Acoustic liner and method for manufacturing same, power propulsion system, and honeycomb

Abstract

The invention relates to an acoustic liner, a method of manufacturing the acoustic liner, a power propulsion system, and a honeycomb core initial piece. The manufacturing method comprises the following steps: obtaining a perforated plate, a honeycomb core initial part and a back plate; wherein the honeycomb core initial part comprises a plurality of honeycomb units which are isolated from one another; each honeycomb unit comprises a resonant cavity defined by a plurality of wall surfaces in a surrounding mode, each wall surface comprises a wall surface body area and a first wall surface connecting area which are arranged adjacently in the axial direction, and the wall surface body areas and the first wall surface connecting areas are of wall surface structures; the material of the first wall surface connecting area is a resin adhesive, and the material of the wall surface body area is different from the material of the first wall surface connecting area.

Description

Technical Field

[0001] The invention relates to an acoustic lining component and a manufacturing method thereof, a power propulsion system, and a honeycomb core initial component. Background Art

[0002] The propulsion system, such as the turbofan engine commonly used in gas turbine engines as a civil aviation engine, has a particularly obvious fan noise as the large bypass ratio engine is used. At present, the noise reduction method for aircraft engines is to install acoustic linings in the nacelle air inlet, reverse thrust and nozzle to reduce noise.

[0003] Acoustic lining is a common means of controlling turbine noise. Typical acoustic lining parts, taking single-degree-of-freedom acoustic lining as an example, include perforated plates (porous face sheet), honeycomb core (honeycomb core) and rigid backing sheets (impervious backing sheet). Taking the simplest degree-of-freedom acoustic lining as an example, the silencing principle of acoustic lining can be regarded as an arrangement and combination of a large number of Helmholtz resonance cavities. The acoustic resistance is determined by the micropores, and the size of the resonance cavity determines its resonant frequency, that is, the acoustic reactance. After the sound waves of a specific frequency pass through the small holes on the perforated plate and enter the honeycomb cavity, resonance will occur, so that the sound energy is converted into internal energy and consumed. In this way, the two cooperate to achieve the purpose of noise reduction at a specific frequency.

[0004] At present, the manufacturing method of the sound lining includes the following steps: first, a small acoustic hole is punched on a side panel to prepare a perforated plate, then a layer of adhesive film is laid on the surface of the honeycomb core and subjected to a thermal film breaking process (such as hot air blowing) at a certain pressure and temperature, and the adhesive film in the honeycomb core grid is broken by the action of temperature and pressure, so that it only sticks to the wall of the honeycomb core grid, and then the perforated plate and the back plate (a layer of adhesive film is laid between the back plate and the honeycomb core) are laid into an autoclave to complete the curing and molding of the honeycomb sandwich sound lining.

[0005] The inventors found that there are many perforations with a diameter of about Φ1mm-3mm (for example, 2mm) on the perforated plate, so the problem of adhesive film blocking the holes is easy to occur during the bonding process of the acoustic lining. In order to solve the problem of perforated plate blocking the holes during the preparation of the acoustic lining structure, the preparation method of the traditional acoustic lining is to first make acoustic holes on a side panel to obtain a perforated plate, and then lay a carrier-free adhesive film on one side of the honeycomb and undergo a thermal film breaking process under a certain pressure and temperature, and the adhesive film in the honeycomb core grid is broken by the action of temperature and pressure, so that it only sticks to the wall of the honeycomb core grid. After that, the perforated plate is laid on the side of the honeycomb that has been thermally broken, and the back plate is laid on the other side of the honeycomb (a layer of adhesive film is laid between the back plate and the honeycomb), and finally enters the autoclave to complete the curing molding of the honeycomb sandwich structure acoustic lining.

[0006] However, the thermal film breaking process has very high requirements on the film material, process temperature, time and pressure, and requires special thermal film breaking equipment, which is very expensive, the process is complex and difficult to control, and the process cycle is long.

[0007] Therefore, the art needs an acoustic lining component and a manufacturing method thereof, a power propulsion system, and a honeycomb core initial component to further simplify the processing and manufacturing process of the acoustic lining component, so that the processing and manufacturing cost of the acoustic lining component is further reduced. Summary of the invention

[0008] An object of the present invention is to provide a method for manufacturing an acoustic lining.

[0009] Another object of the present invention is to provide an acoustic lining.

[0010] Another object of the present invention is to provide a power propulsion system.

[0011] Another object of the present invention is to provide a honeycomb core initial component.

[0012] According to one aspect of the present invention, a method for manufacturing an acoustic lining component comprises: obtaining a perforated plate, a honeycomb core initial component, and a back plate; wherein the honeycomb core initial component comprises a plurality of honeycomb units isolated from each other; each of the honeycomb units comprises a plurality of walls surrounding and defining a resonance cavity, wherein the wall comprises a wall body region and a first wall connection region adjacently arranged in the axial direction, wherein the wall body region and the first wall connection region are both wall structures; the material of the first wall connection region is a resin adhesive, and the material of the wall body region is different from the material of the first wall connection region; the perforated plate and the back plate are respectively located at the axial ends of the honeycomb core initial component and connected to the honeycomb core initial component; the perforated plate is placed on one axial side of the honeycomb unit having the first wall connection region, so that the perforated plate is connected to the first wall connection region, and the back plate is placed on the other axial side of the honeycomb unit to form an intermediate; the intermediate is thermally cured to melt the resin adhesive in the first wall connection region to form an acoustic lining component in which the perforated plate and the wall body region are bonded together by resin adhesive.

[0013] In the scheme of the manufacturing method of the acoustic lining introduced above, a wall body area and a first wall area are set on the wall of the honeycomb unit, and a resin adhesive is used in the first wall area, so that the honeycomb core and the perforated plate can be firmly connected without an adhesive film, that is, the resin adhesive in the first wall area melts under the action of thermal curing to achieve bonding, which overcomes the defects of the thermal film breaking process of the adhesive film in the prior art, which has very high requirements on the adhesive film material, process temperature, time and pressure, and requires special thermal film breaking equipment, is very costly, has a complex process that is difficult to control, and has a long process cycle. The processing and manufacturing process of the acoustic lining is simplified, and the processing and manufacturing cost of the acoustic lining is further reduced.

[0014] In one or more embodiments of the manufacturing method, the honeycomb unit also includes a second wall connection area, the second wall connection area is axially adjacent to the wall body area, and the second wall connection area is a wall structure, and the material of the second wall connection area is a resin adhesive; the manufacturing method also includes: the step of forming the intermediate also includes: the back plate is connected to the second wall connection area; the step of forming the acoustic lining component also includes: melting the resin adhesive of the second wall connection area to form an acoustic lining component in which the back plate and the wall body area are bonded together by resin adhesive.

[0015] In one or more embodiments of the manufacturing method, the wall of the honeycomb unit consists of the wall body area and the first wall connection area.

[0016] In one or more embodiments of the manufacturing method, the length of the first wall connection region axially extending from the wall body region is 0.5 mm-4 mm.

[0017] In one or more embodiments of the manufacturing method, the perforated plate has a perforation size of 1 mm-3 mm, and one or more perforations are arranged corresponding to one honeycomb unit, so that sound waves enter the resonance cavity formed by the honeycomb unit.

[0018] In one or more embodiments of the manufacturing method, a cross section of the resonance cavity defined by a plurality of walls of the honeycomb unit is hexagonal.

[0019] In one or more embodiments of the manufacturing method, the material of the wall body area is aramid, glass fiber, or metal.

[0020] According to another aspect of the present invention, an acoustic lining member is manufactured by the manufacturing method described above.

[0021] A power propulsion system according to another aspect of the present invention includes the acoustic lining member described above.

[0022] In one or more embodiments of the power propulsion system, the power propulsion system is a gas turbine engine, and the acoustic lining is arranged in an air inlet, a thrust reverser, and / or a nozzle of the gas turbine engine.

[0023] According to another aspect of the present invention, a honeycomb core initial component is used in the manufacturing method as described above, and the honeycomb initial component includes: a plurality of honeycomb units isolated from each other; each of the honeycomb units includes a resonance cavity defined by a plurality of walls, and the wall includes a wall body area and a first wall connection area adjacent to each other in the axial direction, and the wall body area and the first wall connection area are both wall structures; the material of the first wall connection area is a resin adhesive, and the material of the wall body area is different from the material of the first wall connection area. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The above and other features, properties and advantages of the present invention will become more apparent through the following description in conjunction with the accompanying drawings and embodiments, in which:

[0025] Figure 1 It is a schematic diagram of the structure of a gas turbine engine.

[0026] Figure 2 It is a schematic structural diagram of a honeycomb core initial component according to an embodiment.

[0027] Figure 3 It is a schematic diagram of the exploded structure of an intermediate body of an acoustic lining member of an embodiment.

[0028] Figure 4 It is a schematic flow chart of a method for manufacturing an acoustic lining according to an embodiment.

[0029] Reference numerals:

[0030] 100-Power Propulsion System

[0031] 102-Hanging

[0032] 103-Intake

[0033] 104-Fan cover

[0034] 105-Thrust Reverse Device

[0035] 106-Nozzle

[0036] 10- Acoustic Lining

[0037] 1- Perforated plate

[0038] 11-Piercing

[0039] 2- Honeycomb core initial parts

[0040] 21-Cellular Unit

[0041] 210-Resonance Cavity

[0042] 211-Wall

[0043] 2110-Wall body area

[0044] 2111-First wall connection area

[0045] 200-Intermediate

[0046] 300-film

[0047] 3- Back panel. DETAILED DESCRIPTION

[0048] The present invention is further described below in conjunction with specific embodiments and drawings. More details are elaborated in the following description to facilitate a full understanding of the present invention. However, the present invention can obviously be implemented in a variety of other ways different from the description herein. Those skilled in the art can make similar generalizations and deductions based on actual application situations without violating the connotation of the present invention. Therefore, the protection scope of the present invention should not be limited by the content of this specific embodiment.

[0049] At the same time, the present application uses specific words to describe the embodiments of the present application, such as "one embodiment", "an embodiment", and / or "some embodiments" to refer to a certain feature, structure or characteristic related to at least one embodiment of the present application. Therefore, it should be emphasized and noted that "one embodiment" or "an embodiment" mentioned twice or more in different locations in this specification does not necessarily refer to the same embodiment. In addition, certain features, structures or characteristics in one or more embodiments of the present application can be appropriately combined.

[0050] It is understood that flow charts are used in the present application to illustrate the operations performed by the system according to the embodiments of the present application. It should be understood that, according to the actual situation, the previous or following operations are not necessarily performed precisely in order. Other operations may also be added to these processes, or one or more operations may be removed from these processes.

[0051] The following embodiments introduce the propulsion system for the application of acoustic lining parts, taking the application to gas turbine engines, specifically the nacelle of turbofan engines as an example, but it is not limited to this. It can be applicable to any propulsion system, including propulsion systems with fans, blades, propeller fans, etc. It is also not limited to gas turbine engines. For example, it can be a hybrid propulsion system including a gas turbine engine, or a pure electric drive propulsion system with fans, blades, propeller fans, to reduce fan noise and / or intake noise. Figure 1As shown, the propulsion system 100 is a gas turbine engine, including a pylon 102, an air inlet 103, a fan cover 104, a thrust reverser 105, and a nozzle 106. The noise reduction effect of the acoustic lining 10 is better when the acoustic lining 10 is arranged at the air inlet 103, the thrust reverser 105, and / or the nozzle 106, but it is not limited to this, and can also be arranged at other positions.

[0052] Although the above method is illustrated and described as a series of actions for simplicity of explanation, it should be understood and appreciated that these steps are not limited by the order of the actions, because according to one or more embodiments, some actions may occur in a different order and / or concurrently with other actions from those illustrated and described herein or not illustrated and described herein but understandable to those skilled in the art.

[0053] refer to Figures 2 to 4 As shown, in some embodiments, the method for manufacturing the acoustic lining member 10 may include:

[0054] S100. Obtain a perforated plate 1, an initial honeycomb core member 2, and a back plate 3;

[0055] The perforated plate 1, the honeycomb core initial component 2, and the back plate 3 can be obtained by on-site processing, or can be processed or purchased in advance.

[0056] Among them, reference Figure 2 As shown, the honeycomb core initial part 2 includes a plurality of honeycomb units 21 isolated from each other; each honeycomb unit 21 includes a plurality of walls 211 surrounding and defining a resonance cavity 210, the wall 211 includes a wall body region 2110 and a first wall connection region 2111 adjacently arranged in the axial direction, the wall body region 2110 and the first wall connection region 2111 are both wall structures; the material of the first wall connection region 2111 is a resin adhesive, and the material of the wall body region 2110 is different from the material of the first wall connection region 2111. Preferably, the length of the first wall connection region 2111 extending axially from the wall body region 2110 is 0.5 mm-4 mm. The inventors have found that this extension length range can ensure that the bonding effect is firm and reliable, and will not cause excessive resin to overflow and cause the perforations of the perforated plate to be clogged with resin.

[0057] S200. The perforated plate 1 and the back plate 3 are respectively located at both ends of the axial direction of the honeycomb core initial member 2 and connected to the honeycomb core initial member 2, reference Figure 3 As shown, the perforated plate 1 is placed on one axial side of the honeycomb unit 21 having the first wall connection area 2111, so that the perforated plate 1 is connected to the first wall connection area 2111, and the back plate 3 is placed on the other axial side of the honeycomb unit 21 to form an intermediate body 200 of the acoustic lining. At this time, the perforated plate 1 is located on the top side of the honeycomb unit 21, and the back plate 3 is located on the bottom side of the honeycomb unit 21.

[0058] In some embodiments, the perforations 11 of the perforated plate 1 have a size of 1 mm-3 mm, and one or more perforations 11 are arranged corresponding to one honeycomb unit 21 , so that sound waves enter the resonance cavity 210 formed by the honeycomb unit 21 .

[0059] S300. Thermally cure the intermediate 200 to melt the resin adhesive in the first wall connection area 2111, thereby forming an acoustic lining member 10 in which the perforated plate 1 and the wall body area 2110 are bonded together by the resin adhesive.

[0060] It can be understood that, since the perforated plate 1 is located at the top side, the resin adhesive melts due to gravity and will not spread out the perforated plate 1 to block the perforations.

[0061] By adopting the manufacturing method introduced above, a wall body area and a first wall area are set on the wall of the honeycomb unit, and a resin adhesive is used in the first wall area, so that the honeycomb core and the perforated plate can be firmly connected without a film, that is, the resin adhesive in the first wall area melts under the action of thermal curing to achieve bonding, which overcomes the defects of the thermal film breaking process of the film in the prior art, which has very high requirements on the film material, process temperature, time and pressure, and requires special thermal film breaking equipment, is very costly, has a complex process that is difficult to control, and has a long process cycle. The processing and manufacturing process of the sound lining parts is simplified, so that the processing and manufacturing cost of the sound lining parts is further reduced.

[0062] The perforated plate, back plate and honeycomb core described above are similar to the general meanings in the field of acoustic lining, and will not be explained in detail here. As shown in the figure, the cross section of the resonance cavity 210 formed by the multiple walls 211 of the honeycomb unit 21 is hexagonal, which has the advantages of light weight, high strength, high rigidity, good stability, and good sound insulation and noise reduction effects. However, this is not a limitation, and other structures can also be used.

[0063] The material of the wall body region 2110 can be aramid, glass fiber, metal, such as aluminum, etc. The melting point of the wall body region 2110 generally needs to be higher than that of the first wall connection region 2111 to avoid affecting the curing effect. The resin adhesive of the first wall connection region 2111 can be, for example, an epoxy resin adhesive. The step of curing the intermediate 200 can be curing in an autoclave, but is not limited thereto.

[0064] like Figure 3In the illustrated embodiment, the structure in which the back plate 3 is connected to the honeycomb unit 21 is realized by the adhesive film 300, but it is not limited thereto. For example, it can also be realized by a resin adhesive. In some embodiments, the honeycomb unit 21 also includes a second wall connection area, the second wall connection area is axially adjacent to the wall body area 2110, and the second wall connection area is a wall structure, and the material of the second wall connection area is a resin adhesive; the manufacturing method also includes: the step of forming the intermediate 200 also includes: the back plate 3 is connected to the second wall connection area; the step of forming the acoustic lining member 10 also includes: melting the resin adhesive in the second wall connection area to form the acoustic lining member 10 in which the back plate 3 is bonded to the wall body area 2110 by resin adhesive. This further simplifies the manufacturing process and reduces manufacturing costs.

[0065] refer to Figure 2 as well as Figure 3 As shown, the wall surface 211 of the honeycomb unit 21 is composed of a wall body region 2110 and a first wall connection region 2111 . Such a honeycomb unit 21 has a simple structure and is further easy to manufacture and process.

[0066] In summary, the beneficial effects of the acoustic lining components and their manufacturing methods, power propulsion systems, and honeycomb core initial components introduced in the above embodiments include but are not limited to: by setting a wall body area and a first wall area on the wall of the honeycomb unit, and using a resin adhesive in the first wall area, a firm connection can be achieved between the honeycomb core and the perforated plate without an adhesive film, that is, the resin adhesive in the first wall area melts under the action of thermal curing to achieve bonding, which overcomes the defects of the thermal film breaking process of the adhesive film in the prior art, which has very high requirements on the adhesive film material, process temperature, time and pressure, and requires special thermal film breaking equipment, is very costly, has a complex process that is difficult to control, and has a long process cycle, thereby simplifying the processing and manufacturing process of the acoustic lining components, and further reducing the processing and manufacturing cost of the acoustic lining components.

[0067] Although the present invention is disclosed as above with preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications without departing from the spirit and scope of the present invention. Therefore, any modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention shall fall within the protection scope defined by the claims of the present invention.

Claims

1. A method for manufacturing an acoustic lining member (10), characterized in that: include: Obtaining a perforated plate (1), an initial honeycomb core component (2), and a back plate (3); The honeycomb core initial component (2) comprises a plurality of mutually isolated honeycomb units (21); each of the honeycomb units (21) comprises a resonance cavity (210) defined by a plurality of walls (211) surrounding the resonance cavity, the walls (211) comprising a wall body region (2110) and a first wall connection region (2111) adjacent to each other in the axial direction, the wall body region (2110) and the first wall connection region (2111) both being wall structures; the material of the first wall connection region (2111) is a resin adhesive, and the material of the wall body region (2110) is different from the material of the first wall connection region (2111); The perforated plate (1) and the back plate (3) are respectively located at the axial ends of the honeycomb core initial component (2) and connected to the honeycomb core initial component (2); the perforated plate (1) is placed on one axial side of the honeycomb unit (21) having a first wall connection area (2111), so that the perforated plate (1) is connected to the first wall connection area (2111), and the back plate (3) is placed on the other axial side of the honeycomb unit (21) to form an intermediate body (200); The intermediate (200) is thermally cured so that the resin adhesive in the first wall connection area (2111) melts, thereby forming a sound lining member (10) in which the perforated plate (1) and the wall body area (2110) are bonded together by the resin adhesive.

2. The manufacturing method according to claim 1, characterized in that The honeycomb unit (21) further comprises a second wall connection region, the second wall connection region is axially adjacent to the wall body region (2110), the second wall connection region is a wall structure, and the material of the second wall connection region is a resin adhesive; The manufacturing method further comprises: The step of forming the intermediate body (200) further includes: connecting the back plate (3) to the second wall connection area; The step of forming the acoustic lining member (10) further includes: melting the resin adhesive in the second wall connection area to form an acoustic lining member (10) in which the back plate (3) and the wall body area (2110) are connected by resin adhesive.

3. The manufacturing method according to claim 1, characterized in that: The wall surface (211) of the honeycomb unit (21) is composed of the wall surface main body area (2110) and the first wall surface connection area (2111).

4. The manufacturing method according to claim 1, characterized in that: The length of the first wall connection area (2111) extending axially from the wall body area (2110) is 0.5mm-4mm.

5. The manufacturing method according to claim 1, characterized in that: The perforated plate (1) has a perforation (11) with a size of 1 mm to 3 mm, and one or more perforations (11) are arranged corresponding to a honeycomb unit (21), so that sound waves enter the resonance cavity (210) formed by the honeycomb unit (21).

6. The manufacturing method according to claim 1, characterized in that: The cross section of the resonance cavity (210) defined and formed around the multiple walls (211) of the honeycomb unit (21) is hexagonal.

7. The manufacturing method according to claim 1, characterized in that: The material of the wall body area (2110) is aramid, glass fiber, or metal.

8. An acoustic lining member (10), characterized in that: The method is obtained by the manufacturing method according to any one of claims 1 to 7.

9. A power propulsion system (100), characterized in that: It comprises the acoustic lining member (10) as claimed in claim 8.

10. The propulsion system (100) according to claim 9, characterized in that: The power propulsion system is a gas turbine engine, and the acoustic lining component (10) is arranged on an air inlet (103), a thrust reverser (105), and / or a nozzle (106) of the gas turbine engine.

11. A honeycomb core initial component (2), characterized in that: For use in the manufacturing method according to any one of claims 1 to 7, the honeycomb initial component (2) comprises: A plurality of mutually isolated honeycomb units (21); Each of the honeycomb units (21) comprises a resonance cavity (210) defined and formed around a plurality of walls (211), wherein the walls (211) comprise a wall body region (2110) and a first wall connection region (2111) adjacent to each other in the axial direction, wherein the wall body region (2110) and the first wall connection region (2111) are both wall structures; the material of the first wall connection region (2111) is a resin adhesive, and the material of the wall body region (2110) is different from the material of the first wall connection region (2111).

Images