Abstract:
A panel apparatus for positioning between a human body and a region of body armor absorbs impact energy associated with a projectile or other object impacting the body armor. The panel is also operable to absorb overpressure energy associated with a blast wave from an explosive device such as an improvised explosive device or a bomb. The panel may be secured to an interior of conventional tactical body armor, body armor carriers, or the like. The panel includes a multilayer construction and includes an inflatable primary gas chamber and a separate non-inflatable secondary gas chamber in some embodiments. The primary and secondary gas chambers are stacked in substantially parallel planes and are oriented substantially parallel to the body armor.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application claims benefit of the following patent applications which are hereby incorporated by reference: Ser. No. 61/468,100 for Multipurpose Cooling and Trauma Attenuating Device and Associated Methods filed Mar. 28, 2011, and Ser. No. 61/587,104 for Multipurpose Cooling and Trauma Attenuating Panel and Associated Methods filed Jan. 16, 2012. 
     
    
     BACKGROUND 
       [0002]    The present disclosure relates generally to protective body armor and more particularly to devices and methods for passively cooling or insulating a wearer and also for reducing bodily trauma associated with various types of impacts. 
         [0003]    Conventional personal protective equipment, or body armor, is typically used to prevent bodily injury associated with impacts of various kinds. Body armor can be positioned on a wearer&#39;s body to physically block objects that may be advancing toward the wearer, such as bullets, fragments from a nearby explosion or other types of debris that may fly through the air toward the wearer. Conventional body armor generally includes one or more rigid plates or pads that are strapped to a user&#39;s body. The plates can be made of a variety of materials known in the art. Plates or pads of this nature can include metal or other natural or synthetic materials. 
         [0004]    One problem associated with conventional body armor is heat dissipation away from the wearer. Body armor generally prevents body heat convection away from the wearer, especially in hot and arid conditions such as those experienced in desert combat operations. Individuals who wear conventional body armor in such environments can experience accelerated fatigue and diminished performance due to heightened body temperature due to the presence of body armor on the wearer&#39;s body. 
         [0005]    Another problem associated with conventional body armor includes blunt trauma resulting from an impact. Often, a projectile or fragment will impact a piece of body armor and will be stopped, thereby preventing direct contact between the projectile or fragment and the wearer&#39;s body. However, the kinetic energy associated with the velocity and mass of the projectile or fragment is transferred to the body armor and consequently to the individual wearing the body armor. This transfer of energy to the individual can result in severe mechanical trauma to the region of the wearer&#39;s body positioned near the impact zone. Although the body armor may stop the fragment or projectile, the trauma associated with the impact can lead to serious bodily injury or death to the wearer. Such trauma can injure soft tissue and internal organs including the heart, lungs, kidneys, liver, stomach, brain, bones and circulatory regions. 
         [0006]    To prevent the severity of such impact trauma to the body, conventional body armor is oftentimes made thicker and denser, resulting in heavier and bulkier armor that can interfere with a wearer&#39;s range of motion. Bulky body armor of this nature can be detrimental when worn in combat or endurance situations where the heavy weight and bulk decreases the wearer&#39;s performance in the field. 
         [0007]    Others have attempted to provide a panel or supporting material that can be positioned between a body armor pad or plate and the wearer&#39;s body. Such panels are generally configured to absorb some of the kinetic energy that is transferred to the wearer from the projectile or fragment. For example, U.S. Pat. No. 6,012,162 provides high impact absorbing body armor including a hardened outer armor section and an underlying inflatable reservoir for cushioning projectile impact. 
         [0008]    Conventional devices for preventing body trauma associated with body armor impact are often bulky and do not provide adequate range of motion or ventilation for the wearer, resulting in overheated and uncomfortable conditions. 
         [0009]    What is needed then is an improved device and associated methods of use and manufacture for passively or actively cooling or insulating a wearer of body armor while also absorbing energy associated with an impact or a pressure wave. 
       BRIEF SUMMARY 
       [0010]    One object of the present disclosure is to provide an apparatus for absorbing impact energy associated with a projectile or fragment impacting a piece of body armor. In some embodiments, the present disclosure provides a detachable panel that can be positioned between a piece of body armor and a user&#39;s body. The panel can include several layers defining multiple independent gas chambers for storing pressurized gas. In some embodiments, the apparatus includes a front panel for covering a user&#39;s chest and a back panel for covering a user&#39;s back. The front and back panels in some embodiments may be interchangeable for ease of use. In other embodiments, the front and back panels may be pre-formed to fit the unique curvature of each side of a user&#39;s body. 
         [0011]    A further object of the present disclosure is to provide a panel apparatus for attachment to a body armor garment. The panel apparatus includes an outer layer including an outer fabric and a first gas barrier layer disposed on the outer fabric. A middle layer is positioned adjacent the outer layer, the middle layer including a middle fabric having first and second middle fabric sides and including a second gas barrier layer disposed on the first middle fabric side and a third gas barrier layer disposed on the second middle fabric side. An inner layer is positioned adjacent the middle layer. The inner layer includes an inner fabric having a fourth gas barrier layer disposed on the side of the inner fabric facing the middle layer. A primary gas chamber is defined between the inner layer and the middle layer. A secondary gas chamber is defined between the outer layer and the middle layer. 
         [0012]    Another object of the present disclosure is to provide an apparatus for absorbing impact forces. The apparatus includes a first sheet including an outer fabric and a first gas barrier layer disposed on the outer fabric. A second sheet is positioned adjacent the first sheet, the second sheet including a second fabric having first and second sides and including a second gas barrier layer disposed on the first side and a second gas barrier layer disposed on the second side. A third sheet is positioned adjacent the second sheet. The third sheet includes a third fabric having a fourth gas barrier layer disposed on the side of the third sheet facing the second sheet. A primary gas chamber is defined between the second and third sheets. The outer fabric comprises a fastener. 
         [0013]    Another object of the present disclosure is to provide a method of retrofitting a conventional body armor garment to reduce trauma to a wearer associated with an impact on the body armor garment, the method comprising the steps of: (a) attaching a first attachment fastener to the garment; and (b) securing an inflatable trauma attenuating panel directly to the first attachment fastener. The panel includes an outer layer including an outer fabric and a first gas barrier layer disposed on the outer fabric. The panel also includes a middle layer including a middle fabric having first and second middle fabric sides and including a second gas barrier layer disposed on the first middle fabric side and a third gas barrier layer disposed on the second middle fabric side. The panel also includes an inner layer including an inner fabric having a fourth gas barrier layer disposed on the side of the inner fabric facing the middle layer. A primary gas chamber is defined between the inner layer and the middle layer, and a secondary gas chamber is defined between the outer layer and the middle layer. 
         [0014]    Yet another object of the present disclosure is to provide a kit for retrofitting a conventional body armor garment to include one or more inflatable panels for attenuating trauma forces. 
         [0015]    A further object of the present disclosure is to provide a body armor system including a body armor garment and one or more inflatable panel devices for attenuating trauma forces incident upon a wearer of the body armor system. 
         [0016]    Numerous other objects, features and advantages of the present disclosure will be readily apparent to those skilled in the art upon a reading of the following disclosure when taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1A  illustrates a plan view of an embodiment of a trauma attenuating panel in accordance with the present disclosure. 
           [0018]      FIG. 1B  illustrates a cross-sectional view of Section  1 B- 1 B from  FIG. 1A  showing an embodiment of a trauma attenuating panel in accordance with the present disclosure. 
           [0019]      FIG. 1C  illustrates a detail partial cross-sectional view of Section  1 C from  FIG. 1B  showing an embodiment of a trauma attenuating panel in accordance with the present disclosure. 
           [0020]      FIG. 2  illustrates a plan view of an embodiment of the interior of an embodiment of a conventional body armor garment such as a carrier or a tactical vest. 
           [0021]      FIG. 3  illustrates an elevation view of an embodiment of a rear portion of a body armor garment including an embodiment of a panel apparatus in accordance with the present disclosure disposed thereon. 
           [0022]      FIG. 4  illustrates a plan view of an embodiment of a front portion of a body armor garment including an embodiment of a panel apparatus in accordance with the present disclosure disposed thereon. 
           [0023]      FIG. 5  illustrates a side view of a person wearing a body armor system in accordance with the present disclosure including front and back trauma attenuating panels positioned against a wearer&#39;s body. 
           [0024]      FIG. 6  illustrates a partial cross-sectional view of an alternative embodiment of a trauma attenuating panel in accordance with the present disclosure. 
           [0025]      FIG. 7  illustrates a partial cross-sectional view of an embodiment of a trauma attenuating panel showing primary and secondary gas chambers in accordance with the present disclosure. 
           [0026]      FIG. 8  illustrates a partial cross-sectional view of an embodiment of an outer layer, or first sheet. 
           [0027]      FIG. 9  illustrates a partial cross-sectional view of an embodiment of a middle layer, or second sheet. 
           [0028]      FIG. 10  illustrates a partial cross-sectional view of an embodiment of an inner layer, or third sheet. 
           [0029]      FIG. 11  illustrates a partial cross-sectional view of an embodiment of a panel apparatus in accordance with the present disclosure including outer, middle and inner layers and primary and secondary gas chambers. 
           [0030]      FIG. 12  illustrates a plan view of an outer layer, or first sheet, of a panel apparatus in accordance with the present disclosure. 
           [0031]      FIG. 13  illustrates a plan view of first and second trauma attenuating panels with mating edges in a manufacturing configuration. 
           [0032]      FIG. 14  illustrates a plan view of an alternative embodiment of a panel apparatus including a plurality of attachment patches. 
           [0033]      FIG. 15  illustrates a perspective view of an embodiment of vest including a pair of panel devices secured. 
           [0034]      FIG. 16  illustrates a plan view of an embodiment of a vest including a pair of panel devices secured together. 
           [0035]      FIG. 17  illustrates a plan view of an embodiment of a panel device including a plurality of sensors. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    Referring now to the drawings, one embodiment of the present disclosure provides a trauma attenuating panel apparatus illustrated generally in  FIG. 1A  and designated by the numeral  300 . It is understood that in the drawings, not all reference numbers are included in each drawing, for the sake of clarity. In addition, positional terms such as a “upper,” “lower,” “side,” “top,” “bottom,” “vertical,” “horizontal,” “inner,” “outer,” “middle,” etc. refer to the apparatus when in the orientation shown in the drawing. The skilled artisan will recognize that objects in accordance with the present disclosure can assume different orientations when in use. 
         [0037]    Referring further to  FIG. 1A , one embodiment of a panel apparatus  300  in accordance with the present disclosure is illustrated. Panel  300  is generally shaped to fit against a human torso in some embodiments. In other embodiments, panel  300  may be shaped to fit against other parts of a human body, such an arm, leg, head, hand, foot, neck, etc. Also, panel  300  may be shaped to fit against an animal&#39;s body such as a dog or a horse. Panel  300  includes a lower edge  324  and an upper edge  322  having a first shoulder region  328   a  and a second shoulder region  328   b . A recessed neck region  322  is defined between first and second shoulder regions  328   a ,  328   b  in some embodiments. Panel  300  is generally formed of several layers of woven or non-woven material layers secured together and including at least one primary gas chamber defined between at least two of the layers. A plurality of vent holes  330  may be defined in panel  300 . In some embodiments, each vent hole  330  is a clearance hole extending completely through panel  300 . In other embodiments, panel  300  may be formed without any vent holes. Additionally, panel  300  includes a plurality of welds  332 . Each weld  332  includes a region where any two or more layers of the multiple layers that make up panel  300  are joined together. Each weld may be formed in some embodiments by RF welding the various layers together. Other material joining techniques known in the art may also be used to join the separate layers. Each vent hole  330  also generally includes an annular weld surrounding each vent hole  330  to prevent pressurized gas stored between layers to escape through the vent hole  330 . 
         [0038]    Referring to  FIG. 1B  and  FIG. 1C , in some embodiments, panel  300  includes at least three discrete layers joined together to form a multi-layer panel. A first layer, or outer layer  302  includes a first material. Outer layer  302  may also be described as a first sheet  302 . A second layer, or middle layer  304 , is positioned adjacent outer layer  302 . Middle layer  304  may be described as a second sheet. A third layer, or inner layer  306 , is positioned adjacent middle layer  304 . Inner layer  306  may be described as a third sheet. 
         [0039]    In some embodiments, each individual layer  302 ,  304 ,  306  includes multiple materials and may include a unique construction as compared to the other layers. 
         [0040]    Outer layer  302  includes an outer fabric  336  and a first gas barrier layer  334  disposed on the outer fabric  336 , as seen in  FIG. 10 . In some embodiments, the outer fabric  336  may include a hook and loop compatible fabric such as a Velcro-compatible material. For example, outer layer  302  is generally configured to be secured to a body armor garment such as a ballistic vest, a ballistic vest liner, a body armor carrier, a helmet, or any other body armor garment. The term body armor garment may be defined as any type of structure used to dampen an impact force such as conventional body armor plates and vests, helmets, impact-resistant clothes such as reinforced shirts or pants or other body armor equipment known in the art for humans or for animals. As seen in  FIG. 10 , in some embodiments, outer layer  302  may include multiple sub-layers. For example, in some embodiments outer layer  302  includes an outer fabric  336  including a hook and loop compatible material attached to a first gas barrier layer  334 . 
         [0041]    Outer fabric  336  includes a hook and loop compatible material in some embodiments. Outer fabric  336  may include a hook fabric or a loop fabric for use in a hook and loop fabric fastener system such as Velcro. 
         [0042]    First gas barrier layer  334  in some embodiments includes a gas impermeable substance such as a urethane, which may also be described as polyurethane. In other embodiments, first gas barrier layer  334  may include a urethane, or polyurethane, sheet attached or bonded to outer fabric  336 . First gas barrier layer  334  may be coated directly onto the backside of outer fabric  336  to form a gas-impermeable backing, or gas barrier, on outer fabric  336 . Outer layer  302  generally faces away from a wearer. First gas barrier layer  334  includes urethane or polyurethane film and is extruded directly onto outer fabric  336  in other embodiments. In some embodiments, first gas barrier layer  334  includes a urethane or a polyurethane coating applied to outer fabric  336  to form outer layer  302 . In various other embodiments, first gas barrier layer  334  includes other suitable gas barrier materials known in the art such as vinyl, rubber, PVC, PET, PVA or other suitable materials. 
         [0043]    In some embodiments, outer layer  302  includes a hospital grade female hook and loop compatible fabric with a urethane backing. In some embodiments, the hook and loop compatible fabric covers substantially the entire exterior surface of panel  300 , as seen in  FIG. 12 , thereby allowing attachment of a corresponding hook and loop fastener at any location onto outer layer  302 . By providing substantially an entire surface of hook and loop fabric on outer layer  302  of vest  300 , a user may be able to interchangeably secure panel  300  to various garments or tactical equipment with different hook and loop fastener patch locations. It is noted that in some embodiments the weld regions do not retain hook and loop compatible functionality following RF welding. 
         [0044]    In other embodiments, only a portion of outer layer  302  includes a hook and loop compatible fabric. For example, as seen in a second embodiment in  FIG. 14-16 , in some embodiments, one or more outer patches can be positioned on the exterior of panel  10 . A first shoulder patch  20   a  is attached to first shoulder region  18   a , and a second shoulder patch  20   b  is attached to second shoulder region  18   b . First and second shoulder patches  20   a ,  20   b  can include a male or female hook-and-loop compatible fabric such as a Velcro-type material. Additionally, a bottom patch  24  is attached to panel  10  at the lower edge  22 . Bottom patch  24  can also include a male or female hook-and-loop compatible fabric such as a Velcro-type material. In some embodiments, vent holes can also be defined to extend through one or more of the patches  20   a ,  20   b ,  24 . 
         [0045]    Referring now to  FIG. 15 , an embodiment of a vest  12  is generally illustrated. Vest  12  includes a first panel  10   a  and a second panel  10   b . First panel  10   a  can include a front panel, and second panel  10   b  can include a back panel. First panel  10   a  is configured to fit against a human&#39;s chest, and back panel  10   b  is configured to fit against a human&#39;s back. The first and second panels  10   a ,  10   b  can be releasably secured together using a plurality of straps. For example, a first shoulder strap  50   a  can include a male or female hook-and-loop compatible fabric fastener region configured to engage first shoulder patch  20   a . First shoulder strap  50   a  also releasably engages a shoulder patch positioned in a similar location on second panel  10   b . Similarly, a second shoulder strap  50   b  can include a male or female hook and loop compatible fabric fastener region configured to engage second shoulder patch  20   b . Second shoulder strap  50   b  also releasably engages a shoulder patch positioned in a similar location on second panel  10   b . Thus, first and second shoulder straps  50   a ,  50   b  are releasably securable to both first and second panels  10   a ,  10   b . One or more waist straps  52  can be used to secure the lower edges of first and second panels  10   a ,  10   b  in a similar fashion. As seen in  FIG. 15 , a side gap  26  is formed between first and second panels  10   a ,  10   b . Side gap  26  is shaped for passage of a wearer&#39;s arm. A neck gap  28  is also defined between first and second panels  10   a ,  10   b  and is shaped for passage of the wearer&#39;s neck. When the vest  12  is positioned on a wearer&#39;s body, vest  12  can provide neutral or positive buoyancy to a conventional body armor system that is positioned on the exterior of the vest  12  on the wearer&#39;s body. 
         [0046]    Referring now to  FIG. 16 , in some embodiments, a vest  12  includes a first panel  10   a  and a second panel  10   b . A plan view of first and second panels is illustrated generally in  FIG. 15 . First panel  10   a  includes first and second shoulder patches  20   a ,  20   b , and second panel  10   b  includes third and fourth shoulder patches  20   c ,  20   d . First shoulder strap  50   a  is attached to first and third shoulder patches  20   a ,  20   c , and second shoulder strap  50   b  is attached to second and fourth shoulder patches  20   b ,  20   d . First panel  10   a  also includes a first bottom patch  24   a , and second panel  10   b  includes a second bottom patch  24   b . Each patch can include a hook-and-loop compatible fabric. First and second waist straps  52   a ,  52   b  are securable to first and second waist patches  24   a ,  24   b  for releasably securing first and second panels together. As seen in  FIG. 3 , one or more welds  14  extend through one or more patches  20   a ,  20   b ,  24   a ,  20   c ,  20   d ,  24   b . Such welds are used to secure each patch to its corresponding panel. By welding each patch directly to its panel, expense and time associated with manufacture can be reduced. Additionally, conventional stitching may be used in addition to on-patch welds to secure the various patches to the panels. However, by providing a welded connection between the panels and patches, improved performance can be achieved over other designs that include only stitching. Also seen in  FIG. 3 , in some embodiments, one or more vent holes  16  extend through each patch. Vent holes  16  extending through each patch allow for ventilation in the areas on each panel covered by a patch. Additionally, vent holes  16  extending through each patch allow for forced air convection to pass through each panel area covered by a patch. Vest  12  can generally be positioned on a user&#39;s body before body armor is fitted over the vest. 
         [0047]    Middle layer  304  in some embodiments may include a woven material coated on both sides with gas barrier layers such as a polyurethane coating. For example, in some embodiments, seen for example in  FIG. 9  and  FIG. 11 , middle layer  304  includes a middle fabric  340 . In some embodiments, middle fabric  340  includes a woven nylon material. In some embodiments, middle fabric  340  includes a fabric linear mass density of between about 100 and about 1000 denier. In further embodiments, middle fabric  340  includes a woven nylon material having a fabric linear mass density of about 200 denier. In additional embodiments, middle fabric  340  includes a woven nylon material having a fabric linear mass density of about 500 denier. Middle fabric  340  or outer fabric  336  or both may include reinforcing fibers such as spectra, dyneema, aramid or other suitable reinforcing fibers in additional embodiments. 
         [0048]    Middle fabric  340  includes a first side having a second gas barrier layer  338  disposed thereon and a second side having a third gas barrier layer  342  disposed thereon to form middle layer  304 . Each third and fourth gas barrier layers  338 ,  342  may include a urethane or polyurethane material deposited directly onto respective sides of middle fabric  340  to form a gas barrier for preventing gas from travelling through middle layer  304 . In some embodiments, both first and gas barrier layers  338 ,  342  are extruded onto middle fabric  340  of middle layer  304 . Each gas barrier layer may alternatively include a urethane or polyurethane film bonded to the middle fabric  340 . In various other embodiments, third and fourth gas barrier layers  338 ,  342  may include other suitable gas barrier materials known in the art such as vinyl, rubber, PVC, PET, PVA or other suitable materials. 
         [0049]    Inner layer  306  generally includes an inner fabric  346  and a fourth gas barrier layer  344 . Fourth gas barrier layer  344  may be coated directly onto inner fabric  346  in some embodiments. In other embodiments, fourth gas barrier layer  344  may be extruded onto inner fabric  346 . In other embodiments, fourth gas barrier layer  344  may include a urethane or a polyurethane film bonded to inner fabric  346 . Inner fabric  346  in some embodiments includes a woven nylon material. In some embodiments, inner fabric  346  includes a woven nylon material having a fabric linear mass density between about 100 denier and about 1000 denier. In further embodiments, inner fabric  346  includes a woven nylon material having a fabric linear mass density of about 200 denier. In additional embodiments, inner fabric  346  includes a woven nylon material having a fabric linear mass density of about 500 denier. Inner fabric  346  may include a reinforcing material such as spectra, dyneema or aramid fibers, or other suitable reinforcing fibers, in some embodiments. Fourth gas barrier layer  344  generally provides a gas barrier on inner fabric  346  of inner layer  306  to prevent gas from passing through inner layer  306 . 
         [0050]    In some embodiments, inner layer  306  includes an antimicrobial coating disposed on the surface of inner fabric  346  on the side opposite fourth urethane coating  344 . For example, in some embodiments, the anti-microbial coating includes a nano-crystal coating having the trade name Oxi-Titan. The nano-crystal coating may be sprayed directly onto inner fabric  346  in a thickness of between about 5 and about 10 nanometers and allowed to dry, as seen in  FIG. 6 . In some embodiments, a desired nano-crystal layer thickness of about seven nanometers provides desired performance characteristics. The nano-crystal coating provides increased surface area contact with a wearer&#39;s body, improves evaporation of moisture, includes a hydrophobic surface to prevent water droplet formation, provides an antimicrobial and antifungal surface and/or increases heat transfer in some embodiments. In additional embodiments, the anti-microbial coating includes a photocatalytic agent. The antimicrobial coating may be applied to either side of the panel apparatus or to both sides of the panel apparatus. 
         [0051]    Each of outer, middle and inner layers  302 ,  304 ,  306 , or first, second and third sheets, respectively, may be assembled separately prior to being joined together as a panel apparatus  300  in some embodiments. For example, outer layer  302  is assembled by forming a first gas barrier layer  334  on an outer fabric  336  such as a male or female hook and loop compatible fabric. Middle layer  304  is separately formed by securing second and third gas barrier layers  338 ,  342  on a middle fabric  340  such as a woven nylon material. Inner layer  306  is also separately formed by forming a fourth gas barrier layer  344  on an inner fabric  346  such as a woven nylon material. Each of the outer, middle, and inner layers  302 ,  304 ,  306  may be pre-formed and provided as separate rolls or sheets of material prior to panel apparatus  300  construction. 
         [0052]    During panel construction, each of outer, middle and inner layers  302 ,  304 ,  306  are spread out on a surface such that middle layer  304  is positioned between outer and inner layers  302 ,  306 . Outer layer  302  is positioned relative to middle layer  304  such that first gas barrier layer  324  on outer layer  302  is facing second gas barrier layer  338  on middle layer  304 . Also, inner layer  306  is positioned relative to middle layer  304  such that third gas barrier layer  342  on middle layer  304  faces fourth gas barrier layer  344  on inner layer  306 . An embodiment of this configuration is illustrated generally in  FIG. 11 . 
         [0053]    During construction, the individual layers are all cut to shape using a die. The layers may be cut to shape either before the layers are joined together or after the layers are joined together. The discrete layers are layered in the desired pattern and are dielectrically welded together at each weld location. The welding process may be referred to as a conventional RF welding process in some applications. The outer and middle layers may be retained in a corrugated configuration during the welding process to define the primary gas chamber in some embodiments. However, in other embodiments, the layers may be joined without providing any pre-defined corrugation pattern. The dielectric welding press can include a die punch to cut the vent holes passing through the panel in the same welding procedure. 
         [0054]    The three layers  302 ,  304 ,  306 , as illustrated in  FIG. 11  may then be joined together using a conventional joining procedure. In some embodiments, the three layers  302 ,  304 ,  306  are stacked as individual sheets, stamped in a press, and RF-welded at desired weld locations, forming a weld pattern as seen in  FIG. 1A . A conventional RF-welding procedure may be used to join the three layers together, forming a plurality of weld locations across the body of the panel as well as a welded perimeter. Each weld location  332  includes a region where first, second and third layers  302 ,  304 ,  306  are joined together in a gas-impermeable seal. In some embodiments, the radio-frequency welding process is adapted for joining urethane or polyurethane materials. In such embodiments, wherein each gas barrier layer in the panel includes a urethane or a polyurethane material, an RF welding procedure may be used to provide an optimized welded assembly having desired characteristics. The multiple layers having been welded together may then be cut to a desired panel shape, as seen in panel  300  in  FIG. 1A  and also as seen in  FIG. 13 . 
         [0055]    During the welding process, a primary gas chamber  308 , seen for example in some embodiments in  FIG. 7  and  FIG. 11 , is formed between inner layer  306 , or third sheet, and middle layer  304 , or second sheet. Primary gas chamber  308  may be selectively inflated or deflated using a valve  348  on panel  300 , seen in  FIG. 1A . Valve  348  includes an opening, or port, in panel  300  in fluid communication with primary gas chamber  308 . Valve  348  may be coupled to a pressure source such as a manual or powered pump. A filler gas may be introduced into primary gas chamber  308  by forcing the gas into primary gas chamber  308  through valve  348 . As such, primary gas chamber  308  is selectively inflatable. A gas chamber is selectively inflatable where the chamber is configured to be inflated to a desired pressure in a controlled manner. In some embodiments, primary gas chamber  308  is configured to be inflated to a pressure between about 10 psig and about 100 psig. In further embodiments, primary gas chamber  308  is configured to be inflated to a pressure between about 10 psig and about 50 psig. In additional embodiments, primary chamber  308  is configured to be inflated to a pressure between about 20 psig and about 25 psig. The pressure rating of primary gas chamber  308  may depend on the thicknesses and other material properties of the materials chosen for the outer, middle and inner layers  302 ,  304 ,  306 . Various filler gases may be used to inflate primary chamber  308  in different embodiments of panel  300  to provide various performance characteristics. In some embodiments, primary gas chamber  308  may be filled with air, nitrogen, helium, or other suitable inert gases known in the art. 
         [0056]    In further embodiments, the present disclosure provides a trauma attenuating panel including a primary gas chamber  308  configured to be filled with a filler gas having a pressure between about 10 and about 50 psig. It has been discovered that, unexpectedly, a primary gas chamber pressure of between about 20 psig and about 25 psig may provide enhanced trauma attenuation when primary gas chamber is filled with air or nitrogen in some embodiments. In some experimental tests, a backface signature reduction of around 60% was achieved using a primary chamber inflated with a filler gas having a pressure of between about 20 psig and about 25 psig. In other embodiments, primary gas chamber is configured to be filled with a filler gas having a gas pressure between about 10 psig and about 100 psig to achieve desired attenuation performance. 
         [0057]    A secondary gas chamber  310  may be formed between middle layer  304 , or second sheet, and outer layer  302 , or first sheet, in some embodiments. Unlike primary gas chamber  308 , in some embodiments, secondary gas chamber  310  is not coupled to an opening, or port, in panel  300 . As such, secondary gas chamber  310  includes a finite volume of gas that cannot be increased or decreased in a controlled manner. Secondary gas chamber  310  in some embodiments is trapped between two adjacent layers during the RF welding assembly procedure. During the process of joining outer layer  302  to inner layer  304 , a small amount of gas becomes trapped between first gas barrier layer  334  on outer layer  302  and second gas barrier layer  338  on middle layer  304 . That amount of gas is retained between outer layer  302  and middle layer  304  due to the welded seal  332  formed around the perimeter of panel  300 . The trapped air volume is typically fixed, meaning the amount of gas stored in the secondary chamber  310  cannot be selectively increased or decreased by the user. Thus, secondary gas chamber  310  cannot be inflated or deflated. Thus, panel  300  includes an inflatable primary gas chamber  308  and a non-inflatable, or fixed, secondary gas chamber  310 . Although an embodiment including primary gas chamber  308  disposed between inner layer  306  and middle layer  304  is illustrated and described herein, it will be appreciated by those of skill in the art that, in other embodiments, selectively inflatable primary gas chamber  308  may be disposed between outer layer  302  and middle layer  304 , and fixed secondary gas chamber  310  may be disposed between inner layer  306  and middle layer  304 , in some alternative embodiments. 
         [0058]    In such alternative embodiments, the primary gas chamber  308  may be positioned between the inner layer  306  and the middle layer  304 , as seen in  FIG. 6 . In some embodiments, both the primary gas chamber  308  and the secondary gas chamber  310  are selectively inflatable. In further embodiments, only the primary gas chamber  308  is selectively inflatable. In other embodiments, only the secondary gas chamber  310  is selectively inflatable. 
         [0059]    The primary and secondary gas chambers are generally oriented in substantially parallel planes and are oriented substantially parallel to the plane of a body armor panel disposed on the body armor garment in some embodiments. 
         [0060]    Referring now to  FIG. 2 , in some embodiments, a vest  312  includes a conventional ballistic or tactical vest, also referred to as a body armor garment. Vest  312  may be referred to as a body armor carrier in some embodiments and generally includes a vest front  314  and a vest rear  316 . Vest front  314  is generally shaped to fit against a wearer&#39;s front torso, and vest back  316  is generally shaped to fit against a wearer&#39;s rear torso. Vest front  314  and vest rear  316  may be attached using first and second shoulder straps  320   a ,  320   b  in some embodiments. Vest  312  may include a body armor carrier without soft or hard body armor panels installed therein but capable of receiving body armor panels. 
         [0061]    In some embodiments, the present disclosure provides a body armor system including a body armor garment having a front and a rear and including a pair of inflatable panel devices  300  as described above. The panel devices are configured for detachable securement to the interior of the body armor garment via one or more fasteners disposed between each one of the pair of panel devices and the respective front or back of the body armor garment. The panels are generally positioned to be arranged between the wearer&#39;s body and the body armor garment. 
         [0062]    As seen in  FIG. 2 , in some embodiments, one or more fasteners, or attachment patches  350   a ,  350   b ,  350   c ,  350   d  may be attached to vest  312 . In some embodiments, each attachment patch includes an adhesive-backed hook and loop compatible fabric patch configured to detachably engage the hook and loop fabric compatible outer fabric  336  on outer layer  302  of panel  300 . Any conventional type of body armor garment, including but not limited to a body armor carrier, body armor plate, body armor apparel, helmet, etc. may be retrofitted to receive a trauma attenuating panel apparatus  300  by affixing one or more attachment patches  350  to the interior surface of the body armor garment and securing a panel device  300  to the attachment patch. For example, as seen in  FIG. 2-FIG .  4 , a conventional body armor garment in the form of a vest  312  includes first and second patches  350   a ,  350   b  attached to the interior surface of vest rear  316  and third and fourth patches  350   c ,  350   d  attached to the interior surface of vest front  314 . As such, a first trauma attenuating panel  300   a  may be secured to the interior of vest front  314 , as seen in  FIG. 4 , and a second trauma attenuating panel  300   b  may be secured to the interior of vest rear  316 , as seen in  FIG. 3 . The hook and loop compatible fabric connections between each panel  300   a ,  300   b  and body armor garment  312  allow detachable installation onto and removal from body armor garment  312 . Further, because substantially the entire surface of each outer layer  302  includes hook and loop compatible fabric in some embodiments, each panel  300   a ,  300   b  may be detached and interchangeably repositioned relative to vest  312  to accommodate various body sizes and shapes. Further, each panel  300   a ,  300   b  may be used interchangeably with various models and types of body armor garments. 
         [0063]    When a body armor system including body armor garment  312  is positioned on a wearer  318 , as seen in  FIG. 5 , first panel  300   a  engages the front torso of the wearer, and second panel  300   b  engages the rear torso of the wearer  318 . The first panel  300   a  is positioned between vest front  314  and wearer  318 , and the rear panel  300   b  is positioned between vest rear  316  and wearer  318 . Thus, each panel  300  provides a cushion between vest  312  and wearer  318  for absorbing body trauma associated with an impact on vest  312  and also for providing thermal management for the wearer during use. 
         [0064]    A body armor system in accordance with the present disclosure in the form of a trauma attenuating vest is generally illustrated in  FIG. 5  and includes conventional vest  312  retrofitted to include at least one trauma attenuating panel attached to the vest front and the vest rear. 
         [0065]    Referring to  FIG. 13 , in some embodiments, a plurality of trauma attenuating panels may be formed from three discrete sheets of material forming outer, middle and inner layers  302 ,  304 ,  306 . The discrete sheets may be joined in an RF welding process to form welded regions corresponding to multiple panels. Each panel may be welded and cut in an alternating upright and inverted pattern as seen in  FIG. 13  to maximize usage of the sheet materials. Thus, a first trauma attenuating panel includes a first side edge shaped to be coextensive with a second side edge of an inverted second trauma attenuating panel positioned adjacent the first trauma attenuating panel. 
         [0066]    Referring further to  FIG. 1A , on some embodiments, each trauma attenuating panel device  300  includes a plurality of linear welds and a plurality of circular welds. Each circular weld surrounds a vent hole to prevent gas stored in primary and secondary gas chambers from leaking through the vent hole. Each linear weld provides an attachment between each discrete layer. In some applications, following repeated primary gas chamber inflation and deflation, or following an impact on the panel, a stress concentration may be formed at the end of each linear weld. Such a stress concentration may cause delamination of the layers at the end of the linear weld and may contribute to rupture of the primary or secondary gas chamber. To overcome the stress concentration problem, each linear weld may include a rounded weld end region on each end of the linear weld having a diameter larger than the width of the linear weld body. Each rounded weld end region can distribute stresses around each weld end more evenly and prevent stress concentration or accelerated wear that may lead to local rupture in some applications. 
         [0067]    The panel apparatus of the present disclosure may provide a passive cooling effect in some embodiments. Experimental tests have indicated some embodiments of panel apparatus  300  in accordance with the present disclosure may reduce a wearer&#39;s local ambient body temperature between about 4.5 and about 9.1 degrees between body armor and torso. 
         [0068]    In many applications, it may be desirable to incorporate various sensing capabilities into one or more panels  10  on a body armor system in accordance with the present disclosure. In such applications, the panel device can provide not only an energy dissipation function but it may also perform telemetry and data-gathering functions associated with environmental and physiological signals. A variety of sensors can be attached to or embedded within each panel device. In some embodiments, sensors can be attached to the exterior of a panel device either on the innermost layer adjacent the body or on the outermost layer. Sensors can also be positioned between internal layers and can be secured in place during the dielectric welding process described above for joining individual layers together. Additional circuitry and electrical connectors can also be disposed between various layers in the multilayer sheet construction of panel  10 . 
         [0069]    Physiological health monitoring systems can be implemented on panel device  300 , seen in  FIG. 1A  or a second embodiment of panel device  10  seen in  FIG. 14  to form a physiological health monitoring panel  12 , seen for example in  FIG. 17 . Typically, operational readiness of an individual in a combat environment or field operation is conventionally based on a subjective assessment of the individual&#39;s physiological condition based on input from the individual and from observations of others such as co-deployed team members or remote monitoring commanders. Such subjective determinations of various factors such as physiological and mental health can be unreliable. What is needed is a wearable sensor system to monitor and store data associated with a wearer&#39;s physiological condition. In some applications, it is desirable to couple such a physiological monitoring capability with energy absorbing capability described above associated with various embodiments of a panel apparatus for wear underneath a body armor garment. A body armor system incorporating both inflatable panels for energy absorption and also physiological monitoring systems can provide a mobile platform for assessing physiological and cognitive performance during field operations. 
         [0070]    Physiological sensors can include a life sign detection system which assess and integrates various human vital signs. Referring now to  FIG. 17 , in some embodiments, one or more physiological sensors can be disposed on an inside surface of panel  10  or embedded near the inside surface of panel  10 . 
         [0071]    One or more blood hemorrhage sensors  86  can be positioned on panel  10 . Each blood hemorrhage sensor  86  can be connected to a connector block  98  via one or more hemorrhage sensor leads  94 . Each hemorrhage sensor lead includes an electrical conductor such as a copper wire. Connector block  98  is adapted for electrical connection to an external module such as a transmitter or a data collector in some embodiments. Each hemorrhage sensor  86  is adapted to detect the presence of blood and to emit an electronic signal via hemorrhage sensor lead  94  if a pre-determined amount of blood is detected. Such a sensor would recognize whether the wearer is bleeding out into the space between the panel  10  and the torso or body  70 . In some embodiments, panel  12  of the present disclosure provides generally vertical channels  102 , as illustrated in  FIG. 17 . The spaces between adjacent welds provide corrugations, or channels  102 , against the torso in some embodiments. When a wearer bleeds out into the space between the panel  12  and the body  70 , blood can enter the vertical corrugations defined between the torso and the panel  12 . The blood may then encounter a blood hemorrhage sensor  86  positioned at various locations on panel  12 . 
         [0072]    Also seen in  FIG. 17 , panel  12  in some embodiments includes one or more body heat sensors  84 . Each body heat sensor  84  can be used to monitor the body temperature of the wearer of panel  12 . When the body heat sensor detects a body heat greater than a predetermined level, the physical activity of the wearer can be limited. Similarly, when the body heat is lower than a predetermined level, activity can be enhanced. A heat sensor lead  92  is connected to each body heat sensor  84 . Heat sensor lead  92  includes an electrically conductive wire in some embodiments. Heat sensor lead  92  can be connected to connector block  98 . A voltage signal representative of the body heat of the wearer can be monitored via heat sensor lead  92 . 
         [0073]    Also seen in  FIG. 17 , panel  12  includes one or more heat rate sensors, or electrocardiograph, sensors  88 . Each heart rate sensor can be used to monitor the heart rate of the wearer. When the heart rate becomes too high, activity can be decreased, and when the heart rate becomes too low, activity can be enhanced. A heart rate sensor lead  96  can be attached to each heart rate sensor  88 . In some embodiments, heart rate sensor lead  96  can include an electrically conductive wire. Heart rate sensor lead  96  can be connected to connector block  98 . A signal representative of the heart rate of the wearer is transmitted over heat rate sensor lead  96  to a data collector, a display or a transmitter for remote monitoring. 
         [0074]    Each sensor and lead can be dielectrically welded to panel  10  onto an outer layer or between layers, including between fabric and gas barrier layers. Alternatively, each sensor and lead can be woven into the layer material or adhesively glued to one or more layers. In some embodiments, one attachment means is used to affix a sensor and a different attachment means is used to secure the associated lead. By embedding leads and/or sensors between layers using a dielectric welding process, sensors and/or leads can be shielded from environmental contaminants such as dirt, debris, moisture, chemicals, wind, etc. 
         [0075]    An antenna system (RF, UHF, etc.) can be integrated into and/or affixed to the appropriate sheet structure layer to transmit data to various types of wireless networks, including WAN, LAN, PAN, Bluetooth, etc. Additional sensors can include respiration rate, skin temperature, and body movement sensors. Additionally, a GPS sensor and/or transmitter can be positioned on panel  10 . Additionally, in some embodiments, a blast over-pressure sensor (BOP) can be attached to or in communication with first and/or second panel  10   a ,  10   b . Blast over-pressure sensor is operable to transmit an overpressure signal representative of the presence of a blast pressure wave associated with an explosion. A piezoelectric accelerometer can also be attached to or in communication with first and/or second panel  10   a ,  10   b . The piezoelectric accelerometer is operable to emit an accelerometer signal representative of a sudden impact force applied to the wearer of vest  12 . The accelerometer signal can include a voltage or current signal in some embodiments. 
         [0076]    Additional types of sensors that can be secured to panel  10  include radiation and chemical detection sensors. For example, a dosimeter can be attached to or in communication with first and/or second panel  10   a ,  10   b . The dosimeter emits a radiation signal representative of environmental radiation levels. Each signal can be monitored either locally or remotely in real-time, at pre-determined sampling intervals or on-demand. 
         [0077]    In further embodiments, the present disclosure provides a kit apparatus for retrofitting a conventional body armor garment to reduce body trauma to a wearer associated with an impact on the body armor garment, comprising. The kit includes an inflatable trauma attenuating panel including at least three discrete layers joined together to form an inflatable primary gas chamber and an independent, non-inflatable secondary gas chamber, wherein each panel includes an outer layer including a first hook and loop fabric. The apparatus also includes at least one attachment pad for detachably securing the trauma attenuating panel to the body armor garment, the attachment pad including a second hook and loop compatible fabric configured to detachably engage the first hook and loop compatible fabric. 
         [0078]    In additional embodiments, the present disclosure provides a method of manufacturing a trauma attenuating panel, the method comprising providing at least three layers, a first layer including a hood and loop compatible fabric and a gas barrier layer, a second layer including a woven fabric and at least one gas barrier layer and a third layer including a woven fabric and a gas barrier layer. The method further includes securing the three discrete layers together to form an inflatable primary gas chamber disposed between the second and third layers and an independent non-inflatable secondary gas chamber disposed between the first and second gas layers. 
         [0079]    In yet another embodiment, the present disclosure provides a panel apparatus for use on a canine. The device includes a panel device as describe din various embodiments above. The panel device is designed to rest against the back of a dog. Canine body armor garments may then be positioned to rest against the panel. The panel may include a plurality of vent holes for allowing passive cooling of the dog during chase or non-chase situations. The panel device can be formed of any panel construction embodiment described above, or combinations thereof. 
         [0080]    Prototype test results indicate the panel device will also serve the canine law enforcement market. By creating a cooling and trauma attenuating panel and vest slightly smaller than standard canine body armor, the panel or vest can be placed onto the back of the dog and used to conduct thermal energy away from the dog and into the body armor above. 
         [0081]    Additionally, the principles and embodiments of the present disclosure are provided in some embodiments as an equine saddle pad including a panel device as described in various embodiments herein and configured to be positioned on the back of a horse between the horse&#39;s body and a saddle. 
         [0082]    Thus, it is seen that the apparatus and methods disclosed herein achieve the ends and advantages previously mentioned. Numerous changes in the arrangement and construction of the parts and steps will be readily apparent to those skilled in the art, and are encompassed within the scope and spirit of the present disclosure as defined by the appended claims.