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
Engineering Contradiction Analysis
1Productivity
If manual positioning of composite spacers between ceramic tiles is used, then assembly flexibility is maintained, but assembly time and labor intensity increase significantly
Solution Approach 1:
The preform is prepared in advance with precisely positioned apertures and recesses that correspond to the exact locations where ceramic tiles and composite spacers need to be placed. This preliminary configuration of the preform structure eliminates the need for manual positioning during assembly, as components simply fit into their predetermined locations, thereby increasing assembly speed while maintaining positioning accuracy
Solution Approach 2:
The preform acts as an intermediary structure between the face sheets and the ceramic tiles/spacers. It provides a standardized interface with pre-configured apertures and recesses that guide component placement, serving as a mediator that translates the complex manual positioning task into a simple insertion process, thus improving productivity without sacrificing ease of operation
2Productivity
If automated preform systems are implemented, then assembly time is reduced, but manufacturing complexity increases
Solution Approach 1:
The preform is designed as a segmented structure with distinct functional zones including apertures for tile insertion, recesses for spacer placement, and attachment regions for face sheets. This segmentation allows each zone to be optimized independently for its specific function, simplifying the overall manufacturing process while enabling automated assembly through standardized geometric features
Solution Approach 2:
The preform utilizes variations in geometric parameters such as aperture size, recess depth, and wall thickness to differentiate functional regions. These parameter changes are achieved through standard manufacturing processes, allowing the complex-looking preform to be produced efficiently. The geometric parameter variations provide the necessary functionality without requiring complex manufacturing equipment or processes
3Manufacturing precision
If preforms with integrated tile positioning are used, then manufacturing precision is improved, but material usage and cost increase
Solution Approach 1:
The preform is designed to perform multiple functions simultaneously: it provides structural support between face sheets, positions ceramic tiles through apertures, locates composite spacers via recesses, and distributes impact forces. This multi-functionality is achieved within a single integrated component using efficient material distribution, avoiding the need for separate positioning fixtures or additional materials, thereby maintaining manufacturing precision without excessive material consumption
Data Source
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.