Patent Publication Number: US-9835414-B2

Title: Ballistic vest carrier cover system with pouches for hard armor panels

Description:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable 
     REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to police equipment, more particularly, to outer carrier wearing of soft body armor, law enforcement duty belts and methods for suspending them. 
     2. Description of the Related Art 
     Standard equipment for peace officers includes the wearing of an undershirt or turtleneck, a ballistic soft body armor vest, and a police uniform shirt over the vest. The body armor vest includes a carrier, two armor panels, and attachable/detachable fasteners, typically hook and loop fasteners. One armor panel fits into a front carrier through an opening in the bottom of the front carrier and the other armor panel fits into a rear carrier through an opening in the bottom of the rear carrier. The attachable/detachable fasteners attach the front and rear carriers together around the wearer&#39;s waist and over the shoulders to form the vest. 
     The body armor vest traps excess body heat around the torso in warm weather and is uncomfortable due to the constant compression and weight of the armor. It is also very inconvenient to remove the body armor carrier prior to the conclusion of the wearer&#39;s shift. For this reason there has been a move towards the wearing of outer carrier ballistic vests. 
     Most outer carrier vests are made from heavy-duty nylon or polyester materials and are fitted to a particular brand of soft body armor panels. The panels are removed from the front and rear carriers and inserted into the bottom of the carrier vest. The carrier vest has attachable/detachable, typically hook and loop, fasteners at the sides for adjustment and removal. Use of the carrier vest&#39;s fasteners rather than those supplied by the manufacturer with the body armor panels may void the armor warranty. The carrier vests are made to somewhat match the look of a uniform shirt on the outside and are typically worn over a police shirt. The carrier vest is independent from the duty belt and sits above it on the torso. 
     There are occasional situations where additional armor protection is desired. The additional protection can take the form of hard armor plates covering the front and rear torso. Typically, the hard armor plates are installed in a separate carrier and donned when needed. The extra bulk from the plate carrier can further restrict the movements of the wearer. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is a front pouch, a rear pouch, and optional side pouches for hard armor plates incorporated into any ballistic vest carrier cover. 
     Briefly, the carrier cover has a mantle that goes over the wearer&#39;s shoulders from a front panel at the front waist to rear panel at the rear waist. The mantle has a fabric outer layer, an optional interlining to protect the outer layer from abrasion from the body armor panel carriers, and a liner that is typically a polyester mesh. 
     The liner is attached to the outer layer to form a front pocket and a rear pocket that receive the body armor panel carriers. Side armor openings and optional lateral openings provide access to the pockets. The armor openings allow the use of the body armor waist straps that are supplied with the body armor for individual adjustment. The front and rear panel carriers are attached together at the shoulders using the body armor shoulder straps supplied with the body armor. 
     Waist panels extend from the lower end of the rear panel at the armor openings, over the waist straps, and detachably attach at the front panel armor openings. The waist panels are preferably composed substantially of a stretch fabric and detachably attach to the front panel any type of detachable fasteners, preferably zippers. 
     The present invention incorporates a front pouch and/or a rear pouch into a carrier cover of any type. The front and rear pouches are inside the front and rear armor pockets, respectively, with access from the outside of the carrier cover. The present invention also contemplates the optional incorporation of side pouches in the side panels of the carrier cover. 
     In one configuration, the pouch is attached to the inside of the outer layer within the pocket. The pouch is a single fabric sheet that is attached to the outer layer around the sheet perimeter. In another configuration, the pouch is a bag that hangs in the pocket. The upper edges of the bag are attached to the outer layer so that the bag hangs freely within the pocket. Optionally, the bottom end of the bag is tacked to the outer layer. 
     In one configuration, the top end of the pouch is accessed via a lateral opening in the outer layer. The lateral opening is closed by a openable fastener, such as a zipper, hook and loop fastener, or snaps. In another configuration, the front pouch is accessed via a vertical opening in the outer layer that is closed by an openable vertical fastener, such as a zipper, hook and loop fastener, or snaps. Optionally, the opening and fastener are hidden behind a placket that is pulled aside for access. 
     In one embodiment, the pouches are sized to accept one size of armor plate so they do not slide around inside the pouches. In another embodiment, the pouches can be used with a variety of armor plates having different widths. The pouches have internal vertical sizing strips that are strips of detachable fasteners, preferably hook and loop fasteners or snaps. The sizing strips come in opposed pairs so that the armor plate is kept centered. 
     In another embodiment, the pouches can be used with a variety of armor plates having different thicknesses. The pouch is sized for the thickest plate and internal loop fasteners mate to a corresponding hook fastener on the thinner plates. 
     Optionally, there are side pouches in the waist panels for side armor plates. In one configuration, the waist panel has an outer layer and an inner layer that are attached at the top edge, bottom edge, rear edge, and the lower portion of the front edge, forming the pouch and a vertical side armor pouch opening. The lower portion extends upwardly far enough so that the side armor plate does not fall out after being installed. 
     In another configuration, the outer and inner layers are attached around the edges, forming the pouch. The top end of the side pouch is accessed via a lateral opening in the outer layer that is closed by an openable fastener, such as a zipper, hook and loop fastener, or snaps. 
     Objects of the present invention will become apparent in light of the following drawings and detailed description of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the nature and object of the present invention, reference is made to the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of the ballistic vest carrier cover of the present invention; 
         FIG. 2  is a front view of the carrier cover of  FIG. 1  showing several options; 
         FIG. 3  is a cross-sectional view of one fabric structure of the carrier cover of  FIG. 1  taken at A-A; 
         FIG. 4  is a perspective view of a long-sleeve pullover shirt for use with the carrier cover of the present invention; 
         FIG. 5  is a view of the inside of the carrier cover of  FIG. 1 ; 
         FIG. 6  is a perspective view of the carrier cover of  FIG. 1  with body armor carriers installed; 
         FIG. 7  is a side cross-sectional view of the bottom opening for installing the armor carrier; 
         FIG. 8  is a front view of a carrier cover showing the front armor pocket and the single sheet front armor pouch in phantom with a lateral opening; 
         FIG. 9  is a side cross-sectional view of  FIG. 8  taken at B-B of the front armor pocket and the single sheet embodiment of the front armor pouch with the lateral opening; 
         FIG. 10  is a front view of a carrier cover showing the front armor pocket and the bag front armor pouch in phantom with a lateral opening; 
         FIG. 11  is a side cross-sectional view of  FIG. 10  taken at C-C of the front armor pocket and the bag front armor pouch with the lateral opening; 
         FIG. 12  is a front view of a carrier cover showing the front armor pocket and the single sheet front armor pouch in phantom with a vertical opening; 
         FIG. 13  is a top cross-sectional view of  FIG. 12  taken at D-D of the front armor pocket and the single sheet front armor pouch with the vertical opening; 
         FIG. 14  is a rear view of a carrier cover showing the rear armor pocket and the rear armor pouch in phantom; 
         FIG. 15  is a front view of a carrier cover showing the front armor pocket and the front armor pouch with optional sizing strips in phantom and an optional thickness loop fastener in phantom; 
         FIG. 16  is a top cross-sectional view of  FIG. 15  taken at E-E showing the front armor pocket and the front armor pouch with the optional sizing strips and the optional thickness loop fastener; 
         FIG. 17  is a view of the bottom rear of a carrier cover showing a first configuration of the side armor pouches in phantom with a vertical opening; 
         FIG. 18  is a right side view of a carrier cover showing a first configuration of the right side armor pouch in phantom with a closed lateral opening; 
         FIG. 19  is a left side view of a carrier cover showing the  FIG. 18  configuration of the left side armor pouch in phantom with an open lateral opening; 
         FIG. 20  is a front cross-sectional view of  FIG. 18  taken at F-F of the right side armor pouch; 
         FIG. 21  is a front view of a carrier cover showing a partial installation of a front armor panel into the front pouch in partial phantom; 
         FIG. 22  is a front view of a carrier cover showing a front armor panel installed the front pouch in phantom; 
         FIG. 23  is a rear view of a carrier cover showing a rear armor panel installed the rear pouch in phantom; 
         FIG. 24  is a right side view of a carrier cover showing a right side armor panel installed the right side pouch in phantom; and 
         FIG. 25  is a left side view of a carrier cover showing a left side armor panel installed the left side pouch in phantom. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present application hereby incorporates by reference in its entirety U.S. Provisional Patent Application No. 62/115,341, on which this application is based. 
     The present invention is a front pouch, a rear pouch, and optional side pouches for hard armor plates incorporated into a ballistic vest carrier cover. 
     The present invention contemplates that the pouches can be incorporated into any carrier cover. One such carrier cover is described in U.S. Pat. Nos. 8,528,112 and 8,776,262, incorporated herein by reference. 
     As shown in  FIGS. 1 and 2 , the carrier cover  10  has a mantle  12  that goes over the wearer&#39;s shoulders from the front waist to rear waist and with a neck opening  16  that goes over the head. The mantle  12  includes a front panel  60  and a rear panel  62 . The mantle  12  has a fabric outer layer  17 , an optional interlining  18 , and a liner  19 , as shown in  FIG. 3 . The carrier cover  10  is typically designed to fit over a matching shirt  11 , as shown in  FIG. 4 . From a distance and at first glance, the combination of carrier cover  10  and shirt  11  are intended to appear as a standard uniform shirt. The combination preserves the officers tactical advantage gained by wearing “concealed” armor that is more comfortable to wear versus most outer carriers which do not match the shirts they are worn over. 
     The optional interlining  18  attached to the outer layer  17  protects the outer layer  17  from abrasion from the body armor panel carriers  40 ,  42 , thereby providing strength and durability to the carrier  10 . 
     The liner  19  is composed of a knit or woven material that may be wicking or non-wicking in performance. Typically, the majority of the liner  19  is a heavyweight polyester mesh. 
     The liner  19  is attached to the outer layer  17  at several places, as shown in  FIG. 5 . The layers  17 ,  19  are attached at the front waist, as at  33 , at the rear waist, as at  34 , at the neck opening  16 , as at  35 , along the right side from a right front armor opening  48  adjacent to the front waist  33  to right rear armor opening  50  adjacent to the rear waist  34 , as at  36 , and along the left side from a left front armor opening  49  adjacent to the front waist  33  to left rear armor opening  51  adjacent to the rear waist  34 , as at  37 . The front armor openings  48 ,  49  are separated by the front waist attachment  33 , and the rear armor openings  50 ,  51  are separated by the rear waist attachment  34 . The attachments  33 - 37  can be stitched and reinforced with durable fabrics, such as polyester or nylon, to prevent abrasion and wear. 
     Because the outer layer  17  and liner  19  are only attached at the edges, two pockets are formed, a front pocket  44  and a rear pocket  46 , between the outer layer  17  and liner  19  for receiving the body armor panel carriers  40 ,  42 , as shown in  FIG. 6 . Openings  48 - 51  between the waist attachments  33 ,  34  and the ends of the side attachments  36 ,  37  provide access to the pockets  44 ,  46  for installing and removing the armor panel carriers  40 ,  42 . 
     Optionally, and in addition to the side openings  48 - 51 , the present invention contemplates that there may be lateral openings  76  in the liner  19  for inserting the armor panel carriers  40 ,  42  into the pockets  44 ,  46 . Either the front, the rear, or both the front and rear can have a lateral opening  76 . In one configuration, the waist attachments  33 ,  34  are zippers, hook and loop fasteners, or other openable fasteners that facilitate inserting the armor panel carriers  40 ,  42  into the pockets  44 ,  46  from the bottom. In another configuration, the lateral opening  76  is formed by overlapping edges  77 ,  78  of the liner  19 , as in  FIG. 8 . The edges  77 ,  78  are closed by a zipper, a hook and loop fastener, or other openable fastener  79 . 
     The armor openings  48 - 51  allow the use of the body armor waist straps  86  that are supplied with the body armor for individual adjustment. Each waist strap fastener  88  attaches to a mating hook and loop fastener  82  on the body armor panel carrier  40 ,  42 , while extending around the wearer&#39;s side. 
     Optional tunnels  52 ,  53  at each shoulder between the front pocket  44  and the rear pocket  46  allow fastening of the front and rear armor panel carriers  40 ,  42 . Optional openings  54 ,  55  in the liner  19  at the shoulders  25  facilitate attaching the two armor panel carriers  40 ,  42  together at the shoulders  25  using the body armor shoulder straps  88  supplied with body armor. Each shoulder strap fastener  88  attaches to a mating hook and loop fastener  84  on the body armor panel carriers  40 ,  42 , while extending over the wearer&#39;s shoulder. 
     Waist panels  74 ,  75  extend from the lower end of the rear panel  62  at the armor openings  50 ,  51 . The waist panels  74 ,  75  allow for improved ventilation, better fit, and freer motion, and are preferably composed substantially of a stretch fabric. The amount of stretch is significantly more than what is considered a non-stretch material. The present invention considers that a material that increases in length by at least 8% when under tension is a stretch material. The waist panels  74 ,  75  help hide the body armor panel carriers  40 ,  42  and body armor straps  86  outside of the pockets  44 ,  46 , thereby facilitating the illusion of a standard uniform shirt. 
     The waist panels  74 ,  75  removably attach to the front panel  60  by detachable panel fasteners  63 ,  64 . Any type of detachable fasteners can be used including hook and loop fasteners, snaps, buckles, and hook and eye closures. The preferred panel fasteners  63 ,  64  are zippers  65 ,  66  because they are difficult to remove during an altercation. 
     Hard armor plates are well-known in the industry. They are rigid plates, typically made of coated steel, ceramic, polyethylene, or carbon composites. Front armor plates are made to cover the front torso, rear armor plates are made to cover the rear torso, and side armor plates are made to cover the side rib cage. The front and rear armor plates are generally contoured to fit the front and rear torso of a wearer and come in a range of sizes, typically from 8″×10″ to 11″×14″. They are also found in a range of thickness, ranging from ¼″ to 1¼″. Various combinations of materials and thicknesses provide for a wide range of available protection levels. Side armor plates typically have a single curve to hug the body. They come in a range of sizes from 6″×6″ to 8″×10″ and in thicknesses from ½″ to 1¼″. 
     The present invention incorporates a front pouch  102  and/or a rear pouch  104  into a carrier cover  10  of any type. The front pouch  102  is inside the front armor pocket  44  with access from the outside of the carrier cover  10  to facilitate quick installation of a front armor plate  92 . The rear pouch  104  is inside the rear armor pocket  46  with access from the outside of the carrier cover  10  to facilitate quick installation of a rear armor plate  94 . 
     The present invention also contemplates the optional incorporation of side pouches  106 ,  108  in the side panels  74 ,  75  of the carrier cover  10  with access from the outside of the carrier cover  10  to facilitate quick installation of side armor plates  96 ,  98 . 
     One configuration of the front pouch  102  is shown in  FIGS. 8 and 9 . The front pouch  102  is attached to the inside of the outer layer  17  within the pocket  44 . The front pouch  102  is a single fabric sheet  112  that is attached to the outer layer  17  around the sheet perimeter  114 . The single sheet  112  is attached only to the outer layer  17  so it does not interfere with installation of the front armor carrier  40  into the front pocket  44 . In reference to the incorporated pouch, the outer layer  17  is intended to include any interlining  18  that may be attached to the outer layer  17 . 
     In another configuration, shown in  FIGS. 10 and 11 , the front pouch  102  is a bag  118 . The upper edges  120 ,  122  of the bag  118  are attached to the outer layer  17  so that the bag  118  hangs freely within the front pocket  44 . Optionally, the bottom end  124  of the bag  118  is tacked to the outer layer  17  so that it does not fold or otherwise crease in a way that prevents easy installation of the front armor plate  92 , as described below, interfere with installation of the front armor carrier  40  into the front pocket  44 . As with the single sheet  112 , the bag  118  is attached only to the outer layer  17  so it does not interfere with installation of the front armor carrier  40 . 
     In the embodiment of  FIGS. 8-11 , the top end of the front pouch  102  is accessed via a front lateral opening  128  in the outer layer  17  that extends across the front panel  60  high on the chest. The front lateral opening  128  is closed by a front openable fastener  130 , such as a zipper, hook and loop fastener, or snaps. 
     In another embodiment, the front pouch  102  is accessed via a front vertical opening  134 , as shown in  FIGS. 12 and 13 . The front vertical opening  134  in the outer layer  17  extends vertically along the front panel  60  from below the neck  16  to above the waist  59 , preferably in the center of the front panel  60 . A vertical front opening  134  is closed by a vertical openable fastener  136 , such as a zipper, hook and loop fastener, or snaps. Optionally, as shown in  FIG. 12 , the vertical fastener  136  and vertical opening  134  are hidden behind a placket  22 . The placket  22  is pulled aside for access to the vertical fastener  136  and vertical opening  134 . 
     In the embodiment of  FIGS. 12 and 13 , the front pouch  102  is a single fabric sheet  138  that is attached around the perimeter  140  to the outer layer  17 . As with the single sheet  112  above, the single sheet  138  is attached only to the outer layer  17  so it does not interfere with installation of the front armor carrier  40  into the front pocket  44 . 
     The rear pouch  104  is shown in  FIG. 14 . A lateral opening  150  in the outer layer  17  extends across the rear panel  62  high on the back, just below the neck  16 . The rear pouch  104  can take either the single sheet form or the bag form described above with reference to the front pouch  102 . 
     The rear lateral opening  150  is closed by a rear openable fastener  152 , such as a zipper, a hook and loop fastener, or snaps. 
     The sheet  112 ,  138  and bag  118  of the front and rear pouches  102 ,  104  are composed of a fabric material that is robust enough to handle the weight and abrasion from armor plates  92 ,  94 . Materials include coated nylon and nylon and polyester meshes. 
     In one embodiment, the pouches  102 ,  104  are intended for use with a single size and thickness of armor plates  92 ,  94 , and are sized accordingly so that the armor plates  92 ,  94  do not slide around inside the pouches  102 ,  104 . 
     In another embodiment, the pouches  102 ,  104  are intended for use with a variety of armor plates  92 ,  94  having different widths. To prevent the armor plates  92 ,  94  from sliding from side to side, the pouches  102 ,  104  have internal vertical sizing strips  160   a ,  160   b  (collectively,  160 ), as shown in  FIGS. 15 and 16  with the single sheet embodiment of the front pouch  102 . The sizing strips  160  come in opposed pairs  160   a ,  160   b  so that the armor plate  92 ,  94  is kept centered on the torso when installed in the pouch  102 ,  104 . The sizing strips  160  are strips of detachable fasteners, preferably hook and loop fasteners. Other detachable fasteners may be used, such as strips of snaps. 
     In another embodiment, the pouches  102 ,  104  are intended for use with a variety of armor plates  92 ,  94  having different thicknesses. The pouches  102 ,  104  are sized so that the thickest plate  92 ,  94  fits snuggly. To prevent the thinner armor plates  92 ,  94  from sliding around, the pouches  102 ,  104  each have an internal loop fastener  162 , as shown in  FIGS. 15 and 16 , that mates to a corresponding hook fastener on the plate  92 ,  94 . 
     Optionally, each pouch  102 ,  104  can accept more than one armor plate  92 ,  94  at the same time in the event the wearer wants more protection than is available from a single plate  92 ,  94 . 
     Optionally, there is a right pouch  106  in the right waist panel  74  and a left pouch  108  in the left waist panel  75  for side armor plates  96 ,  98 , as shown in  FIGS. 17-20 . The present invention contemplates several configurations for the side pouches  106 ,  108 . 
     One configuration of the side pouches  106 ,  108  is shown in  FIG. 17 . Referring to the right pouch  106  (the left pouch  108  is the mirror image), the waist panel  74  has an outer layer  192  and an inner layer  194  that are attached at the top edge  196 , bottom edge  198 , rear edge  200 , and the lower portion  204  of the front edge, forming the pouch  106  and a vertical right pouch opening  186  through which the pouch  106  is accessed. The lower portion  204  extends upwardly far enough so that the side armor plate does not fall out after being installed. Consequently, the opening  186  typically does not need an openable fastener. The outer layer  192  and inner layer  194  are preferably composed of a stretch fabric, which provides pressure to retain the armor plate  96  in the pouch  106 . The inner layer  194  is preferably composed of a mesh fabric. 
     The present invention does contemplate, however, the opening  186  may have an openable fastener. 
     Another configuration of the side pouches  106 ,  108  is shown in  FIGS. 18-20 . As shown in  FIG. 20 , the waist panel  74  has an outer layer  174  and an inner layer  176  that are attached around the edges  178 , forming the pouch  106 . The top end of the right pouch  106  is accessed via a lateral opening  170  in the outer layer  174  or between the outer layer  174  and inner layer  176  that extends across the right waist panel  74 . The lateral opening  170  is optionally closed by an openable fastener  172 , such as a zipper, hook and loop fastener or snaps. 
     The carrier cover  10  is used in two steps. First, the armor panel carriers  40 ,  42  are installed into the pockets  44 ,  46 , as in  FIG. 6 , and the shoulder straps  88  are arranged as necessary over the shoulders  25 , attaching the front and rear armor panel carriers  40 ,  42  together. The carrier cover  10  is placed over the wearer&#39;s head and the waist straps  86  attach the armor panel carriers  40 ,  42  together at the waist. Each waist panel  74 ,  75  is pulled over the waist straps  86  and the fasteners  63 ,  64  are attached, whereby the waist straps  86  are hidden by the waist panels  74 ,  75 . 
     At this point, none of the armor plates are installed. The wearer goes about his business, walking, driving, etc. 
     When a situation arises where the extra protection afforded by the armor plates is desired, the plates can be installed without taking the carrier cover  10  off. The front fastener  130 ,  136  is opened to gain access to the front pouch  102 . The front armor plate  92  is inserted into the front pouch  102 , as in  FIG. 21 , and the fastener  130 ,  136  is closed, as in  FIG. 22 . The rear fastener  152  is opened to gain access to the rear pouch  104 . The rear armor plate  94  is inserted into the rear pouch  104  and the fastener  152  is closed, as in  FIG. 23 . If the wearer has a partner, it may be easier for the partner to install the rear armor plate  94 . 
     If the pouches  102 ,  104  include sizing strips  160 , the appropriate strips  160   a ,  160   b  are attached and/or detached to size the pouch  102 ,  104  to the armor plate  92 ,  94  that is being used. 
     If the carrier cover  10  has the preferred side pouches  106 ,  108  of  FIG. 17 , the side panel fasteners  63 ,  64  are detached to provide access to the inside of the side panels  74 ,  75 . The right side armor pouch opening  186  is pulled open to gain access to the right side armor pouch  106  and the right side armor plate  96  is inserted through the opening  186  into the pouch  106 , as in  FIGS. 24 and 25 . The left side armor plate  98  is inserted into the left side armor pouch  108  through the left side armor pouch opening  188 . Then the side panel fasteners  63 ,  64  are reattached. 
     The present invention also contemplates that the armor plates can be installed and worn in the normal course of the day. If the armor plates are light enough, they will have only a small effect on wearer. 
     Thus it has been shown and described a ballistic vest carrier cover system with pouches for hard armor panels. Since certain changes may be made in the present disclosure without departing from the scope of the present invention, it is intended that all matter described in the foregoing specification and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense.