level III body armor has a polyethylene fiber layer  36  that is approximately ½″ thick whereas the Level IV has a polyethylene fiber layer  36  that is approximately ¾″ thick. 
     Alternative Arrangement of Body Armor 
     An alternative arrangement of body armor  50  is presented. Body armor  50  has a front side  52  also known as the impact side or strike face, a back side  54  opposite the front side  52 , a left side  56 , a right side  58 , a top side  60  and a bottom side  62 . Body armor  50  is comprised of a plurality of layers as are described herein. While body armor  50  is of a generally constant thickness, body armor  50  slightly arcuately curves from front  52  to back  54 , so as to provide a better ergonomic fit for the user. In this arrangement, when viewed from the front side  52  the upper corners are chamfered or rounded, so as to provide additional freedom of motion for the user&#39;s arms. 
     First Layer  64 —Cover Material 
     The first layer  64  or front cover layer of body armor  50  provides the exterior surface of the body armor  50 . This first layer  64  is formed of only a single layer of material, or alternatively two, three or more layers of material which are stacked on top of one another for added protection. The number of layers of material and the thickness of each of these layers can be increased or decreased depending on the application. In the event that a plurality of layers are used, they are either bonded to one another to form a single sheet with the use of adhesive, heat, pressing, stitching, gluing, welding or any other process; or alternatively, each of these layers are not bonded to one another and instead are merely positioned in overlapping condition with one another. 
     In the arrangement shown, first layer  64  is formed of a polyester material that is water resistant and/or water proof. Being water resistant or water proof helps to keep the body armor  50  clean and dry. This is especially important considering that body armor  50  is often held close to the body and therefore is often exposed to high moisture levels for extended periods of time. In addition, various components of body armor  50  are adversely affected by water and/or moisture. 
     A countless number of materials are suitable for this application, including a broad array of polyesters, nylons and the like. One material that has been tested with success includes black 78T 600 Denier Polyester with a Urethane coating (impregnated into the material and/or positioned on the inside surface of the material) &amp; DWR. This material is slick to the touch and therefore allows for easy insertion and removal into a vest. In addition, the urethane coating provides a strong moisture barrier. 
     Second Layer  66 —Armor Plate 
     Second layer  66  of body armor  50  is positioned behind the first layer  64 . Second layer  66  is a hard armor plate. 
     Second layer  66  is formed of a hard ceramic armor plate made of any form of ceramic material such as Alumina Silicon, Aluminum Oxide (Al 2 O 3 ) ceramic tile, hot pressed boron carbide and/or silicon carbide which is useful in stopping and/or breaking up projectiles. 
     In the arrangement shown the armor plate  66  is formed of a plurality of smaller ceramic tiles  68 . The smaller ceramic tiles  68  are positioned in end-to-end alignment with one another, either in one single layer, however multiple layers are hereby contemplated. 
     In the arrangement shown, the individual small ceramic tiles are approximately square when viewed from the front or the back. The individual small ceramic tiles are approximately 2 inches by 2 inches, with a thickness of between ¼ of an inch to 1 inch, more specifically approximately ½ of an inch. However any other size and shape is hereby contemplated. 
     The individual tiles also arcuately curve from their front side to their back side. That is, when viewed from above or below, the individual small ceramic tiles  68 , have a slight curvature, or take the shape of a partial portion of a cylinder. In this arrangement, the outside left  56  and right  58  sides are perpendicular to the front  52  and back  54  sides, and therefore the left  56  and right  58  sides are positioned at a slight angle to one another. In this way, a plurality of individual ceramic tiles  68  can be stacked side to side with flat and flush sides face engagement. When stacked together in this manner, the plurality of individual small ceramic tiles  68  form a single continuous arcuate armor plate  66 . 
     Care is taken to ensure that the left  56 , right  58 , top  60  and bottom  62  edges of the small ceramic tiles  68  are square and flat within extremely close and tight tolerances to ensure that when placed in edge-to-edge engagement with other small ceramic tiles  68  maximum engagement is accomplished. This maximizes the strength of bond between engaging tiles, as well as minimizes any gap between adjacent small ceramic tiles  68  so as to prevent a projectile from finding a weak spot between small ceramic tiles  68 . 
     In the arrangement shown, when the small ceramic tiles  68  are approximately 2 inches across, the amount of side-to-side curvature amounts to approximately 7°. That is, the left side  56  and the right side  58  of the small ceramic tiles  68  angle inward towards one another at approximately 7°. When four of these small ceramic tiles  68  are stacked in edge-to-edge alignment, the left-most edge angles inward towards the right-most edge at an angle of approximately 28° (or 7°+7°+7°+7°=28°). It has been tested that this amount of curvature is comfortable for a user and also provides some amount of deflection for projectiles and enhanced impact strength due to its curvature. With that said, any other amount of curvature is hereby contemplated, such as small ceramic plate curvature of 0.5°, 1°, 2°, 3°, 4°, 5°, 6°, 8°, 9°, 10°, 11°, 12°, 13°, 14°, 15°, 16°, 17°, 18°, 19°, 20°, or more or less or any amount therebetween. 
     In the arrangement shown, armor plate  66  is formed of five vertically stacked rows  70  of small ceramic tiles  68 . Each row  70  is approximately the length of four small ceramic tiles  68  stacked in side-to-side alignment. As such, in one arrangement, armor plate  66  could be formed of only twenty total small ceramic tiles  68 . However, to improve strength of armor plate  66 , each row  70  is staggered with respect to the immediately above and/or below row  70 . In one arrangement, as is shown, rows  70  are staggered such that the seams between two small ceramic tiles  68  fall squarely in the middle of the small ceramic tile  68  directly above and/or below the row  70 . That is, said another way, the offset is 50%; or said another way, when the small ceramic tiles  68  are approximately 2 inches wide, the offset is 1 inch which is the maximum offset one tile can be to another. However any other offset is hereby contemplated from 0% to 50% offset, such as 5-10% offset, 5-20% offset, 5-25% offset, 5-30% offset, 5-40% offset, 25% offset, 33% offset, or the like. 
     When an offset is used, this requires the use of partial small ceramic tiles  68  to provide the generally square shape of the armor plate  66 . Specifically, the armor plate  66  is formed of sixteen full small tiles  72 . Corner tiles  74  are used in the outside corners of the upper most row  70 . These corner tiles  74  are essentially the same as full small tiles  72  with their upper outside corner cut off or chamfered angling inward from the bottom of the plate to the top of the plate. This is done to provide room for the user&#39;s arms and makes the body armor  50  more comfortable to wear. In addition, the second row  70  down from the top row  70  and the second row  70  up from the bottom row  70  include partial side tiles  76  that are used to fill in the gaps left by the offset or staggering of the rows  70 . These partial side tiles  76  are essentially half the lateral width of the full small ceramic tiles  72 . 
     Corner tiles  74  and partial side tiles  76  are either formed in their size and shape. Alternatively, the corner tiles  74  and partial side tiles  76  are cut from full small ceramic tiles  72 . 
     While any ceramic ballistic plate can be used for the small ceramic tiles  68 , 99.5% Amumina-Oxide with Magenesium-Oxide tiles manufactured by CerCo, LLC of Shreve, Ohio have been tested with success. 
     The armor plate  66  is formed out of these individual small ceramic tiles  68  in the following manner. The small ceramic tiles  68  are stacked in side-to-side alignment and then bonded together to one another. Any form of bonding can be used such as coating the aligned small ceramic tiles  68  with an adhesive and baking them with heat and pressure to cure the adhesive thereby forming a solid unitary armor plate  66 . 
     One manner and method of bonding the small ceramic tiles  68  that has been tested with success includes using 3M&#39;s Scotch-Weld™ structural adhesive film, AF 163-2 which designates a family of thermosetting modified epoxy structural adhesives in film form which are available in a variety of weights with or without a supporting carrier. The advantages of using this adhesive include: high bond strength from −67° F. to 250° F.; high fracture toughness and peel strength; excellent resistance to high moisture environments beore and after curing; short cure time at ˜225° F. (˜90 minutes); capable of low pressure bonding; vacuum cure capability; x-ray opacity (allows for use of x-ray NDI methods); excellent shop open time for long shelf life; has a higher tack properties than other adhesive films; among countless other advantages. 
     Mold  77  is used to form armor plate  66  using 3M&#39;s Scotch-Weld™ structural adhesive film, AF 163-2. Mold  77  is generally made of a metallic material such as aluminum, steel or any other metallic material. Mold  77  has a generally flat elongated body  77 A with a lip  77 B positioned at its lower edge that protrudes upwardly from the elongated body  77 A. A curved portion  77 C curves upwardly from the upper surface of the main body  77 A. Curved portion  77 C connects at its lower end to the inside edge of lip  77 B. The curved portion  77 C is sized and shaped to match the curvature of small ceramic tiles  68 . In one arrangement, the upper surface of main body  77 A, and curved portion  77 C, as well as the inside edge of lip  77 B are covered or coated with a non-stick surface. The nonstick surface prevents the structural adhesive film from sticking to these surfaces of mold  77 . In one arrangement, the nonstick surface is Teflon tape or Teflon coating. 
     To form armor plate  66 , the protective backing is removed from a first layer of structural adhesive film  77 D and the adhesive film  77 D is laid on and over the curved portion  77 C of mold  77 . Next, the plurality of full small ceramic tiles  72 , corner tiles  74  and partial side tiles  76  are assembled in end to end relation with one another as is depicted in the arrangement shown in  FIG. 5 . Once the tiles  72 ,  74 ,  76  are assembled, a second layer of structural adhesive film  77 D is applied over the front side  52  of the aligned small ceramic tiles  72 ,  74 ,  76 . The structural adhesive film  77 D in one arrangement is cut to shape such that it only extends to the outside edges of the small ceramic tiles  68 ; in an alternative arrangement, the structural adhesive film  77 D wraps around the exterior edge of the small ceramic tiles  68  in partial overlapping condition where some of the edge of the small ceramic tiles  68  is left exposed, or alternatively in full overlapping condition where the entirety of the edge of the small ceramic tiles  68  is covered. Once the structural adhesive film  77 D is placed over the aligned small ceramic tiles  68 , the mold is placed in a vacuum bag  78 . A release film  77 E is positioned over the top surface of the structural adhesive film  77 D to prevent the structural adhesive film  77 D The vacuum bag  78  is large enough to hold a plurality of molds  77  at a single time, as many as 5, 10, 15, 20, 25, 30, 35 or more molds. Next, the adhesive coated armor plate  66  is placed in an autoclave, oven or kiln, the vacuum bag  78  is connected to a vacuum source and vacuumed to an effective pressure. In one arrangement, an effective pressure is between 1 psi and 100 psi, more specifically between 1 psi and 100 psi, more specifically, between 5 psi and 50 psi, and more specifically between 10 psi and 30 psi, and more specifically approximately 20 psi. Simultaneously, the bagged armor plate  66  is baked or heated at an effective temperature for an effective amount of time. The effective temperature is between 100° F. and 650° F., more specifically between 200° F. and 400° F., more specifically between 200° F. and 350° F., more specifically between 200° F. and 300° F., more specifically between 225° F. and 250° F., and more specifically approximately 225° F., however any other temperature is hereby contemplated. The effective amount of time is between 10 minutes and 6 hours, more specifically between 20 minutes and 4 hours, more specifically between 25 minutes and 3 hours, more specifically between 3 minutes and 2 hours, more specifically between 30 minutes and 90 minutes, and more specifically between 30 minutes and 60 minutes, and more specifically approximately 30 minutes, however any other amount of time is hereby contemplated. That is, in one arrangement a temperature of approximately 225° F.+/−25° F. is used for approximately 30 minutes +/−30 minutes. In one arrangement, vacuum is maintained after heating has been terminated until the arrangement, including mold  77  and armor plate  66 , have cooled to below 200° F., more specifically to below 175° F., more specifically to below 150° F., more specifically to below 120° F., more specifically to below 100° F. In another arrangement, one or more armor plates  66 , such as 2, 3, 4, 5, 10, 15, 20 or more, are stacked vertically in the mold  30  with spacers therebetween and cured together under vacuum. Once the armor plate  66  is heated and cooled, the single monolithic armor plate is removed from the mold  32  and vacuum bag  78 . 
     Positive results have been achieved by pumping the vacuum bag  78  down to approximately 20 psi, baking the assembly from room temperature to approximately 225° F. for approximately 30 minutes, removing the tent, and continuing to pull 20 psi from the vacuum bag  78  until the assembly cools to approximately 120° F. 
     This arrangement results in structural adhesive film  77 D coating the entire front side  52  and back side  54  of the armor plate  66 . In addition an amount of structural adhesive film  77 D flows between the seams of the individual small ceramic tiles  68 . In addition, depending on the application, the exterior edge of the small ceramic tiles  68  are also coated with structural adhesive film  77 D. This continuous film and the penetration between the seams adds to the strength and rigidity and durability of the armor plate  66 . 
     Another advantage of the arrangement of using a plurality of small ceramic tiles  68  to form a unitary armor plate  66  is that x-ray testing is not required, which saves cost and a manufacturing step. This is because the small size of the small ceramic tiles  68  and the utilization of the structural adhesive film  77 D do not allow for micro-cracks that affect the performance of the body armor  50  as any micro-crack would terminate at the intersection of two small ceramic tiles  68 . This is in contrast to when the armor plate is formed of a single continuous piece of ceramic wherein a micro crack can extend across the length of the entire plate. In addition, by coating the armor plate  66  in structural adhesive film  77 D this helps the small ceramic tiles  68  prevent new cracks from forming during standard wear and tear. That is, the structural adhesive film  77 D provides a layer of protection to the armor plate  66  which improves the longevity and durability of the body armor. 
     Third Layer—Ballistic Material 
     The third layer  80  is a layer of ballistic material. The third layer  80  may be made of a single layer of ballistic material or made of multiple layers of ballistic material. The third layer  80  of ballistic material serves as a large footprint to soak up energy from the projectile when struck. The ballistic material helps to prevent the projectile from passing through the layer. 
     In one arrangement, the third layer  80  is made of one or multiple layers of an aramid-type material such as Kevlar or Kevlar® XP, or any other aramid-type material or ballistic material. It is hereby contemplated that the third layer  80  is made of a single layer, or as many as 2 layers, 3 layers, 4 layers, 5 layers, 6 layers, 7 layers, 8 layers, 9 layers, 10 layers, 11 layers, 12 layers, 13 layers, 14 layers, 15 layers, 20 layers, 25 layers, 30 layers, 50 layers or up to or 100 layers or any amount in between, or more layers of ballistic material. In one arrangement, a single layer of Kevlar XP is used, it is published that a single layer of Kevlar XP has the density of 11 layers of Kevlar. As such, it is hereby contemplated that 11 layers of Kevlar can be used to replace the single layer of Kevlar XP for equivalent results. 
     In this arrangement, the single or multiple layers of ballistic material are cut to the same dimensions and laid in flat-overlapping condition with one another. The layers are either counted by hand or by machine to ensure that the appropriate number of layers are used. Alternatively, the layers are weighed to ensure the appropriate number of layers are used. 
     In one arrangement, these layers of material are simply laid in loose overlapping condition without being adhered or bound to one another. In an alternative arrangement, these layers of material are bound or adhered to one another using an adhesive, stitching, welding, gluing, or any other manner of connection. In an alternative arrangement, the third layer  80  of ballistic material comes as a single sheet comprised of the multiple layers as is described herein. 
     Fourth Layer—Rigid Backing Plate 
     The fourth layer  82  is a rigid backing plate. The fourth layer  82  rigid backing plate also serves as a large footprint which soaks up energy from the projectile when struck but adds structural rigidity as this layer is inherently rigid in nature. Due to its rigidity, the fourth layer  82  rigid backing plate also serves to reduce or prevent back face deformation (“BFD”) or back face signature (“BFS”). 
     In one arrangement, the fourth layer  82  is made of a polyethylene fiber or ultra-high-molecular-weight polyethylene fiber (UHMWPE”) that is strong, thin, light, and has good impact resistance as well as good energy dispersal characteristics. Spectra® and/or Spectra Shield® and/or Spectra Shield® II fiber manufactured by Honeywell has been tested with success as the fourth layer  82 . In one arrangement, Spectra Shield® II SR-3136 and SR-3137 have been used with success. 
     Spectra® or Spectra Shield® fiber is a bright white polyethylene fiber that is produced using a gel-spinning process. Pound-for-pound, it is 15 times stronger than steel, more durable than polyester and has a specific strength that is 40 percent greater than aramid fiber. Polyethylene is a remarkably durable plastic. Spectra® is one of the world&#39;s strongest and lightest fibers. The gel-spinning process and subsequent drawing steps allow Spectra fiber to have a much higher melting temperature (150° C. or 300° F.) than standard polyethylene. 
     Spectra® displays outstanding toughness and extraordinary visco-elastic properties, Spectra® fiber can withstand high-load strain-rate velocities. Light enough to float, it also exhibits high resistance to chemicals, water, and ultraviolet light. It has excellent vibration damping, flex fatigue and internal fiber-friction characteristics, and Spectra fiber&#39;s low dielectric constant makes it virtually transparent to radar. 
     In this arrangement 1 to 100 layers are used, more specifically 10 to 50 layers, more specifically 20 to 40 layers, and more specifically approximately 36 layers are used. These layers are placed in overlapping condition with one another. The layers are either counted by hand or by machine to ensure that the appropriate number of layers are used. Alternatively, the layers are weighed to ensure the appropriate number of layers are used. 
     Once stacked, the layers are placed in a female cavity  32 A of mold  32  and pressed by male plunger  32 B while heat is added. In one arrangement a plurality of rigid backing plates  82  are formed at a single time by stacking the layers of material and separating them by a spacer, such as a curved piece of steel, aluminum or other spacing material. 
     In one arrangement, the layers of material include or are impregnated with an adhesive, binder or other material which when pressed and/or heated bonds to adjacent layers of material. In one arrangement, the layers are stacked in mold  32  and pressed at an effective pressure for an effective amount of time. In one arrangement an effective pressure is between 100 lbs./in 2  and 5000 lbs./in 2 , more specifically between 1000 lbs./in 2  and 3000 lbs./in 2 , more specifically between 1500 lbs./in 2  and 2750 lbs./in 2 , and more specifically approximately 2500 lbs./in 2 . In one arrangement an effective amount of time is between 10 minutes and 4 hours, more specifically between 20 minutes and 2 hours, more specifically between 30 minutes and 90 minutes, more specifically between 30 minutes and 60 minutes, and more specifically for approximately 30 minutes. In one arrangement, the effective pressure is maintained on the mold  32  until the temperature of the mold  32  drops below an effective cool temperature, which in one arrangement is below 200° F., or below 175° F., or below 150° F., or below 120° F., or below 100° F. In this arrangement, the press begins at approximately at room temperature and ends at approximately room temperature with and heat added over time until the assembly heats to the effective temperature. The combination of the heat and pressure and time causes the multiple layers to form a single unitary rigid piece that resists delamination and back face deformation or back face signature. 
     In an alternative arrangement, the layers of material of the ballistic material  80  are pressed with the layers of material of the fourth layer  82  to form a rigid backing plate comprised of the third layer  80  and the fourth layer  82 . That is, the aramid-type material is pressed with the UHMWP-type material to form a single piece. 
     Fifth Layer  84 —Cover Material 
     The fifth layer  84  or rear cover layer of body armor  50  provides the back exterior surface of the body armor  50 . In one arrangement, this fifth layer  84  is formed of the same material as the first layer  64 , and therefore reference is made thereto. 
     Foam Layer 
     A foam layer  86  is positioned around the exterior edges of armor plate  66 . In one arrangement, the armor plate  66  is approximately ½ of an inch thick, and is approximately 1 inch smaller in side-to-side and top-to-bottom size than rigid backing plate  82  and ballistic material  80 . The foam layer  86  is positioned in this exposed region  88  of third layer  80 . The foam layer  86  fills in the gap or step between exposed region  88  of third layer  80  and the front of the armor plate  66  so as to provide a flat and flush front surface. That is, when in position, the front of foam layer  86  and armor plate  66  are in parallel with one another. 
     Any foam material is used and hereby contemplated for use as foam layer  86 . A high-density, durable and strong foam material has been used with success. In one arrangement, foam layer  86  is punched out of a single sheet of foam material. This reduces assembly time and provides a strong and durable design. In this arrangement, the interior edge of the punched-out region of the foam layer is sized and shaped within close tolerances to fit the exterior edge of armor plate  66 . The exterior edge of foam layer  86  is sized and shaped to fit and align with the exterior edge of the other components of body armor  50 . 
     This foam layer  86  also provides a suitable area for mounting an electronic component  89  therein. That is, in one arrangement, an electronic component  89  is connected to, mounted in, or otherwise held by foam layer  86 . Electronic component  89  includes a GPS tracking device, a ballistic impact sensor, a communications module (such as a cell phone type module, a radio, or the like), an RFID tag, a video or audio recording device, a computing device or any other electronic component. The compressible nature foam layer  86  and its position approximate the other rigid components of body armor  50  provide an excellent mounting structure as well as providing protection for the sensitive electronic components. In one arrangement the electronic component  88  includes a battery which is charged by way of inductive charging and/or motion powered such that when the body armor  50  is worn, the electronic component is powered and/or charged by the motion of the wearer. In an alternative arrangement, electronic component  89  is connected to any other portion of body armor  10 / 50 . 
     Foam Piping 
     Once the internal components of the body armor  50  are assembled, foam piping  90  is positioned around the exterior edge. Any foam material is used and hereby contemplated for use as foam piping  90 . A high-density, durable and strong foam material has been used with success. In one arrangement, foam piping  90  comes in a roll and has a layer of adhesive on an interior edge, or alternatively on an interior and exterior edge, which adheres to the other components of body armor  50 . The foam piping  90  is sized and shaped to be approximately the width of the edge of the other components of body armor  50 . In one arrangement, 1 inch wide #2 density crosslink KE with EVA foam tape of approximately 0.0625 inch thickness with 3M #950 PSA adhesive on one side has been used with success. Foam piping  90  provides some level of cushion around the exterior edge of body armor  50 . 
     Fabric Band 
     A fabric band  92  is positioned around the exterior edge of body armor  50 . Fabric band  92  is formed of any suitable material such as polyester, nylon, a ballistic material or the like. The fabric band  92  overlaps a portion of the front cover material  64 , extends across the entire edge and overlaps a portion of the rear cover material  84 . In one arrangement, black # F 72 83% Nylon 17% Lycra has been used with success. 
     Assembly 
     This embodiment is assembled in the following manner. 
     The third layer  80 , the ballistic material, is connected to the back  54  side of the armor plate  66  using an adhesive. Any adhesive is hereby contemplated for use. In one arrangement, a single layer of 3M™ adhesive transfer tape 9485PC has been used with success. 9485PC is a high performance acrylic adhesive. 9485PC provides high tack and shear strength, excellent temperature and solvent resistance, excellent adhesion to plastics and foams and can be used for joining materials that are relatively smooth, thin and have low residual stress. 9485PC is designed for temperature exposure to 450 degree Fahrenheit for short periods of time and is ideal for bonding a wide variety of similar and dissimilar materials. As such, it is durable and provides a long useful life and strong bond. Once bonded together, the exposed region  88  extends around the exterior edge of the armor plate  66 . 
     The fourth layer  82  is connected to the back  54  side of the third layer  80 , the ballistic material by way of adhesive. Any adhesive is hereby contemplated for use. In one arrangement, the same adhesive tape 9485PC is used in a similar manner described above with respect to the connection of the third layer  80  to the armor plate  66 . 
     The foam layer  86  is connected to the front  52  surface of the exposed region  88  of the second third layer  80 , the ballistic material. Any adhesive is used to connect the foam layer  86  to the third layer  80 . In the arrangement shown, since the front side of the third layer  80  the ballistic material is covered with an adhesive tape, the foam layer  86  simply sticks to this exposed region  88  of adhesive tape. 
     Once the internal components of the body armor  50  are assembled, the foam piping  90  is wrapped around the exterior edge of the body armor. The foam piping  90  is adhered using adhesive tape or any other adhesive. 
     After the foam layer  86  is adhered around the armor plate  66 , and the foam piping  90  is wrapped around the body armor  50 , the first layer  64 , the front cover material, is connected to the front of the body armor. To do so, adhesive is applied to the front surface  52  of the armor plate  66  and adhesive is applied to the rear  54  surface of the front cover material  64 . Any adhesive is hereby contemplated for use. In one arrangement, 3M™ Scotch-Weld™ Nitrile High Performance Plastic Adhesive 1099L has been used with success. 1099L is a low viscosity, fast drying and heat curable plastic adhesive. It resists weathering, water, oil, plasticizer migration, and alphalitic fuels. As such, it is durable and provides a long useful life and strong bond. Once the two surfaces are coated and the adhesive is allowed to partially set-up or become sticky, the two components are connected to one another. 
     A similar process is used to connect the fifth layer  84 , the rear cover material to the back  54  side of the fourth layer  82 , the rigid backing plate  82 . That is, in one arrangement the 1099L adhesive is used. 
     Once these components are fully assembled the fabric band  92  is wrapped around the exterior edge of the body armor  50  and adhered thereto. Any adhesive is hereby contemplated for use. In one arrangement, the 1099L adhesive is used as is described herein. Care is taken to ensure that a certain portion of the fabric band  92  overlaps itself (approximately 1 inch) to ensure complete coverage of the internal components. 
     In an alternative arrangement of assembly, the first layer  64  is stitched to the fabric band  92  and the fifth layer  84  is adhered to the back side of the fourth layer  82  either using adhesive or an adhesive tape as is described herein. Next, the first layer  64  with attached fabric band  92  is placed over the other components of the body armor  50  and the fabric band  92  is adhered to the body armor  50  using adhesive or adhesive tape as is described herein. 
     After the body armor  50  is fully assembled, in another arrangement a plurality of body armor  50  plates are stacked on top of one another and pressure and/or heat are applied for an extended period of time to force the multiple layers into engagement with one another, to activate and cure the various layers of adhesive, thereby forming a more-dense and rigid body armor  50 . 
     In this way an improved body armor is formed. 
     In Use: As a projectile strikes the front  52  of the body armor  50 , the projectile passes through the front cover material  64 . Next, the projectile strikes the armor plate  66 . Specifically, the projectile strikes one or more small ceramic tiles  68  ( 72 ,  74 ,  76 ). This causes the stricken small ceramic tiles  68  to fracture. This causes the projectile to transfer a great amount of energy to the armor plate  66 . While the stricken small ceramic tiles  68  fracture, the adjacent small ceramic tiles  68  remain unbroken and able to absorb additional projectiles without degradation of effectiveness. Further, the structural adhesive film on both the front  52 , back  54  and between the various individual small ceramic tiles  68  helps to hold the plurality of ceramic plates  68  together and prevent fractures across the entire armor plate  66 . 
     After striking the armor plate  66 , the projectile and/or the force thereof, engages the ballistic material  80 . Due to the features of the ballistic material  80  this layer acts as a catcher&#39;s mitt and absorbs additional energy from the projectile. The long molecules and strands of the ballistic material  80  help to resist the projectile passing through the ballistic material  80 . 
     Next, the remaining force of the projectile is absorbed by the rigid backing plate  82 . Due to the structural rigidity of the backing plate  82 , the force of the projectile is absorbed with minimal back face deformation (“BFD”) or back face signature (“BFS”). 
     In this way, the body armor  50  stops multiple projectiles and thereby saves lives. That is, by having a plurality of small ceramic tiles  68 , each of these small ceramic tiles  68  act as their own independent piece of body armor and are unaffected by impacts to the surrounding small ceramic tiles  68 . Furthermore, by coating the plurality of small ceramic tiles  68  with structural adhesive film  77 D this provides additional rigidity to the assembly. In addition, by adhering each layer to the other, this improves the rigidity of the entire assembly, which further improves the density of the assembly and helps to stop projectiles. 
     Alternative Embodiments: While a chest plate has been presented herein, the invention is not so limited. Other embodiments and manners of using the technology presented herein are also contemplated. This includes side plates for a person&#39;s torso, shoulder plates, helmets, groin plates, or plates for any other portion of a person&#39;s body. The technology can also be incorporated into panels for vehicles. It is also hereby contemplated to place plates under the seat of combat aircraft such as helicopters, planes, jets or the like. 
     Accordingly, a new, useful and nonobvious body armor and method of making the same is presented. From the above discussion it will be appreciated that the body armor  10  presented provides a substantial improvement upon the state of the art. Specifically, the body armor presented is lightweight, is inexpensive and simple to manufacture, can sustain multiple ballistic impacts, can sustain high ballistic impacts, breaks apart the projectile, all while being comfortable to wear. 
     It will be appreciated by those skilled in the art that other various modifications could be made to the device without parting from the spirit and scope of this invention. All such modifications and changes fall within the scope of the claims and are intended to be covered thereby.