Oct 7, 2025

US12435954 - Flexible body armor

Implementations described and claimed herein provide a ballistic filler for a flexible soft body armor and methods of manufacturing the same. In one implementation, a first portion having a first subpanel is stitched directly to a second subpanel with a stitching pattern. The first subpanel has one or more layers of woven fabric, and the second subpanel has one or more layers of unidirectional fabric. A second portion backs the first portion. The second portion has one or more layers of unstitched unidirectional fabric.

Assignee: TYR Tactical, LLC
Inventors: Jason Beck
Filing date: 2023-08-01

The patent describes a flexible body armor ballistic filler that incorporates multiple layers of woven and unidirectional ballistic fabrics, specifically using high strength yarn and ultrahigh molecular weight polyethylene yarn. The assembly consists of stitched panels that enhance the armor’s protective capabilities while maintaining flexibility.

Claim 1

A flexible body armor ballistic filler comprising: a first subpanel comprising a plurality of layers of flexible ballistic woven fabric generated from a high strength yarn; a second subpanel backing the first subpanel, the second subpanel comprising a plurality of layers of unidirectional ballistic fabric generated from ultrahigh molecular weight polyethylene yarn the first subpanel stitched to the second subpanel to form a first panel; and a second panel comprising a plurality of layers of unidirectional ballistic fabric generated from ultrahigh molecular weight polyethylene yarn, the plurality of layers being stitched tougher; a third panel comprising one or more unstitched ballistic ply structures generated from the high strength yarn, wherein the first panel, the second panel and the third panel are stitched together at a proximate end and a distal end to define a ballistic filler assembly. a first subpanel comprising a plurality of layers of flexible ballistic woven fabric generated from a high strength yarn; a second subpanel backing the first subpanel, the second subpanel comprising a plurality of layers of unidirectional ballistic fabric generated from ultrahigh molecular weight polyethylene yarn the first subpanel stitched to the second subpanel to form a first panel; and a second panel comprising a plurality of layers of unidirectional ballistic fabric generated from ultrahigh molecular weight polyethylene yarn, the plurality of layers being stitched tougher; a third panel comprising one or more unstitched ballistic ply structures generated from the high strength yarn, wherein the first panel, the second panel and the third panel are stitched together at a proximate end and a distal end to define a ballistic filler assembly.

Google Patents

https://patents.google.com/patent/US12435954

USPTO PDF

https://image-ppubs.uspto.gov/dirsearch-public/print/downloadPdf/12435954