Composite Preform Stitching for Armor Tile Positioning
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Solution Overview
Problem
The manual and labor-intensive process of assembling composite armor systems, which involves positioning spacers between ceramic tiles to absorb impact forces, is time-consuming and inefficient.
Innovation Solution
A method using a composite preform that circumscribes an area and includes a shaped sidewall with flanges to automatically position and secure armor tiles between face sheets, reducing manual labor through the use of robotic assembly and vacuum-assisted resin transfer molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly process is used to position spacers between ceramic tiles, then the armor system can be assembled, but the process is time-consuming and labor-intensive
Solution Approach 1:
The preform is pre-shaped with integrated spacers and flanges before assembly. The spacers are pre-positioned within the preform structure, and the flanges are pre-formed to extend beyond the tile perimeter. This preliminary preparation eliminates the need for manual spacer positioning during assembly, significantly reducing assembly time and labor requirements while maintaining precise spacer placement.
2Reliability
If composite spacers are manually positioned between tiles, then impact forces can be absorbed, but the process requires significant manual labor
Solution Approach 1:
The preform merges multiple components into a single integrated structure. The spacers, flanges, and preform body are combined into one piece that performs multiple functions: providing spacer positioning, tile support, and force distribution. This merging eliminates the need for separate manual positioning operations and reduces the number of assembly steps while ensuring reliable force absorption between tiles.
3Extent of automation
If automated robotic assembly is used, then assembly efficiency is improved, but the preform structure must be precisely designed for robotic manipulation
Solution Approach 1:
The preform extends in multiple dimensions with flanges that protrude beyond the tile perimeter in a third dimension. This dimensional extension creates accessible features for robotic grippers and positioning mechanisms, enabling automated manipulation without requiring complex internal structures. The flanges provide external reference points and manipulation interfaces that simplify robotic assembly while maintaining precise tile positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates the rapid and cost-effective assembly of composite armor laminates by automating the placement of tiles and dispersing impact forces across a wider area, enhancing the reliability and efficiency of the armor system.
Implementation Method 1
dispersing impact forces across a wider area
Implementation Method 2
vacuum-assisted resin transfer molding
Data Source
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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.