MODULAR ACCESSORY SYSTEM

CROSS REFERENCE TO RELATED APPLICATIONS

[0001]This application is a continuation of U.S. Nonprovisional Application No. Ser. No. 18/350,362, filed Jul. 11, 2023, which is a continuation of U.S. Nonprovisional Application No. Ser. No. 17/737,202, filed on May 5, 2022, and claims benefit of U.S. Provisional Application No. 63/184,603 filed on May 5, 2021.

BRIEF DESCRIPTION OF THE DRAWINGS

[0002]FIG. 1 is a front view of the body armor system.

[0003]FIG. 2 is a rear view of the body armor system.

[0004]FIG. 3 is a front isometric view of the body armor system.

[0005]FIG. 4 is a right side view of the body armor system.

[0006]FIG. 5 is a rear isometric view of the body armor system.

[0007]FIG. 6 is a front view of the body armor system without the shoulder suspension members.

[0008]FIG. 7 is a rear view of the body armor system without the shoulder suspension members.

[0009]FIG. 8 is a front view of the upper protector.

[0010]FIG. 9 is a rear view of the upper protector.

[0011]FIG. 10 is another rear view of the upper protector.

[0012]FIG. 11 is yet another rear view of the upper protector.

[0013]FIG. 12 is a side view of the upper protector.

[0014]FIG. 13 is a side view of the upper protector with the shoulder suspension members inserted therein.

[0015]FIG. 14 is an isometric view of the upper protector with the shoulder suspension members inserted therein.

[0016]FIG. 15 is an isometric view of the upper protector with the throat guard removed.

[0017]FIG. 16 shows a step of the insertion of the throat guard into the upper protector.

[0018]FIG. 17 shows another step of the insertion of the throat guard into the upper protector.

[0019]FIG. 18 shows yet another step of the insertion of the throat guard into the upper protector.

[0020]FIG. 19 is an isometric view of the upper protector with the throat guard installed.

[0021]FIG. 20 shows a lateral expansion feature of the upper protector.

[0022]FIG. 21 shows a lateral expansion feature of the upper protector.

[0023]FIG. 22 is a front view of a deltoid guard.

[0024]FIG. 23 is a rear view of the deltoid guard showing an open seam line for the insertion of body armor.

[0025]FIG. 24 shows the attachment of an identification panel onto the deltoid guard.

[0026]FIG. 25 shows the attachment of an identification panel onto the deltoid guard.

[0027]FIG. 26 shows the attachment of an identification panel onto the deltoid guard.

[0028]FIG. 27 shows the attachment of the deltoid guard to the upper protector.

[0029]FIG. 28 shows the attachment of the deltoid guard to the upper protector.

[0030]FIG. 29 shows the upper protector with the deltoid guard attached thereto.

[0031]FIG. 30 shows the upper protector with the deltoid guard attached thereto.

[0032]FIG. 31 shows the upper protector with the deltoid guard attached thereto.

[0033]FIG. 32 is a front isometric view of the armor carrier.

[0034]FIG. 33 is a rear isometric view of the armor carrier.

[0035]FIG. 34 is a side view of the armor carrier.

[0036]FIG. 35 shows a front accessory panel to be attached to the armor carrier.

[0037]FIG. 36 shows the attachment of the front accessory panel to the armor carrier.

[0038]FIG. 37 shows the insertion of attachment members of the front accessory panel into corresponding openings on the armor carrier.

[0039]FIG. 38 shows the insertion of attachment members of the front accessory panel into corresponding openings on the armor carrier.

[0040]FIG. 39 shows the insertion of attachment members of the front accessory panel into corresponding openings on the armor carrier.

[0041]FIG. 40 the closed state of a zippered pouch of the armor carrier in which armor is inserted and retained.

[0042]FIG. 41 shows the open state of a zippered pouch of the armor carrier in which armor is inserted and retained.

[0043]FIG. 42 shows a modular accessory system on the sides of the armor carrier.

[0044]FIG. 43 shows a bicep protector.

[0045]It will be recognized that some or all of the Figures are schematic representations for purposes of illustration and do not necessarily depict the actual relative sizes or locations of the elements shown. The Figures are provided for the purpose of illustrating one or more embodiments of the invention with the explicit understanding that they will not be used to limit the scope or the meaning of the claims.

DETAILED DESCRIPTION OF THE INVENTION

[0046]In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the badge system of the present invention. It will be apparent, however, to one skilled in the art that the badge system may be practiced without some of these specific details. Throughout this description, the embodiments and examples shown should be considered as exemplars, rather than as limitations on the badge system. That is, the following description provides examples, and the accompanying drawings show various examples for the purposes of illustration. However, these examples should not be construed in a limiting sense as they are merely intended to provide examples of the badge system rather than to provide an exhaustive list of all possible implementations of the badge system.

[0047]Specific embodiments of the invention will now be further described by the following, non-limiting examples which will serve to illustrate various features. The examples are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those of skill in the art to practice the invention. Accordingly, the examples should not be construed as limiting the scope of the invention. In addition, reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.

Body Armor System

[0048]With reference to FIGS. 1-7 shown is an embodiment a body armor system comprising an armor carrier 200 disposed over an upper protector 100. The upper protector is also referred to herein as a mantel and/or accessory hub. The upper protector is disposed over the shoulders and provides protection for the upper shoulders and neck area of the wearer. The upper protector also provides structure to comfortably retain the weight of the carrier across the shoulders and upper body of the wearer. In some embodiments, the upper protector includes shoulder suspension members 101 inserted into openings on the anterior and posterior of the upper protector, about the shoulder area, which assist in supporting the weight of the armor carrier 200. In some embodiments, a deltoid guard 110 is attached to either or both sides of the upper protector. The armor carrier 200 is disposed over the upper protector 100, resting on the shoulders of the wearer and generally protects the thorax of the wearer. The system uses combinations of soft and hard armor to provide protection against blunt objects, sharp objects, ballistics, and fragmentation.

[0049]Upper Protector

[0050]With reference to FIGS. 8-11, shown is an embodiment of the mantel 100 without the armor carrier 200. The mantel includes a primary yoke 102 which comprises the supporting structure of the protector that drapes at least partially over the thorax (upper back and upper chest) of the wearer. The yoke 102 retains a throat guard 104 which is inserted at its edges into corresponding openings on the yoke 102. At the center of either or both of the front and back of the yoke 102 is a sliding attachment point 103. In some embodiments, the attachment point 103 comprises hook and loop fastener or another removable fastener such as a snap or buckle which engages a corresponding attachment point on the inside of the armor carrier 200. The attachment point 103 is configured to slide in a vertical direction along the upper protector 100 in order to allow the armor carrier 200 to articulate relative to the upper protector 100 to maximize comfort and mobility for the wearer. Also shown are openings 105 which receive the shoulder suspension member 101 as further shown and described herein.

[0051]With reference to FIGS. 12-14 shown are side views of the mantel 100. In some embodiments, hook and loop fastener 106 is provided at the top of the shoulder area which is configured to engage corresponding shoulder straps of the armor carrier 200 in certain configurations. Also show are front and rear openings 105 and 105′ which receive the ends of the shoulder suspension member 101 as shown in FIG. 10. In some embodiments, the shoulder suspension member 101 is a removable, semi-rigid support that helps distribute the load across the wearers shoulders caused by the weight of the armor carrier 200 when the carrier is installed over the upper protector 100.

[0052]The mantel and accessory hub 100 is configured to function as a primary point of attachment of various accessories, including those described herein such as the throat guard and deltoid/bicep protectors so that the system functions in a modular manner and avoids the need to move such accessories back and forth between bulkier armor carriers. In this way, the mantel and accessory hub 100 is intended to be worn underneath an armor carrier or plate carrier while retaining the desired accessories to allow for selective use of a desired armor carrier without having to reposition or re-attach the accessories to that armor carrier. Accordingly, in some embodiments the mantel and accessory hub 100 does not include hard armor, i.e. rigid plates. In some embodiments, the mantel and accessory hub 100 does not include pockets that would otherwise be designed to intended to receive hard armor. Also, given a use case wherein the mantel and accessory hub 100 is designed as a modular system worn underneath a larger and heavier armor carrier, in some embodiments, the primary yoke 102 covers only the thorax (upper back and upper chest area) of the wearer and, in some embodiments, does not extend to cover the abdomen, lower abdomen, middle back, or lower back areas of the wearer.

[0053]Removable Throat Guard

[0054]With reference to FIGS. 15-19, the functionality of the removable throat guard 104 is shown. In FIG. 15, the throat guard 104 is completely removed from the upper protector 100. In some embodiments, the throat guard 104 is generally V-shaped with two upper horns that opening into the collar 107 of the upper protector 100 and a bottom portion that openings into a central pocket 108 of the upper protector 100. FIG. 19 shows the throat guard 104 in its fully installed position.

Lateral Expansion for Comfort and Mobility

[0055]FIGS. 20-21 depict a lateral expansion feature of the upper protector which aids in the comfort and mobility of the wearer. Sewn between the central pocket 108 and the respective sides of the yoke 102 is a resilient elastic material 109 which allows the shoulder portions of the yoke 102 to expand and contract relative to the central portion. This expansion feature also aids the wearer in putting on the upper protector 100 by providing more room and adjustability. Alternatively, the resilient elastic material 109 could be substituted for a zipper or other expandable/contractable closure to assist the wearer in putting on and taking off the upper protector 100.

Deltoid Guard

[0056]FIG. 22 is a front view of the deltoid guard 110, which has a generally triangular or trapezoidal shape and, in some embodiments, has one or more openings 111 which receive an identification panel 112. As shown in FIG. 23, the interior of the deltoid guard 110 is configured to receive and retain soft armor, hard armor, fragmentation armor, or combinations thereof. Also at the rear of the deltoid guard 110 is an expandable element 113 such as an elastic strap which retains the guard against the arm of the wearer. FIGS. 24-26 depict an example of the attachment of a wedge-like identification panel 112 onto the deltoid guard, namely by inserting one or more corners or edges of the identification panel 112 into the one or more corresponding openings 111 on the deltoid guard. The identification panel 112 may be reversible and printable and may also include hook and loop fastener for additional adhesion to the deltoid guard 110. In some embodiments, however, hook and loop fastener is obviated due to the insertions of the corners or edges of the identification panel 112 into one or more corresponding openings 111 on the deltoid guard. The identification panel 112 can also be attached elsewhere on the body armor system.

[0057]FIGS. 27-28 depict the attachment of the deltoid guard 110 to the upper protector 100. In some embodiments, a small removable fastener 114 such as a buckle is attached at the shoulder area of the upper protector 100 which receives a corresponding fastener attached to the top of the deltoid guard 110. In other embodiments, the deltoid guard 110 may be fixed to the upper protector 100. In either configuration, an elastic material 115 may be provided at the connection to facilitate expansion and articulation of the deltoid guard 110 with respect to the upper protector 100 to aid wearer comfort. FIGS. 29-31 show various views the upper protector with the deltoid guard attached thereto.

[0058]In some embodiments, the deltoid guard 110 is relatively smaller than traditional designs and does not protect the bicep area in order to enhance mobility. However, as shown in FIG. 44, a supplemental bicep guard 110′ may be implemented, which attaches to the deltoid such that the bicep guard can articulate with respect to the deltoid guard. In some embodiments, the bicep guard 110′ is disposed at least partially underneath the deltoid guard 110 and attaches either to the deltoid guard or the upper protector by a buckle, elastic, and/or wedge received in an opening on the deltoid protector and/or the upper protector. This allows for a modular, scalable arm protection system that maximizes comfort and mobility.

Armor Carrier

[0059]With reference to FIGS. 32-34, in some embodiments the armor carrier 200 is configured to work in conjunction with the upper protector 100, with the armor carrier 200 placed over the upper protector 100. However, the armor carrier 200 can be used independently from the upper protector 100 in modular fashion as determined by the wearer, the circumstances, and the desired protection. The armor carrier 200 includes bi-lateral shoulder straps 207 which attach the front panel 202 to the back panel 203 at the top of the shoulders. In some embodiments, the shoulder straps 207 of the armor carrier 200 are adjustable by hook and loop fastener or other removable fasteners and the free ends can be tucked into corresponding openings on the front and/or back panels 202 and 203. Also provided are bi-lateral abdomen straps 201 which attach the front panel 202 to the back panel 203 around the lower thorax or abdomen of the wearer. The bi-lateral side straps 201 comprise and/or include an accessory modular accessory system 206. The armor carrier includes an optional font flap 208 and a rear flap 205 which are removably attached to the carrier 200. In some embodiments, the rear flap 205 is attached to the armor carrier 200 at the respective shoulder straps 207 by a fastener 204, such as by a buckle.

Accessory Panel

[0060]With reference to FIGS. 35-39, show in a front accessory panel 208 which is removably attached to the front panel 202 of the armor carrier. The front accessory panel 208 is configured to easily align and attach to the front panel 202 using magnetic and/or mechanical attachments. In some embodiments, the inside surface of the flap 208 includes one more magnets 209 which are configured to align and attach to corresponding magnets on the front accessory panel 208. In some embodiments, an interior aspect of the accessory panel 208 includes a raised wedge 211 which is received in a corresponding opening on the armor carrier, as shown in FIG. 36. In some embodiments, the wedge may be located on the armor carrier with the corresponding opening provided on the accessory panel 208.

[0061]In some embodiments, the top edge of the front accessory panel 208 includes one or more rigid attachment members or fasteners 210 (buckles, clasps, or prongs) that are retained in corresponding openings on the upper portion of the front panel 202 of the armor carrier 200. In some embodiments, the rigid attachment member or fastener 210 is configured to enter through an connect with an opening designed to secure accessories, such as a 1″-1.5″ opening on the armor carrier 200 or an accessory, a laser cut opening, a MOLLE webbing system-compatible opening. This attachment configuration assures that the front accessory panel 208 is aligned and secured with respect to the front panel 202 for ease of attachment and use. FIGS. 37-39 depict the insertion of buckles of the front accessory panel into corresponding openings on the armor carrier.

Armor Pouches

[0062]FIGS. 40-41 show the closed and opened state of a pouch 300 at the front panel 202 of the armor carrier in which armor (soft, hard, fragmentation, or the like) is inserted and retained. A corresponding pouch is located on the back panel 203 and may also receive and retain armor (soft, hard, fragmentation, or the like). In some embodiments, the pouches have a zippered opening to provide a much easier means for adding and removing body armor to the carrier in comparison to traditional sleeves and openings which are typically accessed at an interior aspect of a carrier. In some embodiments, the zippered pouches are configured to extend outward to accommodate curved body armor plates without bunching or discomfort for the wearer. The pouches may be configured to be removable from the respective front and back panels of the armor carrier by hook and loop fasteners, wedges or edges received in corresponding openings on the panels, or other releasable fasteners.

[0063]With reference to FIGS. 1-7, 33-34, 37-38, and 42, shown a modular accessory system 206 on the side straps 201 of the armor carrier. The modular accessory system 206 comprises a main body 206a having a thickness t. The main body 206a of the modular accessory system 206 includes one or more spaced-apart rows 112 of apertures 213 provided in a substantial pattern of rows and columns, which can be used as mounting points for accessories such as sheaths, holsters, and the like, which accessories have corresponding snaps that fit inside the apertures 213. The apertures, as shown in FIG. 42, pass through the entire thickness t of the main body 206a of the modular accessory system 206.

[0064]In some embodiments, the modular accessory system 206 facilitates the attachment of sliding or moveable accessories. The accessories may be attached by any male-female attachment fitting that passes through the apertures. The modular accessory system 206 also includes rivets 214, which are provided in pairs along substantially parallel horizontal boundaries 215 delimiting top and bottom ends of the side strap 201. The side strap 201 includes ends 216 or opposing boundary ends that intersect the horizontal boundaries of the side strap 201 to provide the geometric shape of the modular accessory system 206. As clearly depicted in FIG. 42, the apertures 213 do not align with the rivets 214 (i.e., the rivets 214 are axially offset from the apertures 213). The ends 216 of the side strap 201 of the modular accessory system 206 may include an adjustable or slidable accessory 217 configured as a connection device or accessory adaptor, as shown in FIG. 42.

[0065]In some embodiments modular accessory system 206 includes an elongated main body 206a with opposing boundary ends and a pattern of spaced-apart apertures. The accessory 217, in some embodiments configured as a connection device with at least one attachment fitting, is sized to engage the apertures. The accessory 217 is slidable along the length of the elongated main body by selective engagement with the apertures, which thereby changes the effective wearable length or circumference of the accessory system. The accessory 217 may be attached by any male-female fitting that passes through the apertures. In some embodiments, the accessory 217 configured as a connection device is selectively positioned along the apertures to couple the accessory to an opposing accessory or coupler, where selective positioning of the connection device along the apertures changes the effective wearable length or circumference of the main body of the accessory system. The pattern configuration of the spaced-apart apertures provides multiple discrete positions along the length of the main body, allowing an accessory configured as a connection device to be repositioned by disengaging from a first aperture and engaging a second aperture to adjust fit. As used herein, “effective wearable length” refers to a distance or circumference defined by the position of attachment points or connection devices by which the main body is removably and adjustably attached around a wearer's lower thorax, abdomen, or waist and/or to an armor carrier.

[0066]The spaced-apart rows of apertures on the main body 206a enable selective positioning of sliding or moveable accessories, including connection devices such as buckles, clasps, prongs, bridge clips, and wedge or edge fittings, to facilitate modular and sizeable coupling to an opposing accessory or coupler. In some embodiments, the apertures are sized to receive MOLLE-compatible fittings, laser cut opening fittings, grommets, or wedges, thereby enabling sliding engagement of connection devices and accessories along the main body.

Materials

[0067]It is appreciated and understood that the body armor system described herein can be of a multi-material construction. In some embodiments, the fabrics that face inward toward the wearer or otherwise come in contact with the body of the wearer, such as the collar, are composed of a no-snag pack cloth or nylon material. This avoids snagging on rough skin or facial hair. In some embodiments, the body armor system utilizes rivets or grommets as a supplement or replacement for bar tacks or other sewing connections to minimize the amount of visible traditional stitching which can snag and otherwise wear out over time. Rivets and grommets also improve manufacturing tolerances and ease of manufacturing in general, as less manual sewing is required and the unit can be more easily built from a template.

[0068]As referred to herein, soft body armor, or soft ballistics, refer to a relatively soft and flexible but strong material, such as Kevlar or polyethylene, inserted into or otherwise forming a garment (or portion thereof) worn by a user for protective purposes. Generally, soft armor is distinguished from hard armor, as referred to herein, the latter typically presented in the form of thick, rigid plates made of firm, durable materials such as ceramic, ceramic composites, polyethylene, fibers, Kevlar, steel, and the like. Hard armor plates do not readily deform or otherwise conform to the body of the wearer. In many cases, protective garments utilize a combination of soft and hard armor in order to strike a balance between wearability, comfort, and mobility on the one hand, and maximum protection on the other hand.

[0069]It is to be noticed that the term “opening” as used herein and in the claims shall be deemed limited as it may refer to any number of slots, slits, apertures, channels, covered areas, or the like. It is to be noticed that the term “comprising,” used in the claims, should not be interpreted as being limitative to the means listed thereafter. Thus, the scope of the expression “a device comprising means A and B” should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B. Put differently, the terms “including”, “comprising” and variations thereof mean “including but not limited to”, unless expressly specified otherwise.

[0070]Similarly, it is to be noticed that the term “coupled”, also used in the claims, should not be interpreted as being limitative to direct connections only. Thus, the scope of the expression “a device A coupled to a device B” should not be limited to devices or systems wherein an output of device A is directly connected to an input of device B. It means that there exists a path between an output of A and an input of B which may be a path including other devices or means.

[0071]The enumerated listing of items does not imply that any or all of the items are mutually exclusive, unless expressly specified otherwise. The terms “a”, “an” and “the” mean “one or more”, unless expressly specified otherwise.

[0072]Elements of the invention that are in communication with each other need not be in continuous communication with each other, unless expressly specified otherwise. In addition, elements of the invention that are in communication with each other may communicate directly or indirectly through one or more other elements or other intermediaries.

[0073]One skilled in the art will appreciate that the present invention can be practiced by other than the above-described embodiments, which are presented in this description for purposes of illustration and not of limitation. The specification and drawings are not intended to limit the exclusionary scope of this patent document. It is noted that various equivalents for the particular embodiments discussed in this description may practice the invention as well. That is, while the present invention has been described in conjunction with specific embodiments, it is evident that any alternatives, modifications, permutations and variations will become apparent to those of ordinary skill in the art in light of the foregoing description. Accordingly, it is intended that the present invention embrace all such alternatives, modifications and variations as fall within the scope of the appended claims. The fact that a product, process or method exhibits differences from one or more of the above-described exemplary embodiments does not mean that the product or process is outside the scope (literal scope and/or other legally-recognized scope) of the following claims.