Note: Descriptions are shown in the official language in which they were submitted.
CA 02858880 2014-08-06
COMPOSITE FABRIC ASSEMBLY
This invention relates generally to a composite fabric assembly, and more
particularly to
an improved composite fabric assembly having spike and edge blade resistant
properties
for use with humans and animals, in the manufacture of protective garments and
accessories which are lightweight, flexible, fire retardant, durable and
reliable, and which
can provide protection of body parts in addition to the head, neck,
chest/torso region, as
well as arms and legs.
DESCRIPTION OF THE PRIOR ART
It is well known that various stab resistant articles or garments, such as
protective vests,
have been worn by prison corrections officers and other types of security,
military or law
enforcement personnel, and have even been developed for working animals such
as
dogs or horses. Such spike resistant articles are designed to prevent bodily
penetration
as a result of stabbing or slashing from sharp objects or weapons.
Unfortunately, these
protective articles were generally rigid shields which were externally worn
and were
constructed of heavy, bulky and inflexible metal components such as titanium
or other
extremely hard metal alloys and rigid fabrics. The metallic and fabric
composition of these
cumbersome external vest shields must be of sufficient thickness, rigidity and
strength to
stop impacts imparted by an attacker, and limit coverage of critical body
parts.
Disadvantageously, the bulk and rigidity of such protective vest garments
rendered it
uncomfortable to wear. It is known that some protective vests comprise 50
layers, front
and back, of polymer matrix material (for a total of 100 layers), which
renders such vests
stiff, and having little flexibility. Furthermore, it is rather difficult for
the wearer of a rigid
vest to move and maneuver around quickly and easily which is important
especially if the
wearer is being attacked. Accordingly, such known puncture resistant articles
often prove
to be ineffective predominantly due to the fact that the potential wearer
prefers not to
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wear the bulky torso shield, rather than tolerating its discomfort, as when
used for
extended periods such items can be hot and heavy.
Another, and perhaps a more significant problem with such types of rigid
fabric and
metallic alloy puncture resistant vests, is that they were not concealable.
These known
cumbersome shield vests were almost exclusively externally worn and even if
they were
not worn externally, the bulky nature of such articles make it obvious to a
would be
attacker that the wearer (corrections officer, etc.) is wearing a protective
spike and edge
blade resistant protective shield vest. Since the worn vest article cannot be
concealed the
potential attacker is more prone to stab or slash at a vital area away from
the vest such
as the lower abdomen, groin, neck or head area. Not only is any element of
surprise on
the part of the wearer removed by the unconcealed nature of such cumbersome
rigid
vests, it is highly impractical if not impossible for the undercover personnel
to wear such
bulky items, and even if used these items offer little to no protection of
other body parts
such as the arms and legs, damage to which can and do cause severe, life
threatening
wounds. For example, wounds to the femoral artery can and often kills the
person,
because there is no protective gear for this area.
Thus, there is a need to provide a light weight, flexible composite fabric
assembly which
is flexible, lightweight, fire retardant, durable, and which can provide
protection to
vulnerable body parts of humans and working animals, and which can be removed
quickly and easily. There is a further need for a flexible composite fabric
assembly which
can provide protection of body parts, in addition to the chest/torso region,
such as arms
and legs. In this regard, the present invention substantially fulfills this
need.
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SUMMARY OF THE INVENTION
It is an object and advantage of the present invention to provide an improved
spike and
edge blade resistant composite fabric assembly having ballistic properties
which is light
weight, flexible, durable, thinner in profile by up to 50% of current 50 layer
vests and
which can provide protection to vulnerable body parts of humans and working
animals,
and which can be removed quickly and easily.
It is another object and advantage of the present invention to provide an
improved spike
and edge blade resistant flexible composite fabric assembly having ballistic
properties
which can provide protection of body parts in addition to the chest/torso
region, such as
arms, legs, neck and feet.
According to one aspect of the present invention, there is provided a
composite fabric
assembly comprising a composite fabric assembly comprising at least one layer
of base
fabric, the at least one layer of base fabric being constructed and arranged
to be worn
adjacent to a user; at least a first layer of ballistic fabric having portions
thereof cut at
least partially into strips of material; at least a second layer of ballistic
fabric connected to
the at least a first layer of ballistic fabric, and punched at least partially
therethrough to
form at least one design or shape thereon; and wherein either of the at least
a first layer
of ballistic fabric or the at least a second layer of ballistic fabric are
adjacently connected
to and overlapping the at least a first layer of base fabric whereby the at
least one layer of
base fabric is substantially covered.
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According to another aspect of the present invention, there is provided a
method for
manufacturing a composite fabric assembly comprising providing at least one
layer of
base fabric; providing at least a first layer of ballistic fabric; and
providing at least a
second layer of ballistic fabric connected to the at least a first layer of
ballistic fabric, and;
cutting portions of the at least a first layer of ballistic fabric at least
partially into strips of
material; punching, at least partially therethrough, portions of the at least
a second layer
of ballistic fabric to form at least one design or shape thereon; and
connecting either of
the at least a first layer of ballistic fabric or the at least a second layer
of ballistic fabric to
the at least one layer of base fabric so as to be in an adjacent and
overlapping
relationship therewith, whereby the at least one layer of base fabric is
substantially
covered.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the present invention is described below with
reference to the
accompanying drawings, in which:
Figure 1 is a top view of an embodiment of the first layer of ballistic fabric
of the
composite fabric assembly of the present invention, having portions thereof
cut at
least partially into strips of material;
Figure 2 is a side perspective view of an embodiment of the composite fabric
assembly of the present invention;
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Figure 3 is a side view of a further embodiment of the layering of the fabric
layers
for the composite fabric assembly of the present invention;
Figure 4 is an exploded view of an embodiment of examples of designs or shapes
which have been punched at least partially therethrough either the first or
the
second layer of ballistic fabric; and
Figure 5 is an exploded view of further embodiments of examples of designs or
shapes which have been punched at least partially therethrough either the
first or
the second layer of ballistic fabric.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment, and with reference to Figure 2, the improved
composite
fabric assembly of the present invention is designated in its entirety by the
reference
numeral 1. The protective composite fabric preferably comprises at least one
layer of
base fabric 5 designed to be adjacent to the skin or outer surface of the
wearer 20, with
at least one overlying first ballistic layer 3 connected thereto. At least one
second ballistic
layer 7 is then connected to the first ballistic layer 3 to form the composite
fabric
assembly 1 having spike and edge blade resistant properties for use with
humans and
animals, in the manufacture of protective garments which are lightweight,
flexible, fire
retardant, durable and reliable, and which can provide protection of body
parts in addition
to the head, neck, chest/torso region, as well as arms, legs and feet. It will
also be
understood that if a plurality of fabric layers are utilized, ballistic
resistant can also be
obtained.
It should be noted that the term "Edge Blade", as used by the U.S.A. NIJ
(National
Institute of Justice, Washington, DC) refers to high quality, commercially
machined edged
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knife blades, and that "Spike" refers to lower quality knife blades and spike
style
weapons that have been improvised from other materials.
It will, of course, be understood that more than one layer of base fabric 5
could be
utilized, and preferably multiple layers are utilized. In an exemplary
embodiment, 14
layers are utilized. The base fabric can be selected from, but is not limited
to, a ballistic
grade fabric, a fabric that is a woven fabric, a non-woven fabric, a
dimensionally stable
fabric, a fire retardant fabric, a high density fabric and a high tensile
strength fabric. Two
possible examples of materials that could be utilized are Microflex TM,
manufactured by
Teijin, and Kevlar Correctional TM, manufactured by Dupont, though other
variations to
this are possible also, as would be apparent to one skilled in the art. This
layer of base
fabric 5 is designed to be adjacent to the skin or outer surface of the wearer
20.
Preferably, the layer of base fabric 5 will be thin, flexible, and able to
fold and bend
easily.
At least one layer of ballistic fabric 3 is connected to the layer of base
fabric 5, the layer
of ballistic fabric 3 being cut into strips of material 4, as shown in Figure
1, and being
connected to the layer of base fabric 5 in an overlapping manner whereby the
layer of
base fabric 5 is substantially covered. Possible examples of suitable
materials that could
be utilized are SRM TM, manufactured by Teijin, and Argus TM, manufactured by
Dupont,
though other variations to this are possible also, as would be apparent to one
skilled in
the art. It will also be understood that the first layer of ballistic fabric 3
can also comprise
a plurality of ballistic fabric layers. The first layer of ballistic fabric 3
is connected to the
base fabric 5, by sewing, adhesive, heat or other means. Furthermore, the
strips of
material 4 of the first layer of ballistic fabric 3 are separated by slits 6,
forming gaps,
between each of the strips of material 4.
At least one second ballistic layer 7 is connected to the first ballistic
layer 3 to form the
composite fabric assembly 1, it being understood that more than second
ballistic layer 7
could be utilized. The second ballistic layer 7 will preferably have punched,
at least
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partially therethrough, at least one design or shape 9 thereon, examples of
which can be
seen in Figures 4 and 5, though it will be readily understood that numerous
variations of
designs and shapes, in addition to those shown in Figures 4 and 5, can be
effected. The
purpose of punching the designs or shapes 9 is to increase the flexibility of
the layer, to
prevent the rigidity thereof and increase wearability and overall comfort.
The connection of the second ballistic layer 7 to the first ballistic layer 3
can be done in
an offset manner to provide protection so sharp edges do not go through the
composite
fabric assembly. However, in any event, due to the fact that multiple layers
of fabric are
assembled in a stacked relationship with one another, as can be seen in Figure
3,
protection against spike and/or bladed weapons is provided.
In a still further embodiment, the strips of material 4, and indeed any
portion of the first
layer of ballistic fabric 3 may also have punched thereon, at least partially
therethrough,
at least one design or shape 9. The spacing of the designs or shapes 9 on can
be
varied, as will be understood to allow more protection or more flexibility, it
being
understood that having a greater number of designs or shapes thereon thus
leads to the
composite fabric assembly having more flexibility, while lesser designs and
shapes
allows for greater protection. It will also be understood that combinations of
shapes and
designs could also be used on any of the fabric layers.
It should also be noted that either of the first layer of ballistic fabric 3
or the second layer
of ballistic fabric 9 can be adjacently connected to and overlap and cover the
base fabric
5, whereby the at least one layer of base fabric is covered; either of these
layers can be
interchanged, if desired, in construction of the composite fabric assembly.
Further, one or
more of layers of base fabric 5 can also be used, selectively inserted between
any of the
first layers of ballistic fabric 3 or any of the second layers of ballistic
fabric 9, or even as a
final outer layer of the composite fabric assembly that would first sustain
strike force. In
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this manner, the at least one layer of base fabric can be interspersed at
various locations
throughout the composite fabric assembly.
Figures 2 and 3 illustrate possible variations of the stacking of fabric
layers that can be
effected to form the composite fabric assembly 1. Figure 2 illustrates the
skin or outer
surface of the wearer 20 being covered by the layer of base fabric 5, followed
by
alternating, in sequence, a plurality of layers of the first ballistic layer 3
and the second
ballistic layer 7. Figure 3 illustrates the skin or outer surface of the
wearer 20 being
covered by the layer of base fabric 5, followed by a layer of the first
ballistic layer 3 (noted
as being "2" in Figure 3), then followed by a layer of the second ballistic
layer 7 (noted as
being "3" in Figure 3). These layers are then further connected to two
separate stacked
layers of the first ballistic layer 3, followed by three further stacked
layers of the second
ballistic layer 7, followed by two further layers of the first ballistic layer
3. Of course, it will
be readily understood that numerous variations and combinations as to how the
stacked
layer construction of the composite fabric assembly 1 is assembled can be
varied, as well
as the total number of fabric layers that are utilized. In use, the total
number of fabric
layers to be utilized can be between 7-20 layers, though this can of course be
varied.
Once the composite fabric assembly 1 is assembled, it can be utilized in
within a
protective garment or protective accessory. It should be understood that
garments can
include, but are not limited to, Hats, Helmets, and Liners, Face Gaiters,
Scarves, Neck
Dickey, Jackets, Coats, Ponchos, Gloves, Mitts, Belts, Repelling harnesses and
related
devices, Footwear including. Insoles, shoes, runners, boots and socks, and
hockey or
sports protection equipment. It will also be understood that gear and
accessories can
include, but are not limited to, Blankets, tarps, tents, Backpacks, Bags,
Cushions, Vehicle
Liners, Furniture Liners, Ropes (open and closed end), and Speed Skating Short
Track
Bumper Pads.
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In operation, the composite fabric assembly can be, for example, positioned
within at
least one pocket formed on a surface of the protective garment or protective
accessory.
This pocket can either be externally or internally located. Alternatively, the
composite
fabric assembly could be positioned within internal and external layers of the
protective
garment or protective accessory.
In a still further embodiment, the composite fabric assembly can be
selectively sealable
and enclosed in a membrane-like pouch/shell made of a rip-stop or similar
fabric with
properties including protection against UV-ultra violet light, and being water
proof or
water resistant. This outer shell protects the materials which make up the
composite
fabric assembly. The shell would then be inserted and positioned within the
protective
garment, external carrier or protective accessory.
The present invention has been described herein with regard to preferred
embodiments.
However, it will be obvious to persons skilled in the art that a number of
variations and
modifications can be made without departing from the scope of the invention as
described herein.
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