Contoured Composite Armour Panel Lapping Joint Design
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Solution Overview
Problem
Existing vehicle armor systems have weaknesses at gaps and edges of panels, as well as connection joints, and struggle to effectively cover contoured surfaces without introducing additional internal seam lines.
Innovation Solution
The armor panel is made from a composite material with ceramic tiles embedded in a polymeric matrix, structurally reinforced by fibre fabric, featuring a lapping edge design where tile layers are arranged in an overlapping stairstep relationship to form a recess for seamless integration with adjacent panels, and a method of resin transfer molding to prevent misalignment and ensure structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional plate-like armour panels are used to cover contoured surfaces, then coverage is achieved, but internal seam lines are introduced at connection joints between adjacent panels
Solution Approach 1:
The armour panel is segmented into multiple layers including a strike face layer with interlocking tiles, a core layer, and a rear face layer, where each segment serves a specific function while collectively eliminating seam lines through the integrated lapping joint design
Solution Approach 2:
The lapping joint design nests one panel's edge into a recess formed by overlapping tile layers of the adjacent panel, creating a nested configuration that eliminates gaps and seam lines while maintaining contoured surface coverage
2Reliability
If traditional armour panels are used, then basic protection is provided, but points of weakness exist at gaps and edges of panels
Solution Approach 1:
The strike face layer features locally optimized interlocking tiles with enhanced material properties at edges and corners, where the lapping joint design provides additional layering and material density specifically at vulnerable peripheral regions to eliminate weak points
Solution Approach 2:
The lapping joint design incorporates overlapping tile layers that extend beyond the panel edges, creating a cushioning effect where additional armour layers are positioned in advance at potential weak points to deflect or absorb impacts before they reach critical areas
3Strength
If ceramic tiles are embedded in polymeric matrix with fibre fabric reinforcement, then structural integrity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The armour panel utilizes a composite material system where ceramic tiles are embedded in a polymeric matrix and structurally reinforced by fibre fabric layers, combining the hardness and ballistic resistance of ceramics with the toughness and structural strength of the composite matrix and fabric reinforcement
Solution Approach 2:
The manufacturing process merges multiple functions into a single integrated panel structure, where the strike face layer, core layer, and rear face layer are combined with lapping joints formed in one molding operation, reducing assembly steps while maintaining complex composite structure
Data Source
AI summary
An armor panel provides a continuous armored strike face defined within a periphery. The panel is manufactured from a composite material having a plurality of armor tiles embedded in a polymeric matrix that is structurally reinforced by a layer of fiber fabric. The armored strike face may be contoured to accommodate the base upon which it will be mounted. In some applications, an armor system is assembled from at least two of the armor panels. In such a system, at least a portion of the periphery of each armor panel defines an internal seam edge of the armor system. Each such periphery portion is in a lapping relationship with the corresponding internal seam edge of another armor panel.