Patent Publication Number: US-2023145266-A1

Title: Ballistic Vest

Description:
BACKGROUND OF THE INVENTION 
     Some ballistic vests are constructed as a set of ballistic panels (soft armor) supported in a carrier. Many of these ballistic vests are relatively inflexible, unaccommodating to movement of the user, and thus uncomfortable. A vest that is constructed in accordance with the present invention can help to overcome those deficiencies. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Features of the invention will become apparent to one of ordinary skill in the art to which the invention pertains from a reading of the following description together with the accompanying drawings, in which: 
         FIG.  1    is a right front perspective view of a ballistic vest that is one embodiment of the invention, the vest including a carrier that is made from fabric material and that has pockets that carry ballistic panels; 
         FIG.  2    is a front elevational view of the vest of  FIG.  1   ; 
         FIG.  3    is a back right perspective view of the vest of  FIG.  1   ; 
         FIG.  4    is a left side elevational view of the vest of  FIG.  1   ; 
         FIG.  5    is a schematic illustration of an outer fabric panel that is one component of the carrier of  FIG.  1   , as viewed from the body side; 
         FIG.  6    is a schematic illustration similar to  FIG.  5   , showing a front ballistic panel flap pocket added to the outer layer; 
         FIG.  7    is a schematic illustration of the carrier of  FIG.  6   , showing an inner fabric panel added to the outer fabric panel; 
         FIG.  8    is a schematic illustration similar to  FIG.  7   , showing left and right side panel pockets added to the inner layer of the carrier; 
         FIG.  9    is a schematic illustration similar to  FIG.  8   , with arrows indicating locations of insertion of the ballistic panels into the carrier; 
         FIGS.  10  and  11    are schematic illustrations similar to  FIG.  9   , showing steps in the process of the insertion of the ballistic panels; 
         FIGS.  12 A- 12 C  are a series of views illustrating the final steps in donning the vest of  FIG.  1   ; 
         FIGS.  13  and  14    illustrate the inclusion and positioning of a trauma plate in a pocket; 
         FIGS.  15  and  16    illustrate additional embodiments of the invention, including side ballistic panels. 
     
    
    
     DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The present invention relates to a ballistic vest. The invention is applicable to vest of different constructions. As representative of the invention,  FIG.  1    illustrates a vest  10  that is a first embodiment of the invention. 
     One major component of the vest  10  is a carrier  12 . The other main component of the vest  10  is a plurality of ballistic panels or ballistic inserts (soft armor). In the particular vest  10  that is illustrated, there are four ballistic panels: a front ballistic panel  14 , a back ballistic panel  16 , a left side ballistic panel  18 , and a right side ballistic panel  20 . Other vests in accordance with the invention might have more than four ballistic panels or fewer than four ballistic panels. As described below, the ballistic panels  14 - 20  are inserted into the carrier  12  after the carrier is itself assembled; thereafter, the vest  10  can be donned by the user. 
     The carrier  12  in the illustrated embodiment includes as its two major components a carrier outer layer  30  and a carrier inner layer  60 . One or both of the carrier layers  30  and  60  may be made from a number of individual fabric panels that are joined together, preferably by sewing. 
     Assembly of the carrier  12  preferably starts with the carrier outer layer  30  ( FIG.  5   ). In  FIG.  5   , the outer carrier layer  30  is viewed from the body side, that is, from the side closer to the user when being worn. The outer layer  30  extends over all or substantially all of the exterior of the vest  10  when the vest  10  is being worn by a user. In the illustrated vest embodiment  10 , the outer layer  30  is not flat, but rather is three-dimensional. As such, it is made from a number of individual pieces of fabric sewn together with stitching sections. In other embodiments of the invention, the outer layer  30  can be made from more or fewer fabric pieces, and the pieces may be joined to each other in a manner other than by sewing. 
     Each fabric panel of the carrier panel can utilize stretch knits or woven fabrics of varying weights and elasticity/stretch. Some fabric panels may have more elasticity/stretch than others. The fabrics may incorporate wicking, antimicrobial and/or cooling features throughout the carrier, or such features may be incorporated in strategic panel locations. One material that has been found to be suitable is the type of material that is used for cycling jerseys. 
     Some fabric panels of the carrier  12  are preferably, but not necessarily, made from a different fabric than others. For example, some fabric panels may be made from a higher compression material to help keep the ballistic panels in place during movement; others may be made from a material that has less compression for ease of movement and comfort. The goal is to balance these aspects to achieve the right amount of compression to stabilize the ballistic panels while still providing a high degree of movement and comfort. 
     The carrier outer layer  30  ( FIG.  5   ) has an upper edge  34 , a lower edge  36 , a left side edge  38 , and a right side edge  40 . (The right side edge  40  is to the left as viewed in  FIG.  5   , because the outer layer  30  is viewed, in  FIG.  5   , from the body side or inside.) Two armholes  42   r  and  421  are located near the upper edge  34 . 
     A right section  44  of a front zipper  45  is secured to the right side edge  40  of the outer layer  30 , and a left section  46  of the zipper  45  is secured to the left side edge  38  of the outer layer. One preferred type of zipper that has been utilized is a separating coil zipper. Coil type zippers are known for their ability to operate under high degrees of horizontal strength, are very flexible and are the least likely to become misaligned. However, the invention contemplates that other types of zippers, and other closure technologies, may be utilized. 
     One step in assembly of the carrier  12  is the addition of the front panel flap  50  to the outer layer  30  ( FIG.  6   ). The front panel flap  50  is secured to the inside of the outer layer  30 , just inside the right zipper portion section  44 , preferably by sewing. The front panel flap  50  is formed of two layers of fabric with an open space or pocket between them; only one of these layers (the hidden layer in  FIG.  6   ) is sewn to the outer layer  30 . An opening  53  into this pocket runs along the right zipper section  44 , so that a lateral portion of the front ballistic panel  14  can be inserted laterally into the pocket in the front panel flap  50 , in a manner described below. 
     After the front panel flap  50  is secured to the outer layer  30 , the inner carrier layer  60  ( FIGS.  7  and  8   ) is secured to the outer carrier layer  30 , preferably by sewing. Specifically, an upper edge  67  of the inner layer  60  is secured along the upper edge  34  of the outer layer  30 . A lower edge  68  of the inner layer  60  is secured to the outer layer  30  with two laterally spaced stitching sections  68   r  and  681 , at a location upward from the lower edge  36  of the outer layer  30 . A central opening  68   c  is left between the stitching sections  68   r  and  68   l . The right and left edges of the inner layer  60  are not sewn down to the outer layer  30 . 
     Two arm holes  70   r  and  701  in the inner layer  60  overlie the armholes  42   r  and  421 , respectively, in the outer layer  30 , forming vest armholes  72   r  and  721  in the completed carrier  12 . The inner layer  60  is sewn to the outer layer  30  around the periphery of the vest armholes  72   r  and  721 , to secure the two carrier layers together at those locations. 
     The carrier  12  at this point in the assembly process has two layers of fabric at the areas where the inner layer  60  overlies the outer layer  30 . Because those two layers of fabric, the inner carrier layer  60  and the outer carrier layer  30 , are joined only along their respective upper and lower edges, a panel volume or panel space, designated  80  in the drawings, is formed between the inner layer and the outer layer. The panel space  80  is bounded generally by the top edges  67  and  34  of the inner and outer carrier panels  60  and  30 ; the right and left vest armholes  72   r  and  721 , and the bottom edge  68  of the inner carrier panel. The inner layer  60  can be pulled away from the outer layer  30  to receive and support the front and back ballistic panels  14  and  16 , respectively, in the panel space  80 , in a manner as described below. 
     In a further assembly step ( FIG.  8   ), the right and left side panel pockets  82  and  84 , respectively, are secured to the inner layer  60 , preferably by sewing. Each one of the side panel pockets  82  and  84  preferably includes two layers of fabric material. Each side panel pocket  82 ,  84  has a top opening, which may be closable by a zipper (not shown), to allow for insertion of its respective side ballistic panel  20 ,  18 . 
     When the carrier  12  is thus fully assembled, there are a number of openings or gaps through which the various ballistic panels can be placed into the pockets. Some of these openings or gaps are illustrated in  FIG.  9   . Specifically, the arrow  86  illustrates an opening between the outer layer  30  and the inner layer  60  into which a first lateral section of the front ballistic panel  14  can be inserted into the panel space  80 . The arrow  87  illustrates an opening between the outer layer  30  and the inner layer  60  into which a second lateral section of the front ballistic panel  14  can be inserted into the front panel flap  50 . 
     The arrow  88  illustrates an opening into which the right side ballistic panel  20  can be inserted into the right side pocket  82 . The arrow  90  illustrates an opening into which the left side ballistic panel  18  can be inserted into the left side pocket  84 . The arrow  92  illustrates an opening into which the back ballistic panel  16  can be inserted upwardly into the panel space  80 . Also shown is an opening  94  at the left zipper section  46  into which the front panel flap  50  can be inserted, into the panel space  80  between the inner layer  60  and the outer layer  30 . 
     The ballistic panels can be inserted into the carrier  12  in any selected order. One preferred order of steps is shown in  FIGS.  10  and  11   . In  FIG.  10   , a first lateral section  14   a  of the front ballistic panel  14  is placed through the opening  86  into the panel space  80  between the inner carrier layer  60  and the outer carrier layer  30 . The first lateral section  14   a  of the front ballistic panel  14  is secured (suspended) in the carrier  12  at a fixation point  95 . This fixation may occur via a hook and loop connection, or otherwise. This fixation point  95  is located in the panel space  80 , at or near the top edge of the carrier  12 . 
     The fixation point  95  is primarily to hold the front panel  14  in place in the carrier, in the event of a bullet impacting that area of the vest  10 . Primarily, though, the front panel  14  is substantially held in position in the panel space  80  by a close fit within the carrier as described above, and by the bottom seam  68 . 
     The back ballistic panel  16  is inserted upward through the opening  92  into the panel space  80  between the inner layer  60  and the outer layer  30 . The back ballistic panel  16  is secured (suspended) in the carrier  12  at two fixation points  91  and  93 . This fixation may occur via a hook and loop connection, or otherwise. These fixation points  91  and  93  are located in the panel space  80 , at or near the top edge of the carrier  12 . Again, the fixation points  91  and  93  are primarily to hold the back panel  16  in place in the carrier, in the event of a bullet impacting that area of the vest  10 . 
     The left side ballistic panel  18  is placed through the opening  90  into the left side panel pocket  84 . The right side ballistic panel  20  is placed through the opening  88  into the right side panel pocket  82 . The side panel pockets  82  and  84  are closed with their fasteners. 
     As shown in  FIG.  11   , the second lateral section or remainder  14   b  of the front ballistic panel  14  is placed through the opening  53  into the pocket in the front panel flap  50 . As a result, half of the front ballistic panel  14  is located in the panel space  80  between the outer layer  30  and the inner layer  60 , and the other half is contained within the front panel flap  50 , projecting from the right side edge of the carrier  12  at a location adjacent to but inside the right zipper section  44 . An upper edge portion  14   c  of the panel  14  extends out of an opening in the upper corner of the front panel flap  50 . 
     The user can then don the vest  10 , in a manner as illustrated in  FIGS.  12 A- 12 C . The user&#39;s arms are placed through the vest armholes  721  and  72   r  while donning the vest  10 . The right side of the vest  10 , with the front panel flap  50  projecting, is moved adjacent to the left side of the vest  10 . The projecting front panel flap  50  is flipped over and inserted through the opening  94  ( FIG.  12 B ) between the outer layer  30  and the inner layer  60 , along the left zipper section  46 , thus being moved as one piece into the panel space  80 . This action locates the front ballistic panel  14  completely in the panel space  80  between the outer layer  30  of the carrier  12  and the inner layer  60  of the carrier  12 . 
     The second lateral section  14   b  of the front ballistic panel  14  (the projecting upper edge portion  14   c ) is then secured (suspended) in the carrier  12  at a fixation point  96 . This fixation may occur via a hook and loop connection, or otherwise. This fixation point  96  is located in the panel space  80 , at or near the top edge of the vest. 
     The zipper  45  is zipped up, drawing the left side of the carrier  12  together with the right side of the carrier  12 . In this condition, the front ballistic panel  14  extends across the upper torso area of the user. This is a continuous placement, extending across the front zipper opening of the vest  10 , thus providing complete front protection. The left side ballistic panel  18  overlies the left side of the user&#39;s torso. The right side ballistic panel  20  overlies the right side of the user&#39;s torso. The back ballistic panel  16  overlies the upper back of the user&#39;s torso. 
     An upper section  102  of the back panel  16  is disposed within the panel space  80  in the carrier  12 , above an imaginary line  100  ( FIGS.  4  and  11   ) that extends laterally across the vest  10  at a location at or just below the lower edge of the vest armholes  721  and  72   r . The back panel upper section  102  is fixed to the carrier  12 , within the panel space  80 , at the two fixation points  90  and  92 . These fixation points  90  and  92  (which are above the line  100 ), together with the sewn armholes  721  and  72   r , substantially constrain lateral movement of the back panel upper section  102  in the panel space  80  in the carrier  12 . 
     In contrast, the part of the panel space  80  that is below the imaginary line  100  and above the bottom edge  68  of the inner carrier panel  60 , can be considered as being a tunnel  110 , being open from side to side with no significant lateral obstructions. A lower section  104  of the back panel  16  extends downward from the upper section  102  into this tunnel  110 , below the imaginary line  100  and below the bottom edge of the left and right armholes  721  and  72   r . The lower section  104  of the back panel  16  is supported in the tunnel  110  only by the upper section  102  of the back panel. The back panel lower section  104  is thus substantially freer to move laterally in the tunnel portion  110  of the panel space  80  than is the upper section  102 , as it is substantially less constrained laterally. 
     In the tunnel  110 , the back panel lower section  104  at least partially overlaps the left and right ballistic side panels  18  and  20 . The back panel lower section  104  is movable laterally relative to the left and right ballistic side panels  18  and  20   
     In a similar manner, a lower section  112  of the front panel  14 , disposed in the tunnel  110 , at least partially overlaps the left and right ballistic side panels. The front panel lower section  112  is movable laterally relative to the left and right ballistic side panels  18  and  20 . The front panel lower section  112  and the back panel lower section  104  are also movable laterally relative to each other. 
     As thus constructed, the vest  10  provides numerous benefits when being worn by the user. The ability of the front panel lower section  112  and the back panel lower section  104  to move laterally within the tunnel portion  110  of the carrier panel space  80 , provides a very significant benefit. With the carrier itself being a snug fit on the user&#39;s torso, this feature allows for increased movement of the front and back ballistic panels  14  and  16  with respect to the user&#39;s torso. 
     The vest  10  adjusts itself to the user&#39;s torso. The ballistic panels to some extent “self center” when the vest  10  is donned, because of the flexible fabric and the ability of the lower portions of the front and back panels  14  and  16  to move within the carrier  12 . The ballistic panels  14  and  16  can move, or float, as the body moves. The dimensions of the various parts of the vest  10  are selected so that the parts can move or articulate relative to one another, while staying in generally the right location as needed for protection. As a result, the vest  10  of the present invention is both protective and comfortable. 
     The lower portions of the front and back panels  114  and  16  are constrained laterally only by the compression of the vest  10  on the torso, the armhole blockage (the width of the carrier), and the dimensions of the various parts. The dimensions of each element, and their placement, are selected to enable this limited amount of freedom of movement (articulation) in the tunnel area, which is located at the waist of the user where it is most needed. 
     The elasticity of the fabric material of the carrier  12 , especially the outer layer  30  and the inner layer  60 , also allows for some movement or articulation of the various ballistic panels relative to each other. Because the carrier fabric material is quite thin, the ballistic panels can lie closely against the user&#39;s torso. This structure, as a whole, compares very favorably to a typical vest  10  that is rigid and heavy and non-conforming. 
     As a result, the vest  10  as a whole is not a rigid structure but is rather a flexible structure overall that includes relatively hard areas at the locations of the ballistic panels—with at least several inches of movement possible in many locations and in many directions. This makes the vest  10  much more comfortable. 
     As an analogy, It might be considered that the side panels  18  and  20  are like the rib cage—fixed, relatively stationary—while the front and back panels  14  and  16  are like the shoulder blades—held in place generally by tendons and muscles, but able to move around somewhat relative to the rib cage. Just as the shoulder blades can move around over the rib cage, so too can the front and back panels  14  and  16  move around over the side panels  18  and  20 . 
     Another benefit of the vest  10  lies in the area of load distribution. Specifically, a ballistic vest can be relatively heavy for a law enforcement officer to wear, especially for an extended period of time such as an all-day shift. Also, the load (weight) of a vest is typically carried primarily by the shoulder straps of the vest, bearing down on the officer&#39;s shoulders. Together, these factors can create discomfort or pain, and can tire the wearer. 
     In accordance with the present invention, the vest  10  is preferably configured and sized appropriately for the user, so that there is a snug fit on the user&#39;s torso. The material for the outer and inner carrier layers  30  and  60  is significantly stretchable and elastic. The resulting elasticity of the carrier  12  tends to hold the vest  10  in place on the user&#39;s torso, thus resisting downward movement of the vest along the torso of the user. In addition, the carrier  12  is made from a light weight, relatively inexpensive fabric and therefore can feasibly be made in a variety of sizes to fit different sized users. Thus, the desired snug fit can readily be obtained, while still allowing for the panel articulation described above. As a result, some of the load of the vest  10  is transferred onto the core of the user. This load distribution reduces the apparent load on the shoulder and collarbone area of the user, making it more comfortable to wear the vest  10  for a longer period of time without tiring. 
     The dimensions of the carrier are designed for the individual user (different sizes), to be tight along the core and thus press the ballistic panels snugly against the core of the user&#39;s body. When this occurs, some of the load (weight) of the vest is borne by the user&#39;s core rather than the shoulders, making wearing of the vest for an extended period of time more comfortable. The ballistic panels are in their proper places for protection, when the user stands up straight. When the user bends over, the overall configuration of the carrier fabric deforms as it moves to a different position on the body. The ability of the panels to articulate (move within the carrier) enables the vest to remain comfortable, as compared to a situation in which the panels would be pushed or pulled by the carrier fabric when it moves to a different position on the body. The panels will self center or auto center as the user comes back to a standing position. Because the panels are loose, the carrier can stay snug on the user&#39;s waist and core, thus maintaining the effectiveness of this load bearing feature. 
       FIGS.  13  and  14    illustrate the inclusion and positioning of an optional trauma plate  120  (hard plate) in a pocket  122  on the carrier  12  of the vest  10 . The pocket  122  is located on the outer side (strike face) of the front ballistic panel flap  50 . The plate  120  may be inserted before the vest is donned. The plate  120  ends up on the outside (strike side) of the front ballistic panel  14 , which like the other ballistic panels  16 ,  18 , and  20  is soft armor. The pocket  122  is preferably located so that it and the plate  120  are centered laterally on the front of the vest  10 . 
     In the first embodiment of the invention illustrated and described above, four ballistic panels are provided. The front panel and the back panel overlap each other and also overlap the side panels (see  FIG.  4   ). Other embodiments are possible. In the vest  10   a  shown in  FIG.  15   , for example, both the front panel and the back panel overlap the side panels, but do not overlap each other. In the vest  10   b  shown in  FIG.  16   , for example, no side panels are present, as is the case with many vests, so the front and back panels overlap each other. The front panel and the back panel are configured as needed for the desired amount of overlap. 
     Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, the scope of the invention is limited only by the claims.