Methods and systems for fabrication of composite armor laminates by preform stitching
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.
1. An armored vehicle comprising:
a vehicle hull; and
an armor system covering at least a portion of said hull, said armor system comprising:
a first face sheet;
a preform extending from said first face sheet, said preform defining a plurality of cells that each comprise a first edge adjacent to said first face sheet, a first flange extending substantially perpendicularly from said first edge, a second edge opposite said first edge, a sidewall extending from said first edge to said second edge, and a second flange extending substantially perpendicularly from said second edge;
a plurality of tiles of armor material, each of said plurality of tiles is in a corresponding one of said plurality of cells; and
a second face sheet covering said preform and said plurality of tiles on a side opposite from said first face sheet, at least a first portion of each of said tiles is covered by a second flange of said corresponding cell and at least a second portion of each of said tiles is covered by said second face sheet.
2. A vehicle in accordance with claim 1 wherein said preform circumscribes at least one tile.
3. A vehicle in accordance with claim 1 wherein said preform comprises a plurality of passes of carbon fabric circumscribing said plurality of tiles.
4. A vehicle in accordance with claim 1 wherein said preform is formed integrally with said first face sheet.
5. A vehicle in accordance with claim 1 wherein said first edge of said preform is coupled to said first face sheet using an adhesive.
6. A vehicle in accordance with claim 1 wherein said first edge is coupled to said first face sheet using stitching.
7. A vehicle in accordance with claim 1 wherein said first face sheet is attached to said preform using said first flange.
8. A vehicle in accordance with claim 7 wherein said first flange comprises a first toe and second toe wherein said toes of said first flange extend in opposite directions substantially parallel to said first face sheet.
9. A vehicle in accordance with claim 1 wherein said second edge is coupled to said second face sheet using an adhesive.
10. A vehicle in accordance with claim 1 wherein said second edge is coupled to said second face sheet using stitching.
11. A vehicle in accordance with claim 1 wherein said second edge comprises said second flange extending substantially perpendicularly inwardly from said sidewall, said second face sheet attached to said preform using said second flange.
12. A vehicle in accordance with claim 11 wherein said second flange comprises a first toe and second toe wherein said toes of said second flange extend in opposite directions substantially parallel to said second face sheet.
13. A vehicle in accordance with claim 1 wherein at least one of said preform, said first face sheet, and said second face sheet comprise carbon and epoxy.
14. A vehicle in accordance with claim 1 wherein each of said tiles comprises a ceramic.
15. A vehicle in accordance with claim 1 wherein said first flange comprises a first toe and a second toe, said toes extending substantially perpendicularly from said first edge in opposite directions.
16. A vehicle in accordance with claim 1 further comprising resin infused into voids within and between said tiles, said preform, said first face sheet, and said second face sheet.
17. A vehicle in accordance with claim 1 wherein said armor system comprises a resin infused therein via a vacuum.
18. A vehicle in accordance with claim 1 wherein each of said plurality of cells comprises a size and shape complementary to a predetermined size and shape of a corresponding tile of said plurality of tiles.
19. A vehicle in accordance with claim 1 wherein at least one of said preform, said first face sheet and said second face sheet comprises a resin pre impregnated carbon fabric where the resin has been cured.