Flexible Body Armor Panel Assembly for Vest Mobility

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Solution Overview

Problem

Rigid ballistic panels in personal protective vests restrict freedom of movement, compromising comfort and flexibility while providing safety protection.

Innovation Solution

A personal protective vest system with a soft-flexible armor panel comprising a plurality of layered material segments, each made of different ballistic materials, including ultra-high molecular weight polyethylene fiber composites, para-aramid materials, and woven laminates, which are removably inserted into a vest pocket and sealed within a water-resistant outer cover.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If rigid ballistic panels are used in personal protective vests, then safety protection is improved, but freedom of movement and flexibility deteriorate

Engineering Contradiction:

Improvesafety protectionVSAvoidfreedom of movement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces rigid ballistic panels with flexible armor panels constructed from multiple layers of flexible ballistic material segments. These segments are bonded together to form a composite structure that maintains ballistic protection while enabling freedom of movement. The flexible nature of the panels allows them to conform to the wearer's body movements without restricting motion, thus resolving the contradiction between safety protection and freedom of movement.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent employs composite materials by combining multiple different ballistic material segments (such as aramid, polyethylene, and other fiber composites) into a single flexible armor panel. This composite construction allows the panel to achieve the necessary ballistic resistance while maintaining flexibility and comfort. The combination of different materials optimizes both protective performance and wearability, addressing the contradiction between safety and mobility.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If removable armor panels are used, then ease of operation is improved, but device complexity increases

Engineering Contradiction:

Improveease of insertion and removalVSAvoidpanel assembly structure

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent divides the armor panel into separate, removable segments that can be independently inserted and removed from the vest. Each panel is constructed as a self-contained unit with ballistic material segments bonded to a flexible substrate, allowing for easy installation and removal without compromising the overall protective system. This segmentation enables users to quickly adjust or remove panels as needed, improving ease of operation while keeping each individual panel structurally simple.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20260049793A1Body armor panel for use with personal protective vest and system for assembling same

Publication Date: 2026.02.19 SAFE LIFE DEFENSE LLC

AI summary

A personal protective vest assembly is described herein. The personal protective vest assembly includes a personal protective vest and a body armor panel positioned within the personal protective vest. The body armor panel includes a ballistic material panel assembly that includes a plurality of layered material segments defined between a strike face and a wear face. Each of the layered material segments includes a different ballistic material.