EP-4735823-A1 - BODY ARMOR SYSTEM

Abstract

This invention provides for a body armor system having at least two of; protection levels, mobility/comfort, and body surface area covered. This improved wholistic armor system provides for greater body coverage, better mobility, and better protection, as well as greater clarity for users selecting armor systems based on tradeoffs between armor protection, mobility, and coverage area.

Inventors

• Sundnes, John Phillip

Assignees

• Sundnes, John Phillip

Dates

Publication Date

20260506

Application Date

20240705

Claims (18)

1. 1. A body armor system comprising at least two of; a. improved armor coverage area, b. improved armor mobility, c. improved armor protection levels, whereby the armor is comprised of at least two overlapping panels each a fraction of the required 100% total armor profile for a thickness required for a designed threat, whereby substantially all of the armor coverage area to be protected is covered by at least two layers panels of overlapping armor which individual fractional thicknesses total up to the required 100% armor thickness, when added together in overlap substantially equal to the total armor thickness required for a particular threat and whereby a user may utilize the improved armour system which better suits the users threat situation.
2. 2. The armor system of claim 1, providing a means to collect threat data and group said data into at least two divided levels, for armor protection deigned to meet that level of threat.
3. 3. The armor system of claim 1, providing a means to replicate collected threat data in order to evaluate various armour materials and assemblies’ ability to resist said threat in a controlled environment.
4. 4. The armor system of claim 1, whereby the human body surface area is divided into at least two body area zones related to prioritized importance of protecting that zone from damage for survivability.
5. 5. The armor system of claim 1, whereby armor mobility is classified into at least two levels of mobility such as allowing minimum and maximum exertion, based on evaluations of competent users groups on the criteria of least two of; range of motion, weight, breathability, insulation, thermal burden, comfort, chafing, armor thickness, pliability, and stretch.
6. 6. The armor system of claim 1, whereby the armor protection is defined by resilience to at least one of; puncture, perforation, cutting, abrasion, blunt force trauma, deformation depth, burning, electrocution, insect bite/sting, concussion, blast.
7. 7. The armor system of claim 1, whereby the armor protection is defined by resilience to deleterious contact with, along, against, etc. stationary objects or threats, and categorize said data into at least two levels of severity.
8. 8. The armor system of claim 1, whereby the armored area includes redundant armor panel overlap coverage areas, where overlaps of armor panels to adjacent armor panels exceed the minimum dimension required to meet or exceed at least one of; the dimension of maximum assembly elongation, and the dimension of minimum edge distance as required by armor design or armor regulations.
9. 9. A two-dimensional armor shape for use with the armour system of claim 1, comprising; at least 3 external geometric angles, at least one internal geometric angle, a leading edge that substantially confirms to it’s trailing edge, whereby the armor shape may fold on lines between geometric angles with minimal fold intersections to other fold lines between alternate geometric angles.
10. 10. An armor panel with a two-dimensional shape for use with the armour system of claim 1, whereby an interior fold resistant area is defined by folding along all possible geometric comers, where said folding lines do not intersect other folding lines, where by the surface area of said fold resistant area is less than 50% of the overall armor shape surface area.
11. 11. The armor system of claim 1, whereby the armor assembly comprises; at least two armor panels, each a fractional thickness of the total armor thickness required, attachment of each said armor panel to at least one elastic base layer underneath all said armor panels, at least one elastic element on top of said armor panels, attachment of each said armor panel to said elastic element at a location substantially opposite the attachment of the panel to the base layer, whereby each armor panel is held in relative position to adjacent armor panels, and the armor assembly may elongate, contract, and curve to substantially the extent of said base material and said cover elastic element.
12. 12. The armor system of claim 1, allowing armor panels to expand to a maximum elongation and contraction of the base material and the elastic cover element.
13. 13. The armor system of claim 1, where the armor includes hydrophobic properties.
14. 14. The armor system of claim 1, where the armor includes flame retardant properties.
15. 15. An armor assembly comprising; at least three armor panels each smaller in surface area than the armor assembly, at least two layers of armor panels, each layers’ armor thickness a fraction of the required total armor thickness required for a particular threat, whereby the layers of armor panels overlap in substantially all of the armor assembly surface area and, the total thickness of overlapped panels equals the total armor thickness required for a particular threat, a means to hold said armor panels in relative position to one another, whereby said armor assembly has the required total armor thickness over substantially all of said armor assembly surface area and, said individual armor panels are fixed to the armor assembly and not fixed directly to one another, whereby the assembly remains pliable and optionally elastic.
16. 16. A method for classification of armor comprising; a means to collect a statistical sample of threat data, a grouping of statistical data into at least two levels, a means to replicate threats in a controlled environment for testing of armor materials/assemblies, a rating name or mark assigned to armor materials or assemblies which reist each level, whereby an armor user can select appropriate armor to resist different levels of threat.
17. 17. A method for classification of armor comprising at least two of; protection level as defined as resilience to a particular threat, mobility level as defined by feedback from a competent user group proficient in the activity/task pursued requiring protection, body coverage area level as defined by percentage of the body surface area covered, whereby an armor user may select an armor system with the ideal levels of at least two of; said protection levels, said mobility levels, and said body coverage levels, to best suit the users threat situation.
18. 18. A two dimensional armor shape for use with the armour system of claim 1 comprising, at least 4 sides, a leading side protrusion, a trailing side recess which substantially conforms to said protrusion, whereby when armor panels leading edges overlap other armor panels trailing edges, the leading edges and trailing edges conform to one another. John Phillip Sundnes Patent Attorneys for the Applicant/Nominated Person GLMR

Description

BODY ARMOR SYSTEM CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to United States Provisional Patent Application No. 63525119 filed on 5 July 2023 and United States Provisional Patent Application No. 63525121 filed on 5 July 2023. The entire disclosures of which are hereby incorporated by reference in their entirety and for all purposes. FIELD [0001] This invention relates to body armor, body protection and a system for such as typically used by the military, law enforcement, (personal) security, as well as sport. BACKGROUND [0002] Typically, ballistic and stab protection is covered by vests and helmets. These products only cover about 30% of the body, leaving the rest exposed to harm. Further, there are significant concerns about competing aspects of body armor - typically thought of as 1. Protection levels (resistance to threats), 2. Mobility and comfort, and 3. Cost. What is generally overlooked when selecting a body armor system is the coverage area of the body, with little meaningful improvement since the adoption of vests/helmets decades ago. [0003] There is a need to address armor more wholistically, with the parameters of 1. Protection Levels, 2. Mobility and comfort. And 3. Body surface area coverage. The 4th element can be cost which is generally in flux with new materials and manufacturing methods being developed all the time. [0004] There are numerous body armor systems currently on the market, typically taking the form of protective vests and helmets such as “bullet resistant vests”. These provide significant protection for specific, limited areas of the body. However, these same systems provide little to no protection to critical mobility areas, leaving large areas of the body unprotected due to challenges of covering body parts which bend, flex, and curve in complex and sometimes opposite directions. Joints-like knees and elbows are generally not covered, as robust armor doesn’t resists bending in one direction, and is significantly resistant to bending in two opposite directions concurrently. [0005] There are some protection systems segmented at joints, such as an upper thigh pad and a shin guard, for example, with no protection in between. A knee pad that protects the front of the knee, and omits the back of the knee altogether, has limited use. Further, robust armor elements which cover a joint when straight, may allow gaps or voids to open when the same joint is bent. These segmented systems are not helpful when dealing with military fragments such as grenades and mortar shells, which spray combatants with showers of sharp metal pieces. Covering extremities properly requires the full coverage of joints (not segmented with gaps), so that these types of threats may be repelled. [0006] There is a need for an improved armor system to wholistically address protection, mobility, and coverage area, allowing users to select systems which better suit their perceived threat condition. Further, a system which significantly covers more surface area than a protective torso vest, is advantageous and should include armouring an entire body with extremities and joints, while allowing full range of movement, and preventing gapping or voids in armor coverage from opening up during movement or bending of joints. [0007] Such a system would provide tremendous extra benefit to wearers in various situations, allowing joints and mobile areas to be covered and contoured with armor, and allowing the armor assembly to move, elongate, shorten, expand, etc. so that the wearer can still reasonably or rigorously perform the task duty or activity while wearing the protective armor. [0008] Two examples of situations generally not currently covered by available armor systems follow. Example A is a soldier who is being attacked with fragmenting munitions. Fragmentation/penetration is the leading cause of combat casualties, indiscriminately spraying soldiers with sharp metal fragments of various sizes. An injured soldier stops shooting back, as well as 2-3 more soldiers as the injured soldier now requires the attention of several others for care and evacuation. Additional armor protection can greatly reduce the risk of casualties from fragmented munitions. There is a need to protect a greater body surface area while avoiding gaps between armour panels. [0009] Example B is a law enforcement person wearing a traditional stab resistant vest. These vests can be bulky and uncomfortable. In close quarters a perpetrator could stab or slash the law enforcement person under the arm, where there is a major artery, inflicting significant damage which can result in death from blood loss. There is a need to provide for a more pliable and flexible vest that is easier to conceal (ensuring concealment of the law enforcement status). There is also a need to provide coverage at areas under arms or in groin areas where large arteries have no coverage currently. [00010] It is an object of the invention to substantia