Field of Invention

[0001] This invention relates to armor panels and armour structures and assemblies utilizing armour panels made from high strength materials.

Background

[0002] Armor has traditionally been a trade-off of mobility vs. protection, where significant increases to one generally reduces the property of the other (more mobility less protection, more protection less mobility). This problem has related to water sports enthusiasts who require light weight, and extreme mobility, which face challenging physics of shark bites applying massive pressure to razor sharp pointed teeth. The problem has also plagued law enforcement and military personnel, who face the difficulties of finding comfortable, pliable materials which are also significantly protective for extremity protection. They require high levels of protection, light weight, while still allowing vigorous and unrestrained movement.

[0003] There have been relatively few armor configurations to date that adequately address both issues concurrently.

[0004] There are flexible layered armor systems using fabrics of different weaves warps and knits and using different layers of fabric or fibrous materials that have juxtaposed or alternate orientations of the weaving or knitting, to prevent puncture of spikes or blades (pointed wedges). There have also been many laminated fabrics where there is a bonding, infusing, encapsulating, or other combination of solid material to the profile of fibrous material.

[0005] Traditional bullet resistant vests use layers of high strength fabric material, to catch bullets which generally have rounded noses. These traditional vests allow the fabric a great level of movement in catching the rounded bullets, and function much like a trampoline catching a bowling ball. The significant force of the bowling ball dropping, is dissipated into the moving fabric layer of the trampoline. However, it’s very easy to puncture the fabric layer of a trampoline with an ice pick, as the tiny point simply pushes in between the strands of fabric without needing to break or shear them. This is why many body armor vests can have high bullet resistance and poor knife/stab resistance. [0006] Cutting and puncture from sharp edges is also a major concern on the battlefield. Many of the modem anti-personnel exploding munitions which include grenades, artillery shells, rockets, bombs, missiles, etc., are specifically designed to fragment into many smaller torn metal pieces with razor sharp jagged edges, known as shrapnel. These razor sharp jagged edges are different than the rounded nose of a bullet (like cutting your finger on the inside edge of a metal can). This shrapnel can slice through some armours designed to catch blunt nosed projectiles and cause horrific injuries and fatalities. Razor sharp shrapnel is a significant threat to extremities for modern troops who have little to no extremity protection currently. A quote from a nurse at the battle of Gallipoli - “Terrible, terrible wounds. The bullets aren’t so bad, but the shrapnel from exploding shells is ghastly. It cuts great gashes, ripping muscles and bones to shreds.” - staff nurse Lottie Le Gallais 1915.

[0007] For example, in US 8236711 which is a flexible spike and knife resistant composite material, are 10 layers of fabric which are joined or coated with an adhesive. This assembly utilizes fabric layers which in some cases are coated or laminated, but this design does not use separated and alternating fibrous/textile layers and flexible solid layers. Ten or more layers shown in this design start to be expensive and bulky /restrictive to wear.

[0008] In US 6526 862 is a fabric armor assembly using different layers of fabric in a quasiIsotropic orientation. Essentially the armor is attempting to raise penetration levels by layering different fabrics with different orientations of the weaves or knits. Again, this design does not alternate flexible solid materials and textile/fibrous material layers. We have found that slim spikes (like sewing needles) will push through and between the fibers of textile/fibrous materials relatively easily, even if there are many layers of different orientations of the weave/knit.

[0009] Another example is US 5362527 which is a flexible composite armor which utilizes small shapes of rigid metal bolted to a flexible fabric base. There are many examples of other armors using small rigid plates or armor elements fixed to a flexible base. Again, this is not alternating fibrous / textile layers with flexible solid layers. These designs are generally more expensive to manufacture, requiring both metal manufacturing/shaping, textile cutting/sewing, and then assembly of these disparate groups of materials to completed armor assemblies.

[00010] None of these configurations appears to adequately address maximizing puncture resistance from a slim spike or pointed wedge (knife point), while maximizing flexibility and pliability, as well minimizing the cost to manufacture. There is a need to maximize different physics of different materials with an assembly configuration to allow maximum possible movement between materials, to provide thin and cost efficient armor panels highly resistant to puncture from slim spikes, pointed wedges, or cutting from sharp edges.

Object of the Invention

[00011] It is an object of the present invention to overcome or substantially ameliorate at least one of the above disadvantages, or at least to provide a useful alternative to the above discussed armour systems and panels.

Summary of the Invention

[00012] Working extensively with pointed blades with razor sharp edges, and narrow spikes, we have learned that different material types are better resisting different threats. When sewing fabrics together with needles, for example using a ballpoint or jersey needle in a commercial sewing machine, the tip of the needle is slightly rounded at the end yet still tiny, which needle head will push in between the fibers of the textile material relatively easily without cutting/shearing/breaking them. Even extremely tightly woven or knitted fibrous materials can be sewn in this way, with needles penetrating with relative ease. Therefore, fibrous materials are not ideal for defeating a point. But when a sharp edge such as a knife is working to cut high strength fibrous/textile materials, these fibrous/textile materials excel. This is because the individual fibers/strands are allowed to move, and the knife blade must cut each strand/fiber independently. If you try to cut cloth with a knife, and don’t restrain the cloth, it will simply move with the blade and be difficult to cut.

[00013] It should be noted that solid materials generally are very good at resisting the starting of a cut or the initial puncture, particularly with solid plastic materials, which can be very inexpensive. This is because many plastics have long chains of molecules, and when you attempt to tear the edge of a plastic sheet (without a notch or cut in it) such as common and inexpensive PET or HDPE, it’s very difficult to start. This is because the entire edge of the plastic sheet is stretching and absorbing the force. This is why many plastic packages have notches/cuts in them where they are designed to tear, as without them they are embarrassingly hard to start. Similarly, when you push a point such as a needle or icepick through a solid sheet of this material, the material will stretch/deform from all around the location of the attempted puncture, providing significant resistance to the initial puncture similar to the resistance to the initial tear in an edge. This makes this solid material more resistant to initial puncture because there are no moving fibers/strands to push aside.

[00014] However, once a knife edge has started to cut in solid material, the sharp edge can easily continue the cut. At a molecular level, the blade acts like a wedge that opens up a fracture in the material. The shear forces are then concentrated at the apex of the cut, and once started the cut is easy to continue. Consider plastic packaging, which may be for a bag of potato chips or encapsulating a screwdriver. If you try to tear open the packaging from a smooth edge of the plastic material, is embarrassingly hard to start. However, if there is a notch/rip in the plastic, you can then rip it open easily. It can take relatively high energy to puncture flexible solid material or to start a cut in it, but once the cut is started it takes relatively less energy to continue the cut.

[00015] So, a sharp edge of a knife can excel at cutting a solid material but struggles to cut unrestrained fibrous/textile material. The point of a needle can excel at pushing between the fibers and individual strands of fibrous / textile material, yet struggle to puncture through unrestrained flexible solid material, as there are not individual strands/fibers to push aside.

[00016] Further, there are studies that demonstrate an inverse relationship to puncture forces and rigidity of material. Pushing a point through a flexible solid material with no backing or restraint is very difficult. Cutting through / across unrestrained cloth is very difficult as the fibers may simply move rather than cut. Although it may seem counter intuitive, more rigid materials can actually be easier to puncture, and more flexible materials can be more difficult to puncture. Many armor designs take highly flexible elements and bind them with resins or other bonding agents providing a more solid material, which acts like backing to concentrate high impact/puncture forces to a smaller surface area of the material, which in effect actually reduces its puncture resistance. An example to illustrate this would be trying to hammer a nail into a piece of wood where the wood is resting on a thick folded up towel. The energy of the hammer blow into the nail, will be largely absorbed into the compression of the towel underneath and the nail will struggle to penetrate far into the wood. However if the piece of wood is placed on a more rigid substrate the hammer blow will be focused into the head of the nail, and there will be nowhere else for the energy to dissipate, so the energy will force the nail to penetrate much more deeply. The more rigid the backing, the more penetration you’ll get with the same force applied.

[00017] Therefore combining the physics of fiborous/textile materials whose numerous individual strands and fibers excel at defeating cuts from blades, along with the physics of flexible solid materials which excel at resisting puncture from points with no fibers/strands to push aside, along with the physics of both types of materials being largely unattached to one another, and largely unrestrained, this allowing excessive movement, creates an assembly that is very difficult to penetrate and or cut through.

[00018] This invention, at least in a preferred embodiment, takes advantage of all of these physics’ properties of materials, utilizing alternating and separated solid layers and fibrous layers, in assemblies allowing the maximum amount of movement and flexibility between the layers, which layers are specifically not connected or minimally connected, allows the best resistance to puncture in the minimum armor thickness, and minimum armor cost.

[00019] When a pointed wedge with sharp edges (such as a dagger point) encounters this armor assembly, a number of things occur. The tiny sharp point of the wedge will push aside strands of the fibrous material, and then the port will encounter a solid layer which will offer greater resistance to the point. As the pointed sharp edged wedge presses down, many of the fibers of the textile layers move rather than shear, and the flexible solid material will move away from the point rather than puncture. If there is enough force for the pointed wedge to push past this solid layer it will encounter another fibrous layer which will resist cutting, and another flexible solid layer which will further resist the point. By utilizing alternating substantially unattached layers of material, it has been found that the total number of layers required to defeat a pointed wedge for a specific amount of energy is greatly reduced. An enhancement to this system is the addition of very hard elements to the outer most side of the system, which hard elements may damage or blunt very sharp points/edges therefore making further penetration through the assembly even harder. These harder outermost elements may be in large individual sheets, smaller adjacent elements, or overlapped smaller elements.

[00020] In a first aspect the present invention includes an assembly comprised of at least two layers of fibrous material, at least one layer of solid (non-textile material but may be flexible/pliable such as plastic sheet) material of substantially the same surface area as the fibrous material layers, and a means to hold the minimum three layers of material in relative position to one another while the three layers are substantially not connected to one another, where by the layers of fibrous material alternate with at least one layer of solid material.

[00021] Preferably there are four textile fibrous players alternating with three non -textile (flexible or (semi)rigid) layers, for a total of seven layers.

[00022] Preferably there are multiple fibrous textile layers adjacent to one another, and multiple layers of flexible solid material adjacent to one another.

[00023] Preferably the alternating layers of fibrous material and solid material have a low coefficient of friction between the adjacent layers allowing separate layers to freely slide relative to one another.

[00024] Preferably the alternating layers are held in relative position by minimal attachment at the approximate center of the surface area of the material through all layers.

[00025] Preferably the minimal attachment between layers occurs continuously or discontinuously substantially at the perimeter of the surface area of material.

[00026] Preferably the means to hold the alternating layers of fibrous and flexible solid materials in relative position is by no attachment between the layers, but by enclosing the stack of alternating layers in a complete or partial pocket enclosure, which pocket enclosure is not attached or minimally attached to the stack of alternating layers.

[00027] Preferably the alternating layers of fibrous and flexible solid materials are held in relative position by (dis) continuously binding the perimeter edge of the stack of alternating layers with a bonding agent.

[00028] Preferably the alternating layers of fibrous and flexible solid materials are held in relative position by binding the perimeter edge with at least two locations of attachment.

[00029] Preferably the fibrous materials is a high strength fabric which may be a weave, knit, felt, or other, utilizing fibers including aramid fibers, UHMWPE, stainless steel strands, or other high strength fibers. [00030] Preferably, the fibrous material is comprised of a plurality of void shapes interlinked such as chain mail.

[00031] Preferably the solid material layer(s) utilizes a flexible yet high strength material such as PET, or HDPE, or Cuben Material, or other solid non-woven non-knit material.

[00032] Preferably the solid material layer(s) are comprised of high strength fibrous material bonded, coated, infused, or otherwise treated to restrain individual fibers/strands from being pushed aside during puncture.

[00033] Preferably the binding agent to coat, infuse, or otherwise bond materials includes resins, or any poly urea including hot sprayed poly urea.

[00034] Another aspect of this invention is the use of this armor system in a marine environment such as with sharks or rays or sharp barnacles, where layered armor systems are not currently used.

[00035] Another aspect of this invention is the use of this armor system in critical body areas such as underarms, groins, necks, where pliability and flexibility is critical and yet most armor systems do not offer protection currently.

[00036] Another aspect of this invention is the use of this armor system for extremity protection including coverage of knees, elbows, hips etc. where high flexibility and mobility is desired and most armor systems do not cover these areas currently.

[00037] Another embodiment of the invention utilizes a waterproof sealed enclosure on the outside perimeter of the layered armor element, such that the enclosure can feature positive buoyancy, neutral buoyancy, or negative buoyancy.

[00038] Preferably, the individual alternating layers are loosely bonded or not bonded to other layers, such that each layer can move with, deform to, or otherwise encapsulate around or away from a threat object, with said movement significantly independent of other layers.

[00039] Preferably, the means to relatively align the alternating layers of material is loose stitching. [00040] Preferably, the loose stitching may be designed to break or fail to allow complete unrestrained movement of the individual layers while under significant stress.

[00041] Preferably, the loose attachment of the layers is designed to elongate under significant stress imposed by a threat object.

[00042] Preferably, the means to relatively align the alternating layers is a flexible or elastic outer covering or pocket, wherein the alternating protective layers are not bonded or attached to one another in any way.

[00043] Preferably, a layer of discontinuous plates may be placed on an individual layer or layers, and are comprised of a high strength metal, plastic, or composite, bonded to said layer by mechanical bonding, adhesive, or casting/creating the plate on within or partially within the individual layer.

[00044] Preferably, at least one outermost layer(s) features a continuous or semi continuous (semi) rigid plate, which can distribute a concentrated force from a threat to be distributed to a larger surface area underneath.

[00045] Preferably, the alternating layers of high strength fiberous material and solid materials have no physical gaps in between, yet they are significantly unconnected to one another to allow maximum freedom of movement.

[00046] Preferably the outermost layer includes a hard rigid element or elements designed to deform a point or an edge such that the deformed point or edge has greater surface area which reduces its ability to puncture through the assembly.

[00047] Preferably the hard rigid elements are arranged to a flexible material such that the material is bendable and pliable the gaps between adjacent rigid elements which form hinges.

[00048] Preferably the hard rigid elements overlap with one another.

[00049] Preferably the hard rigid elements are in two or more layers whereby the gaps between adjacent rigid elements and one layer are covered by rigid elements of a second layer. [00050] In another aspect is the new use of PET plastic for armor panels in the marine environment to resist the effect of cutting and puncture such as for shark bites.

[00051] In another aspect is the new use of HDPE plastic for armor panels in a marine environment to resist the effect of cutting and puncture such as for shark bites.

[00052] Preferably, the layers include any form of poly urea.

Brief Description of Drawings

[00053] Figure 1 depicts an improved armor assembly with two layers of textile material and one layer of a solid (non-textile) flexible material with a central attachment between the layers.

[00054] Figure 2 depicts the same armor assembly of Figure 1 bending from a force applied.

[00055] Figure 3 depicts a similar armor assembly of figure 1 only using a pocket to hold the layers in relative position to one another, with a force applied.

[00056] Figure 4 depicts the same armor assembly of figure one and figure 2 in an isometric view showing two layers of the fibrous textile material one layer of non-textile (flexible or (semi)rigid) material in between with a linear arrangement of central attachments.

[00057] Figure 5 depicts and armor assembly of three layers of fibrous textile material two layers of non-textile (flexible or (semi)rigid) material, with an encapsulating pocket.

[00058] Figure 6 depicts the same five alternating layer assembly of figure 5 with a threat object supplying a lateral force, moving the layers laterally in relation to one another.

[00059] Figure 7 depicts a five-layer assembly with four layers of fibrous textile material three layers of non-textile (flexible or (semi)rigid) material all held in relative position by perimeter attachments.

[00060] Figure 8 depicts the same seven-layer assembly of figure 7 in a top-down view isometric perspective view. [00061] Figure 9 depicts a seven layer assembly of four layers of fibrous textile material, three layers of non-textile (flexible or (semi)rigid) material and a bonding agent applied to the perimeter edge of the assembly.

[00062] Figure 10 depicts a similar seven-layer armor assembly of Figure 9 where the encapsulating agent is applied to the entire exterior of the assembly.

[00063] Figure 11 depicts a single layer of high strength fibrous textile material with a bonding agent applied and bonded to the top of the material.

[00064] Figure 12 depicts a single layer of fibrous textile high strength material being infused with a bonding agent where the bonding agent simply fills most of the voids between the fibers.

[00065] Figure 13 Shows a magnified view of fibrous textile material, where you can clearly see fiber strands in two directions/orientations and a blunt needle with a downward force pushing in between fibers. This figure illustrates why fibrous textile materials are relatively poor at preventing puncture from points.

[00066] Figure 14 depicts a similar magnified high strength fibrous textile material of figure 13 with a force applied from a knife. This figure demonstrates significant resistance high strength fabric can have from being cut with a blade, particularly when the fibrous textile material is allowed to move with the force of the blade.

[00067] Figure 15 depicts a top down view of solid material being impacted by the downward force of a blunted needle showing concentric rings of stretching forces of the solid material being stretched centrally towards the attempted puncture from the blunted needle.

[00068] Figure 16 depicts the same elements of figure 15, however shown in section where the blunted needle with a downward force is deforming the solid material and the solid material is stretching centrally towards the location of the attempted puncture.

[00069] Figure 17 depicts a sharp knife blade cutting through solid material. Essentially the edge of the knife creates a fracture at the point it contacts the material, and the knife acts like a wedge pushing apart the material on both sides of the knife blade. [00070] Figure 18 depicts the same image of figure 17 from the underside showing the solid material being cut where the apex of the cut occurs at the thin sharp edge of the knife.

[00071] Figure 19 depicts a five-layer armor assembly of three layers of textile fibrous material 51 two layers of flexible solid material 52 on top of a compressible energy absorbing backing with a blunted needle applying a downward force, where much of the downward force is simply absorbed by the compressive backing material.

[00072] Figure 20 depicts a similar five-layer armor system comprised of three layers of textile fibrous material and two layers of a flexible solid material, with a blunted needle in downward force applied. The rigid backing serves to help the puncturing force focus that force into a tiny surface area.

[00073] Figure 21 depicts a five layer armor assembly comprised of three layers of a textile fibrous material and two layers of a non-textile (flexible or (semi)rigid) material. One attachment is an elongating attachment, and another attachment is designed to break.

[00074] Figure 22 depicts the same five-layer armor assembly of figure 21 with a force applied from a threat object, elongating attachments.

[00075] Figure 23 depicts the same five-layer armor assembly of figure 21 with a force applied from a threat object, elongating one attachment, and breaking the other.

[00076] Figure 24 depicts a three-layer armor assembly comprised of two layers of fibrous textile material one layer of non-textile (flexible or (semi)rigid) material in a binding matrix which encapsulates all three layers.

[00077] Figure 25 depicts the same armor assembly as figure 24, where the downward force of a threat object is deforming the entire flexible pliable armor assembly.

[00078] Figure 26 depicts and armor assembly comprised of two layers of a textile fibrous material and a single layer in between of a non-textile (flexible or (semi)rigid) material where in the binding matrix not only encapsulates all the layers but is also infused in between the fibers and strands of the fibrous textile material. [00079] Figure 27 depicts a five layer armor system comprised of three layers of a textile fibrous material and two layers of a non-textile (flexible or (semi)rigid) material and (semi) rigid plates bonded to the topmost layer.

[00080] Figure 28 depicts the same assembly as figure 27 where a pointed threat object is blunted or damaged upon contact with the (semi) rigid outer plate.

[00081] Figure 29 depicts a similar assembly as figure 28 with another overlapping layer of rigid outer plates 140 affixed 141 to a (semi) rigid material whereby the (semi) rigid material can distribute a concentrated threat force to a greater surface area of armor underneath, and offset the gaps in the underlying rigid armor plates

Detailed Description of Embodiments

[00082] Figure 1 depicts an improved armor assembly with two layers of fibrous textile material 51 one layer of a solid (non-textile but may be flexible) material 52 a central attachment between the layers 53, allowing a substantial surface area of each layer to be unbonded and allow greater movement and flexibility.

[00083] Figure 2 depicts the same armor assembly of Figure 1 with a force 56 applied to the two layers of fibrous textile material 51 and the one alternated layer of non-textile (flexible or (semi)rigid) material 52 with central attachment 53. Note the perimeter edges are unrestrained 60 and may move freely.

[00084] Figure 3 depicts a similar armor assembly of Figure 1, with a force 56 applied whereby the assembly is bending. The two layers of fibrous textile material 51 and alternate layer of flexible solid material 52 in between, with no attachment between these alternating layers held together by end encapsulating pocket 61 which also is not attached to either the textile layer 51 or the flexible solid layer 52 note there is no attachment between the alternating layers 59.

[00085] Figure 4 depicts the same armor assembly of Figure 1 and Figure 2 in an isometric view showing two layers of the fibrous textile material 51 one layer of non-textile (flexible or (semi)rigid) material in between, and a linear arrangement of central attachments 53. [00086] Figure 5 depicts an armor assembly of three layers of fibrous textile material 51 two layers of non-textile (flexible or (semi)rigid) material 52, and an encapsulating pocket 62, and no attachment 59 between the layers or between the layers and the encapsulating pocket.

[00087] Figure 6 depicts the same five alternating layer assembly of figure 5 with a threat object 65 supplying a lateral force 56 which allows the armor assembly of five alternating layers and the flexible enclosure material 62 to move 66 in the same direction as the force applied 56.

[00088] Figure 7 depicts a five-layer assembly with four layers of fibrous textile material 51 three layers of non-textile (flexible or (semi)rigid) material 52, perimeter attachments 53, and substantially no other attachment or bonding between the layers 59.

[00089] Figure 8 depicts the same seven-layer assembly of figure seven in a top-down view isometric perspective showing the attachments 53 as discontinuous along substantially the perimeter of the assembly.

[00090] Figure 9 depicts a seven-layer assembly of four layers of fibrous textile material 51 three layers of non-textile (flexible or (semi)rigid) material 52 and a bonding agent 100 applied to the perimeter edge of the assembly to hold the alternating 7 layers in relative position note there is substantially no other bonding or attachment 59 in between the layers.

[00091] Figure 10 depicts a similar seven-layer armor assembly of Figure 9 where the encapsulating agent 100 is applied (dis) continuously to entire exterior of the assembly including the perimeter edge. This can optionally make the entire assembly waterproof. Note that there is still significantly no attachment 59 between the alternating seven layers.

[00092] Figure 11 depicts a single layer of high strength fibrous textile material 51 with a bonding agent applied 100 and bonded to the top of the material binding the fibers together so that the composite material performs similar to non-textile (flexible or (semi)rigid) material. This bonding agent may be a resin, flexible resin, (hot sprayed) poly urea, or similar high strength agent.

[00093] Figure 12 depicts a single layer of fibrous textile high strength material 51 being infused with a bonding agent 101 being applied 103 from a container 104 into a hybrid material 102 comprised of the high strength fibrous material and the bonding agent 101. Unlike Figure 11 where the bonding agent is substantially on top of and on another plane as the fibrous textile material, in Figure 12 the bonding agent and the fibrous textile material exist on the same plane where the bonding agent simply fills all the voids between the fibers.

[00094] Figure 13 shows a magnified view of fibrous textile material, where you can clearly see fiber strands 110 in one direction and perpendicular fiber strands 111 in section view and a blunt needle 114 with a downward force 112 whereby the needle tip is pushing away 115 individual fibers 111 and perpendicular fibers 110 so that the needle 114 can easily penetrate in between said fibers without cutting them or breaking them. This figure illustrates why fibrous textile materials are relatively poor at preventing puncture from small points by themselves, regardless of the number of layers used.

[00095] Figure 14 depicts similar magnified high strength fibrous textile material of figure 13 with a force applied 117 from a knife blade 118. Here you can see again individual fibers 110 and perpendicular fibers 111 where the perpendicular fibers 111 have some movement available 116 allowing some of the fibers 111 to move away from the force 117 of the knife blade 118, prior to said fibers 111 being broken or sheared. This figure demonstrates the significant resistance high strength fabric can have from being cut with a blade, particularly when the fibrous textile material is allowed to move with the force of the blade.

[00096] Figure 15 depicts a top down view of solid material 120 being impacted by the downward force of a blunted needle 114 showing concentric rings 121 of stretching forces 122 of the solid material being stretched centrally towards the attempted puncture from the blunted needle 114. Many inexpensive plastic sheet materials develop long chains of molecules that are very resistant to tearing and puncture via long chains of molecules. Within figure 16 is an illustration of those long molecules stretching without allowing the puncture.

[00097] Figure 16 depicts the same elements of Figure 15, however shown in section, where the blunted needle 114 with a downward force 112 is deforming the solid material 120 and the solid material is stretching 122 centrally towards the location of the attempted puncture. Figures 15 and 16 illustrate the advantage of a flexible solid material where small points cannot simply push individual fibers and strands to either side, such as would occur in a fibrous textile material, which allows the point to progress in between fibers. Rather, the solid (non-textile) material which is flexible will flex and deform and resist the puncture more strongly than fibrous textile materials. Solid (non-textile) materials that are (semi) rigid and/or hardened, may deform at the point of the threat (i.e., needle) increasing its surface are and decreasing it’s puncture potential.

[00098] Figure 17 depicts a sharp knife blade 118 cutting through solid material 120. Essentially the edge of the knife creates a fracture at the point it contacts the material 124 and the knife acts like a wedge pushing apart 123 the material on both sides of the knife blade 118. This concentrates the energy of the knife 117 to the apex of the material 124 contacting the sharp edge of the knife. Once the cut has started it takes relatively little energy to continue the cut as the energy is focused to a very thin sharp edge. Also, the thickness of the knife acts as a wedge, providing a mechanical advantage to pull/tear apart the material to either side of the blade.

[00099] Figure 18 depicts the same image of Figure 17 from the underside showing the solid material 120 being cut where the apex of the cut 124 occurs at the thin sharp edge of the knife 118 and the knife blade 118 acting as a wedge to force apart 123 the solid material 120 at either side of the knife blade 118. The knife handle 129 is also shown in this perspective. Figures 17 and 18 show the relative weakness of solid material to resist a cut once the cut has started. This is evidenced in daily life by plastic packaging that is very difficult to tear open unless there is a notch or a corrugated cut to allow the tear to start (which notches are very commonly manufactured for this specific reason). Once a tear, cut or rip is started it is relatively easy to continue, but again the initial tear cut or rip or puncture is difficult at first, because the solid material will stretch and deform prior to separating.

[000100] Figure 19 depicts a five-layer armor assembly of three layers of textile fibrous material 51 two layers of flexible solid material 52 on top of a compressible energy absorbing backing 130 with a blunted needle 114 applying a downward force 112. Note much of the downward force 112 is simply absorbed by the downward compression 131 of the compressive backing material 130, and the blunted needle 114 has not penetrated very deeply. This can also be achieved by textile material layers being able to compress and absorb energy, more so than nontextile (maybe solid) layers and allow the overall cross section of armor to compress and absorb the energy of a threat.

[000101] Figure 20 depicts a similar five-layer armor system comprised of three layers of textile fibrous material 51 two layers of a flexible solid material 52 a blunted needle 114 with a downward force applied 112. In this figure there is a rigid backing 132 and when the downward force is applied 112 to the blunted needle 114 the rigid backing 132 resists any movement 133, and so the downward force 112 pushes the blunted needle 114 more deeply through the layers of the armor assembly. Figures 19 and 20 demonstrate the extreme importance of flexible pliable layers whether they are fibrous textile materials or flexible solid materials. When (semi) rigid layers are utilized within the assembly the rigidity may serve to help the puncturing force focus that force into a tiny surface area. When the armor assembly allows maximum movement of the material layers independent of one another than the lower rigidity of the assembly creates a significantly higher puncture resistance. Ideally rigid layers are located to outer most locations.

[000102] Figure 21 depicts a five-layer armor assembly comprised of three layers of a textile fibrous material and two layers of a non-textile (flexible or (semi)rigid) material 52. One attachment is an elongating attachment 73 at the substantial perimeter of the assembly. The other attachment is an attachment designed to break under force 74.

[000103] Figure 22 depicts the same five-layer armor assembly of figure 21 with a force applied 56 from a threat object 65. The solid layer 52 and the textile layer 51 are both starting to deform to absorb the energy 56 of the threat object 65. Notice the solid layer 52 is stretching 80 towards the center of the location of the threat point impact and the perimeter edges of the solid material 52 are moving towards 79 the threat impact location. This demonstrates the importance of substantial surface areas of adjacent materials not being bonded together, and ideally having a low coefficient of friction to allow and aid slide-ability relative to one another. The elongating attachment 73 and the designed break attachment 74, are both moving in the direction 79 of the solid material.

[000104] Figure 23 depicts the same five layer armor assembly of Figure 22 with three layers of non-textile (flexible or (semi)rigid) material 52 two layers of fibrous textile material 51 more significant force 56 applied to a threat object 65 which is deforming the layers 77 and 76 it is allowing the perimeter edges of the materials to contract and move in the direction 79 of the threat object. The designed break attachment 74 is now breaking 75 under the severe force 56 of the threat object 65, which breaks allow greater movement of the material layers. The elongating attachment 73, is elongating further allowing the materials to move, deform, contract, for example, which movement reduces the actual puncture by absorbing the threat downward force 56 energy. [000105] Figure 24 depicts a three-layer armor assembly comprised of two layers of fibrous textile material 51 one layer of non-textile (flexible or (semi)rigid) material 52 in a binding matrix 90 which encapsulates all three layers, where by the binding matrix is flexible and pliable and allows movement of the armor assembly. The force applied 56 from the threat object 65 pushes the binding matrix 90 to deform in a similar direction 66. Also, the binding matrix may be shock absorbing as well to allow threat forces to be absorbed and lessen / dissipate concentrated puncture forces.

[000106] Figure 25 depicts these same armor assembly of figure 24 with two layers of textile fibrous material 51 a single alternate layer of non-textile (flexible or (semi)rigid) material 52 all fully encapsulated by a binding matrix 90 which is pliable and flexible. The downward force 56 of the threat object 65 is deforming the entire flexible pliable armor assembly.

[000107] Figure 26 depicts an armor assembly comprised of two layers of a textile fibrous material and a single layer in between of a non-textile (flexible or (semi)rigid) material where in the binding matrix 94 not only encapsulates all the layers but is also infused in between the fibers and strands of the fibrous textile material, which creates two composite layers, each comprised of the fibrous textile material infused with the binding agent 90 the composite layer noted as 94. Textile layer 51 is shown without encapsulating / infusing agents for reference and comparison to the composite layer 94. Note the binding agent matrix may also be compressive/shock absorbing to absorb and dissipate concentrated threat forces.

[000108] Figure 27 depicts a five layer armor system comprised of three layers of a textile fibrous material 51 two layers of a non-textile (flexible or (semi)rigid) material 52 attachments between the layers 53 and hardened rigid plates 140 bonded 141 to the topmost layer of fibrous textile material 51.

[000109] Figure 28 depicts the same assembly as Figure 27 where a pointed threat object 142 receives a blunted or damaged 143 penetrating tip from downward force 112 upon contact with the rigid outer plate 140. This damaged penetrating tip, even if it breaks through the rigid outer plate 140, will have reduced penetration ability due to its deformed penetrating tip.

[000110] Figure 29 depicts the same assembly as figure 28 with another overlapping layer of rigid outer plates 140 affixed 141 to a (semi) rigid material 144, where by the (semi) rigid material can distribute a concentrated threat force to a greater surface area of armor underneath, and alternately the (semi) rigid layer may move in the direction of the threat object to the extent that the layers underneath will compress and, gaps in the outermost rigid plates 140 are offset to the gaps in the underlying rigid armor plates 140, which are affixed to a textile fibrous layer 51. This provides additional protection should a threat object find a gap in one layer of plates, that threat object will find a solid rigid plate underneath in the next layer of rigid armor plates. The panel armor assembly whereby the textile material is composed of high strength fibers arranged to form a fabric. Preferably the textile material includes fabric made from metal. Preferably the non-textile material is composed of a metal. Preferably the non-textile material is composed of a composite material. Preferably the non-textile material is composed of a (semi) synthetic polymer. Preferably the textile or non-textile material utilizes any poly urea material. Preferably any poly urea material is used in addition.

[000111] Advantages of the present invention, at least in a preferred emdodiment, include:

1. Improved puncture and cut resistance with increased flexibility of the assembly.

2. More pliability of the armour panel assembly, which allows for more comfortable garment particularly in highly mobile extremities.

3. Improved puncture resistance to weight, which creates effective armour for activities where weight is critical such as water sports. Low weight is also critical for vigorous movement on land, such as law enforcement or military traversing significant areas on foot.

4. An armour assembly with high degrees of puncture and cut resistance which is lighter and thinner, and more cost effective than other systems currently offered.

5. An armor system which is thin and light flexible and pliable suitable for extremity protection whereas many current armor systems do not protect the extremities.

6. An armor assembly which is pliable and flexible can be made to cover and protect body areas requiring significant movement, which are largely unprotected currently, such as underarms, groins, and necks. [000112] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.