Sandwich structure panel and method of manufacturing

Abstract

Noise attenuation of sandwich structures and / or structural panels and methods of manufacturing such panels using ultrasonic welding are described. The method includes receiving a backing member, a sheet, and a honeycomb structure; assembling the honeycomb structure between the backing member and the sheet; and ultrasonically welding the backing member and the sheet together.

Description

Technical Field

[0001] This disclosure relates generally to aircraft components, and more specifically to sandwich structure panels. Background Technology

[0002] Gas turbine engines that power aircraft in flight generate noise, and acoustic treatments within the engine can be used to attenuate some of this noise. A single-degree-of-freedom (SDOF) acoustic panel configuration may include a honeycomb core disposed between a backing sheet and a porous (e.g., perforated) facing sheet. The space between the backing sheet and the facing sheet defines a noise attenuation cavity. A two-degree-of-freedom (DDOF) acoustic panel configuration may include two honeycomb cores joined together at an intermediate porous partition. The arrangement of the two honeycomb cores and the partition between the backing sheet and the porous (e.g., perforated) facing sheet defines two noise attenuation cavities.

[0003] The components of this acoustic treatment are typically assembled and joined together using an adhesive mesh process, where membrane adhesives are used to bond the edges of the cell units to the facing and backing sheets. During the joining process, some excess adhesive material can flow into and clog the pores formed in the facing sheet of the acoustic panel. This pore clogging by the adhesive material can reduce the noise attenuation efficiency of the acoustic panel. Existing methods for securing the panel components together also encroach on space that could otherwise be used for the acoustic treatment of the panel. Improvements are desired. Summary of the Invention

[0004] In one aspect, this disclosure describes a method for manufacturing a sandwich structure panel. The method includes:

[0005] Receives the first outer skin, the second outer skin, and the honeycomb core;

[0006] The honeycomb core is assembled with the first outer skin and the second outer skin such that:

[0007] The honeycomb core is disposed between the first outer skin and the second outer skin;

[0008] The first outer skin has a peripheral portion disposed on the outer periphery of the honeycomb core;

[0009] The second outer skin has a peripheral portion disposed on the outer periphery of the honeycomb core and facing the first outer skin, the peripheral portion of the second outer skin being adjacent to the peripheral portion of the first outer skin; and

[0010] The peripheral portions of the first outer skin and the peripheral portions of the second outer skin are ultrasonically welded together.

[0011] In another aspect, this disclosure describes a method for manufacturing an aircraft component. The method includes:

[0012] Accepting backing components, sheets, and honeycomb structures;

[0013] Assemble the honeycomb structure between the backing member and the sheet; and

[0014] The backing component and the sheet are ultrasonically welded together.

[0015] In another aspect, this disclosure describes a sandwich structure panel, comprising:

[0016] First outer skin,

[0017] A second outer skin, disposed relative to the first outer skin to define a cavity between the first and second outer skins; and

[0018] A honeycomb core disposed in the cavity between the first and second outer skins;

[0019] in:

[0020] The first outer skin has a peripheral portion disposed on the outer periphery of the honeycomb core;

[0021] The second outer skin has a peripheral portion disposed on the outer periphery of the honeycomb core and facing the first outer skin, the peripheral portion of the second outer skin being adjacent to the peripheral portion of the first outer skin; and

[0022] The peripheral portions of the first outer skin and the peripheral portions of the second outer skin are welded together.

[0023] Further details of these and other aspects of the subject matter of this application will become apparent from the accompanying drawings and the detailed embodiments included below. Attached Figure Description

[0024] Now refer to the attached diagram, in which:

[0025] Figure 1 A schematic axial cross-sectional view of an exemplary turbofan gas turbine engine including one or more sandwich structure panels as described herein is shown.

[0026] Figure 2 This is a perspective cross-sectional view of an exemplary sandwich structure panel in the form of a single-degree-of-freedom (SDOF) acoustic panel.

[0027] Figure 3 This is a perspective cross-sectional view of another exemplary sandwich structure panel in the form of a two-degrees-of-freedom (DDOF) acoustic panel;

[0028] Figure 4 This is a schematic perspective view of an exemplary conduit including a sandwich structure panel as described herein;

[0029] Figure 5 It is along Figure 4 The line 5-5 is cut off. Figure 4 A schematic cross-sectional view of the pipeline;

[0030] Figure 6 It is along Figure 4 The line 6-6 in the middle is cut off Figure 4 A schematic cross-sectional view of the pipeline;

[0031] Figure 7 This is a flowchart illustrating an exemplary method for manufacturing an aircraft component in the form of a sandwich panel;

[0032] Figure 8A The backing member of a sandwich panel formed from precursor sheets is schematically shown;

[0033] Figure 8B It schematically shows that Figure 8A The backing component is assembled with the base and the backing component is ultrasonically welded to the base;

[0034] Figure 8C The schematic diagram illustrates the combination of a honeycomb structure and an facing sheet with... Figure 8A The backing components are assembled together;

[0035] Figure 8D It schematically shows that Figure 8C ultrasonic welding of sheet materials Figure 8A The backing components and welding to the honeycomb structure;

[0036] Figure 9A An exploded view of a sandwich structure panel in the form of a DDOF acoustic panel is schematically shown.

[0037] Figure 9B schematically shown Figure 9A Ultrasonic welding components for sandwich panel structures;

[0038] Figure 10 This is a schematic diagram of a portion of another exemplary sandwich structure panel; and

[0039] Figure 11 This is a schematic diagram of a portion of another exemplary sandwich structure panel. Detailed Implementation

[0040] This document describes sandwich structure components (e.g., panels) for aircraft and methods for manufacturing such components. These components are suitable for a variety of structural and / or noise reduction applications, including, for example, structures (i.e., fuselages) of aircraft or other mobile platforms, aircraft engines, automotive applications, buildings, and / or other structural applications. In various embodiments, the components described herein may include, for example, walls, panels, linings, or ducts, or portions thereof. In some embodiments, the components may serve as acoustic treatments and may be referred to as “acoustic panels” or “acoustic linings” with desired noise reduction characteristics. These components may be mounted to line ducts (e.g., inlet or bypass ducts) of gas turbine engines, or may be mounted in any other location, such as inside the cabin of an aircraft or outside the aircraft, where noise reduction is desired. While the following description relates to acoustic treatments (e.g., panels) for aircraft applications, it should be understood that the sandwich structure components and methods described herein are applicable to other applications.

[0041] In some embodiments, the components and methods described herein utilize ultrasonic welding to join portions of the components together, thereby reducing or eliminating the need for adhesive materials (e.g., glue) used in conventional assembly methods such as adhesive meshing. In the case of acoustic panels, reducing or eliminating adhesive material reduces or eliminates the risk of excess adhesive material flowing in and clogging the holes formed in the sheet-facing and / or partition surfaces of such acoustic panels. In some embodiments, the use of ultrasonic welding can simplify the construction of sandwich structure panels. In some embodiments, ultrasonically welded joints between portions of the acoustic panel can effectively utilize space to leave more available space for the acoustically treated areas of the acoustic panel.

[0042] Terms such as “attach,” “connect,” and “coupling” can include direct attachment, connection, or coupling (where two elements are in contact with each other) and indirect attachment, connection, or coupling (where at least one additional element is located between the two elements). The term “substantially” as used herein can be used to modify any quantity representation, which is permissible to vary without causing a change in its associated essential function. Various aspects of different embodiments are described with reference to the accompanying drawings.

[0043] Figure 1 A gas turbine engine 10 of the type preferably provided for use on an aircraft is shown, which typically includes a fan 12 in series flow communication, a multi-stage compressor 14 for pressurizing air, a combustor 16, and a turbine section 18 for extracting energy from combustion gases, wherein ambient air is propelled by the fan, and the compressed air is mixed with fuel in the combustor and ignited to produce an annular flow of hot combustion gases.

[0044] Engine 10 may include one or more sandwich-structured panels (collectively referred to herein as “panel 20”) that serve as acoustic treatments (e.g., panels or linings) disposed at different locations within engine 10 to achieve desired noise reduction. It should be understood that panel 20 can be used in other types of engines (e.g., turbine shafts, turboprop engines, auxiliary power units (APUs)) and other types of noise reduction applications. In some embodiments, panel 20 may be used in structural applications that are not necessarily intended to provide noise reduction.

[0045] In some cases, panel 20 (e.g., an acoustic liner) may be disposed within engine 10 upstream and / or downstream of fan 12, such that noise generated by fan 12 can be attenuated. For example, panel 20 may be integrated into inlet 22 of engine 10 and disposed upstream of fan 12. Alternatively or additionally, panel 20 may be integrated into (e.g., annular) bypass duct 24 and define the radially outer and / or radially inner surfaces of bypass duct 24. In various embodiments, panel 20 may be adapted, for example, fan housing, intermediate housing, bypass duct 24, exhaust duct, thrust reverser duct, and exhaust center body of engine 10. In some embodiments, panel 20 may be adapted for use in hot core ducts of engine 10, in which bonded acoustic materials are typically not used due to elevated temperatures. Depending on the specific application, panel 20 may have a generally planar or non-planar (e.g., curved, arcuate, annular) form (e.g., single-curvature or hypercurvature).

[0046] Figure 2 This is a perspective cross-sectional view of an exemplary sandwich structure panel in the form of a single-degree-of-freedom (SDOF) acoustic panel 20A. The SDOF acoustic panel 20A may include a backing member 26, a facing sheet 28, and a honeycomb structure 30 disposed between the backing member 26 and the facing sheet 28. The facing sheet 28 may be spaced apart from the backing member 26 to define a cavity 32 (e.g., for noise attenuation) between the backing member 26 and the facing sheet 28.

[0047] As explained below, the honeycomb structure 30 can be ultrasonically welded to the backing member 26 and / or the facing sheet 28. The honeycomb structure 30 may include walls serving as partitions that define sub-cavities (cells) within the cavity 32. The honeycomb structure 30 can serve as the core of the SDOF acoustic panel 20A. In some embodiments, the backing member 26 may be in the form of a sheet or plate. However, it should be understood that the backing member 26 can be of any suitable shape and thickness. For example, the backing member 26 can be part of another component of the engine 10, such as the wall of the inlet 22 or bypass duct 24 of the engine 10, which provides a suitable rear wall for the cavity 32. The backing member 26 and the facing sheet 28 can serve as the outer skin of the SDOF acoustic panel 20A disposed on opposite sides of the honeycomb structure 30.

[0048] Figure 3 This is a perspective cross-sectional view of an exemplary sandwich structure composite panel in the form of a two-degrees-of-freedom (DDOF) acoustic panel 20B. The DDOF acoustic panel 20B may include a backing member 26, partitions 34, honeycomb structures 30A and 30B, and a facing sheet 28. Partitions 34 may be spaced apart from the backing member 26 to define a cavity 32A (e.g., for noise attenuation) between the backing member 26 and the partitions 34. The honeycomb structure 30A may be disposed between the backing member 26 and the partitions 34. As explained below, the honeycomb structure 30A may be attached to the backing member 26 and / or the partitions 34 by ultrasonic welding.

[0049] The facing sheet 28 may be spaced apart from the partition 34 to define a cavity 32B (e.g., for noise attenuation) between the partition 34 and the facing sheet 28. A honeycomb structure 30B may be disposed between the facing sheet 28 and the partition 34. Similarly, the honeycomb structure 30B may be attached to the facing sheet 28 and / or the partition 34 by ultrasonic welding. Due to its construction, the DDOF acoustic panel 20B can resonate and attenuate noise at multiple frequencies or over a wider frequency range than the SDOF acoustic panel 20A in some embodiments.

[0050] Refer to each Figure 2 and Figure 3The SDOF acoustic panels 20A and DDOF acoustic panels 20B, and the honeycomb structures 30A and 30B (generally referred to as "honeycomb structure 30"), may each comprise juxtaposed units with multiple end openings of hexagonal or other (e.g., triangular, rectangular, polygonal) cross-sectional profiles. For example, in the case of the SDOF acoustic panel 20A, the walls of the units defining the honeycomb structure 30 may extend from the backing member 26 to the facing sheet 28, and structural support may be provided between the facing sheet 28 and the backing member 26. In the case of the DDOF acoustic panel 20B, the walls of the units defining the honeycomb structure 30B may extend from the partition 34 to the facing sheet 28, and the walls of the units defining the honeycomb structure 30A may extend from the backing member 26 to the partition 34.

[0051] In some embodiments, the honeycomb structure 30 may be of the type referred to as a "honeycomb" core. For example, the honeycomb structure 30 may be made of a suitable non-metallic material (e.g., a polymer), a fiber-reinforced composite material (e.g., a carbon fiber / resin matrix), or a metallic material (e.g., an aluminum-based material).

[0052] In noise attenuation applications, the outer facing sheet 28 may be porous (e.g., perforated) and may include a plurality of through-holes 36 formed therein (e.g., drilled). In some embodiments, the through-holes 36 may have a substantially circular cross-sectional shape, but other cross-sectional shapes such as elliptical or rectangular may also be suitable. For example, the through-holes 36 may include one or more slits. In some embodiments, one or more through-holes 36 may communicate with each cell defined by the honeycomb structure 30, and each cell may serve as a resonator. In some embodiments, a mesh of high-impedance material, such as a porous material, may be disposed inside or outside the cells defined by the honeycomb structure 30 (e.g., combined above or below the facing sheet 28) and may alter the noise attenuation performance of the SDOF acoustic panel 20A. The facing sheet 28 may be made of a suitable metal, plastic, or composite material. For example, the facing sheet 28 may be made of a fiber-reinforced composite material (e.g., carbon fibers embedded in a polymer resin) or a metallic material (e.g., aluminum-based or metallic). In some embodiments, the facing sheet 28 may have a thickness that allows the facing sheet 28 to be ultrasonically welded to another component. In various embodiments, the facing sheet 28 can have a thickness, for example, between 1 mm and 6.5 mm. However, other thicknesses may be suitable for various applications.

[0053] The backing member 26 may be non-perforated and comprises a non-porous, impermeable sheet, plate, or other relatively rigid material. The backing member 26 may be made of a suitable metal, plastic, or composite material. For example, the backing member 26 may be made of a fiber-reinforced composite material (e.g., carbon fibers embedded in a polymer resin) or a metallic material (e.g., aluminum-based or metallic). In some embodiments, the backing member 26 may have a thickness that allows the backing member 26 to be ultrasonically welded to another component.

[0054] In noise attenuation applications, the partition 34 may be a porous (e.g., perforated) sheet or plate and may include a plurality of through holes 38 formed (e.g., drilled) therein for acoustically connecting cavities 32A, 32B together. The partition 34 may serve as an intermediate (e.g., perforated) outer skin disposed between honeycomb structures 30A and 30B. The partition 34 may be made of a suitable metal, plastic, or composite material. For example, the partition 34 may be made of a fiber-reinforced composite material (e.g., carbon fibers embedded in a polymeric resin), a metallic (e.g., aluminum-based or metallic) material, or a fibrous material (e.g., fiber cloth and mesh). In some embodiments, the partition 34 may comprise a perforated sheet having a substantially identical construction to the sheet 28 facing outwards. In some embodiments, the partition 34 may have a thickness that allows the partition 34 to be ultrasonically welded to another component. In various embodiments, the partition 34 may have a thickness, for example, between 0.3 mm and 2.5 mm. However, other thicknesses may be suitable for various applications.

[0055] The honeycomb structure 30 can be used as a relatively low-density core disposed between two relatively strong outer skins, such as backing member 26, facing sheet 28, and / or partition 34. In structural applications, the resulting sandwich panel 20 can provide a combination of relatively high structural stiffness and low weight, as the outer skins provide resistance to in-plane and lateral bending loads, while the core provides resistance to shear loads. In non-noise attenuation applications, the facing sheet 28 and / or partition 34 can be left unperforated (i.e., without through-holes 36, 38). The materials of the components of panel 20 can be selected to be suitable for ultrasonic welding together.

[0056] Figure 4 This is a perspective view of an exemplary conduit 40 that may include one or more panels 20. The conduit 40 may be, for example, part of an inlet 22 of an engine 10, or part of a bypass conduit 24 that may form part of the engine 10. The conduit 40 may include, for example, an annular base 42 to which the panels 20 may be mounted. The base 42 may be made of a suitable polymeric material, a fiber-reinforced composite material (e.g., carbon fibers embedded in a polymer resin), or a metallic material (e.g., aluminum-based).

[0057] Figure 5 It is along Figure 4 A schematic cross-sectional view of the pipe 40 taken by line 5-5. One or more panels 20 may be mounted to the radially inner and / or radially outer side of the base 42. In some embodiments, a single panel 20 may be mounted to the base 42 and cover a portion or substantially the entire circumferential span of the base 42. In some embodiments, multiple panels 20 may be mounted to the base 42 in a circumferentially adjacent manner to cover a portion or substantially the entire circumferential span of the base 42. Figure 5 In the example shown, two adjacent semi-circular panels 20 are shown mounted radially inward to the base 42. A central parting line 44 is schematically shown between the adjacent panels 20. Multiple panels 20 can be mounted to any suitable base 42 to collectively provide an acoustic treatment area with a desired shape and size.

[0058] Figure 6 It is along Figure 4 The line 6-6 in the middle is cut off Figure 4 A schematic cross-sectional view of the pipe 40. The panel 20 can be formed to mate with a contour defined in the base 42 of the pipe 40, and can be as follows: Figure 6 The honeycomb structure 30 can be inserted into the base 42 as shown. Figure 6 The perimeter P is shown, and the perimeter P represents the outer boundary of the honeycomb structure 30 in a plane that intersects with and is substantially parallel to the panel 20. In other words, the perimeter P can be the outer edge of the acoustic treatment area of ​​the panel 20.

[0059] The backing member 26 may have a cross-sectional profile substantially consistent with the cross-sectional profile of the base 42. For example, the backing member 26 may have a “cap” shaped cross-sectional profile, comprising a main portion 26A disposed within the periphery P of the honeycomb structure 30 and a peripheral portion 26B disposed outside the periphery P of the honeycomb structure 30. In other words, the backing member 26 may extend outward beyond the periphery P of the honeycomb structure 30. The backing member 26 may also include a transition portion 26C interconnecting the respective peripheral portion 26B with the main portion 26A. The transition portion 26C may provide a stepped transition between the main portion 26A and the respective peripheral portion 26B. The stepped transition provided by the transition portion 26C can eliminate the need for a tilted or “pan-down” region of the panel 20 that would be away from the acoustic treatment area of ​​the panel 20. Therefore, compared to, for example, a tilted transition, the stepped transition provided by the transition portion 26C can contribute to a larger acoustic treatment area in the available space of the panel 20. In some embodiments, the transition portion 26C may be substantially perpendicular to the main portion 26A. However, in some embodiments, the transition portion 26C may instead be not perpendicular to the main portion and provide a ramped transition that interconnects the main portion 26A with the corresponding peripheral portion 26B.

[0060] The facing sheet 28 may include a main portion 28A disposed within the periphery P of the honeycomb structure 30 and a peripheral portion 28B disposed outside the periphery P of the honeycomb structure 30. In other words, the facing sheet 28 may extend outward beyond the periphery P of the honeycomb structure 30. The peripheral portion 28B of the facing sheet 28 may face a corresponding peripheral portion 26B of the backing member 26. The peripheral portion 28B of the facing sheet 28 may be adjacent to and (e.g., ultrasonically) welded to the corresponding peripheral portion 26B of the backing member 26.

[0061] The components of panel 20 can be welded together at weld joint 46 or welded to base 42. A ratio can be used... Figure 6 The diagram shows more or fewer welded joints 46. For example, the main portion 26A of the backing member 26 may be welded to the base 42. The peripheral portion 26B of the backing member 26 may be welded to the base 42. The peripheral portion 26B of the backing member 26 and the peripheral portion 28B facing the sheet 28 may be welded together to form a lap joint. The main portion 28A facing the sheet 28 and the honeycomb structure 30 may be welded together.

[0062] Figure 7 This is a flowchart illustrating an exemplary method 100 for manufacturing a sandwich structure component such as panel 20. Aspects of method 100 may be combined with the method steps or other aspects described herein. Aspects of method 100 are... Figures 8A-9B As shown in the figure. Method 100 may include: receiving a backing member 26, a facing sheet 28 (or partition 34) and a honeycomb structure 30 (box 102); assembling the honeycomb structure 30 between the backing member 26 and the facing sheet 28 (or partition 34) (box 104); and ultrasonically welding the backing member 26 and the facing sheet 28 (or partition 34) together (box 106).

[0063] Welded joint 46 ( Figure 6 (As shown) can be produced by ultrasonic welding, as explained further below. Alternatively, the welded joint 46 can be made using other suitable cryogenic welding methods, such as seam welding or linear friction welding. The welded joint 46 can include the joining or fusion of parts made after softening or mushying a portion of the parts to be joined using heat, with or without a fusible filler material.

[0064] Figure 8AA backing member 26 of a panel 20, formed from (e.g., a flat) precursor sheet 48, is schematically shown prior to assembly with a base 42. The backing member 26 can be formed into the desired shape using any suitable metal or polymer forming technique. In some embodiments where the backing member 26 is made of a metallic material, the backing member 26 may be formed from the precursor sheet 48 by, for example, stamping or conventional welding. In some embodiments where the backing member 26 is made of a polymer, the backing member 26 may be, for example, injection molded or thermoformed from the precursor sheet 48. In some embodiments, the backing member 26 may define a recess 50 into which a honeycomb structure 30 can be inserted. A peripheral portion 26B may be provided on the outer periphery of the recess 50.

[0065] Figure 8B The illustration schematically shows the assembly of the backing member 26 to the base 42 and the ultrasonic welding of the backing member 26 to the base 42 using an ultrasonic generator (sonotrode) 52. In embodiments where the panel 20 is integrated with the base 42, the base 42 may be held on a suitable anvil to facilitate the ultrasonic welding process. In embodiments where the panel 20 is not integrated with and welded to the base 42, the backing member 26 may be held using a suitable anvil or other suitable workpiece holding device during the assembly of the panel 20 and during ultrasonic welding. In some embodiments, an optional metal foil 54 may be placed between the parts to be joined to facilitate ultrasonic welding. In some embodiments where the polymer parts of the panel 20 are ultrasonically welded together, the metal foil 54 may be a relatively thin piece made of a compatible polymer material and placed between the parts to be joined to facilitate ultrasonic welding.

[0066] Compared to some adhesive bonding methods, ultrasonic welding offers flexibility in joining various materials via a relatively strong structural bond. In some embodiments, the relatively high bond strength can promote a smaller welded joint area 46 compared to fasteners such as rivets or bolts. Therefore, compared to existing acoustic panels made using other methods, ultrasonic welding can promote an increase in the acoustically treated area in a given space, a reduction or elimination of the obstruction of through-holes 36, 38 by adhesive materials, and / or a potential weight reduction.

[0067] The ultrasonic welding used in this paper can be a solid-state welding process in which no external heat is added for welding. Ultrasonic welding can be performed using an ultrasonic generator 52. The ultrasonic generator 52 can be moved to the welding position and positioned to contact the workpieces to transfer energy to the workpieces through ultrasonic vibration. The ultrasonic vibration can generate dynamic shear stress between the contact surfaces of the workpieces. Due to localized plastic deformation and heat generation caused by friction between the contact surfaces, a joint may form at the interface between the two workpieces. The ultrasonic generator 52 may be associated with a (e.g., piezoelectric) transducer that converts high-frequency electrical signals into high-frequency mechanical vibrations. The oscillating shear force acting at the interface between the workpieces can cause elastoplastic deformation at the interface. The local temperature at the interface may rise without significantly melting the workpieces and / or filler material. When joining metal parts, welding can be achieved by breaking the surface oxide film of the metal parts. Ultrasonic welding can be considered a relatively low-heat process and can be used to weld metal materials together as well as polymer materials.

[0068] Figure 8C The diagram schematically illustrates the assembly of the honeycomb structure 30 and the facing sheet 28 with the backing member 26 after the backing member 26 has been installed (and optionally welded to) the base 42. Recess 50 ( Figure 8B The honeycomb structure 30 (shown in the diagram) can at least partially fill and cover the sheet 28. In some embodiments, a metal foil 54 may be disposed between the main portion 28A of the sheet 28 and the honeycomb structure 30 to facilitate ultrasonic welding between them. In some embodiments, the metal foil 54 may be disposed between the peripheral portion 28B of the sheet 28 and the peripheral portion 26B of the backing member 26 to facilitate ultrasonic welding therebetween.

[0069] Figure 8D The illustration schematically shows the use of an ultrasonic generator 52 to ultrasonically weld a peripheral portion 28B facing the sheet 28 to a peripheral portion 26B of the backing member 26 to form a welded joint 46. In some embodiments, the ultrasonic generator 52 may also be used to ultrasonically weld a main portion 28A facing the sheet 28 to the honeycomb structure 30.

[0070] In some embodiments, the base 42 can serve as a suitable backing member, and a separate intermediate backing member 26 covering the base 42 may not be required. For example, the honeycomb structure 30 can be inserted into a recess formed in the base 42, and the peripheral portion 28B facing the sheet 28 can be directly ultrasonically welded to the peripheral portion of the base 42, so that the base 42 can serve as a backing member for the panel 20.

[0071] In cases where one or more components, such as backing member 26 or facing sheet 28, are made of fiber-reinforced composite material, ultrasonic welding can also be used in the layer lay-up stage to bond the layers (e.g., pre-impregnated fabric or unidirectional tape) together, and the resulting laminate can then be solidified in an autoclave. In other words, the layer-by-layer ultrasonic additive manufacturing (UAM) process can be used to form one or more components of panel 20.

[0072] Figure 9A An exploded view schematically illustrates a DDOF acoustic panel 20B assembled with a base 42. Method 100 and other aspects described above regarding the manufacture of an SDOF acoustic panel 20A can be used to manufacture the DDOF acoustic panel 20B. In some embodiments, a backing member 26 may be mounted to the base 42 and optionally ultrasonically welded to the base 42 as described above. A honeycomb structure 30A may be assembled to be disposed between the backing member 26 and a partition 34, which may be perforated with through-holes 38. The honeycomb structure 30A may be inserted into a recess 50 defined by the backing member 26. The partition 34 may have a first peripheral portion 34B disposed outside the periphery P1 of the honeycomb structure 30A. The first peripheral portion 34B of the partition 34 may be disposed facing and adjacent to a corresponding peripheral portion 26B of the backing member 26 to provide an overlap joint, thereby allowing ultrasonic welding.

[0073] The partition 34 may also be formed with a "cap" shape similar to the backing member 26. A honeycomb structure 30B may be mounted between the partition 34 and the sheet 28. The partition 34 may define a recess 56 into which the honeycomb structure 30B can be inserted. The partition 34 may also have a second peripheral portion 34D disposed outside the periphery P2 of the honeycomb structure 30B. The second peripheral portion 34D of the partition 34 facilitates ultrasonic welding of the partition 34 to the base 42. Transition portions 34C may interconnect the second peripheral portions 34D to corresponding first peripheral portions 34B of the partition 34. Each transition portion 34C may define a stepped transition or a ramped transition. In some embodiments, the transition portions 34C may be substantially perpendicular to the main portion 34A of the partition 34 disposed within the periphery P1 of the honeycomb structure 30A. The peripheral portion 28B facing the sheet 28 may be disposed outside the periphery P2 of the sheet 28. The peripheral portion 28B of the sheet 28 and the corresponding second peripheral portion 34D of the partition 34 can face each other and be arranged adjacent to each other to define the lap joint, thereby facilitating ultrasonic welding.

[0074] In various embodiments, the assembly sequence of the components of the SDOF acoustic panel 20A or DDOF acoustic panel 20B may differ from those described herein. For example, the entire SDOF acoustic panel 20A or DDOF acoustic panel 20B may be assembled separately from the base 42 and subsequently assembled to the base 42 (e.g., by bonding, welding, fastening). Figure 8C One or more optional metal foils 54 shown can also be used to facilitate ultrasonic welding of components of the DDOF acoustic panel 20B.

[0075] Figure 9B The diagram schematically illustrates the use of an ultrasonic generator 52 to ultrasonically weld components of a DDOF acoustic panel 20B. The DDOF acoustic panel 20B may include multiple weld joints 46 extending through it, and the acoustic welding operation can be performed between assembly steps to provide a pathway for the ultrasonic generator 52 to the components to be welded. One or more weld joints 46 may be formed between a main portion 26A of the backing member 26 and a base 42. One or more weld joints 46 may be formed between a peripheral portion 26B of the backing member 26 and the base 42. One or more weld joints 46 may be formed between a main portion 34A of the partition 34 and a honeycomb structure 30A. One or more weld joints 46 may be formed between a first peripheral portion 34B of the partition 34 and a corresponding peripheral portion 26B of the backing member 26. One or more weld joints 46 may be formed between a second peripheral portion 34D of the partition 34 and the base 42. One or more welded joints 46 may be formed between the peripheral portion 28B facing the sheet 28 and the corresponding second peripheral portion 34D of the partition 34. One or more welded joints 46 may be formed between the main portion 28A facing the sheet 28 and the honeycomb structure 30B.

[0076] In some embodiments, the base 42 may serve as a suitable backing member, and a separate intermediate backing member 26 covering the base 42 may not be necessary in the construction of the DDOF acoustic panel 20B. For example, a honeycomb structure 30A may be inserted into a recess formed in the base 42, and a first peripheral portion 34B of the partition 34 may be directly ultrasonically welded to 42, such that the base 42 can serve as a backing member for the DDOF acoustic panel 20.

[0077] Figure 10This is a schematic diagram of a portion of another exemplary sandwich structure panel 120 that can be applied to structural applications. In some embodiments, the first skin 126 and the second skin 128 are not perforated. Panel 120 may include the elements described above, and the reference numerals for the same elements are increased by 100. Ultrasonic welding may be used to create welded joints 146. One or more welded joints 146 may be created between the main portion 126A of the first skin 126 and the honeycomb structure 130. One or more welded joints 146 may be created between the main portion 128A of the second skin 128 and the honeycomb structure 130. One or more welded joints 146 may be created between the peripheral portion 126B of the first skin 126 and the peripheral portion 128B of the second skin 128. A transition portion 126C of the first skin 126 may define a stepped transition disposed within the periphery of the honeycomb structure 130 between the peripheral portion 126B and the main portion 126A of the first skin 126. The transition portion 128C of the second outer skin 128 may be defined as a stepped transition disposed within the periphery of the honeycomb structure 130 between the peripheral portion 128B of the second outer skin 128 and the main portion 128A of the second outer skin 128.

[0078] The use of ultrasonic welding also facilitates the fabrication of other components, such as brackets 58, flanges, and / or other accessories integrated with the panels, pipes, and bases described herein, by using ultrasonic welding, thereby reducing or eliminating the use of fasteners. UAM may include the use of ultrasonic welding to stack and fuse (e.g., weld) metal or polymer strips 60 in a layer-by-layer manner to construct such components. In various embodiments, the panels described herein can be used in components such as pipes, aircraft longitudinal beams, and aircraft fuselage skins. The panels described herein can be used for shock absorption and / or insulation functions.

[0079] Figure 11 This is a schematic diagram of a portion of another exemplary sandwich structure panel 220 that can be applied to structural applications. In some embodiments, the first skin 226 and the second skin 228 may not be perforated. Panel 220 may include the elements described above, and the reference numerals for the same elements are increased by 200. Ultrasonic welding may be used to create welded joints 246. One or more welded joints 246 may be created between the main portion 226A of the first skin 226 and the honeycomb structure 230. One or more welded joints 246 may be created between the main portion 228A of the second skin 228 and the honeycomb structure 230. One or more welded joints 246 may be created between the peripheral portion 226B of the first skin 226 and the peripheral portion 228B of the second skin 228. A transition portion 226C of the first skin 226 may define a ramped transition disposed within the periphery of the honeycomb structure 230 between the peripheral portion 226B of the first skin 226 and the main portion 226A of the first skin 226.

[0080] The embodiments described in this document provide non-limiting examples of possible implementations of the technology. Upon reading this disclosure, those skilled in the art will recognize that changes can be made to the embodiments described herein without departing from the scope of the technology. In view of this disclosure, those skilled in the art can make further modifications that will be within the scope of the technology.

Claims

1. A method for manufacturing a sandwich structure panel, the method comprising: A receiving annular base having a radially inner side defining a recess; Receives the first outer skin, the second outer skin, and the honeycomb core; The first outer skin is ultrasonically welded to the radially inner side of the annular base, such that the main portion of the first outer skin is received in the recess and the peripheral portion of the first outer skin outside the main portion is welded to the peripheral portion of the annular base outside the recess. The honeycomb core is assembled with the first outer skin and the second outer skin such that: The honeycomb core is disposed between the first outer skin and the second outer skin; The peripheral portion of the first outer skin is disposed on the outer periphery of the honeycomb core; The second outer skin has a peripheral portion disposed on the outer periphery of the honeycomb core and facing the first outer skin, the peripheral portion of the second outer skin being adjacent to the peripheral portion of the first outer skin; as well as The peripheral portions of the first outer skin and the peripheral portions of the second outer skin are ultrasonically welded together.

2. The method according to claim 1, comprising ultrasonically welding the first outer skin to the honeycomb core.

3. The method of claim 1, wherein the first outer skin defines a recess, and the method includes inserting the honeycomb core into the recess.

4. The method according to claim 2, comprising ultrasonically welding the second outer skin to the honeycomb core.

5. The method according to claim 4, wherein, The second outer skin was perforated.

6. The method according to claim 1, wherein, The first outer skin defines a stepped transition between the peripheral portion of the first outer skin and the main portion of the first outer skin, and the main portion of the first outer skin is disposed inside the periphery of the honeycomb core.

7. The method according to claim 1, wherein: The honeycomb core is the first honeycomb core; The peripheral portion of the second outer skin is the first peripheral portion of the second outer skin; The method includes: Receives the third outer sheath and the second honeycomb core; The second honeycomb core is assembled with the second outer skin and the third outer skin such that: The second honeycomb core is disposed between the second outer skin and the third outer skin; The second outer skin has a second peripheral portion disposed on the outer periphery of the second honeycomb core; The third outer skin has a peripheral portion disposed on the outer periphery of the second honeycomb core and facing the second peripheral portion of the second outer skin, the peripheral portion of the third outer skin being adjacent to the second peripheral portion of the second outer skin; and The second peripheral portion of the second outer skin is ultrasonically welded to the peripheral portion of the third outer skin.

8. The method according to claim 7, wherein, The second outer skin defines a stepped transition between the first peripheral portion of the second outer skin and the second peripheral portion of the second outer skin.

9. A method for manufacturing an aircraft component, the method comprising: A receiving annular base having a radially inner side defining a recess; Accepting backing components, sheets, and honeycomb structures; The backing member is ultrasonically welded to the radially inner side of the annular base, such that the main portion of the backing member is received in the recess and the peripheral portion of the backing member outside the main portion is welded to the peripheral portion of the annular base outside the recess. The honeycomb structure is assembled between the backing member and the sheet; as well as The backing component and the sheet are ultrasonically welded together.

10. The method of claim 9, further comprising ultrasonically welding the sheet to the honeycomb structure.

11. The method of claim 9, comprising: The honeycomb structure is inserted into the recess formed in the backing member; as well as The peripheral portion of the backing member outside the recess of the backing member is ultrasonically welded to the sheet.

12. The method of claim 9, further comprising ultrasonically welding strips in a layer-by-layer manner to construct features from the backing member or the sheet.

13. A pipe, comprising: An annular base having a radially inner side that defines a recess; as well as Sandwich structure panel, including: First outer skin, A second outer skin, disposed relative to the first outer skin to define a cavity between the first and second outer skins; and A honeycomb core disposed in the cavity between the first and second outer skins; in: The first outer skin is ultrasonically welded to the radially inner side of the annular base, such that the main portion of the first outer skin is received in the recess and the peripheral portion of the first outer skin outside the main portion is welded to the peripheral portion of the annular base outside the recess, the peripheral portion of the first outer skin being disposed outside the periphery of the honeycomb core. The second outer skin has a peripheral portion disposed on the outer periphery of the honeycomb core and facing the peripheral portion of the first outer skin, the peripheral portion of the second outer skin being adjacent to the peripheral portion of the first outer skin; and The peripheral portions of the first outer skin and the peripheral portions of the second outer skin are welded together.

14. The pipe according to claim 13, wherein, The second outer skin is welded to the honeycomb core.

15. The pipe according to claim 13, wherein, The second outer skin was perforated.

16. The pipe according to claim 13, wherein, The first outer skin defines a stepped transition between the peripheral portion of the first outer skin and the main portion of the first outer skin, and the main portion of the first outer skin is disposed inside the periphery of the honeycomb core.

17. The pipe according to claim 13, wherein The honeycomb core is the first honeycomb core; The cavity is the first cavity; The peripheral portion of the second outer skin is the first peripheral portion of the second outer skin; The sandwich structure panel includes: A third outer skin, disposed relative to the second outer skin to define a second cavity between the second outer skin and the third outer skin; and The second honeycomb core is disposed in the second cavity between the second outer skin and the third outer skin; in: The second outer skin has a second peripheral portion disposed on the outer periphery of the second honeycomb core; The third outer skin has a peripheral portion disposed on the outer periphery of the second honeycomb core and facing the second outer skin, the peripheral portion of the third outer skin being adjacent to the second peripheral portion of the second outer skin; The second peripheral portion of the second outer skin and the peripheral portion of the third outer skin are welded together; and The second and third outer layers were perforated.

Images