Composite segmented flexible armor

Abstract

A composite ballistic material has one or more layers of flexible ballistic fabric and a plurality of scales disposed in an overlapping configuration. Scale configurations may vary depending on an intended use. However, the scales may have a substantially uniform thickness and may also have a mounting portion and an overlapping portion. The mounting portions may be aligned in a single layer. The overlapping portions may extend wider than the mounting portions. The overlapping portions may also be substantially non-planar. The overlapping portions may be arranged so that the overlapping portion of individual scales lies under or over the overlapping portion of adjacent scales. Scales may be initially joined with a binder in rows and subsequently joined to a flexible fabric to create the overlap in a direction substantially perpendicular to the rows.

1 . A composite ballistic material comprising: 
 one or more layers of flexible ballistic fabric; and    a plurality of scales arranged in an overlapping configuration, the individual scales having a mounting portion and an overlapping portion, the mounting portions of the plurality of scales being disposed substantially in a non-overlapping layer, the overlapping portions of the scales having a first surface and a second surface spaced apart by a substantially constant thickness, an amount of the overlapping portion of a single scale that lies over or under other scales being between about 15 to 35 percent of a first overall width of the first surface in a first direction.    
   
   
       2 . The material of  claim 1  wherein the mounting portion of the individual scales has a second width between a first outermost surface and a second outermost surface in the first direction, the second width being smaller than the first width, the overlapping portion extending wider than the first and the second outermost surfaces of the mounting portion.  
   
   
       3 . The material of  claim 1  wherein an amount of the overlapping portion of a single scale that lies over or under other scales being between about 40 to 70 percent of a second overall width of the first surface in a second direction.  
   
   
       4 . The material of  claim 1  wherein the overlapping portion is substantially planar.  
   
   
       5 . The material of  claim 1  wherein the overlapping portion is substantially dome shaped.  
   
   
       6 . The material of  claim 1  wherein the overlapping portion is substantially curved.  
   
   
       7 . The material of  claim 1  wherein each of the plurality of scales is corrugated.  
   
   
       8 . The material of  claim 1  wherein the scales are polycarbonate scales.  
   
   
       9 . A composite ballistic material comprising: 
 one or more layers of flexible ballistic fabric; and    a plurality of scales having a substantially uniform thickness and further having a mounting portion and an overlapping portion, the mounting portions of the plurality of scales being disposed substantially in a non-overlapping layer, the overlapping portions of the plurality of scales being substantially non-planar and being arranged in an overlapping configuration so that the overlapping portion of individual scales lies under or over the overlapping portion of adjacent scales.    
   
   
       10 . The material of  claim 9  wherein the mounting portion of the individual scales has a first width between a first outermost surface and a second outermost surface in a first direction, the overlapping portion of the individual scales extending wider than the first and the second outermost surfaces of the mounting portion.  
   
   
       11 . The material of  claim 9  wherein the overlapping portion is substantially dome shaped.  
   
   
       12 . The material of  claim 9  wherein the overlapping portion is substantially curved.  
   
   
       13 . The material of  claim 9  wherein each of the plurality of scales is corrugated.  
   
   
       14 . The material of  claim 13  further comprising a second overlapping portion, the first overlapping portion and the second overlapping portion disposed on opposite sides of the mounting portion.  
   
   
       15 . The material of  claim 9  wherein the scales are polycarbonate scales.  
   
   
       16 . A method of constructing a composite ballistic material, the method comprising: 
 joining a row of scales having a substantially uniform thickness along a first direction to a plurality of flexible binders, each of the plurality of scales having a mounting portion and an overlapping portion, the mounting portions being disposed on the flexible binder in substantially in a non-overlapping layer, the overlapping portions of the scales being substantially non-planar and arranged in an overlapping configuration so that the overlapping portion of individual scales lies under or over the overlapping portion of adjacent scales; and    joining the plurality of flexible binders to a flexible fabric so that the overlapping portion of scales disposed on a first binder overlap the overlapping portion of scales disposed on a second binder.    
   
   
       17 . The method of  claim 16  wherein joining the plurality of flexible binders to a flexible fabric further comprises disposing a first part of the overlapping portion of scales disposed on the first binder under the overlapping portion of scales disposed on the second binder and disposing a second part of the overlapping portion of scales disposed on the first binder over the overlapping portion of scales disposed on a third binder.  
   
   
       18 . The method of  claim 16  wherein the scales are corrugated.  
   
   
       19 . The method of  claim 16  wherein the flexible fabric is a ballistic fabric.  
   
   
       20 . The method of  claim 16  wherein the overlapping portion of individual scales is curved.  
   
   
       21 . The method of  claim 16  where the mounting portions of the row of scales have a width in the first direction measured between a first outermost surface and a second outermost surface, the overlapping portion of the individual scales extending wider than the first and second outermost surfaces.  
   
   
       22 . The method of  claim 16  wherein the scales are polycarbonate scales.