Composite Armor Preform Stitching for Tile Positioning

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Solution Overview

Problem

The manual and labor-intensive process of assembling composite armor laminates, where a composite spacer is positioned between ceramic tiles to absorb impact forces, is time-consuming and inefficient.

Innovation Solution

A system and method using a shaped preform that circumscribes an area and includes a tile of armor material, where the preform is formed from composite fibers and integrated with face sheets to automate the positioning of tiles, reducing manual labor and enhancing force absorption and distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual positioning of composite spacer between tiles is used, then assembly flexibility is maintained, but assembly time and labor intensity increase significantly

Engineering Contradiction:

Improveassembly speedVSAvoidmanual positioning difficulty

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The composite spacer is pre-formed with protrusions that extend through openings in the face sheet before assembly occurs. This preliminary shaping allows the spacer to automatically guide and position itself between tiles during assembly, eliminating the need for manual positioning while maintaining assembly flexibility.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protrusions on the composite spacer act as intermediary elements that engage with corresponding features on the face sheet and tiles. This intermediary mechanism facilitates automated positioning by providing mechanical guidance and constraint, reducing both assembly time and manual labor requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If composite spacer absorbs impact forces, then adjacent tile damage is reduced, but force distribution area is limited

Engineering Contradiction:

Improvedamage protectionVSAvoidforce distribution area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The composite spacer protrusions extend through openings in the face sheet, utilizing the third dimension (depth/thickness) to distribute forces. By projecting outward and engaging with multiple surfaces, the spacer increases the effective force distribution area beyond what a flat spacer could provide, while maintaining compact overall dimensions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The use of composite material for the spacer provides both high strength for force absorption and potential for complex geometric shaping. The composite nature allows creation of protrusions with optimized force distribution characteristics that can engage multiple tiles and the face sheet simultaneously, expanding the force distribution area.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS8720314B2Methods and systems for fabrication of composite armor laminates by preform stitching

Publication Date: 2014.05.13 THE BOEING CO

AI summary

Methods and systems for an armor system are provided. The system includes a first face sheet and a shaped preform extending from the first face sheet. The preform includes a first edge proximate the first face sheet, a sidewall extending from the first edge to a flange extending substantially perpendicularly from the sidewall. The preform circumscribes an area of the first face sheet. The system also includes a tile of armor material complementarily-shaped to fit within the area circumscribed by the preform. The tile is positioned within the preform such that at least a portion of the tile is between the first face sheet and the flange. The system includes a second face sheet covering the preform and the tile on a side opposite from the first face sheet.