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Patent 2289466 Summary

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(12) Patent: (11) CA 2289466
(54) English Title: SPECIALLY SHAPED MULTILAYER ARMOUR
(54) French Title: BLINDAGE MULTICOUCHE SPECIALEMENT FORME
Status: Deemed expired
Bibliographic Data
(51) International Patent Classification (IPC):
  • F41H 1/02 (2006.01)
  • A41D 31/00 (2006.01)
(72) Inventors :
  • MOUREAUX, BEATRICE (France)
  • PFISTER, FRIEDRICH V. (Switzerland)
  • VAN ZIJL, NICOLAS A. (Switzerland)
(73) Owners :
  • E.I. DU PONT DE NEMOURS AND COMPANY (United States of America)
(71) Applicants :
  • E.I. DU PONT DE NEMOURS AND COMPANY (United States of America)
(74) Agent: BENNETT JONES LLP
(74) Associate agent:
(45) Issued: 2006-09-19
(86) PCT Filing Date: 1998-07-14
(87) Open to Public Inspection: 1999-01-28
Examination requested: 2003-01-24
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US1998/014471
(87) International Publication Number: WO1999/004217
(85) National Entry: 1999-11-12

(30) Application Priority Data:
Application No. Country/Territory Date
08/892,584 United States of America 1997-07-14

Abstracts

English Abstract



Armour, in particular body
armour for female wearers is
made of multiple layers (30) of
penetration-resistant material for
example madc of polyaramid fibers,
specially shaped to fit over a shaped
area to be protected, e.g. the bust
of a female wearer. The armour's
shaped part is held in shape by a
series of darts (37) in successive
layers (30) of the material. Each
dart in a material layer comprises
a generally V-shaped section (35)
whose edges (37) are joined to form
the dart. The V-shaped section (35)
of the material is folded on itself
to form a pleat (40) which is folded
over to one side of the dart (37) to
form an added thickness overlaying
or underlying an adjacent part of
the material (30). The darts (37)
are angularly offset from one another
with the pleats (40) oriented in
directions so that the added thickness
is distributed substantially evenly,
thereby avoiding bulges or stiffness
and improving the wearing comfort.


French Abstract

La présente invention concerne un blindage, et notamment un vêtement pare-balles pour dames, fait de plusieurs couches (30) d'un matériau résistant à la pénétration, tel que des fibres polyaramides. Ce vêtement pare-balles présente une forme adaptée à la zone à protéger qui peut être notamment le buste d'une dame. La partie formée du blindage est maintenue en forme par une série de pinces (37) réalisées dans des couches successives (30) du matériau. Chaque pince d'une couche de matériau est constituée d'une partie généralement en V (35) dont les bords (37) se réunissent pour former la pince. La partie de matériau en V (35) est repliée sur elle-même de façon à constituer un plissé (40) qui vient se replier d'un côté de la pince (37) créant ainsi une surépaisseur par-dessus ou par-dessous la partie de matériau adjacente (30). Les pinces (37) présentent entre elles un décalage angulaire, les plissés (40) étant orientés selon des axes tels que la surépaisseur se répartit de façon sensiblement égale, ce qui permet d'éviter les renflements ou la rigidité, et ce qui permet d'améliorer le confort de l'utilisatrice.

Claims

Note: Claims are shown in the official language in which they were submitted.



CLAIMS

1. Armor made of multiple layers of flexible relatively inelastic penetration-
resistant
material shaped to fit over a shaped area to be protected, wherein the layers
are
held by a plurality of darts in successive layers of the material, each of
said layers
of material having et least one dart and each dart in a layer comprising a
generally
V-shaped section where edges era joined to form the dart, with the V-shaped
section folded on itself and folded over to one side to form an added
thickness
overlaying err underlying an adjacent part of the layer, the darts in said
multiple
layers being angularly offset from one another with the folded V-shaped
sections
oriented so that raid added thickness is distributed substantially evenly
around said
shaped area et least one of the layers of penetration-resistant material
comprising
a fabric bonded to err coated with a reinforcing continuum which extends over
a
selected arcs to be protected of said at least one layer, wish the exception
of the or
each folded-over V-shaped section forming the or each dart, said folded-over V-

shaped section consisting of fabric only.

2. Multilayer shaped armor according to claim 1 in which the folded V-shaped
sections are oriented in different directions.

3. Multilayer shaped armor according to clam a in which pairs of the layers of
material have dams at the same angular location with their folded V-shaped
parts
oriented in opposite directions so they do net overlay one another.

4. Multilayer shaped armor according to claim 3 in which the layers forming
said
pairs with darts at the same angular location are alternate layers.

5. Multilayer shaped armor according to claim 1 in which the darts extend
radially
from at least one point of convergence.

6. Multilayer shaped armor according to claim 5 in which the darts are
angularly
staggered from one another around s point of convergence by an angle which is
equal to or greater than the angle of the V-shaped sections.

7. Multilayer shaped armor according to claim 1 which is body armor comprising
at
least one part shaped to fit over a shaped part of the body.

18


8. Multilayer shaped armor according to claim 7 which is shaped to fit over
the bust
of a female wearer, having two laterally-spaced internally concave recessed
parts
corresponding to the bust, in which the darts are angularly offset around each
of
the two laterally-spaced recessed parts about which said added thickness is
distributed substantially evenly.

9. Multilayer shaped armor according to claim 8 is which said two laterally-
spaced
concave recessed parts corresponding to the bust are formed by darts around
the
upper, lower and outer edges of the recessed parts, defining a continuous
shaped
bust for receiving the two breasts.

10. Multilayer shaped armor according to claim 8 or 9 in which the darts
extend
radially from two laterally-spaced paints of convergence corresponding to the
centers of said recessed parts, the darts extending above and below the two
points
of convergence over an overall angle of at least about 180 degrees.

11. Multilayer shape armor according to claim 1, in which the V-shaped
sections
each make an angle of 10 to 40 degrees.

12. Multilayer shaped armor according to claim 1 comprising darts in at least
three
angularly offset positions about a point of convergence.

13. Multilayer shaped armor according to claim 12 comprising darts in at least
six
angularly offset positions about a point of convergence.

14. Multilayer shaped armor according to claim 1 in which the layers of
penetration-
resistant material comprise polyaramid fibers.

15. Multilayer shaped armor according to claim 1 in which there are
discontinuities in
the reinforcing continuum in the area of the folded oven darts, said
discontinuities
being covered by the folded over layers of the fabric forming the darts, the
angular
offsetting of said darts distributing the darts and said discontinuities in
the
reinforcing continuum of the different layers to avoid bulges and excessive
stiffness.

16. Multilayer shaped armor according to claim 1 in which said reinforcing
continuum
is a polymeric film or coating layer, a metal foil or a sheet of rubber or
elastomer.

19



17. Multilayer shaped armor according to claim 1 in which at least two
successive
layers of penetration-resistant material are glued or bonded together as a
sandwich.

18. A method of manufacturing multilayer shaped armor as defined in claim 1,
comprising:
providing multiple layers of flexible relatively inelastic penetration-
resistant
material to be assembled into the shaped armor, each layer having fold lines
defining at least one dart comprising a generally V-shaped section of the
material,
the darts of the different layers being angularly offset from one another
around at
least one point of convergence, at least one of the layers of penetration-
resistant
material comprising a fabric bonded to or coated with a reinforcing continuum
which extends over a selected area to be protected of said at least one layer
with
the exception of the or each folded-over V-shaped section forming the err each
dart,
said folded-over V-shaped section consisting of fabric only;
- joining the edges of the V-shaped sections to form the dart(s) in each
layer, the
layers with formed darts all having substantially the same peripheral shape
for
assembly into the shaped armor;
- assembling the multiple layers to form the shaped part, with darts of
different
layers angularly offset to one another and with the V-shaped sections of
fabric
folded in directions to distribute the added thickness substantially evenly;
and
- attaching the shaped multiple layers to form the armor.

19. The method according to claim 18 in which pairs of the layers of material
have
darts at the same angular location, the V-shaved sections of these layers
being
folded in apposite directions so they do not overlay one another.

20. The method according to claim 19 in which the pairs of layers with darts
at the
same angular location are assembled in alternate layers.

21. The method according to claim 18 in which the reinforcing continuum is
applied
to the fabric, with the application of bast and pressure, before folding the
darts.

22. The method according to claim 18 in which the reinforcing continuum is
applied
to the fabric after folding of the dart(s).



23. The method of claim 18 ins which a peripheral edge part of the fabric is
free from
the reinforcing continuum, and the successive layers are joined by around
said peripheral edge part of the fabric.

24. The method according to claim 18, 19 or 20 in which the edges of the V-
shaped
sections are joined to form the darts by sewing, stapling, riveting or gluing.

21


Description

Note: Descriptions are shown in the official language in which they were submitted.



CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
TITLE
SPECIALLY SHAPED MULTILAYER ARMOUR
Field of the Invention
The invention relates to armour made of multiple layers of penetration-
resistant
material, and is particularly concerned with body armour comprising a part
specially shaped to fit over a curved area of the body such as female bust, as
well
as its method of manufacture.
Background Art
It is known to use high tenacity fibers such as polyaramid fibers in
multilayer
structures to provide ballistic protection in body armour. Bullet resistant
vests of
multilayer structure have proven very satisfactory as body armour for men and
women, but difficulties have been encountered in improving comfort for female
wearers by shaping the armour to adapt to the female body.
Wearer comfort and the effectiveness of the armour to prevent injury are
closely
related. Depending on the protection Level and the fabric type, about 10 to 50
layers
of fabric are used. This produces a somewhat stiff structure that does not
readily
adapt to pronounced body contours, particularly over the female breast region.
If
the armour does not lie in snug contact with the wearer's body, shock
transmission
becomes uneven and the body armour does not perform as it should. The body
armour's shaped areas are particularly liable to damage by shots at a glancing
angle
of incidence. Moreover, female breasts are specially liable to traumatic shock
injury.
Various proposals for multilayer body armour specially shaped to protect
shaped
areas of the body such as women's breasts have already been made. But making
multilayer armour in special shapes is rendered difficult due to the fact that
the
layers of penetration resistant material are flexible but relatively
inelastic.
Problems have therefore been encountered.
Contouring a front armour panel by joining cut panels of the fabric with
overlapping seams using a special stitching pattern was proposed in U.S.
Patent
4,183,097. However, if the overlapping seams are not large enough, angle shots


CA 02289466 1999-11-12
WO 99104217 PCT/US98/14471
can penetrate the vest, whereas increasing the size of the overlapping seams
creates
a hard rim in a region where women need as much flexibility as possible.
U.S. Patent 4,578,821 proposed inserting a flexible multilayer ballistic panel
into a
front pocket of a carrier garment. This panel is held by a Velcro hook-and-
pile
fastener enabling adjustment to different bust sizes, but the protected area
is
limited and the Velcro fastener cannot ensure good ballistic performance. This
system is hence suitable for low protection levels only.
U.K. Patent Specification 2,231,481 proposed a vest whose inner part has a
foamed
plastic material shaped to fit the breast. A shaped stiff or semi-stiff shock-
absorbing sheet is added to the plastic layers and finally a multilayer
ballistic pack
is inserted, the entire arrangement being enclosed in a bag. With this design,
the
ballistic pack adapts to the shape by folding about a horizontal line. This
can only
be achieved by leaving large openings at the left and right sides of the
chest, so
protection in these side areas will be questionable. Moreover, the vest will
be
relatively heavy, stiff and uncomfortable to wear.
Another proposal made in U.S. Patent 5,020,157 was the use of rigid,
inflexible
cups made of high strength laminated polyethylene material which are worn over
a
woman's breast and under a conventional soft body vest to protect from
injuries
resulting from ballistic impact. The impact-generated pressure will
nevertheless be
transmitted to the cup's rim which could cause injury. In addition, the stiff
cups
will be uncomfortable to wear.
Shaping body armour by molding layers of aramid fabric in a PVC shell with the
aid of pressure at 400-800 kPa and heat at 180-300°C has been proposed
in DE-A-
4423194 and in WO 96/01405. However aramid fibers have an elongation up to
4% which can lead to damage in molding. Moreover, shaping the layers stretches
the fabric which would increase the gaps between the fibers and reduce
ballistic
efficiency. Also, this molding in a PVC shell makes the armour relatively
stiff.
The above-discussed prior proposals for specially shaped multilayer body
armour
have therefore failed to produce a lightweight multiIayer structure which fits
to the
body comfortably while providing excellent ballistic protection and which can
be
manufactured using available equipment operating at ambient temperature.
2
,,r


CA 02289466 1999-11-12
WO 99104217 PCT/US98/1447I
Summary of the Invention
An object of the invention is to obviate the above-mentioned problems of the
prior
art and provide multilayer armour shaped specially to fit over a shaped area,
which
combines reliable ballistic protection and high comfort.
S It is also an object of the invention to provide a simple method for shaping
such
multilayer armour which does not require performance-reducing heat treatment.
These objects are achieved by a novel dart folding technique for building up
layers
shaped by more-or-less uniformly distributed darts in rotating (angularly
offset)
sequence, as described below.
The invention proposes armour, in particular body armour, which is made of
multiple layers of flexible relatively inelastic penetration-resistant
material
specially shaped to fit over a shaped area to be protected.
By "specially shaped" is meant out-of plane parts of a three dimensional
structure
such as a garment.
According to the invention, the layers are held in shape by a plurality of
darts in
successive layers of the material. Each dart in a layer comprises a generally
V-
shaped section whose edges are joined to form the dart, with the V-shaped
section
folded on itself and folded over to one side of the dart to form an added
thickness
overlaying or underlying an adjacent part of the layer.
Also according to the invention, the darts are angularly offset from one
another
with the folded V-shaped sections oriented so that said added thickness is
distributed substantially evenly.
The resulting specially shaped lightweight armour is comfortable to wear
without
compromising the ballistic protection. The absence of cuts in the darts means
that
no lines of weakness are created that could allow penetration of projectiles.
The additional thickness of the folded parts of the V-shaped sections, which
is
distributed substantially evenly around the shaped area, provides extra
protective
layers over these shaped parts where projectiles are more likely to hit at a
glancing
angle and cause injury. However, the excellent ballistic protection does not
result


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
from these thickened parts, but is due mainly to the fact that the design
produces no
weaknesses that would reduce the ballistic effectiveness of the main layers.
The shape produced this way enables a better fit to the body contour while
imposing no restrictions on the extent of the protection provided by the
multilayer
structure. Due to their even distribution, the folded-over parts do not
adversely
ai~ect the flexibility and comfort of the armour. Moreover, the extra weight
of the
folded parts is insignificant. The body armour thus remains lightweight and
comfortable to wear leading to enhanced protection against injury.
The folded V-shaped sections of material form pleats which can all be oriented
in
the same direction, i.e. folded to the same side. However, usually these
pleats are
oriented in different directions. In a preferred embodiment, pairs of the
layers of
material have darts at the same angular location, with their pleats oriented
in
opposite directions so they do not overlay one another. The layers of material
forming these pairs can be adjacent to one another, but are advantageously
alternate layers as this improves flexibility and comfort by avoiding jamming
of
the pleats that could lead to stiffness or bulges.
Angular gaps can be left between the darts where convenient so that
corresponding
angular gaps may be left between some or all of the angularly adjacent pleats
of
different layers. This can contribute to the flexibility of the shaped part,
without
reducing security. What is important is to angularly distribute the pleats in
such a
way that the extra thickness is evenly distributed, avoiding bulges or
stiffness that
could reduce comfort and safety.
In principle, the darts extend generally radially from at least one point or
area of
convergence. Usually, the darts are angularly staggered from one another
around
the point or area of convergence by an angle which is equal to or greater than
the
angle of the V-shaped sections before folding. This avoids unwanted
overlapping
of the edges of the folded pleats.
Each layer of material normally has one dart, or in the case of women's
specially-
shaped body armour, two darts arranged symmetrically on either side of the two
points or areas of convergence. It is however possible for each layer of
material to
have more darts, for example four darts on either side of and extending above
and
below the two points or areas of convergence.
4
,.,


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
A main application of the specially shaped armour of the invention is as body
armour comprising at least one part specially shaped to fit over a shaped part
of the
body such as a torso, a neck and/or collar area, a shoulder area, or an elbow,
knee
or other joint area. The body armour can be soft or relatively stiff or hard
armour in
the form of vests or arm or leg protection and similar apparel.
A particular application is as body armour specially shaped to fit over the
bust of a
female wearer, having two laterally-spaced internally concave recessed parts
corresponding to the bust. In this embodiment, the darts are angularly offset
around
each of the two laterally-spaced recessed parts about which said added
thickness is
distributed substantially evenly.
In this women's specially-shaped body armour, the two laterally-spaced concave
recessed parts corresponding to the bust are usually formed by darts around
the
upper, lower and outer edges of the recessed parts, defining a continuously
shaped
bust ("mono-cup") receiving the two breasts.
1 S Alternatively, two breast cups can be provided, but this is not necessary.
In this
case, it would be possible to provide enough darts angularly staggered from
one
another so that the pleats cover substantially an entire circular area around
each
laterally-spaced recessed part.
The darts of this women's specially-shaped body armour extend radially from
two
laterally-spaced points or areas of convergence corresponding to the centers
of the
recessed parts, above and below the two points or areas of convergence, and
preferably extending over an angle of at least about 180 degrees.
Body armour according to the invention in the form of a vest typically has
front
and rear panels permanently joined together or releasably secured for example
by
Velcro fasteners, the front panel for example being shaped to fit over the
bust of a
female wearer by the described novel arrangement of darts. The invention
concerns
both the entire vest and the front panel, which may be sold separately.
The angle of the V-shaped sections of flexible material depends on the degree
of
curvature required for any particular application. For most applications, the
V-
shaped sections will each make an angle of about 10 to 40 degrees.


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
For women's specially-shaped body armour, an angle of about 15 to 30 degrees,
conveniently 20 to 25 degrees, is preferred as this provides the recessed
parts with
a shape that is suitable for most female breasts.
V-shaped sections having an angle less than 10° are possible for neck
shapes, for
example. When small angles are employed, special care will be taken to
properly
fold and position the relatively narrow pleats (half the angle of the V) to
avoid
creating bulges.
V-shaped sections having an angle more than 40° may be needed for elbow
shapes,
for example.
Usually, the assembled layers of material have at least three dart locations
about
each of the two laterally-spaced recessed parts. However, for some
applications,
two dart locations may suffice, wherein the pleats in different layers at each
dart
location are folded in opposite directions to spread the extra thickness of
the pleats
as much as possible.
An arrangement with six dart locations about each of the two laterally-spaced
recessed parts has proven very satisfactory for women's vests. The maximum
number of dart locations will be determined by the envisaged application and
by
manufacturing considerations.
The shape produced by the special arrangement of darts according to the
invention
can be symmetrical or asymmetrical about one or more points or areas of
convergence. An asymmetric shape can be provided by an asymmetric distribution
of the dart locations, and/or could involve using V-shaped sections {in the
same or
different layers) having different angles, or by asymmetric folding of the
pleats.
As discussed in detail below, the penetration-resistant material is
advantageously
made of polyaramid fibers and, to improve the penetration resistance and
reduce
backface deformation, one or more of the layers (typically only the back
andlor
front layer) may be bonded to a polymer. It is also possible for the body
armour to
include one or more front pockets for receiving ballistic panels, or to be
associated
with other protective layers, to improve the ballistic performance and/or
reduce
back-face deformation where needed. For example, a rigid or semi-rigid front
layer
could be fitted.
b
r ... i ,


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
The Penetration-Resistant Material
Various types of fibers can be applied in the penetration-resistant material
used in
the multilayer body armour according to the invention such as fibers
comprising a
polyolefin, e.g. polyethylene, polyimide, polyester or polyaramid usually
having a
tenacity at least 900 MPa according to ASTM D-885, which equals approximately
7 grams/denier. To provide superior penetration-resistance, preferably the
tenacity
of the fibers is at least 2000 MPa according to ASTM D-885.
Polyaramid fibers are preferred because they can have the required tenacity,
even
surpassing the preferred 2000 MPa limit and, in addition have good chemical
resistance.
The fibers can be present in the material in many forms, preferably as a
knitted
fabric, a woven fabric, as a uniweave structure, unidirectional structure or
muiti-
directional sheet {e.g. having fibers crossing over at an angle between 20 and
90
degrees) or as a non-woven (e.g. felt) layer. Film-like sheets of penetration-
resistant material are also possible.
Far reasons of manufacturing efficiency, availability and geometric strength
(well
defined stable structure) a woven fabric of high tenacity fibers is preferred.
The
fabric construction can suitably be a plain weave made up typically from 42 x
42
or 28 x 28 ends/cm, or 14 x 14 or 6.7 x 6.7 ends/cm, although other woven
structures can equally well be used, depending on the use requirements.
The specific weight of such fabrics is generally from 0.02 to 0.5 kg/m2,
preferably
from 0.05 to 0.5 kg/m2 and more preferably from 0.08 to 0.3 kg/m2 in order to
obtain a balance between penetration resistance and specific weight.
If the specific weight below is 0.02 kg/m2 the ballistic resistance of the
fabric, even
when made from polyaramid fibers, is generally unacceptable whereas if the
specific weight is above 0.5 kglm2, the use of a plurality of fabric layers
becomes
impractical, due to weight constraints.
The fibers used have a suitable denier number (defined as the weight in grams
of
9000 meters of yarn) from 0.1 to 3500, and suitably from 10 to 3500, depending
on
the required fabric weight/ballistic performance ratio. A fiber with a denier
from
1000 to 3000 is used for less demanding applications, while for high
performance/low specific weight applications, a fiber with a denier from 1 to
1000,
and more particular from 50 to 1000 is preferred.
7


CA 02289466 2005-09-21
In many cases, a denier range from I to 3000 for the fibers is excellent.
The fbers can be present in uncoated form, or coated or otherwise pretreated
(e.g.
pre-stretched ar meat-Heated). In case polyaratrtid fiber is used, it is
generally not
necessary to coat or otherwise pre-treat the, fiber other than arranging it in
the
appropriate woven or non-woven laye , however, in Borne cases a coating might
be
applied to t~.e fibers for e. temple in order to increase their bonding to a
polymeric
continuum.
To improve the penetration resistance and reduce backface deformation, one or
more ofthe layers of the above-described fabric, typically only the back
andlor
fxont layer, may be bonded to s polymer layer or impregnated with a polymer in
order to make use of both the properties of the Ethers and the polymeric
continuum.
Such a composite described in 1?P 0 862 722 B 1 published on
January 30, 2002 includes a layer carnposed
of fibers having a tenacity of at feast 900 Mfa (7 gldenier} according to ASTM
D-
885 bonded to a polymeric continuum having a flexural rnodulus of 42 to 1,000
MPa according to ASTM D-790, a tensile strength at break of at Least 10 MPa
according to ASTM D-638 and an elongation to break of at least 100 % according
to ASTM D-538.
In such composites, preferably a thermoplastic polymer is used. Suitable
polymers
include specifc polyethylenes, polyimide, golytther etherketonc, ionomeric
resins,
phenolic-modified resins, poiyescers.
Preferably the thermoplastic polymer is an ionomcric resin, more preferably an
ionomeric resin containing rations selected from the group consisting of
Lithium,
Sodium and Zinc, in particular from 0.1 to 3°/p by weight of such
eations.
Altezaatively, the thermoplastic polymer is a phenolic modified resin, in
particular
a phenolic-polyvinylbutyral resin.
The poiymedc ovntinuum should preferably have a tensile strength at break of
at
least 20 MPa and an elongation to break of at least 200°!u, more
preferably aE least
300%, bout according to ASTM D-638.
The flexibility of the polymeric layer is an important factor for both the
penetratiott~resistance of the composite an;d the wearing comfort of body
armour
incorporating one of more of the composite sheets.


CA 02289466 2005-03-21
'Ihe flexural modulus of the polymer is preferably between ~2 and 1000 MPa,
according to ASTM D-790, in particular between 50 and 804 Ml'a.
A flexural modulus higher than 100D MPa indicates a polymer that is too Stiff
to
effectively withstand puncture or be worn comfortably as body armour, whereas
a
flexural modulus of less than 4Z MPa u~diestes a material which is too
flexible to'
provide any effeciive stiffness to the eotnposition for anti-stab purposes,
Ari
additiazlal advantage of body armow comprising; such a polymer is the reduced
backfact deformation attained when a bullet hiu the body armour,
Another significant property of the polymer layer is the density thereof, in
particular in view of a desirable low specific weight (expressed in kg/m2
composite) for ease o_ f wear of body armour and for ease of handling and
efficient
engin~ring with the aim of weight reduction.
Preferably the density of the layer comprising the polymeric compound is below
2,504 kg/m3, and in particular below 1,500 kg/rn3; ionomeric polymer layers
are
particularly pre~etred in this respect if their density is less than 1,004
kglm3.
The polymeric continuum can be suitably applied as a layer which can be bonded
at one side or at both sides to a fiber-containing .layer, depending vn the
application, and in mare practical terms, on the availability of the
appropriate
manufacturing process. In a preferred embodiment, the fiber-containing Iayer
is
embedded in the polymeric continuum in order to immobilize the fibers,
resulting
in an extremely strong composition. The polymer and fiber layers can be bonded
in
a batch or continuous process, by any means known in the art, such as
calendering,
extrusion coating, gluing, impregnation, thermally bonding, other forms of
laminating Iayexs of two different materials, or even in-situ polymerization
thus
forming a polymer continuum with the fibers. '
Although the continuum has been described a:~ a polymeric continuum, it is
understood that such continuum serves as a reinforcement and can be a
polymeric film or coating layer, a metal foil or a sheet of rubber or
elastomer.
A preferred method of bonding a fiber/polymer .composite layer is thermal
bonding
34 such as molding in the form of a batch process, or in the form of a
continuous
process, in particular by means of a belt press or calender.
When layers of such composite fiberlpolymer are included in the shaped body
armour accdrding to the invention, such sheets caa he shaped using darts and
folded pleats as described herein; there is no need for the application of
heat dutxng
this shaping process. However, it would be possible to include one or more
layers
of a fiberlpolymer composite pre~haped by molding.
9


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
Method of Manufacture
According to another aspect of the invention, a method of manufacturing
multilayer specially-shaped armour begins by providing multiple layers of
flexible
relatively inelastic penetration-resistant material to be assembled into the
shaped
armour. Each layer has fold lines defining at least one dart comprising a
generally
V-shaped section of the material, the darts of the different layers being
angularly
offset from one another around at least one point or area of convergence.
Firstly, the edges of the V-shaped sections are joined to form the darts in
each
layer, the layers with formed darts all having substantially the same
peripheral
shape for assembly into the body armour.
Usually, all of these layers are identical in shape and size. However,
sometimes it
may be convenient to arrange the layers with slightly different shapes or
sizes, for
example in order to accommodate for progressive shaping as the layers build
up.
Then the multiple layers are assembled to form the shaped part with the darts
of
different layers angularly offset to one another and with the V-shaped
sections of
material folded in directions to distribute the added thickness substantially
evenly
around the shaped part.
This forming operation is carned out on a suitable support. To form a vest for
example, the layers can be built up on a bust.
Lastly, the thus-shaped multiple layers are assembled to form the armour.
The gradual build-up of angularly offset ("rotated") darts with folded pleats
in the
progressive layers (from layer number 2) can be referred to as progressive
contouring, as the contouring progresses during the subsequent layers up to
30, 50
or even more layers.
in this way, armour can be tailored by building it up in anatomically correct
fashion. Each single layer of relatively inelastic penetration-resistant
material can
be shaped by folding, joining the dart, folding the pleat and building up the
successive layers.
....... . . r .. . i


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
On the one hand, it is possible to tailor garments such as vests to the
measurements
of individual wearers. On the other hand, shaped garments such as vests can be
made so they can be adapted to fit different wearers.
The folding and fastening technique does not require special equipment or
tools,
but can be handled by existing procedures of modern textile cutting
techniques.
An advantage of this assembly technique is that multilayer shapes can
conveniently
be made using relatively thin layers of the penetration-resistant material
built up to
a very large number of layers, say 50 layers or more. It is well known than
the
ballistic performance improves with the number of layers, even for the same
overall thickness.
Preferably pairs of the layers of material have darts at the same angular
location,
and the V-shaped parts of these layers are folded in opposite directions so
they do
not overlay one another, the pairs of layers with darts at the same angular
location
preferably being assembled in alternate layers.
By this novel technique of building thick protection layers, layers are gained
(at
overlaps where the pleats are folded over) that provide additional protection
against
ballistic impact, valuable especially at shaped areas where bullets or
fragments hit
at an angle (non-perpendicular impact).
The edges of the V-shaped sections can be sewed together to form the darts,
preferably using a polyarimid yarn. Alternatively, these edges could be joined
by
other means such as staples or rivets of polyaramid, or by gluing. The layers
of
impact-resistant material are conveniently joined by sewing.
When the layers of material are attached together, care is taken to maintain
the
shape and to avoid the formation of air pockets. The front panel of the body
armour
can be made by joining together two or more packs of layers of the penetration-

resistant material shaped by assembling layers with angularly offset darts as
just
described.
Brief Description of the Drawings
The invention will be further described by way of example with reference to
the
drawings, wherein:
11


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
Fig. 1 is a front perspective view of a bullet-resistant vest having a front
panel
specially shaped according to the invention for the vest to be worn by a
female;
Figs. 2-1 to 2-12 are schematic plan views each showing one half of one layer
of
material, the twelve layers of Figs. 2-1 to 2-12 being shown before assembly
of the
successive layers to form the shaped front panel of the bullet-resistant vest
of Fig.
1;
Fig. 3 illustrates the formation of a dart in one of these layers;
Figs. 4-1 to 4-4 illustrate folding of the darts of four successive layers
before (or
during) assembly of the layers;
Fig. 5 is a schematic plan view illustrating the angular distribution of the
folded
pleats; and
Fig. 6 is a schematic plan view illustrating how the back panel of the body
armour
of Fig. 1 may be assembled.
Detailed Description
Fig. 1 shows a lightweight bullet-resistant vest comprising a front panel 10,
which
is specially shaped to fit over the bust of a female wearer, and a back panel
20,
each made from an assembly of layers of penetration-resistant material. The
front
panel 10 has a top breast section 14 and a lower breast section 15 shaped to
form
inside two laterally-spaced internally concave recessed parts corresponding to
the
bust. The internal layers of penetration-resistant material making up the
front panel
10 are shaped by a series of anguiarly-offset darts, as will be described with
reference to Figs. 2 to 4.
As shown in Fig. 1, the front and back panels 10,20 of the vest are releasably
secured together by a series of Velcro fasteners, namely Velcro pile fasteners
11 at
the top sides of front panel 10 that cooperate with Velcro hook fasteners
carried by
shoulder straps 21 fitted to back panel 20, and Velcro pile fasteners 12 at
the
bottom sides of front panel I O that cooperate with Velcro hook fasteners
carried by
side straps 22 fitted to the lower part of back panel 20. These side straps 22
carry
an additional Velcro cross-piece 23 and, for added security, a belt 24 with
Velcro
fasteners is provided.
12
,,,


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
The layers of penetration-resistant material making up the front panel 10 are
enclosed between an outer cover sheet and a lining of non-penetration-
resistant
material. To conform this outer sheet to the shape of the front panel 10,
seams 17
which extend up to and over the level of the bust are provided. However, it is
emphasized that according to the invention the inside layers of penetration-
resistant
material have no cuts, but are assembled by a series of anguiarly-offset darts
having folded pleats, as described below with reference to Figs. 2 to 4.
If desired, the outside cover sheet can have a dart with a folded pleat, like
those of
the inside layers of penetration-resistant material.
Figs. 2-1 to 2-I2 each show the right-hand half of one of twelve layers 30 of
penetration-resistant material before assembly of the successive layers to
form the
shaped front panel 10 of the bullet-resistant vest of Fig. 1. The other half
of each
layer 30 is a mirror image about the line X. The lines shown inside the
perimeter of
each layer 30 are only indications serving to locate the folding and joining
lines.
Each layer 30 has two side extensions 31 (corresponding to the parts of the
front
panel 10 that fit around the wearer's waist), side recesses 32 (corresponding
to the
parts of the front panel I 0 that fit under the wearer's arms), rounded upper
parts 33
(corresponding to the parts of the front panel 10 that cover the wearer's
upper
breast, i.e. where the fasteners I 1 are attached), and a concave top 34
(corresponding to the part of the front panel 10 that fits around the wearer's
neck).
Each half of the layer 30 also has a V-shaped section 35 having a central fold
line
36 about which it can be folded and joined to form a dart as illustrated in
Fig. 3.
This Figure shows a layer corresponding to that of Fig. 2-1 or Fig. 2-3. As
shown,
the layer 30 is folded about a vertical fold line 38 coincident with the fold
line 36,
whereupon the layer 30 can be joined by sewing or stapling along the lines 37
defining the V-shaped section 35, to form a dart along the joined lines 37,
leaving a
pleat 40 which consists of the V-shaped section 35 folded over on itself.
As shown for the layers 30 of Figs. 4-1 to 4-4, when two darts 37 are formed
in the
right and left parts of each layer 30, the outer perimeter of the layer 30
adopts a
shape which is essentially the same for all of the layers and corresponds to
the
peripheral shape of the front panel 10. The successive layers 30 can however
have
different sizes and shapes as a function of the shape to be built up.
13


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
By comparing Figs. 2-1 to 2-I2, it can be seen that the successive layers have
darts
37 which are angularly offset from one another around a point of convergence
39,
each sheet 30 having two laterally-spaced points of convergence 39
corresponding
to the centers of the recessed parts in the front panel 10 that are adapted to
receive
the wearer's breast. These points of convergence 39 are approximately at the
same
locations for all twelve layers 30. It is understood that the pointed ends of
the darts
37 could be distributed around an area of convergence, e.g. a circular area
that as a
result is not folded. Such area will be sufficiently large to avoid twisting
and
unwanted "doubling up" at a point of convergence.
I O Alternate pairs of the layers 30 of material - namely those of Figs. 2-1
and 2-3; 2-2
and 2-4; 2-5 and 2-7; 2-6 and 2-8; 2-9 and 2-11; 2-10 and 2-12 - are identical
so the
darts 37 of the layers of each pair are located at the same angular location.
The
darts 37 of the successive layers (Figs. 2-1, 2-2, 2-3 and so on) are
angularly offset
to one another. Those of Figs. 2-1, 2-2 and Figs. 2-3, 2-4 are at 180 degrees
to one
another; those of the other successive layers are at different angles
represented on
Figs. 2-5 to 2-12 by the fold lines 36. Generally, the darts 37 in the odd-
numbered
layers are located on the upper part and those in the even-numbered layers are
located on the lower part of its layer 30, except for the layer 30 of Fig. 2-
10 where
the dart is located in the middle.
In this given example, the angle of the V between the lines 37 forming each
dart is
about 22.5 degrees, so the six darts placed side by side would extend over 135
degrees. However, it can be seen that overall the darts 37 extend over an
angle of
about 195 degrees, starting at one extremity at the top from the darts 37 of
Figs. 2-
9 and 2-I 1, to the darts 37 of Figs. 2-2 and 2-4 at the other extremity at
the bottom,
there being a gap between the other darts 37 - see Fig. S.
As illustrated in Figs. 4-1 to 4-4, the pleats 40 associated with darts 37 are
folded
in alternate directions in order to achieve the best possible distribution of
their
extra thickness when the layers 30 are assembled. Each pleat 40 occupies 1/2
the
width of the V-shaped sections and these pleats 40 are selectively folded in
alternate directions.
In Fig. 4-1 the left pleat 40 in the top of the frst layer 30 is folded to the
right and
the right pleat 40 is folded to the left. Likewise, in Fig. 4-2, the left
pleat 40 in the
lower part of the second layer 30 is folded to the right and the right pleat
40 is
folded to the left.
I4


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
For the corresponding next two layers of Figs. 4-3 and 4-4, the folding of the
con esponding pleats 40 is inverted, i.e. for the third and fourth layers 30
the left
pleats 40 are folded to the left and the right pleats 40 are folded to the
right.
The same pattern of inverting the folding of the pleats 40 is followed in the
S subsequent groups of pairs of layers 30. The principle is that the pleats 40
in darts
37 located at the same location in alternating layers - like those in Figs. 2-
S and 2-7
and in Figs. 2-6 and 2-8 for example - will be folded in opposite directions
so that
when the layers 30 are assembled these pleats 40 will not overlay one another
(see
Fig. S). This folding of the pleats 40 can be done when the darts 37 are
formed, or
when the layers 30 are being assembled.
The layers 30 with their darts 37 are then assembled successively on a bust,
with
the pleats 40 of the successive layers folded as described above. Each layer
30 is
adjusted onto the next (or previous) one by means of needles. The same process
is
repeated for all twelve layers 30, laying the pleats 40 in the selected
directions on
1 S top of the layer 30, except for the last layer where the pleats can be
turned inside to
have a smooth outer surface.
The assembled and shaped layers 30 are held in clamps and sewed (or otherwise
secured together) around their periphery, taking care to maintain the shape
during
sewing and pressing out air to avoid the formation of air pockets. For this,
it is
preferable not to sew continuously around the periphery, but to sew peripheral
sections one at a time, starting at the rounded upper parts 33 and finishing
at the
lower corners. If desired, the part corresponding to the waist can be taken in
to
provide a better shape.
Thanks to the darts 37, the assembled layers 30 are shaped to form two
laterally-
2S spaced recessed parts in a mono-cup configuration adapted to fit over the
wearer's
breasts, and the pleats 40 in the various layers 30 are oriented in directions
so that
the added thickness is distributed substantially evenly around the shaped
parts,
avoiding any bulges or stiffness.
Fig. S schematically illustrates the angular distribution of the pleats 40 in
the
assembled pack. In this Figure the pleats 40 are identified by the number L1
to L12
of their respective layer 30 conesponding to Figs. 2-1 to 2-12. In this
example,
proceeding clockwise, the pleats L 11-L9, L3-L 1, L7-LS, L 12-L 10, L6-L8 and
L2-
L4 are arranged together in pairs folded in opposite directions about the
lines
forming their darts 37. The pleats L1-L7, LS-L12, L10-L6 and L8-L2 are all
IS


CA 02289466 1999-11-12
WO 99104217 PCT/US98/14471
angularly spaced apart from one another by expanses of the layer 30 that are
not
covered by pleats.
Due to the angular staggering of the darts 37 and the selective orientation of
the
pleats 40, no pleats in the pack overlap one another. Moreover, pleats 40
whose
external edges coincide angularly with one another - in this example L3 and L9
-
are separated by a non-pleated part of at least one intermediate layer 30 -
namely
layers L4-L8 - so there is no risk of interference between pleats 40 that
could cause
jamming or bulge formation.
In the final assembly, the pleats 40 are evenly distributed around the outer
parts of
the mono-cup recesses, providing two extra protective layers in this sensitive
zone
in the locations covered by the pleats 40.
If it is desired to have two extra protective areas over the uncovered areas
in Fig. 5,
this can be achieved simply by including extra layers in the pack with darts
at the
desired extra locations.
The front panel i 0 of Fig. 1 can be made by fitting together a chosen number
of
packs of the twelve layers 30 assembled as described, e.g, two packs making up
a
24-layer panel or three packs making up a 36-layer panel, and so on. It is
also
possible to make fractional assemblies, e.g. two and a half packs making up a
30-
layer panel.
Fig. 6 shows how layers of penetration-resistant material can be assembled to
form
the back panel 20 of Fig. 1. Here, layers 50 shaped to form the back panel 20
are
placed together, curved to the back's shape then sewn or otherwise attached
together. All layers 50 except the last five are sewed together around their
periphery at 51 and crosswise at 52. The last five layers 50 (which will be
those
closest the body} are sewed together only around the periphery at 51. Then the
packs are stitched together only in the top and side regions of the periphery
51.
The front and back panels 10,20 are then enclosed in their respective cover
layer
and lining, and the Velcro fasteners and straps fitted.
Example
The shaped front panel of a bullet-resistant vest was manufactured as
described
above with 30 layers of Kevlar~ Style 363F fabric sewed using 930 dtex Kevlar~
16
__.._... ~.._. ........ ...._. ~ . ~ , ~


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
sewing yarn. Kevlar~ is a DuPont Registered Trademark. The layers were
assembled on a bust measuring 94-64-97 cm (size 42). The finished shaped front
panel was mounted on a Plastilina backing material and subjected to standard
ballistic tests. Bullets were aimed at the tip, flank and border of the curved
breast
part under standard conditions. All bullets were stopped within the first half
of the
pack, which is an indication of good ballistic design. Moreover, the backface
deformation on the Plastilina was satisfactory.
17


CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
Legend
L 1-L 12 Layers
10 front panel
11 Velcro pile fastener
12 Velcro pile fastener
14 top breast
section


15 lower breast
section


16 side extension


17 seam


back panel


15 21 top straps


22 Iower straps


23 cross-piece


24 belt


30 Iayer of material cut to shape
31 side extension


32 arm recess


33 upper breast cover


34 neck


V-shaped section
of material


36 fold line


37 joining line


38 vertical fold line


30 39 point or area of
convergence


V-shaped pleat (folded
over)


back layer


51 periphery


35 52 crosswise sewing



CA 02289466 1999-11-12
WO 99/04217 PCT/US98/14471
FIG.1
FIG. 2-1
FIG. 2-2
FIG. 2-3
FIG.2-4
FIG. 2-5
FIG. 2-6
FIG. 2-7
FIG. 2-8
FIG.2-9
FIG. 2-10
FIG. 2-11
FIG. 2-12
FIG. 3
FIG.4-1
FIG. 4-2
FIG. 4-3
FIG. 4-4
FIG. 5
FIG. 6

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 2006-09-19
(86) PCT Filing Date 1998-07-14
(87) PCT Publication Date 1999-01-28
(85) National Entry 1999-11-12
Examination Requested 2003-01-24
(45) Issued 2006-09-19
Deemed Expired 2015-07-14

Abandonment History

There is no abandonment history.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Registration of a document - section 124 $100.00 1999-11-12
Registration of a document - section 124 $100.00 1999-11-12
Application Fee $300.00 1999-11-12
Maintenance Fee - Application - New Act 2 2000-07-14 $100.00 1999-11-12
Maintenance Fee - Application - New Act 3 2001-07-16 $100.00 2001-06-26
Maintenance Fee - Application - New Act 4 2002-07-15 $100.00 2002-07-02
Request for Examination $400.00 2003-01-24
Maintenance Fee - Application - New Act 5 2003-07-14 $150.00 2003-06-27
Maintenance Fee - Application - New Act 6 2004-07-14 $200.00 2004-07-02
Maintenance Fee - Application - New Act 7 2005-07-14 $200.00 2005-06-30
Final Fee $300.00 2006-05-26
Maintenance Fee - Application - New Act 8 2006-07-14 $200.00 2006-06-29
Maintenance Fee - Patent - New Act 9 2007-07-16 $200.00 2007-06-07
Maintenance Fee - Patent - New Act 10 2008-07-14 $250.00 2008-06-10
Maintenance Fee - Patent - New Act 11 2009-07-14 $250.00 2009-06-19
Maintenance Fee - Patent - New Act 12 2010-07-14 $250.00 2010-06-17
Maintenance Fee - Patent - New Act 13 2011-07-14 $250.00 2011-06-08
Maintenance Fee - Patent - New Act 14 2012-07-16 $250.00 2012-06-14
Maintenance Fee - Patent - New Act 15 2013-07-15 $450.00 2013-06-12
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
E.I. DU PONT DE NEMOURS AND COMPANY
Past Owners on Record
DU PONT DE NEMOURS INTERNATIONAL S.A.
MOUREAUX, BEATRICE
PFISTER, FRIEDRICH V.
VAN ZIJL, NICOLAS A.
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Representative Drawing 2000-01-11 1 5
Description 1999-11-12 19 880
Abstract 1999-11-12 1 55
Representative Drawing 2004-10-28 1 8
Claims 1999-11-12 4 161
Drawings 1999-11-12 7 113
Cover Page 2000-01-11 1 57
Description 2005-03-21 19 871
Claims 2005-03-21 4 117
Description 2005-09-21 19 861
Cover Page 2006-08-21 1 45
Correspondence 2004-07-14 1 28
Prosecution-Amendment 2004-09-23 2 49
Assignment 1999-11-12 9 349
PCT 1999-11-12 23 795
Prosecution-Amendment 1999-11-12 1 27
Prosecution-Amendment 2003-01-24 1 41
Prosecution-Amendment 2003-06-06 1 45
Correspondence 2004-04-30 46 2,875
Correspondence 2004-06-16 1 22
Prosecution-Amendment 2005-03-21 8 252
Prosecution-Amendment 2005-04-11 1 29
Prosecution-Amendment 2005-09-21 3 82
Correspondence 2006-05-26 1 31