Modular Spall Liner Tie Layer Segmentation
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Solution Overview
Problem
Existing spall liners with numerous plies of Kevlar face challenges in securing multiple layers effectively, as conventional sewing machines can only handle up to 10-12 plies, leading to diminished durability and ballistic effectiveness if not secured properly, and excessive sewing can also compromise performance.
Innovation Solution
The solution involves adding tie layers to secure each set of plies and then securing these tie layers together, using a modular design with separable fasteners for easy installation and removal, allowing for customization based on threat types and vehicle configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional sewing machines are used to secure multiple plies of Kevlar, then up to 10-12 plies can be secured, but the spall liner thickness and ballistic effectiveness are limited
Solution Approach 1:
The spall liner is divided into multiple modular ply sets, where each set contains a manageable number of plies (within the 10-12 ply sewing capacity) secured to a common tie layer. This segmentation allows the overall thick liner to be constructed by assembling multiple such sets, overcoming the sewing machine limitation while achieving the desired total thickness and ballistic protection.
Solution Approach 2:
Tie layers are introduced as intermediary elements that secure groups of plies together. Instead of attempting to sew through all plies simultaneously (which exceeds machine capacity), the tie layers act as mediators that bind subsets of plies, and these tie layers themselves can be secured to each other, creating a scalable assembly process.
2Quantity of substance
If excessive sewing is performed to secure numerous plies, then more plies can be attached, but durability and ballistic performance are compromised
Solution Approach 1:
By segmenting the plies into discrete sets secured to individual tie layers, the invention limits the number of plies subjected to any single sewing operation to within the optimal 10-12 ply range. This prevents excessive sewing that would compromise material integrity, while still achieving high overall ply counts through the assembly of multiple segmented sets.
Solution Approach 2:
Rather than attempting to secure all plies in a single excessive sewing action (which would harm reliability), the invention uses multiple partial sewing actions, each securing a manageable subset of plies to a tie layer. The cumulative effect of these partial actions achieves the desired total ply count without exceeding the safe sewing limit for any individual operation.
3Quantity of substance
If a thick spall liner is created by adding many plies, then ballistic protection is improved, but the liner becomes difficult to install and remove
Solution Approach 1:
The thick spall liner is constructed from multiple modular ply sets that can be independently assembled and secured to the vehicle interior. This segmentation enables the liner to be installed in sections rather than as a single large piece, significantly improving ease of installation and removal while maintaining the desired total thickness for ballistic protection.
Solution Approach 2:
The invention employs removable tie layers and separable fastener structures that allow the spall liner to be dynamically assembled and disassembled. This dynamic design enables easy installation and removal of the thick liner without permanent attachment, facilitating maintenance, replacement, or reconfiguration based on operational requirements.
4Quantity of substance
If a fixed thick spall liner is installed, then ballistic protection is maximized, but the liner cannot be adapted to different threats or vehicle configurations
Solution Approach 1:
The modular ply set architecture with removable tie layers enables different combinations and configurations of plies to be assembled based on specific threat requirements. Users can select and assemble the appropriate number and arrangement of ply sets to match different ballistic threats or vehicle configurations, while maintaining a ready supply of additional plies for future needs.
Solution Approach 2:
The dynamic, removable design allows the spall liner configuration to be adjusted and reconfigured for different operational scenarios. Ply sets can be added, removed, or repositioned to adapt to varying threat levels and vehicle interior configurations, providing versatility without sacrificing the ability to achieve high thickness when needed for maximum protection.
Data Source
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AI summary
A spall liner including a first plurality of flexible fabric plies of a first dimension secured together and secured to a first tie layer of a second, larger dimension. At least a second plurality of flexible fabric plies are secured together and secured to a second tie layer. The first and second tie layers are secured together. A cover includes separable fastener structure of a first type for removeably securing the liner to the inside hull of a vehicle equipped with separable fastener structure of a second type.