WO2023211658A2

WO2023211658A2 - Ballastic plate carrier

Info

Publication number: WO2023211658A2
Application number: PCT/US2023/017617
Authority: WO
Inventors: Michael E. Cole
Original assignee: Firstspear Technology Group, Llc
Priority date: 2022-04-05
Filing date: 2023-04-05
Publication date: 2023-11-02
Also published as: WO2023211658A3

Abstract

A ballistic plate or panel carrier, system, and method, has at least one panel of lightweight polymer foam or similar material formed by a press ing process to include an integral stiffened perimeter rim or frame bounding and defining an armor plate or panel cavity making the carrier overall inexpensive to manufacture and lightweight, yet adequately securely holds and supports the armor plate or panel and is safe and comfortable. The carrier can further include one or more cover panels for the plate cavity and outer face of the carrier that can optionally be made using the same process, in the case of covering the cavity, to incorporate one or more lightweight energy absorbing and dispersing standoff spacers for reducing traumatic effect on a wearer from ballistic impact on the associated plate or panel, and in the case of the outer face, to include features, e. g., slits, MOLLE PALS webbing, and/or hook and loop or other fastening system, such as, but not limited to a loop pile fabric, for fastening articles, indicia, and the like to the outer surface.

Description

BALLASTIC PLATE CARRIER

[ 0001] This application claims the benefit of U . S . Provis ional Application No . 63 /327 , 746 , filed April 5 , 2022 .

Technical Field

[ 0002] This invention relates generally to a ballistic plate or panel carrier, system, and method, that , more particularly, comprises at least one panel of lightweight polymer foam or similar material formed by a pres sing proces s to include an integral stif fened perimeter rim or frame bounding and defining an armor plate or panel cavity so that the carrier is overall inexpensive to manufacture and lightweight , yet adequately securely holds and supports the armor plate or panel and is safe and comfortable . The carrier can further include one or more cover panels for the plate cavity and outer face of the carrier that can optionally be made us ing the same proces s , in the case of covering the cavity, to incorporate one or more lightweight energy absorbing and dispersing standof f spacers for reducing traumatic ef fect on a wearer from ballistic impact on the as sociated plate or panel , and in the case of the outer face, to include features for mounting accessories such as pouches and the like, and advantageously can be readily and easily adaptable to provide customized fit and comfort . The outer surface of the plate carrying panel can be configured to have a smooth curved shape, to mimic natural body contours to facilitate concealment of the carrier, and can further optionally incorporate a pattern of MOLLE webbing, slits, and/or other openings or mounting elements for attaching pouches and other articles thereto, as a nonlimiting example, in the pattern of a MOLLE PALS system, and which can optionally incorporate a component of a hook and loop or other fastening system, such as, but not limited to a loop pile fabric, for fastening articles, indicia, and the like to the outer surface.

Background Art

[0003] U.S. Provisional Application No. 63/327, 746, filed April 5, 2022, is incorporated herein by reference in its entirety.

[0004] Body armor is recognized as providing valuable protection against ballistic threats, e.g., bullets, shrapnel, blast debris such as flying glass and the like, as well as sharp objects such as knives, ice picks, and homemade weapons commonly used by inmate populations of correctional institutions. Various configurations of body armor are known, including hard plates of different thicknesses and compositions, such as metal alloys, ceramics, laminates of multiple materials, and soft panels of layers of aramid fiber, e.g., available under the tradename Kevlar and other polymers, e.g., polyethylene, and the like. A hard plate is rigid and inflexible, but many soft panels have at least some flexibility. A hard plate may be used alone, or in combination with one or more under or over laying soft panels, and in reduced or non-ballistic threat environments, a soft panel may be used alone. The armor configuration used is often selected based on the expected threat environment, e.g., sharp hand weapon only, rifle, pistol only, blast, and other conditions, such as environment, e.g., temperature, humidity, marine conditions, other loads to be carried, e.g., ammunition, food, shelter, etc., duration of wear, distance to be traveled on foot, time standing verses seated or riding in a vehicle, jumping from a fixed or rotary winged aircraft, etc. As a result, modularity and/or scalability, that is, the ability to assemble an armored garment such as a carrier, vest, or the like, of various combinations of body armor elements, customized for conditions, is often sought.

[0005] It is also often sought to have a lower cost, quality, safe and comfortable plate carrier, particularly that is light weight, and in some cases, reduces the appearance of wearing an armored garment, and may be concealable .

[0006] Armor plates are typically sized to a particular wearer, with length or height, width, and sometimes shape or gender, being common variables. Plates to be worn over the front torso or chest will typically be curved so as to be slightly concave when viewed from above or below, and may have additional concavity when viewed from the side, to create a concavity that will conform at least generally to a wearer's anatomical shape. A military or law enforcement agency will typically order a specific plate sized and shaped for a particular wearer. In regard to fit , female torso shapes present a challenge, as the female chest and stomach are not generally level compared to male torso shapes . When a hard armored plate having a generally f lat or only slightly concave shape is f itted to a female, i f the upper end of the plate rest s on the breasts , and the lower end rest s on the stomach, the plate can have a tilted orientation wherein the upper end is spaced from the upper chest and the lower end follows a line toward the pelvis . As a result , the lower edge of the plate can pres s into the wearers abdomen to cause discomfort . Tailoring of armor carrying garments such as vest s has been attempted with advantages and disadvantages .

[ 0007] Regarding fit and comfort , reference Beck, U . S . Patent No . 9 , 970 , 736 B2 , directed to a female protective vest that utili zes a ballistic hard plate and an underlying soft ballistic armor supported on a carrier of the vest . The Beck carrier is contoured with lateral darts that displace the ballistic hard plate in a direction away from the inner surface and an underlying soft ballistic armor and the wearer in the breast region to eliminate excess compres s ion of the breast tis sue and maintain the hard plate in an orientation generally parallel to the body of the wearer . It is also taught that the darts can form cup portions for the same purpose, and the soft ballistic armor can have a female shape that mirrors the carrier shape . While presumably reducing breast compres sion, the hard armor plate will be tilted in the abovedescribed manner, namely, with the lower plate edge directed toward and potentially into the abdomen of the wearer to cause discomfort .

[0008] Reference also, Fritch U.S. Patent No. 4, 660,223, which discloses protective body armor utilizing a spacer element to prevent undue pressure being exerted on the breasts of woman wearer. The spacer rests on the wearer's rib cage, and an armor plate or panel will rest on the spacer. As a result, the weight of the armor and resultant pressure is partially transferred to the lower rib cage of the wearer. Thus, the spacer holds the armor outward and takes the pressure from the armor. The Fritch spacer can comprise a number of stepped plies, foam construction being mentioned, or it can be a molded insert. The number of steps utilized will be a function of the breast size of the wearer, and the spacer is enclosed in a woven nylon shell. That nylon shell is attached with Velcro strips to another nylon shell within which the armor is inserted, the Velcro on the nylon shell that receives the armor being larger, to afford options for positioning the spacer. The Fritch spacer would appear to provide an adequate solution to the tilting of an amor plate to reduce the occurrence of the lower edge of the plate applying excessive or irritating pressure against the abdomen of a wearer under normal conditions, and could eliminate the need for darts in the lateral region of a carrier for accommodating and taking pressure off of breasts. However, for a wearer whose waist and/or breast size vary, a single size spacer may not provide the desired pres sure relief and/or comfort throughout the range of weight s and breast sizes .

[0009] As another potential shortcoming, when a spacer is placed between an armor plate and a wearers rib cage, the armor plate will be spaced forwardly of the wearer' s torso by an amount egual to the thicknes s of the spacer . This can result in an enlarged ballistic window, that is , a space adjacent to the s ide of the plate through which a pro j ectile traveling diagonally or obliquely relative to the forward direction can pas s so as to strike the chest or abdomen of the wearer . To reduce thi s side balli stic window a side armor plate or panel can be worn . However, a spacer of foam plies or similar construction, attached by as strip of Velcro to the back s ide of a nylon shell holding a f ront armor plate or panel , may be inadequate back up or support for a side armor plate or panel when struck with a ballistic pro jectile, even when the side plate or panel stops the pro jectile, so as to potentially result in injury to the wearer or additional damage to the side plate . This can be due to a condition known as back face deformation . An armor plate or panel will have an outwardly facing surface known as a strike face , which will be struck by incoming pro jectiles , and a back face that faces the wearer . Even the thickest armor plates are expected to have some back face deformation so as to be di splaced toward the wearer when struck by larger or higher velocity pro jectiles . How much back face deformation occurs can be a function of the strength and stiffnes s of any structure backing up the armor plate or panel , as well as the strength of attachment of the backing structure .

[0010] What is sought is a carrier for an armor plate or panel, that overcomes one or more of the shortcomings and limitations discussed above, and that is economical, and simple to use to provide customized fit and comfort.

Summary Of The Invention

[0011] What is disclosed is a ballistic plate or panel carrier that overcomes one or more of the shortcomings and limitations set forth above. Also disclosed is an energy absorbing and dispersing standoff spacer, system, and method for use or incorporation with an armor plate or panel, that can reduce traumatic effect on a wearer from ballistic impact on the associated plate or panel, is economical and readily and easily adaptable to provide customized fit and comfort. [0012] According to a preferred embodiment of the invention, heat and/or pressure shaped foam construction is utilized to construct a ballistic plate or panel carrier or an armor carrying panel thereof, of a garment such as a vest. The panel will utilize a suitable foam such as a polymer foam, such as but not limited to, ethylene vinyl acetate (EVA) , but will be suitably stiffened at certain locations for carrying a relatively heavy armor plate or panel, e.g., 3-10 pounds in weight, without significantly deforming under normal conditions, e.g., running, jumping, swimming, and in this latter regard, the foam construction can provide some added buoyancy to aid a swimmer. The armor carrying panel will utilize a semi-rigid or rigid compressed portion of the foam that also def ines and bounds , and forms a rim or frame about , a shallow cavity that will receive and hold the armor plate or panel . This plate cavity will snuggly fit to the armor plate or panel , and the rigidity and stif fnes s of the rim or f rame will be adequate to hold the plate or panel in the cavity under anticipated lateral loading conditions , and a central region of the panel will also comprise the foam, in a generally uniformly compressed and thus more rigid and stif fened state, to securely hold the armor plate or panel and will be integral with the rim or frame to form a unitary armor plate or panel holding structure, that will be very lightweight , low prof ile, simple and inexpensive to manufacture . As an additional attendant advantage of certain heat formable polymer foams such as EVA, the outer panel comprising the central region of the plate receiving cavity can be bowable or curvable to conform to the curve of an armor plate or panel .

[0013] A cover panel al so preferably of the foam construction can include features for securely attaching to the rim or frame for covering the plate receiving cavity, and can additionally include stif fening features , to enhance the stif fnes s of the armor carrying panel . The cover panel will be joined to the armor carrying panel around at least a portion of the periphery thereof , e . g . , along the sides , top, and bottom, but will preferably be openable or removable to allow acces s to the armor plate or panel . For thi s purpose the peripheral frame or rim about the plate cavity and the perimeter of the inside cover panel can include suitable fasteners . [0014] The outer panel of the armor plate or panel carrier forming the plate carrying cavity can comprise a loop pile fabric layer or layers, and can be slitted or slotted or otherwise Include suitable openings to enable attachment of MOLLE and other accessories, indicia, etc. [0015] According to a preferred aspect of the invention, the armor plate carrying panel will be of unitary construction fabricated from a single sheet or bun of suitable foam such as EVA, of a suitable thickness, heat and/or pressure formed to create the plate cavity and stiffened rim or frame structure thereabout and stiffened plate carrying cavity. An additional panel or panels, e.g., side panel, straps, and the like can be connected to the plate carrying panel using hook fasteners attachable to the loop pile fabric outer layer. The outside panel region can be likewise be compressed and formed into a desired semi- rigidly or rigidly compressed state to provide a suitable load carrying capability for the armor plate or panel and accessories that may be carried using the optional slitting/slotting/openings . Additionally, by covering the outside panel with loop pile fabric, pouches and accessories, unit and agency indicia, cell tags, etc., bearing appropriated hook surface can be securely affixed.

[0016] As another preferred aspect, the plate carrier as illustrated and constructed as explained can have a smooth outer surface and a low profile, or form fitting profile, so as to reduce observability and even be suitable for concealed use, under a shirt, blouse, tunic, coat, etc. Brief Description Of The Drawings

[ 0017] FIG . 1 is a plan view of aspects of an energy absorbing and dispersing standoff spacer system of the invention, including two representative spacer panels , and a cover panel for attachment to the backside of a carrier for an armor plate or panel , directly to the armor plate or panel , or other garment , such as a vest , shirt or the like, each of the panels shown having interlocking features comprising raised protuberances arranged in a predetermined pattern ;

[ 0018] FIG . 2 is a plan view of the spacer panels of FIG . 1 , showing an opposite side including a perimeter defining and bounding a predetermined pattern of concavities for receiving the protuberances of another spacer panel or other panel such as the cover panel ;

[ 0019] FIG . 3 is a fragmentary perspective view of one of the spacer panels of FIGS . 1 and 2 , shown bent or flexed into a curved shape for conforming to the curve of the back side of an armor plate or panel ;

[ 0020] FIG . 4 is a plan view of the spacer panels of FIG . 1 , showing the pattern of concavities for receiving the protuberances ;

[ 0021] FIG . 5 is a side perspective view showing the cover panel of FIG . 1 attached to a representative panel for a carrier or vest containing an armor plate within a plate cavity between the cover panel and other aspect s of the carrier, and showing a plurality of the spacer panels interlockingly joined together and to the cover panel, forming a stack , to illustrate a representative standof f spacing distance achievable using the spacer panels ;

[ 0022] FIG . 6 is another perspective side view of the arrangement of FIG . 5 , showing additional aspects ;

[ 0023] FIG . 7 is a sectional side view of a representative spacer panel showing various aspect s thereof , including the periphery, protuberances and concavities and transition regions ;

[ 0024] FIG . 8 is an enlarged sectional side view of a representative spacer panel showing more particularly an of f set relationship between the perimeter and a representative protuberance and concavity, transition region therebetween, and adjacent compres sed fused regions of the perimeter and protuberance;

[ 0025] FIG . 9 is another perspective side view, showing two of the spacer panels interlocked together, one of the spacer panels being in section to show the transition region and adjacent compres sed fused regions of the perimeter and protuberance ;

[ 0026] FIG . 10 is still another perspective view of two of the spacer panels interlocked together, one of the spacer panels being shown in section to show the transition region and adjacent compres sed fused regions of the perimeter and protuberance in greater detail ; [ 0027] FIG . 11 is a perspective side view showing a stack of the spacer panels interlocked together and with the cover panel on a panel of a representative carrier or other garment ;

[ 0028] FIG . 12 is another plan view of two of the spacer panels of FIG . 1 , showing double-sided hook of a hook and loop fastening system tabs attached at locations about the perimeter, fastenable to the loop fabric layer 52 on the other of the spacer panels;

[0029] FIG. 13 is an end view of the two spacer panels of FIG. 12, attached together using the tabs 60 to hold one of the panels in a bowed or curved shape;

[0030] FIG. 14 is a plan view of a ballistic carrier of the invention, showing an outer surface of a front armor carrying panel thereof with features comprising a pattern of slits for mounting accessories such as pouches and the like thereto;

[0031] FIG. 15 is a plan view of the carrier of FIG. 14, showing cover panel 46 on a back surface of the front armor carrying panel and interlocking features thereof;

[0032] FIG. 16 is an enlarged perspective view of the front panel of the carrier of FIG. 14, with a corner of the cover panel detached from the front panel to reveal a cavity for receiving and carrying an armor plate or panel ;

[0033] FIG. 17 is a plan view of the front panel of the carrier of FIG. 14, without the cover to reveal the full extent of the cavity for receiving and carrying an armor plate or panel; and

[0034] FIG. 18 is an enlarged perspective view of the front panel of the carrier in section, to show compressed regions thereof that impart rigidity and stiffening for securely holding an armor plate or panel within the cavity. Description Of Embodiments Of The Invention

[0035] Referring now to the drawings, in FIGS. 1-18 embodiments of a ballistic plate carrier 24 incorporating features and advantages of the invention, are shown. Also shown is an energy absorbing and dispersing standoff spacer system 20, and method for use or incorporation with carrier 24, that can reduce traumatic effect on a wearer from ballistic impact on the associated plate or panel, is economical and readily and easily adaptable to provide customized fit and comfort .

[0036] According to a first embodiment of the invention, referring to FIGS. 1-13, aspects of several embodiments of an energy absorbing and dispersing standoff spacer system 20 for use with carrier 24 carrying an armor plate or panel 22 (see FIGS. 5, 6, and 11) , and with a garment such as a vest, shirt, or the like, and a method assembling the same according to the invention, is shown. System 20 supplements and integrates with the carrier 24 to reduce traumatic effect on a wearer from ballistic impacts on the associated plate or panel 22, is economical and readily and easily adaptable to provide customizable fit and comfort, particularly for female body shapes.

[0037] Referring particularly to FIGS. 1-6, representative aspects of spacer system 20 are illustrated, including, but not limited to, one or more spacer panels, represented by spacer panels 26, 28, 30, adapted and configured for integration with carrier 24 for placement between an armor plate or panel 22 and a wearer's body. Any or each of spacer panels 26, 28, 30, is configured to be interlockingly attachable to any of the other spacer panels 26, 28, 30, or with a cover panel 46 of carrier 24, or directly to an armor plate or panel 22, to form a stack 44, and can include one or more features for securely yet manually removably, interlocking with another panel, 26, 28, 30, 46 in a predetermined manner, to provide underlying coverage to one or more associated armor plate or plates or panels, to provide desired standoff distancing from a wearer, energy absorption and dissipation characteristics, comfort and fit. At least one of spacer panel 26, 28, 30 preferably possess a limited resilient compressibility sufficient for providing the desired energy absorption and dissipation as well as comfort.

[0038] Each spacer panel 26, 28, 30, and cover panel 46 has a first surface 32, comprising at least one protuberance 34 extending outwardly in a first direction DI, defined and bounded by a perimeter 36. Direction DI can be oriented to face toward armor plate 22 and carrier 24, or toward a wearer, as desired or required for a particular application. Each spacer panel 26, 28, 30 additionally has an opposite second surface 40, comprising at least one concavity 42 having a predetermined shape and size, respectively, to be configured and adapted for cooperatively receiving and interlocking with a protuberance 34 of another panel in forming a desired stack 44. Here, it can be observed that each of the panels 26, 28, 30 has protuberances 34 arranged in a predetermined pattern, as a nonlimiting example, a Chevron pattern, and opposite concavities 42 arranged in that same pattern, such that the protuberances 34 of one of the cover panel s , 26 , 28 , 30 , 46 are simultaneously cooperatively receivable in the concavities 42 of another of the panel s 26 , 28 , 30 , to interlocked the panels together to prevent or limit relative lateral movement and also so as to not unintentionally separate in the first and second directions . This interlocking configuration can be observed to additionally intimately position adjacent panels with the first surface 32 of one panel directly abutting the second surface 40 of the next panel , which is des ired for energy from impact forces transmitted from an as sociated armor plate or panel to be seguentially absorbed and progres s ively di s sipated within the stack 44 compri sing any number of panel s 26 , 28 , 30 , and 46 . Here it can be further observed that concavities 42 directly align with an associated protuberance 34 , and that es sentially the protuberance 34 bounds or forms the inner periphery of the concavity 42 . This is preferred and des irable as it enables optimally densifying a stack of the panels for energy absorption, keeping in mind that succes sive panels do not have to be the overall size and contain the same number of interlocking features as the other panel or panels with which the panel is used . However, using aligned protuberances 34 and concavities 42 is des irable additionally as it allows providing a transition region 48 about each protuberance 34 and also the associated concavity 42 , transition region 48 es sentially forms the corner of the lateral facing walls of the concavity 42 , the lateral walls being formed mainly by the surrounding edges of the perimeter 36 , as will be explained next . [ 0039] Protuberances 34 are shaped and sized to be matingly cooperatively receivable within the respective concavities 42 , and in that regard it is neces sary that these features be retainable together to resist lateral relative movement as could otherwi se be anticipated to occur as a result of diagonal or oblique contact or impact forces and compres s ion of protuberances 34 resulting from ballistic strikes and resulting back face deformation of the armor plate or panel 22 , stabbing forces from sharp objects , potentially also blast forces , and other forces anticipated to be encountered in typical environment s where armored garments are utilized . The restraint against lateral movement will al so be suf ficient for res isting s igni ficant deformation from forces exerted against a stack 44 resulting f rom normal body movements , such as running, jumping, twisting, fighting, wrestling, falling, etc . However, to absorb impact forces , and accommodate bending or curving of the spacer panels 26, 28 , 34 for conforming to curvature of an as sociated armor plate or panel 22 , ability of protuberances 34 and perimeter 36 to move relatively in the first and second directions is desirable to a limited extent .

[ 0040] To achieve the desired resistance to lateral movement and displacement , transition region 48 between each protuberance 34 and perimeter 36 is preferably configured to enable limited movement of an individual protuberance 34 and the surrounding perimeter 36 in direction DI and the oppos ite direction, that is , toward or away from a wearer' s body and the carried armor plate 22 , generally suf ficiently les s than an amount of the thickness in the first and second direction of the perimeter or protuberance, such that in the event of such movement, the panels will remain sufficiently interlocked together to maintain the integrity of the overall spacer system 20.

[0041] To facilitate a secure interlock between joined together panels 26, 28, 30, and 46, a small region of the perimeter 36 and/or the protuberance immediately adjacent and contiguous to the transition region 48, denoted as a compressed region 50, preferably comprises a highly compressed and thus more dense section of material, e.g., EVA foam, which is thereby much more semi-rigid or rigid and stiffened, compared to adjacent regions of the individual protuberance 34 and perimeter 36 which are subjected to less compression (and heat in some instances, depending on formulation, additives, catalysts utilized with the EVA foam) . The thus increased semi-rigid or rigid, stiffened compressed regions 50 are sufficient in lateral extent to define and retain the size and shape of the concavity 42 for cooperatively receiving a protuberance 34, and also for restraining or containing protuberance 36 against significant relative lateral movement, thus interlocking them together. Here, it should be noted that with some polymer foams, namely, varieties of EVA and additives, the closed cell wall structure of all or portions of compressed regions 50 can essentially be fused together forming a rigid or semi-rigid and thus stiffened structure, while the transition region 48 is molded to be sufficiently thin to have flexibility. In this latter regard, it is anticipated that a surface and/or absorptive coating or coatings can be applied to further stif fen regions 50 , as des ired or required for a particular application .

[ 0042] It is been found that compres sion and heating a starting EVA foam sheet or bun in a mold having an internal cavity with the shape of the spacer panel can be used to create the required compres sed regions 50 limited to the closely adj acent regions of the perimeter 36 and individual protuberances 34 , and at the same time, the more flexible transition region 48 disposed directly between the compres sed regions 50 , to provide the desired shape retention laterally and relative movement capability in the first and second directions (toward/away from wearer' s body) . For thi s purpose, the mold used will preferably have a very thin pas sage between the larger cavities for forming the protuberances 34 and perimeter 36 from a sheet or bun of EVA or other suitable foam . It can be seen in the drawings that compres sed region 50 es sentially comprises the edge of the perimeter 36 and protuberance 34 and tapers convergingly toward transition region 48 therebetween, and thus transition region 48 while highly compres sed, will comprise only a small amount of remaining foam material, to have the desired f lexibility in the first and second directions . The retention of the compres sion of the compres sed regions 50 and result ing rigidity and sti ffness , can be further facilitated by using a foam compos ition that has a greater hardening when sub jected to heat and pressure, e . g . , thermosetting characteri stic , including to an extent such that walls of the foam cells are fused together and stif fened in the limited area of the compres sed region .

[ 0043] According to another preferred aspect of the invention, a cover panel 4 6 or platform of carrier 24 or garment covering or compri sing an armor plate or panel 22 des irably also utilized the above-described compres sed regions 50 about the protuberances 34 for providing a suitable interlocking capability, but the opposite surface of the cover panel 46 will be flat or curved, for intimately contacting an armor plate or panel 22 in surface to surface relation . It should be apparent that an appropriate surface of a garment such as a shirt can include mating interlocking features such as protuberances 34 or concavities 42 , as desired for a particular application . As an attendant advantage of utiliz ing the outwardly extending protrusions 34 on cover panel 46 , if used alone, some ventilating and sweat directing capability is provided, as well as some cushioning . Additionally, it can be observed that protrusions 34 are located across the entire surface of cover panel 46 such that spacer panels of desired sizes and shapes can be interlockingly attached thereto at di f ferent locations . In this regard, dotted lines on panel 46 , e . g . , encompas sing 1 , 2 , 3, or 4 of the Chevrons , illustrate dif ferent size spacer panels that can be utilized alone, or in stacks of varying heights to achieve a desired standof f capability and f it .

[ 0044] According to another embodiment of the spacer aspect of the invention, the at least one spacer panel 26 , 28 , and/or 30 can be disposed in surface-to-surface elation to the back face of all or a portion of an armor plate or panel 22 covering a front torso, rear torso, and/or side or sides of a wearer. As a non-limiting example, a spacer panel stack 44 will be located behind and support a lower portion of an armor plate or panel 22, for instance a front or chest armor plate or panel 22 to accommodate breasts of a wearer above the spacer panel 26, 28 and/or 30, to provide a custom fit capability for females and others with protruding chest features, see FIG. 5. According to another related embodiment, a stack 44 will comprise at least one of the spacer panels 26, 28, 30 having a combined thickness of protuberances between the first surface and second surface of the spacer panel, or if two or more spacer panels are used, between an outer one of the spacer panels and the second surface of an opposite outer one of the panels, about equal to the thickness of a breast of wearer as measured from the skin covering the rib cage of the wearer to the outermost portion of the breast, e.g., the forward extension of the breasts. This can be with the breasts not otherwise restrained, or restrained by wearing of a bra or other restraint, such as a sports bra that will comfortably compress and flatten the breasts.

[0045] Individual spacer panels 26, 28, 30, and a cover panel 46, can have matching thickness, different thicknesses, and matching or different widths and lengths, and the same or different shapes, e.g., rectangular, oval, round, triangular, polygonal, trapezoid, etc., when viewed from the front or rear, and rectangular, straight, curved, tapered, barrel, hourglass, etc., shaped when viewed from the side. This enables construction of a stack or stacks of spacer panels adjacent to a breast or breasts, e.g., below, above, beside, between, to reduce pressure from an armored plate or panel 22 covering the breast or breasts, and to be highly customized to fit the contour/shape of the wearer' s body, and importantly, to be varied and altered from time to time to fit changes, such as weight gain or loss, breast enlargement or reduction, shape change, without the need for fitting and ordering a single shape spacer. As a non-limiting example, one or more rectangular, kidney, oval, etc., shaped spacer panels may be used directly below the breasts, with a triangular spacer panel partially between the breasts, above in the cleavage area, below, or both, and can be tapered to provide a closer fit, that is, generally conform to the slope of the breasts, stomach, chest, pelvis, and better interaction with other worn items and gear such as a cummerbund or duty belt to be worn around the waist. As an advantage, because the spacer panels are interlockingly joined, the interlocking features can be sized and shaped as desired so that any number and combination of the spacer panels can be used, e.g., mixed and matched, to achieve a desired overall shape and armor plate or panel standoff, again see FIG. 1. Here, as a non-limiting example, the interlocking features, e.g., concavities 42, mating protuberances 36, of the spacer panels, can have chevron or parallelogram shapes, oriented obliquely to the sagittal plane of a wearer's body, triangular, round, or other shape, to also provide capabilities such as convection venting, central or lateral sweat containment and drainage, etc.

[0046] According to another embodiment of the invention, the protuberances 36 of a spacer panel 26, 28, 30 comprising a unitary member of a polymer foam such as EVA which is known to still be flexible and shapable using heat and/or pressure after molding. In FIG. 5, a representative armor plate or panel 22 shape is shown and it can be envisioned that an originally flat EVA or other foam panel can be hand positioned or permanently heat or pressure shaped to virtually exactly conform to the shape of the back face of the armor panel 22 or a covering panel 46 or layer. According to a related embodiment of the invention, the at least one protuberance 36 on the first surface 32 of the spacer panel 26, 28, 30 and the surrounding perimeter 36 are integrally joined by a semi-rigid or rigid and stiffened compressed regions 50 thereof and flexible transition region 48 therebetween (preferably integrally constructed of the foam material) , see FIGS. 7-10. Thus, when interlockingly engaged, the concavity of a first spacer panel 26, 28, or 30 and the protuberance of a mating spacer panel 26, 28, or 30, or cover panel 46, will have overlapping perimeters 36 of the foam for energy absorption anticipation, and also for comfort, and the stiffened compressed regions 50 will also overlap, to enhance and support restraint against lateral movement of the interlocked protuberances 34 and concavities 42, so as to be capable of retaining the original shape of those features under various anticipated loading conditions, e.g., wearer is running, jumping— such as from a hovering rotary winged aircraft, swimming, parachute landing, climbing, etc . , even when the spacer panels 26, 28, 30 are flexed for fitting, see FIG. 3.

[0047] According to another related embodiment, the semi-rigid or rigid stiffened compressed regions 50 can be seen to rim or frame the protuberances 36, with transition region 48 disposed therebetween. To provide the desired mix of resilient elasticity and compressibility in the first and second directions, but plasticity against relative lateral movements, ss a nonlimiting example, as shown in FIG. 7, the protuberances 36 of a spacer panel 26, 28, 30 can have a thickness T1 of about 1/2 inch, respectively, so that the spacer panel 26, 28, 30 will have an overall thickness of about 1 inch, and two of the spacers panels 26, 28, 30 when interlockingly engaged will have an overall thickness T2 of about 1 1/2 inch, see FIG. 6. In this configuration and manner of interlocking, thus the overall thickness of the stack 44 does not have to have an integer multiple of the thickness T of the individual spacer panels 26, 28, 30. It should also be noted that the thickness T1 of the protuberances 36 and thus the depth of the concavities 42 can be varied for a particular application. In this regard, thickness T could have a value of 1/4 inch; 1/8 inch; 3/4 inch; 1 inch, etc., depending on the application, anticipated force and energy dissipation requirements, fit, etc.

[0048] According to another embodiment of the invention, each of the spacer panels 26, 28, 30, and cover panel 46, comprises an outer fabric layer 52 of loop pile fabric, to serve as a component of a hook and loop fastening system. This is advantageous as it provides a pleasant non-plasticky skin feel and will have some sweat absorption properties. The spacer panels 26, 28, 30, and cover panel 46, can comprise a foam construction such as an EVA foam, as described above, that is heat formable, and thus the individual spacer panels 26, 28, 30, and the cover panel 46, can be curved using a heat gun or the like to the curvature of a garment, or an under lying body region, or other backing member to which the panel is desirably conformingly shaped and will be joined to, see FIGS. 3 and 13. The loop pile fabric can have one or more 2 sided strips or tabs 60 of the hook component of a hook and loop fastening system, see FIG. 12, so as to strengthen the attaching force joining 2 panels or joining a panel to a garment or other backing member also having a loop pile surface feature, e.g., tab or strip. This has advantages, including providing the ability to bow one spacer panel 26, 28, 30 joined to another panel 26, 28, 30 (FIG. 13) , to better fit to an interior face of an armor plate or panel, and to provide a space for ventilation between the joined panels, or to better level or standoff an armor plate or panel to avoid an edge like the lower edge pressing into a wearer' s abdomen, or better transition between a curved back face of an armor plate and a flat or concave abdomen. Of course, this function can also be accomplished by use of a tapered or smaller spacer panel or panels appropriately located. [0049] As a result of the presence of stack 44 of spacer panels of the invention, a side plate worn in concert with the associated armor plate or panel 22 will be supported by the stack 44 against side and oblique ballistic impact forces, illustrated by force F in FIG. 11. Also, if a cummerbund is worn tightly, the resilient elasticity of the spacer stack can act as a comfort cushion, particularly when bending down or to the side.

[0050] Referring also to FIGS. 14-18, according to another embodiment of the invention, the pressure and heat shaped foam construction of the spacer stack 44 can also be utilized to construct ballistic carrier 24, including cover panel 46, and a panel or panels thereof for carrying one or more armor plates or panels 22, as represented by front panel 58. In FIG. 14, carrier 24 is shown including front panel 58, and opposite rear panel (behind front panel 58) , connected together in the well-known manner with straps 66 extending therebetween at the shoulder regions and waist regions of a wearer. This is a very common arrangement for ballistic plate carriers and vests, and front panel 58 will cover the wearer' s front torso, and the rear panel will cover the back .

[0051] Front panel 58 as well as cover panel 46 will each preferably comprise a unitary construction of a suitable foam such as EVA, pressure and heat formed from a sheet or bun, suitably stiffened at strategic locations for carrying a relatively heavy armor plate or panel 22, e.g., 3-10 pounds in weight, without significantly deforming and moving or jostling of the plate or panel 22 under normal conditions, e.g., running, jumping, swimming, etc. In this latter regard, the foam construction can advantageously provide some added buoyancy to aid the swimmer .

[0052] Referring in particular to FIGS. 16, 17, and 18, like with the spacer panels 26, 28, 30 described above, which will be attachable to cover panel 46 using protuberances 34 thereon (FIG. 15) in the abovedescribed manner, the armor carrying panel 58 will utilize semi-rigid or rigid, stiffened compressed regions 50 about the inner periphery of a rim or frame 54 that comprises an outer perimeter 36 of front panel 58 to define and abound a shallow cavity 56 for receiving and carrying an armor plate or panel 22, but importantly without an associated transition region, as flexibility to the extent described above is not desired in association with carrying the armor panel.

[0053] In particular, rim or frame 54 of panel 58 of carrier 24 is compression and heat molded to the shape and size (or a marginally larger size) of the outer periphery of an armor plate or panel 22 so as to bound and define shallow cavity 56 that will snugly and securely receive and hold the armor plate or panel 22. This snug fit, and the rigidity and stiffness of the surrounding compressed region 50 of the rim or frame 54, with the cover panel 46 securely attached thereto has been found to be adequate to hold the plate or panel 22 in the cavity under anticipated conditions and activities. The cover panel 46 will preferably be tightly and securely joined to the rim or frame 54 around substantially all of the periphery of the cavity 56 , to plate or panel 22 in position . At least one edge of cover panel 46 is desirably detachable from the rim or frame 54 of panel 58 (or entirely removable ) to allow access to the armor plate or panel 22 . For this purpose, the peripheral rim or frame 54 about the cavity 56 and the perimeter of the inside cover panel can include suitable fasteners . Here, cover panel 46 will be covered with a loop pile fabric layer 52 as des cribed above, and thus the rim or frame 54 about the plate receiving cavity 56 can include strips or tabs 60 of hook fastener component as shown, as a non-limiting example .

[ 0054] It is contemplated that front panel 58 ( as well as the companion rear panel ) will be of unitary foam construction such that a center region 68 will be integral with rim or f rame 54 and formed f rom the same foam panel or bun . Center region 68 i s preferably compres sed and heated during the molding proces s of panel 58 also to be semi-rigid or rigid, and thus stif fened, which is advantageous for shape retention of that panel and particularly cohesion with the immediately adjacent rim or frame 54 . Referring more particularly to FIG . 18 , it can be observed that center region 68 is significantly les s thick than the surrounding rim or frame 54 , which is a result of this additional compres sion , forms and bounds the plate carrying cavity 56 , which will des irably have a thicknes s or extent in direction DI that will be about equal to the thicknes s of the armor plate or panel 22 . When armor plate or panel 22 i s snugly received within cavity 56, together with stif fened rim or frame 54 , and covered by cover panel 46 secured to frame 54, particularly when stiffened by protuberances 34 on the opposite side, the resulting assembly will have adequate strength and integrity for securely supporting and holding the armor plate or panel 22, even during running, jumping, falling, fighting, and other strenuous movements .

[0055] As an optional aspect, it may be desired for concealing carrier 24 beneath clothing, and the compressed thickness of center region 68 will contribute to a reduced overall profile of panel 58 when viewed from the side. To further reduce profile, panel 58 can have an integrated outer perimeter 64 thereabout having a tapered shape that extends convergingly toward the lateral side. This outer perimeter 64 can be formed in a unitary manner with the other aspects of panel 58, the tapered profile being achieved with compressed regions

50 which will also add rigidity and stiffness. A region of the outer perimeter 64 between compressed regions 50 can have an uncompressed state, or a compressed state less than that of compressed regions 50. Additionally, with unitary molding, compression of the outer perimeter

64 can contribute to the stiffening of rim or frame 54, compared to if perimeter 64 were not significantly compressively formed. Here, it should be noted that with some polymer foams, namely, varieties of EVA and additives, the closed cell wall structure of all or portions of compressed regions 50 of panel 58 can essentially be fused together forming a rigid or semi rigid and thus stiffened structure. In this latter regard, it is anticipated that a surface and/or absorptive coating or coatings can be applied to further stiffen rim or frame 54.

[0056] The outer surface of front panel 58 can likewise comprise a loop pile fabric layer 52, and can be slitted or slotted as illustrated by the pattern of slits 62, to enable attachment of accessories, such as MOLLE accessories and pouches. It is contemplated that the armor plate carrying panel will be of unitary construction made from a single sheet or bun of suitable foam such as EVA, of a suitable thickness, heat and/or pressure formed to create the plate cavity and stiffened rim region. The outer surface will likewise be semi- rigidly or rigidly compressed to provide a suitable load carrying capability. By optionally covering the outer surface with loop pile fabric, pouches and accessories, unit and agency indicia, cell tags, etc., bearing appropriated hook surface can be securely affixed. Also optionally, the outer surface can comprise, e.g., attached, adhered, or fused thereto, a layer of another stiffening material such as a panel of ultrahigh molecular weight polyethylene material, which can be optionally slitted in the illustrated manner for attachment of articles such as pouches and the like, if desired or required for a particular application.

[0057] In light of all the foregoing, it should thus be apparent to those skilled in the art that there has been shown and described a ballistic plate or panel carrier, system, and method for use or incorporation with an armor plate or panel. However, it should also be apparent that, within the principles and scope of the invention, many changes are possible and contemplated, including in the details , material s , and arrangements of parts which have been described and illustrated to explain the nature of the invention . Thus , while the foregoing description and discussion addres ses certain preferred embodiments or elements of the invention, it should further be understood that concepts of the invention, as based upon the foregoing des cription and di scus sion, may be readily incorporated into or employed in other embodiments and constructions without departing from the s cope of the invention . Accordingly, the following claims are intended to protect the invention broadly as well as in the specific form shown, and all changes , modifications , variations , and other uses and applications which do not depart f rom the spirit and scope of the invention are deemed to be covered by the invention, which is limited only by the claims which follow .

Claims

Claims What i s claimed is :

1 . A ballistic plate carrier, comprising at least one unitary panel of compres sed foam having an integral stif fened perimeter rim or frame bounding and defining a cavity for receiving and holding an armor plate or panel .

2 . The ballistic plate carrier of claim 1 , compri sing an outer surface having a pattern of slits or openings therethrough for attaching articles thereto .

3 . The ballistic carrier of claim 1 , compri sing an outer surface of a component of a hook and loop fastening system for attaching articles thereto .

4 . The ballistic plate carrier of claim 1 , compri sing a cover panel attached to the stiffened perimeter rim or frame in covering relation to the cavity, and comprising an outwardly facing surface having features cooperatively engageable with mating features on a spacer panel for attaching the spacer panel thereto .

5 . The ballistic plate carrier of claim 1 , wherein the stif fened perimeter rim or frame i s composed of the foam compres sed to a first extent, and the panel further comprises an outer perimeter integrally formed with the stif fened perimeter rim or frame composed of the foam in an uncompres sed state or compres sed to a second extent les s than the first extent .

6 . The ballistic carrier of claim 1 , wherein the foam comprises EVA .

7 . The ballistic carrier of claim 1 , compri sing a cover panel attached to the stiffened perimeter rim or frame in covering relation to the cavity, the cover panel having an outwardly facing surface comprising outwardly extending protuberances arranged in a pattern and cooperatively retained in a like pattern of concavities in a spacer panel , attaching the spacer panel to the outwardly facing surface .

8 . The ballistic carrier of claim 1 , wherein the spacer panel has an opposite surface comprising a pattern of outwardly extending protuberances cooperatively retained in a like pattern of concavities in a second spacer panel , attaching the second spacer panel to the cover panel .

9 . The ballistic carrier of claim 7 , wherein each of the outwardly extending protuberances of the spacer panel is surrounded by a perimeter of a stif fened compres sed foam .

10 . A carrier for an armor plate having a predetermined plate thicknes s , the carrier compris ing at least one unitary panel of polymer foam, the panel compri sing a center region facing in a first direction and bounded by a perimeter integral therewith, the perimeter having an integral inwardly located rim that extends about and laterally joins the center region, the rim extending in the first direction from the center region to define a cavity receiving the armor plate and having an extent in the first direction about egual to the thickness of the armor plate.

11. The carrier of claim 10, wherein the foam comprising the rim is in a compressed state.

12. The carrier of claim 11, wherein a portion of the perimeter about the rim is uncompressed or has a compressed state less than the compressed state of the rim .

13. The carrier of claim 11, wherein the foam comprising the center region is in a compressed state.

14. The carrier of claim 13, wherein the compressed state is less than a compressed state of the perimeter .

15. The carrier of claim 10, wherein the foam comprises EVA.

16. The carrier of claim 10, wherein the center region comprises a pattern of slits therethrough.

17. The carrier of claim 16, wherein the pattern is a MOLLE PALS pattern.

18 . The carrier of claim 10 , compris ing a cover panel attached to the perimeter in covering relation to the armor plate .

19 . The carrier of claim 18 , wherein the cover panel comprises an outwardly facing surface compri sing outwardly extending protuberances arranged in a pattern and cooperatively retained in a like pattern of concavities in a spacer panel , attaching the spacer panel to the outwardly facing surface .

20 . The carrier of claim 19 , wherein the spacer panel has an opposite surface comprising a pattern of outwardly extending protuberances cooperatively retained in a like pattern of concavities in a second spacer panel, attaching the second spacer panel to the cover panel .